GEA VARIVENT X Manual de usuario

Hygienic valves

GEA VARIVENT® Shuttle valve type X and W, X_V and W_V

Operating instruction (Translation from the original language)

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These Operating Instructions are the English translation of the original operating

instructions in the sense of the EU Machinery Directive. This document is

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.

The TEFASEP® gold designation is a trademark of GEA Tuchenhagen GmbH

registered in Switzerland.

We kindly request that you answer a few short questions about these Operating

Instructions. Use the following QR code or link to access the questionnaire:

https://www.ntgt.de/ra/s.aspx?s=367112X57707125X58087

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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 9

2.2 Operator’s Duty of Care 10

2.3 Subsequent changes 10

2.4 General safety instructions and dangers 11

2.4.1 Principles for safe operation 11

2.4.2 Environmental Protection 11

2.4.3 Electrical Equipment 12

2.5 Supplementary Regulations 12

2.6 Qualification of personnel 12

2.7 Safety equipment 13

2.7.1 Signs 13

2.8 Residual dangers 14

2.9 Danger zones 16

3 Description 17

3.1 Design 17

3.2 Functional description 19

3.2.1 Spring-to-close actuator (Z) 19

3.2.2 Spring-to-open actuator (A) 19

3.3 Intended Purpose 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 24

5.4 Pipe ends - General table of measurements 26

5.5 Tool 27

5.6 Lubricants 27

5.7 Weights 27

6 Assembly and installation 28

6.1 Safety instructions 28

6.2 Notes on installation 28

6.3 Control head 28

6.4 Valve with Detachable Pipe Connection Elements 29

6.5 Valve with Welded Ends 29

6.6 Pneumatic connections 30

6.6.1 Air Requirement 30

6.6.2 Establishing Hose Connections 30

6.7 General 31

7 Start-up 32

7.1 Safety instructions 32

7.2 Notes on commissioning 32

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8 Operation and control 33

8.1 Safety instructions 33

9 Cleaning 34

9.1 Cleaning 34

9.1.1 Cleaning Process Examples 34

9.1.2 Cleaning effect 34

9.2 Passivation 35

10 Maintenance 36

10.1 Safety instructions 36

10.2 Inspections 37

10.2.1 Product contact seals 37

10.2.2 Pneumatic connections 37

10.2.3 Electrical connections 38

10.3 Maintenance intervals 38

10.4 Prior to disassembly 39

10.5 Disassembling Valve X 39

10.5.1 Manually lift valve X 39

10.5.2 Exposing the Lower Valve Disk 41

10.5.3 Removing the Lower Valve Disk 42

10.5.4 Removing the Control Top 44

10.5.5 Disconnecting the Valve from the Housing 45

10.5.6 Removing the Upper Valve Disk 46

10.6 Disassembling Valve W 47

10.6.1 Manually lift valve W 47

10.6.2 Removing the Control Top 48

10.6.3 Disconnecting valve W from the housing 48

10.6.4 Releasing the Valve Disk 50

10.7 Maintenance 53

10.7.1 Cleaning the Valve 53

10.7.2 Replacing the V-Ring 54

10.7.3 Exchanging the O-ring (TEFASEP gold) 56

10.7.4 Lubricating Seals and Threads 58

10.8 Installation 58

10.8.1 Installing the valve 58

10.8.2 Torques for the Clamps and Clamp Connections 59

10.8.3 Check stroke 59

11 Alarms 61

11.1 Malfunctions and remedies 61

12 Decommissioning 62

12.1 Safety instructions 62

12.2 Disposal 62

12.2.1 General notes 62

12.2.2 Valve Actuator Disposal 62

13 Spare parts list - shuttle valve X 63

14 Spare parts list - shuttle valve X_V 70

15 Spare parts list - Shuttle valve W 74

16 Spare parts list - shuttle valve X_V 81

17 Appendix 84

17.1 Lists 84

17.1.1 Abbreviations and terms 84

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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

[email protected]

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 valve is intended only for the described purpose. Using the device for any

other purpose is considered contrary to its designated use. GEA Tuchenhagen

will not accept any liability for damage resulting from improper setting: the risk

lies entirely with the operator of the facility. The prerequisite for the reliable and

safe operation of the valve 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, maintenance and

servicing instructions.

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 valve 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”.

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:

Safety

Intended use

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•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.

•Observe the Technical Data specified and the limits of use!

Hint!

Carry out regular checks. This way you can ensure that these

measures are actually observed.

2.3 Subsequent changes

Safety

Operator’s Duty of Care

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