GEA VARIVENT Operating Instructions Manual
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GEA VARIVENT Operating Instructions Manual

Mixproof valve l with lifting actuator, suitable for pigging operation
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Operating Instructions
®
VARIVENT
Mixproof Valve L with Lifting Actuator, suitable for
pigging operation
Edition 26/08/2016
English
Table of Contents
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Summary of Contents for GEA VARIVENT

  • Page 1 Operating Instructions ® VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016 English...
  • Page 2 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. ®...

  • Page 3: Table Of Contents

    Table of Contents Notes for the Reader ............................6 Binding Character of These Operating Instructions ..................6 Notes on the Illustrations ..........................6 Symbols and Highlighting ..........................7 Abbreviations and Terms ..........................8 Safety ................................10 Safety Note ..............................10 Operator's Duties ............................
  • Page 4 Torques for the Clamps and Clamp joint ....................51 • Checking the Function ..........................51 Disposal ................................52 • General Notes ............................. 52 • Valve Actuator Disposal ..........................52 ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...
  • Page 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...

  • Page 6: Notes For The Reader

    For detailed views and dimen- sions of the valve please refer to the design documents. ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 7: Symbols And Highlighting

    Notes for the Reader Symbols and Highlighting 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 high- lighting. DANGER Warning: Fatal Injuries. Failure to observe the warning can cause serious damage to health, or even death. ...

  • Page 8: Abbreviations And Terms

    Inch IPS US pipe dimension Iron Pipe Size International standard issued by the International Organization for Standardi- zation Unit of measurement of weight [kilogram] ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...
  • Page 9 Notes for the Reader Abbreviations and Terms Abbreviation Explanation Unit of measurement of force [kilonewton] Unit of measurement of volume [litre] max. maximum Unit of measurement of length [millimetre] m Unit of measurement of length [micrometre] metric Unit of measurement of work [newton metre] 1 Nm = 0.737 lbft NIT OF TORQUE Pound-Force (lb) + Feet (ft)

  • Page 10: Safety

    NOTE Carry out regular checks. This way you can ensure that these measures are actually observed. ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 11: Qualification Of Staff

    Safety Qualification of Staff Qualification of Staff This section contains information about the qualifications that staff working on the valve must have. Operating and maintenance staff must • have the necessary qualification to carry out their tasks, • be instructed with regard to possible dangers, •...

  • Page 12: Supplementary Regulations

    • work and safety instructions applicable in the facility, • installation and operating regulations for use in potentially explosive areas. ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 13: Instructions For The Safe Operation

    Safety Instructions for the Safe Operation Instructions for the Safe Operation Dangerous situations during the operation can be avoided by safety-conscious and proactive behaviour of the staff. General Principles To ensure the safe operation of the valve the following principles apply: •...

  • Page 14: Commissioning/Setup Mode

    • Regularly check that all emergency stop devices are working correctly. ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 15: Shutting Down

    Safety Instructions for the Safe Operation Shutting Down For shutting down, the following principles apply: • Switch off the compressed air. • Switch off the valve via the main switch. • Padlock the main switch (if fitted) in the off position to prevent it from being switched back on.

  • Page 16: Disassembly

    • After completion of all work, check that the protective devices are fully functional. ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 17: Signage

    Safety Signage Signage Dangerous points on the valve are indicated 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 hazard warning...

  • Page 18: Residual Risk

    • The housing sockets have very sharp edges. When transporting and assembling the valve be sure to wear suitable protective gloves. ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 19: Residual Dangers

    Spring tension in the actu- Danger to life caused by compression spring in ator the actuator. Do not open the actuator but return it to GEA Tuchenhagen for proper disposal. Danger of injury Danger presented by The operator must exercise caution and moving or sharp-edged prudence.

  • Page 20: Declaration Of Conformity

    CE documentation GEA Tuchenhagen GmbH Am Industriepark 2-10 21514 Büchen Büchen, 16/02/2015 Franz Bürmann i.V. Matthias Südel Managing Director Team Leader Product Development ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 21: Transport And Storage

    Transport and Storage Transport Transport and Storage Scope of Supply On receipt of the valve check whether • the details on the type plate correspond to the data in the order and delivery docu- ments, • the equipment is complete and all components are in good order. Transport For transport, the following principles apply: •...

  • Page 22: Storage

    24 hours prior to any handling (disassembling the housings / activation of actuators) so that any ice crystals formed by condensation water can melt. ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 23: Intended Purpose

    The valves type L_H and L_S are pressure equipment (without safety function) in the sense of the pressure equipment directive: Directive 97/23/EC. They are classified according to Annex II, article 3, section 3. In the event of any deviations, GEA Tuchen- hagen GmbH will supply a special Declaration of Conformity.

