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Table of Contents

...................................................................................................................................... 6

Safety

............................................................................................................................................................. 10

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General Principles ...................................................................................................................................... 13

•

Installation .................................................................................................................................................. 13

•

Commissioning/Setup Mode ...................................................................................................................... 14

•

Setting into Operation ................................................................................................................................. 14

•

Operation .................................................................................................................................................... 14

•

Shutting Down ............................................................................................................................................ 15

•

Maintenance and Repair ............................................................................................................................ 15

•

Disassembly ............................................................................................................................................... 16

•

Environmental Protection ........................................................................................................................... 16

•

Electrical Equipment ................................................................................................................................... 16

Signage .......................................................................................................................................................... 17
Residual Risk ................................................................................................................................................. 18

•

Hazard Areas ............................................................................................................................................. 18

•

Residual Dangers ....................................................................................................................................... 19

•

Declaration of Conformity ........................................................................................................................... 20

Transport and Storage

................................................................................................................................. 21

Scope of Supply ............................................................................................................................................. 21
Transport ........................................................................................................................................................ 21
Storage ........................................................................................................................................................... 22

Intended Purpose

......................................................................................................................................... 23

Design and Function

.................................................................................................................................... 25

Design ............................................................................................................................................................ 25
Leakage-Proof Shut-Off ................................................................................................................................. 26

•

Introduction ................................................................................................................................................. 26

•

Cleaning ..................................................................................................................................................... 26

•

CIP Solution ............................................................................................................................................... 26

Installation and Commissioning

................................................................................................................. 27

Notes on Installation ....................................................................................................................................... 27

Содержание VARIVENT

Страница 1: ...Operating Instructions VARIVENT Mixproof Valve L with Lifting Actuator suitable for pigging operation Edition 26 08 2016 English...

Страница 2: ...GmbH Am Industriepark 2 10 D 21514 B chen Phone 49 4155 49 0 Fax 49 4155 49 2423 Mail sales geatuchenhagen gea com Web http www tuchenhagen com This document is protected by copyright All rights rese...

Страница 3: ...tion 14 Shutting Down 15 Maintenance and Repair 15 Disassembly 16 Environmental Protection 16 Electrical Equipment 16 Signage 17 Residual Risk 18 Hazard Areas 18 Residual Dangers 19 Declaration of Con...

Страница 4: ...aintenance 35 Inspections 35 Product Contact Seals 35 Pneumatic Connections 35 Electrical Connections 35 Maintenance Intervals 36 Prior to dismantling the Valve 36 Disassembling the Valve 37 Removing...

Страница 5: ...5 Technical Data 53 Type Plate 53 Technical Data 53 Cleaning Connection 55 Resistance of Sealing Materials 56 Pipe Ends 57 Tools 57 Lubricants 58 Weights 58 Spare Parts Lists 59 Dimension Sheets 73...

Страница 6: ...rk on or use the valve regarding the procedures to follow Carefully read these Operating Instructions before starting any work on or using the valve Your personal safety and the safety of the valve ca...

Страница 7: ...G Warning Serious Injuries Failure to observe the warning note can result in serious damage to health The arrow identifies a precautionary measure you have to take to avoid the hazard CAUTION Warning...

Страница 8: ...at standard temperature and pressure DN DIN nominal width DIN German standard issued by DIN Deutsches Institut f r Normung e V German Institute for Standardization EN European Standard EPDM Material d...

Страница 9: ...lyethylene psi Anglo American Unit of measurement of pressure Pound force per square inch All pressure ratings bar psi stand for over pressure barg psig if this is not explicitly described differently...

Страница 10: ...care includes planning the necessary safety measures and moni toring that these measures are observed The following principles apply Only allow qualified staff to work on the valve The operator must a...

Страница 11: ...es and DIN EN 50281 1 2 for dusts The following minimum qualifications are required Vocational training as a specialist who can work on the valve independently Sufficient instruction to work on the va...

Страница 12: ...or use in potentially explosive areas User groups Staff Qualifications Operating staff Adequate instruction and sound knowledge in the following areas Function of the valve Valve operating sequences W...

Страница 13: ...the valve Immediately report any faults or noticeable changes on the valve to the person responsible Observe the accident prevention regulations and all local regulations Installation For installatio...

Страница 14: ...ow properly qualified staff to set the valve into operation Establish all connections correctly The safety devices for the valve must be complete fully functional and in perfect condition Check the fu...

Страница 15: ...ervals specified in the maintenance schedule Only allow qualified staff to carry out maintenance or repair work on the valve Before starting any maintenance or repair work the valve must be switched o...

