GEA VARIVENT C Manual de usuario
Hygienic valves
GEA VARIVENT® Double seal valve type C
Operating instruction (Translation from the original language)
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COPYRIGHT
These Operating Instructions are the English translation of the original operating
instructions in the sense of the EU Machinery Directive. This document is
protected by copyright. All rights reserved. The document may not, in whole or in
part, be copied, reproduced, translated or reduced to an electronic medium of
machine-readable form without the express permission of GEA Tuchenhagen
GmbH.
LEGAL NOTICE
Word marks
The designations VARIVENT® and T.VIS® are protected trademarks of GEA
Tuchenhagen GmbH.
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TABLE OF CONTENTS
1 General Information 5
1.1 Information on the Document 5
1.1.1 Binding Character of These Operating Instructions 5
1.1.2 Notes on the Illustrations 5
1.1.3 Symbols and Highlighting 5
1.2 Manufacturer address 6
1.3 Contact 6
1.4 EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC 7
1.5 Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive
2006/42/EU 8
2 Safety 9
2.1 Intended use 9
2.1.1 Requirements for operation 9
2.1.2 Pressure equipment directive 9
2.1.3 ATEX directive 9
2.1.4 Improper operating conditions 10
2.2 Operator’s Duty of Care 10
2.3 Subsequent changes 11
2.4 General safety instructions and dangers 11
2.4.1 Principles for safe operation 11
2.4.2 Environmental Protection 12
2.4.3 Electrical Equipment 12
2.5 Supplementary Regulations 12
2.6 Qualification of personnel 12
2.7 Safety equipment 14
2.7.1 Signage 14
2.8 Residual dangers 15
2.9 Danger zones 16
3 Description 18
3.1 Design 18
3.2 Functional description 19
3.2.1 Actuator Function 19
4 Transport and storage 20
4.1 Storage conditions 20
4.2 Transport 20
4.2.1 Scope of supply 21
5 Technical data 22
5.1 Type plate 22
5.2 Technical data 22
5.3 Resistance and permitted operating temperature of the sealing materials 23
5.4 Pipe ends - General table of measurements 25
5.5 Tool 26
5.6 Lubricants 26
5.7 Weights 26
6 Assembly and installation 28
6.1 Safety instructions 28
6.2 Notes on installation 28
6.3 Valve with Detachable Pipe Connection Elements 28
6.4 Valve with Welded Ends 29
6.5 Pneumatic connections 30
6.5.1 Air Requirement 30
6.5.2 Establishing Hose Connections 30
6.5.3 Hose fitting valve C 32
6.6 Electrical connection with T.VIS control top 34
7 Start-up 36
7.1 Safety instructions 36
7.2 Notes on commissioning 36
8 Operation and control 37
8.1 Safety instructions 37
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9 Cleaning 38
9.1 Cleaning 38
9.1.1 Cleaning Process Examples 38
9.1.2 Cleaning effect 38
9.1.3 Cleaning the leakage cavity 39
9.1.4 Rinsing operations 39
9.2 Passivation 39
10 Maintenance 40
10.1 Safety instructions 40
10.2 Inspections 41
10.2.1 Product contact seals 41
10.2.2 Pneumatic connections 41
10.2.3 Electrical connections 41
10.2.4 Signs on the valve 42
10.3 Maintenance intervals 42
10.4 Prior to disassembly 42
10.5 Disassembling the Valve 43
10.5.1 Ventilating the Actuator for Disassembly 43
10.5.2 Removing the Valve Insert 45
10.5.3 Separating the Valve from the Actuator 47
10.5.4 Removing the flush valve C 48
10.6 Maintenance 48
10.6.1 Cleaning the Valve 48
10.6.2 Replacing Seals 50
10.6.3 Lubricating Seals and Threads 51
10.7 Installation 52
10.7.1 Reconnect the cleaning hose 52
10.7.2 Torques for the Clamps and Clamp Connections 54
10.7.3 Checking the function 54
11 Alarms 56
11.1 Malfunctions and remedies 56
12 Decommissioning 57
12.1 Safety instructions 57
12.2 Disposal 57
12.2.1 General notes 57
12.2.2 Valve Actuator Disposal 57
13 Parts list - Double seal valve C 58
14 Parts list - 0 connection (0/C) 68
15 Parts list - Flush Valve SPV 70
16 Parts list - Hose connection diagram 72
17 Dimension Sheet - VARIVENT® mixproof valve C 75
18 Appendix 77
18.1 Lists 77
18.1.1 Abbreviations and terms 77
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1 General Information
1.1 Information on the Document
The present Operating Instructions are part of the user information for the
product. The Operating Instructions contain all the information you need to
transport, install, commission, operate and carry out maintenance for the product.
1.1.1 Binding Character of These Operating Instructions
These Operating Instructions contain the manufacturer's instructions to the
operator of the product and to all persons who work on or use the product
regarding the procedures to follow.
Carefully read these Operating Instructions before starting any work on or using
the product. Your personal safety and the safety of the product can only be
ensured if you act as described in the Operating Instructions.
Store the Operating Instructions in such a way that they are accessible to the
operator and the operating staff during the entire life cycle of the product. When
the location is changed or the product is sold make sure you also provide the
Operating Instructions.
1.1.2 Notes on the Illustrations
The illustrations in these Operating Instructions show the product in a simplified
form. The actual design of the product can differ from the illustration. For detailed
views and dimensions of the product please refer to the design documents.
1.1.3 Symbols and Highlighting
In these Operating Instructions, important information is highlighted by symbols
or special formatting. The following examples illustrate the most important types
of highlighting.