  • Page 24: Improper Operating Conditions

    EC Machinery Direc- tive on your own. In general, only original spare parts supplied by GEA Tuchenhagen GmbH should be fitted. This ensures the reliable and economical operation of the valve.

  • Page 25: Design And Function

    Design and Function Design Design and Function Design Designation Actuator T.VIS control module Sealing ring Bearing disk Lantern Valve disk Double-disk Air connection Electrical connection Leakage housing...

  • Page 26: Leakage-Proof Shut-Off

    Kay data of the CIP solution • Operating pressure: min. 2 bar (29 psi) , max. 5 bar (72,5 psi) • Operating temperature: max. 135 °C ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 27: Installation And Commissioning

    Installation and Commissioning Valve with Detachable Pipe Connection Elements Installation and Commissioning Notes on Installation Valve types L_HC/L_HL are installed in suspended position, valve types L_SC/LSL in standing position. Care must be taken to ensure that the valve housing, the pipe system and the leakage cavity can drain properly.

  • Page 28: Valve With Welding Ends

    Passivate the seam after welding. Fit the seals. Assemble the valve and depressurize the actuator.  The valve disk is lowered.  Done ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 29: Pneumatic Connections

    Installation and Commissioning Pneumatic Connections Pneumatic Connections Air Requirement For valve types L_HL / L_HC / L_SC / L_SL Actuator type Size Air requirement (dm /stroke) at 1.01325 bar at 0°C as per DIN 1343 BD/BL DN 25, 40, 50 0.66 CF/CL DN 65...

  • Page 30: Hosing Diagram

    Installation and Commissioning Pneumatic Connections Hosing Diagram Actuator Lifting actuator Only for standing variant L_S Lifting of valve disk Lifting of double-disk Central air supply ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 31: Electrical Connections

    Installation and Commissioning Commissioning Electrical Connections DANGER Live parts Electrical shock can result in serious personal injury or death.  Only allow properly qualified staff to carry out work on the electrical equipment.  Prior to establishing electrical connections check the maximum permissible oper- ating voltage.

  • Page 32: Cleaning And Passivation

    • Chemicals • Degree of soiling These factors can be combined in such a way as to make an optimal cleaning result probable. ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 33: Cleaning Of The Leakage Outlet System

    Cleaning and Passivation Passivation Cleaning of the leakage outlet system The leakage chamber is cleaned via a spray nozzle in the double disk, which is connected to a valve seat cleaning pipe. Here, only general recommendations can be made about the number and duration of spray cleaning. Because depending on the prevailing conditions such as type of product, temperatures, cleaning agents, cleaning intervals, etc., longer or more frequent cleanings may be required.

  • Page 34: Malfunctions

    O-rings Leakage in the lantern Sealing ring defective Replace the sealing ring Leakage in the leakage cavity V-rings defective Replace V-rings ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 35: Maintenance

    Maintenance Inspections Maintenance Inspections Between the maintenance periods, the valves must be checked for leakage and proper function. Product Contact Seals Carry out the following steps:  Regularly check: – Stem seal between upper housing and lantern – V-ring in the valve disks –...

  • Page 36: Maintenance Intervals

    Shut off the control air supply. Disconnect the power supply. Take the valve, with all housings and housing connections if possible, out of the pipe section.  Done ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 37: Disassembling The Valve

    Maintenance Disassembling the Valve Disassembling the Valve Removing the Control Module  No solenoid valve must be actuated electrically or manually. Requirement  The pneumatic and electrical connections on the plant side can remain on the control module. IMPORTANT NOTE The permanent magnet on the switch bar is fragile.
  • Page 38 Detach the pneumatic connections (Y2, Y3) on the lifting actuator.  Only for variant L_S: Detach the pneumatic connection (Y1). Pull off the control module (B) upwards.  Done ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 39: Disconnecting The Valve From The Housing

    Maintenance Disassembling the Valve Disconnecting the Valve from the Housing IMPORTANT NOTE The surfaces of the balancer (16) are sealing surfaces. Damage will result in valve malfunctions.  When removing the valve from the pipe take care not to hit the balancer against the housing.

  • Page 40: Separating The Valve Insert From The Actuator

    Draw off the leakage housing (73), O-ring (5), sealing rings (1), bearing disk (4) and bearing (2). Remove the guide ring (21). For version L_HL Carry out the following steps:  Remove the spraying nozzle (74). ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 41: Dismantling The Lifting Actuator

    Maintenance Disassembling the Valve For versions L_HC Carry out the following steps: and L_HL  For version L_HC, remove the snap seal (74) with O-ring.  Done NOTE The spraying nozzle and snap seal are wearing parts. Dismantling the Lifting Actuator ...