Страница 16: ...e the storage conditions see Storage Page 22 Environmental Protection Harm to the environment can be avoided by safety conscious and proactive behaviour of the staff For environmental protection the f...

Страница 17: ...by warning signs prohibition signs and mandatory signs The signs and notes on the valve must always be legible Any illegible signs must be replaced immediately Signs on the valve Sign Meaning General...

Страница 18: ...ill suddenly lift the actuator Therefore release the spring tension before detaching the clamp joint 46 by supplying the actuator A with compressed air Before starting any service maintenance or repai...

Страница 19: ...tension in the actu ator Danger to life caused by compression spring in the actuator Do not open the actuator but return it to GEA Tuchenhagen for proper disposal Danger of injury Danger presented by...

Страница 20: ...sic safety and health protection requirements of the EU machine directive This declaration will become invalid if any alterations are made to the machine which have not been agreed with us Authorised...

Страница 21: ...Handle valves with care to avoid damaged caused by impact or careless onloading and unloading The outside synthetic materials are susceptible to breaking The control modules must be protected from ani...

Страница 22: ...id damage leave the components in their original packaging if possible If during transport or storage the valve is going to be exposed to temperatures 0 C it must be dried and suitable measures be tak...

Страница 23: ...y Operating the valve within the limits of its designated use also involves adhering to the operating inspection and maintenance instructions Pressure Equipment Directive The valves type L_H and L_S a...

Страница 24: ...if Persons or objects are in the danger zone Safety devices are not working or were removed Malfunctions have been detected on the valve Damage has been detected on the valve Maintenance intervals ha...

Страница 25: ...tion Design Design and Function Design No Designation A Actuator B T VIS control module 1 Sealing ring 4 Bearing disk 9 Lantern 15 Valve disk 16 Double disk 22 Air connection 24 Electrical connection...

Страница 26: ...y penetration of fluids from the tank into the pipe or vice versa is excluded under normal operating conditions Cleaning CIP solution is introduced into the leakage outlet system through a separate CI...

Страница 27: ...valves are connected to a control module with several solenoid valves make sure that the air supply pressure in the main actuator does not fall below the operating point Valve with Detachable Pipe Co...

Страница 28: ...ressed air at max 10 bar IMPORTANT NOTE Seals are wearing parts Old seals will cause malfunction of the valve When fitting the valve be sure to fit new housing O rings Carry out the following steps 1...

Страница 29: ...utter Carry out the following steps 1 Shut off the compressed air supply 2 Use the hose cutter to cut the pneumatic hoses square 3 Push the air hose into the air connector on the control module 4 Re o...

Страница 30: ...ng Instructions VARIVENT Mixproof Valve L with Lifting Actuator suitable for pigging operation Edition 26 08 2016 Hosing Diagram 1 Actuator 2 Lifting actuator Y1 Only for standing variant L_S Y2 Lifti...

Страница 31: ...ive areas Carry out the following steps Connect in accordance with the connection diagram and the instructions in the corresponding operating instructions for the control module Done NOTE The proximit...

Страница 32: ...ocess The cleaning effect must be checked regularly by the plant operator Cleaning process examples Typical cleaning parameters in dairy operations Example of a two phase cleaning process Sodium hydro...

Страница 33: ...alve seats are clean All attached systems for cleaning the valves should be used regularly in order to ensure optimum results and to prevent any damage to the valve The spray cleaning purifies the lea...

Страница 34: ...ical system Check actuation external controller and routing of elec trical lines Solenoid valve defective Replace the solenoid valve Valve works against a hydrauli cally closed pipe Open the pipe Doub...

Страница 35: ...nections Carry out the following steps 1 Check the operating pressure at the pressure reducing and filter station 2 Regularly clean the air filter in the filter station 3 Check that the air hoses sit...

Страница 36: ...type and temperature of the cleaning solution ambient conditions Prior to dismantling the Valve Requirement Make sure that during maintenance and repair work no process is in operation in the area co...

Страница 37: ...the permanent magnet Protect the permanent magnet against impact stress WARNING Spring tension in the valve Danger of injury when opening the clamp joint at the actuator 46 or at the housing 43 as the...

Страница 38: ...tor suitable for pigging operation Edition 26 08 2016 4 Depressurize the actuator 5 Remove the semi annular clamps from the control module R 6 Detach the pneumatic connections Y2 Y3 on the lifting act...

Страница 39: ...valve from the pipe take care not to hit the balancer against the housing Carefully draw out the valve IMPORTANT NOTE Seat ring and valve disk are precision parts Damage will result in valve malfuncti...