Danger
Warning: Fatal Injuries
Failure to observe the warning can result in serious damage to health, or
even death.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Warning: Explosions
Failure to observe the warning can result in severe explosions.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
General Information
Information on the Document
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Warning!
Warning: Serious Injuries
Failure to observe the warning can result in serious damage to health.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Caution!
Warning: Injuries
Failure to observe the warning can result in minor or moderate damage to
health.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Notice
Warning: Damage to Property
Failure to observe the warning can result in serious damage to the
component or in the vicinity of the component.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Carry out the following steps: = Start of a set of instructions.
1. First step in a sequence of operations.
2. Second step in a sequence of operations.
®Result of the previous operation.
®The operation is complete, the goal has been achieved.
Hint!
Further useful information.
1.2 Manufacturer address
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
1.3 Contact
Tel.:+49 4155 49-0
Fax:+49 4155 49-2035
www.gea.com
General Information
Manufacturer address
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1.4 EU Declaration of Conformity in accordance with the EC Machinery Directive
2006/42/EC
General Information
EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC
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1.5 Translated copy of the EU - Declaration of conformity in accordance with the
Pressure Equipment Directive 2006/42/EU
Manufacturer: GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
We hereby declare that the machine named below
Designation: Valve with actuator
Type: VARIVENT®
due to its design and construction as well as in the versions sold by us, meet the basic safety and health requirements of the following
guideline:
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized standards, in
particular:
EN ISO 12100: 2010
Remarks: •This declaration will become invalid if any alterations are
made to the machine which have not been agreed with us
•We also declare that the relevant technical documentation for
this machine has been prepared in accordance with Annex
VII, Part A, and agree to submit the documentation on
justified request of national authorities on a data carrier
Person authorised for compilation and handover of technical
documentation:
GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2-10
21514 Buchen, Germany
Büchen, 24 January 2020
Franz Bürmann
Managing Director i.V. Matthias Südel
Head of Engineering
General Information
Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive 2006/42/EU
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2 Safety
2.1 Intended use
The double-seal valve type C is used for the mixproof separation of cleaning
media at flow path intersections in pipe systems.
The medium should preferably flow in the opening direction of the valve disk to
avoid pipe hammers when the valve is opened or closed.
If the valve is used in the opposite direction (valve closing), a damping cylinder
can be used to avoid pressure drops.
Do not install the valve in spring-opening, as this will open when there is a current
or air failure and leads to product mixing.
Hint!
The manufacturer will not accept any liability for damage resulting
from any use of the valve which is not in accordance with the
designated use of the valve. The risk is borne solely by the operating
company.
2.1.1 Requirements for operation
The prerequisite for reliable and safe operation of the component is proper
transportation and storage as well as professional installation and assembly.
Operating the unit within the limits of its designated use also involves adhering to
the operating, inspection and maintenance instructions.
2.1.2 Pressure equipment directive
The component is a piece of pressure equipment (without safety function) in the
sense of the pressure equipment directive 2014/68/EU. Classified according to
Annex II in category 1.
According to the scope of directive 2014/34/EC, article 1, paragraph 2, f, the
exception of the directive applies, due to conformity with the machine directive
2006/42/EU.
The nominal diameters smaller than DN 25 are subject to article 4, paragraph 3
of the Pressure Equipment Directive which specifies sound engineering practice.
Nominal diameters ≥ IPS 4“; DN 125 valid for the fluid group II.
In the event of any deviations, GEA Tuchenhagen GmbH will supply a specific
Declaration of Conformity.
2.1.3 ATEX directive
In areas with an explosive atmosphere, only valves suitable for use in such areas
may be used.
Refer to and observe the additional operating instructions “ATEX version valves”.
For details regarding the marking of valves for potentially hazardous areas also
refer to the additional operating instructions “ATEX version valves”.
Safety
Intended use
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If these valves are used in areas with a potentially explosive atmosphere, you
must absolutely comply with directive 2014/34/EC with respect to all ignition
hazards.
2.1.4 Improper operating conditions
The operational safety of the component can not be guaranteed under improper
operating conditions. Therefore avoid improper operating conditions.
The operation of the component is not permitted if:
•Persons or objects are in the danger zone.
•Safety devices are not working or were removed.
•Malfunctions have been detected on the component.
•Damage to the component has been detected.
•Maintenance intervals have been exceeded.
2.2 Operator’s Duty of Care
The operating company of the component has a special responsibility for the
proper and safe handling of the component within their company. Only use the
component when it is in perfect operating condition in order to prevent danger to
persons and property.
This operating manual contains information that you and your employees need
for safe operation over the life of the component. Be sure to read these Operating
Instructions carefully and ensure that the measures described here are observed.
The operator's duty of care includes planning the necessary safety measures and
monitoring that these measures are observed. The following principles apply:
•Only qualified personnel may work on the component.
•The operating company must authorize personnel to carry out the relevant
tasks.
•Order and cleanliness must be maintained at the work stations and in the
entire area surrounding the component.
•Personnel must wear suitable work clothing and personal protective
equipment. As the operating company must ensure that work clothing and
personal protective equipment are used.
•Inform personnel regarding any properties of the product which might pose a
health risk and the preventative measures to be taken.
•Have a qualified first-aid representative on call during the operation. This
person must be able to initiate any necessary first-aid measures in case of an
emergency.
•Clearly define procedures, competences and responsibilities for those
working in the area of the component. Everybody must know what to do in
case of an emergency. Instruct the staff in this respect at regular intervals.
•The signs on the component must always be complete and easy to read.
Check, clean and replace the signs as necessary at regular intervals.
Safety
Operator’s Duty of Care
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