  • Page 42: Maintenance

    Only use detergents which are non-abrasive and not aggressive towards stainless steel. Carry out the following steps: Disassemble the valve, see “Disassembling the Valve“ (Page 37). Carefully clean the individual parts.  Done ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 43: Replacing Seals

    Maintenance Maintenance Replacing Seals Insertion tool  Insert the V-rings/VR-rings without grease. To facilitate fitting, use water with a drop Requirement of washing-up liquid to remove the surface tension. In order that no rust is trans- ferred, the washing-up liquid solution must be made up in a ceramic, plastic, or stainless steel container.
  • Page 44 Pay attention that water does not drip into the VR-ring groove on the valve disk. Put in the V-ring RA. Make sure the installation position of the V-ring RA is correct (see illustration). ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...
  • Page 45 Maintenance Maintenance Use the insertion tool to press in the V-ring RA – evenly press in at several opposite points along the circumference. Insert the V-ring RA evenly. Prior to installation in the housing V-rings RA outside lightly grease. Remove visible fat residues.

  • Page 46: Lubricating Seals And Threads

    They have the NSF- H1 (USDA H1) registration. PARALIQ GTE 703 can be ordered from GEA Tuchenhagen under part no. 413-064, and Rivolta F.L.G. MD-2 can be ordered under part no. 413- 071.

  • Page 47: Assembling The Valve

    Maintenance Assembling the Valve Assembling the Valve Assembling the Lifting Actuator Carry out the following steps: Fit O-rings (O3, O4, O5) to the LFT-R lifting actuator (L) and fix it to the lantern (9) using the hinged clamp (46). Provide the bushing (B) with O-rings (O1, O2.1) and fit it on the mandrel, part no. 221-105.93, 221-105.94.

  • Page 48: Equipping The Double-Disk

    Equip the double-disk (16) with V-rings (8, 9), snap seal with O-ring (5), leakage housing (73), O-ring (5), sealing ring (1), bearing (2) and bearing disk (4).  Done ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 49: Assembling The Actuators

    Maintenance Assembling the Valve Assembling the Actuators IMPORTANT NOTE The permanent magnet on the switch bar is fragile. Damage to the permanent magnet.  Protect the permanent magnet against impact stress. Carry out the following steps: Hold the driver sleeve with hook spanner at (M1) and tighten the double-disk by inserting a tubular hex.

  • Page 50: Fitting The Valve Into The Housing

    Actuate the lift stroke of the double-disk at (Y3) and carefully introduce the valve insert into the housing, secure with the hinged clamp (43). Connect the air connections (Y1, Y2, Y3).  ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 51: Torques For The Clamps And Clamp Joint

    Maintenance Assembling the Valve Torques for the Clamps and Clamp joint Tighten the clamp joint and clamps on the valve to the torques specified in the table. Torques to be set Torques lbft Clamps on the control module Clamp joint Cast clamps Clamp joint 16.2...

  • Page 52: Disposal

     GEA Tuchenhagen accepts unopened actuators and arranges for proper disposal free of charge. Carry out the following steps: Remove the actuator. Safely pack the actuator and send it to GEA Tuchenhagen GmbH.  Done ® Operating Instructions · VARIVENT...

  • Page 53: Technical Data

    Technical Data Technical Data Technical Data Type Plate The type plate clearly identifies the valve. Type plate of the valve The type plate provides the following key data: 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.
  • Page 54 - Oil content: Quality class 3, preferably oil free max. 1 mg oil in 1m ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 55: Cleaning Connection

    Technical Data Cleaning Connection Cleaning Connection Connection for hose DN 40...100 Ø8/6 mm 1.5"...4" OD Ø8/6 mm Operating pressure for optimum cleaning • min. 2 bar (29 psi) • max. 5 bar (72.5 psi) The resistance of the material of the CIP connection (olive, support sleeve, PTFE hose) depends on the type, pressure and temperature of the medium conveyed.

  • Page 56: Resistance Of Sealing Materials

    Product with a fat content of max. 35% Product with a fat content of more than – Oils – * depending on the installation position ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 57: Pipe Ends

    Technical Data Tools Pipe Ends Dimensions for Pipes in DN Metric Outside diameter Wall thickness Inside diam- Outside diameter eter acc. to DIN 11850 Dimensions for Pipes in Inch OD Inch OD Outside diameter Wall thickness Inside diam- Outside diameter eter acc.

  • Page 58: Lubricants

    PARALIQ GTE 703 413-064 Weights Size Weight (kg) DN 40, 1.5" DN 50, 2" DN 65, 2.5" DN 80, 3" DN 100, 4" ® Operating Instructions · VARIVENT Mixproof Valve L with Lifting Actuator, suitable for pigging operation Edition 26/08/2016...