Страница 40: ...sing a 4 mm mandrel 2 Detach the hinged clamp 46 3 Pull the actuator A together with slider G rod guide ring F adapter A1 with O ring 12 and locking flange V out of the lifting actuator 14 4 Unscrew t...

Страница 41: ...from the driver sleeve M 2 Push the piston K with fitted driver MN and driver sleeve M upwards against the lifting actuator flange L 1 and remove the snap ring SR from the piston K using nippers 3 Pu...

Страница 42: ...are precision parts Damage to these parts can result in malfunctions Handle the valve with care IMPORTANT NOTE Damage to the valve Damage to the valve can result in a malfunction Observe the safety in...

Страница 43: ...the insertion tool to fit the V ring Replacing the V ring CAUTION The scriber can slip off when the V ring is removed Danger of injury Grip the valve disk in a vice with protected jaws Unscrew the cur...

Страница 44: ...s lists Replacing the V ring RA CAUTION The scriber can slip off when the V ring is removed Danger of injury Grip the valve disk in a vice with protected jaws Unscrew the curved side of the scriber Ca...

Страница 45: ...ng the circumference 5 Insert the V ring RA evenly 6 Prior to installation in the housing V rings RA outside lightly grease Remove visible fat residues 7 Replace all the other seals identified in the...

Страница 46: ...ring 3 Grease the thread on the housing of the rinsing valve at the indicated positions 1 2 4 Grease the balancer Done NOTE GEA Tuchenhagen recommends Rivolta F L G MD 2 and PARALIQ GTE 703 These lub...

Страница 47: ...drel part no 221 105 93 221 105 94 Place the O ring O2 2 on the top and push the assem bled parts into the driver sleeve M 3 Push the driver MN with the O ring O6 into the driver sleeve M and pre tens...

Страница 48: ...Valve with cleaning nozzle Carry out the following steps Equip the double disk 16 with V rings 7 8 cleaning nozzle 74 leakage housing 73 O ring 5 sealing ring 1 bearing 2 and bearing disk 4 Valve with...

Страница 49: ...36 and tighten the valve disk 15 together with the installed V ring 94 at C 3 Insert the locking flange V into the lifting actuator L 4 Do not grease the thread on the adapter AD and on the piston rod...

Страница 50: ...s the port of the lantern must point downwards free draining IMPORTANT NOTE The valve disk and the seat ring are precision parts Damage to these parts can result in malfunctions Support the weight of...

Страница 51: ...ecessary see Table Valve stroke Page 51 Done Valve stroke Torques to be set Torques Nm lbft Clamps on the control module 1 0 7 Clamp joint Cast clamps M6 9 6 6 Clamp joint Cast clamps M8 22 16 2 Cast...

Страница 52: ...ctronic parts Lubricants containing oil and grease Separate the different materials and dispose of them correctly sorted Also observe the instructions regarding disposal in the operating instructions...

Страница 53: ...ical data of the valve Key data of the valve Type LESC OD3 SZ TM1 Serial Serial number Material 1 4404 AISI316L EPDM FDA Control air pressure bar psi min 6 0 87 max 8 0 116 Product pressure bar psi 7...

Страница 54: ...aterial Technical data Compressed air supply Designation Description Air hose Metric Material PE LD Outside dia 6 mm Inside dia 4 mm Inch Material PA Outside dia 6 35 mm Inside dia 4 3 mm Product pres...

Страница 55: ...connection olive support sleeve PTFE hose depends on the type pressure and temperature of the medium conveyed Connection for hose DN 40 100 8 6 mm 1 5 4 OD 8 6 mm Resistance of the CIP connection Medi...

Страница 56: ...ed service life not resistant Table Resistance of Sealing Materials Medium Temperature Sealing material general operation temperature EPDM 40 135 C 40 275 F FKM 10 200 C 14 392 F HNBR 25 140 C 13 284...

Страница 57: ...5 60 3 x 2 50 8 1 65 47 6 x 2 5 63 5 1 65 60 2 x 3 76 2 1 65 72 9 x 4 101 6 2 11 97 38 x Tool Part no Hose cutter 407 065 Belt wrench 408 142 V ring insertion tool 229 109 88 Open end spanner ends gro...

Страница 58: ...105 94 DN 25 to DN 100 221 105 95 DN 125 6 IPS Wrench insert machined faced a f 27 34 5 229 119 06 Hook spanner for tightening the driver sleeve 50 5 60 5 408 205 Snap ring pliers for holes up to DN...