  • Page 59: Spare Parts Lists

    Spare Parts List Date: 26/08/2016 Page: 59 of 72 Spare_parts_lists.fm Mixproof Valve L_SL Spare Parts Lists Mixproof Valve L_SL GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 [email protected], http://www.tuchenhagen.com...
  • Page 60 924-308 924-309 Leakage housing 1.4404 221-000665 221-000665 221-000641 221-000641 221-000643 Cleaning nozzle PVDF 221-334.01 221-334.01 221-334.02 221-334.02 221-334.02 GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 [email protected], http://www.tuchenhagen.com...
  • Page 61 Housing LES-90 1.4404 221-633.23 221-633.25 221-633.27 221-633.28 221-633.20 ® ® Actuator VARIVENT See spare parts list for actuator type VARIVENT Adapter LFT-R EN AW- 221-614.01 221-614.01 221-614.01 221-614.01 221-614.01 6082 T6 T.VIS control top See spare parts list for control top type T.VIS...
  • Page 62 Housing LES-90 1.4404 221-633.22 221-633.24 221-633.26 221-633.17 221-633.18 ® ® Actuator VARIVENT See spare parts list for actuator type VARIVENT Adapter LFT-R EN AW- 221-614.01 221-614.01 221-614.01 221-614.01 221-614.01 6082 T6 T.VIS control top See spare parts list for control top type T.VIS...
  • Page 63 Spare Parts List Date: 26/08/2016 Page: 63 of 72 Spare_parts_lists.fm Mixproof Valve L_SC Mixproof Valve L_SC GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 [email protected], http://www.tuchenhagen.com...
  • Page 64 930-662 930-663 930-663 930-663 HNBR 930-646 930-646 930-647 930-647 930-647 Leakage housing 1.4404 221-000665 221-000665 221-000641 221-000641 221-000643 GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 [email protected], http://www.tuchenhagen.com...
  • Page 65 Housing LES-90 1.4404 221-633.23 221-633.25 221-633.27 221-633.28 221-633.20 ® ® Actuator VARIVENT See spare parts list for actuator type VARIVENT Adapter LFT-R EN AW- 221-614.01 221-614.01 221-614.01 221-614.01 221-614.01 6082 T6 T.VIS control top See spare parts list for control top type T.VIS...
  • Page 66 Housing LES-90 1.4404 221-633.22 221-633.24 221-633.26 221-633.17 221-633.18 ® ® Actuator VARIVENT See spare parts list for actuator type VARIVENT Adapter LFT-R EN AW- 221-614.01 221-614.01 221-614.01 221-614.01 221-614.01 6082 T6 T.VIS control top See spare parts list for control top type T.VIS...
  • Page 67 Spare Parts List Date: 26/08/2016 Page: 67 of 72 Spare_parts_lists.fm Mixproof Valve L_HL Mixproof Valve L_HL GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 [email protected], http://www.tuchenhagen.com...
  • Page 68 221-000665 221-000665 221-000641 221-000641 221-000643 Cleaning nozzle PVDF 221-334.01 221-334.01 221-334.02 221-334.02 221-334.02 Cleaning connection 1.4301 221-237.08 221-237.08 221-237.08 221-237.08 221-237.08 GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 [email protected], http://www.tuchenhagen.com...
  • Page 69 221-365.08 221-365.08 221-365.09 221-365.10 221-365.10 221-365.11 221-365.11 221-365.12 ® Actuator See spare parts list for actuator type VARIVENT Adapter LFT-R EN AW- 221-614.01 221-614.01 221-614.01 221-614.01 221-614.01 6082 T6 T.VIS control top See spare parts list for control top type T.VIS...
  • Page 70 221-365.08 221-365.08 221-365.09 221-365.10 221-365.10 221-365.11 221-365.11 221-365.12 ® Actuator See spare parts list for actuator type VARIVENT Adapter LFT-R EN AW- 221-614.01 221-614.01 221-614.01 221-614.01 221-614.01 6082 T6 T.VIS control top See spare parts list for control top type T.VIS...
  • Page 71 26/08/2016 Page: 71 of 72 Spare_parts_lists.fm Flushing Valve SPV Flushing Valve SPV Type C and C-S Type M GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 [email protected], http://www.tuchenhagen.com...
  • Page 72 * Type C: Standard for C valves * Type M: ECO-MATRIX * Type C-S: for C valves at elevated temperatures (metal cylinder) GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423...

  • Page 73: Dimension Sheets

    3" OD 4" OD 83.5 135.5 50.5 27.5 33.8 46.5 58.8 ØE ØF 34.9 47.6 60.3 97.6 Stroke GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 [email protected], http://www.tuchenhagen.com...
  • Page 74 Excellence · Passion · Integrity · Responsibility · GEA-versity GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology.

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