Страница 59: ...ark 2 10 D 21514 B chen Germany Telephone 49 4155 49 0 Telefax 49 4155 49 2423 sales geatuchenhagen gea com http www tuchenhagen com Date 26 08 2016 Page 59 of 72 Spare_parts_lists fm Spare Parts List...

Страница 60: ...4 932 035 932 024 932 035 932 028 932 039 8 V ring EPDM FKM 932 019 932 032 932 019 932 032 932 023 932 034 932 023 932 034 932 027 932 038 9 Lantern 1 4301 221 236 16 221 236 16 221 236 02 221 236 02...

Страница 61: ...ing an actuator as a spare part the adapter A must be ordered and fitted addition Spare Parts List Inch Sizes Item Designation Material 1 5 OD 2 OD 2 5 OD 3 OD 4 OD Sealing set complete EPDM FKM 221 0...

Страница 62: ...643 74 Cleaning nozzle PVDF 221 334 01 221 334 01 221 334 02 221 334 02 221 334 02 91 Cleaning connection 1 4301 221 237 08 221 237 08 221 237 08 221 237 08 221 237 08 94 V ring RA EPDM FKM 221 365 07...

Страница 63: ...ndustriepark 2 10 D 21514 B chen Germany Telephone 49 4155 49 0 Telefax 49 4155 49 2423 sales geatuchenhagen gea com http www tuchenhagen com Date 26 08 2016 Page 63 of 72 Spare_parts_lists fm Spare P...

Страница 64: ...930 004 930 004 930 004 930 004 930 004 7 V ring EPDM FKM HNBR 932 021 932 033 932 088 932 021 932 033 932 088 932 024 932 035 932 090 932 024 932 035 932 090 932 028 932 039 932 100 8 V ring EPDM FK...

Страница 65: ...ting actuator type T Grease RIVOLTA F L G MD 2 100g tube not included in the sealing set 413 136 Do not grease item 7 8 and 94 A2 When ordering an actuator as a spare part the adapter A must be ordere...

Страница 66: ...000641 221 000641 221 000643 74 Snap seal PVDF 221 000522 221 000522 221 000523 221 000523 221 000523 91 Cleaning connection 1 4301 221 237 08 221 237 08 221 237 08 221 237 08 221 237 08 94 V ring RA...

Страница 67: ...ndustriepark 2 10 D 21514 B chen Germany Telephone 49 4155 49 0 Telefax 49 4155 49 2423 sales geatuchenhagen gea com http www tuchenhagen com Date 26 08 2016 Page 67 of 72 Spare_parts_lists fm Spare P...

Страница 68: ...V ring EPDM FKM 932 019 932 032 932 019 932 032 932 023 932 034 932 023 932 034 932 027 932 038 9 Lantern DL 1 4301 221 236 16 221 236 16 221 236 02 221 236 02 221 236 03 15 Valve disk T_R 1 4404 221...

Страница 69: ...001187 221 001188 221 001189 1 Sealing ring EPDM FKM 924 085 924 083 924 085 924 083 924 085 924 083 924 085 924 083 924 085 924 083 2 Bearing Bearing 3A PTFE carbon SUSTA PVDF 935 002 935 099 935 002...

Страница 70: ...34 01 221 334 02 221 334 02 221 334 02 91 Cleaning connection 1 4301 221 237 08 221 237 08 221 237 08 221 237 08 221 237 08 94 V ring EPDM FKM 221 365 07 221 365 10 221 365 07 221 365 10 221 365 08 22...

Страница 71: ...rk 2 10 D 21514 B chen Germany Telephone 49 4155 49 0 Telefax 49 4155 49 2423 sales geatuchenhagen gea com http www tuchenhagen com Date 26 08 2016 Page 71 of 72 Spare_parts_lists fm Spare Parts List...

Страница 72: ...03 221 464 03 221 464 10 2 Housing SPV 1 4305 221 464 08 221 464 08 221 464 08 3 Outlet SPV 1 4301 221 464 05 221 464 09 221 464 05 4 Piston SPV PVDF 221 464 04 221 464 04 221 464 04 5 Pressure spring...

Страница 73: ...ets Mixproof Valve Types L_SC L_SL L_HC L_HL Dimension sheet Dimension DN 40 DN 50 DN 65 DN 80 DN 100 1 5 OD 2 OD 2 5 OD 3 OD 4 OD A 74 86 104 119 138 71 83 5 98 111 135 5 C 90 90 125 125 125 90 90 12...

Страница 74: ...countries Founded in 1881 the company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index GEA Mechanical Equipment GEA Tuch...

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