GEA D-tec D Manuale utente
Aseptic Valves
GEA D-tec® double-chamber valve type D/DV
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 D-tec® and TEFASEP® designations are trademarks of GEA Aseptomag AG
registered in Switzerland.
The designation T.VIS® is a protected trademark 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 EC Declaration of Conformity for Complete Machines in accordance with the EC Machinery Directive
2006/42/EC, Annex II 1. A 7
2 Safety 8
2.1 Intended use 8
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 Staff 12
2.7 Safety equipment 14
2.7.1 Signs 14
2.8 Residual dangers 16
2.9 Danger zones 17
3 Description 19
3.1 Design of the valve 19
4 Transport and storage 21
4.1 Storage conditions 21
4.2 Transport 21
4.2.1 Scope of supply 22
5 Technical data 23
5.1 Type plate 23
5.2 Technical data 23
5.3 Resistance of the sealing materials 24
5.4 Pipe ends - General table of measurements 26
5.5 Tool 26
5.6 Lubricants 27
5.7 Weights 28
6 Assembly and installation 29
6.1 Safety instructions 29
6.2 Notes on installation 29
6.3 Control head 29
6.4 Valve with Detachable Pipe Connection Elements 29
6.5 Valve with welded ends 30
6.6 Pneumatic connections 31
6.6.1 Air requirement 31
6.6.2 Establishing Hose Connections 31
Hose connection diagram - double-chamber valve type D/DV with control top T.VIS 32
Hose connection diagram - double-chamber valve D/DV without control top 33
6.7 Electrical connections 34
6.7.1 Electrical connection with T.VIS control top 34
6.7.2 Adjusting the initiator 35
7 Start-up 37
7.1 Safety notes 37
7.2 Notes on commissioning 37
8 Operation and control 38
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8.1 Safety instructions 38
9 Cleaning 39
9.1 Cleaning 39
9.1.1 Cleaning Process Examples 39
9.1.2 Cleaning effect 39
9.2 Sterilisation 40
9.3 Passivation 40
10 Maintenance 41
10.1 Safety instructions 41
10.2 Inspections 42
10.2.1 Leakage outlet 42
10.2.2 Pneumatic connections 42
10.2.3 Electrical connections 42
10.2.4 Signs on the valve 43
10.3 Servicing intervals 43
10.4 Prior to disassembly 45
10.5 Disassembling the valve 45
10.5.1 Disassembling the main valve 45
Removing the control top 46
Disconnecting the valve from the housing 48
10.5.2 Disassembling the valve insert of the main valve 50
10.5.3 Disassembling the side valve 56
10.5.4 Disassembling the valve insert of the side valve 57
10.6 Assembling the valve 59
10.6.1 Assembling the valve insert of the main valve 59
10.6.2 Assembling the main valve 67
10.6.3 Assembling the valve insert of the side valve 70
10.6.4 Assembling the side valves 71
10.6.5 Torques for the Clamps and Clamp Connections 72
10.6.6 Checking the function 73
10.7 Maintenance 75
10.7.1 Cleaning valve / replacing worn parts 76
10.7.2 Note on seal replacement 77
10.7.3 Replacing the V-ring 77
10.7.4 Changing the stem diaphragm 78
10.7.5 Exchanging the O-ring (TEFASEP gold) 78
10.7.6 Lubricating seals and threads 81
11 Alarms 82
11.1 Malfunctions and remedies 82
12 Decommissioning 83
12.1 Safety instructions 83
12.2 Disposal 83
12.2.1 General notes 83
12.2.2 Valve Actuator Disposal 83
13 Parts list - D-tec double-chamber valve type D/DV 84
14 Parts list - D-tec valve insert D/DV-SV-NC/NO 90
15 Parts list - lift actuator _LB-DV 95
16 Dimension sheet - double-chamber valve type D/DV 98
17 Appendix 102
17.1 Lists 102
17.1.1 Abbreviations and terms 102
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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 EC Declaration of Conformity for Complete Machines in accordance with the EC
Machinery Directive 2006/42/EC, Annex II 1. A
Manufacturer: GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Buchen, Germany
We as the manufacturer hereby declare in sole responsibility that the
machine designated below, based on its design and type as well as in the
version brought to market by us, complies with the basic safety and
health requirements of the EC Machinery Directive.
This declaration will become invalid if any alterations are made to the
machine which have not been agreed with us.
Designation: Valve with actuator
Type: D-tec® stem diaphragm
Model: N/DV, W/DV, P/DV, D/DV
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized
standards, in particular:
DIN EN ISO 12100 Safety of Machines -
General design principles
- Risk assessment and
risk reduction
Other applied standards
and technical
specifications:
--
Remarks: 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 request
by the market supervisory authorities.
Person authorised for compilation and
handover of technical documentation:
GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2-10
21514 Buchen, Germany
Büchen, 08/08/2018
Michael Wulle
Managing
Director
i.V. Matthias Südel
Senior Director
Product Development Flow Components
General Information
EC Declaration of Conformity for Complete Machines in accordance with the EC Machinery Directive 2006/42/EC, Annex
II 1. A
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2 Safety
2.1 Intended use
Aseptic double-chamber valves are mix-proof stroke valves for highly hygienic
and aseptic process systems and permit the safe separation of incompatible
media. The media separation is done via the integrated sterile chamber (ISB),
which is separated hermetically from the atmosphere with a seal each to both
product lines and via two side valves (inlet and outlet).
For safe operation, it is mandatory that the following points are observed in the
different process steps:
Transfer
During a media transfer through the main valve both side valves must be closed
completely.
Fig.1: Product transfer
Cleaning sterile chamber
After a media transfer the sterile chamber must be flushed at least with one
sterile medium. After the main valve has been closed, both side valves can be
put in the open position and thus permit the flushing of the sterile chamber.
Fig.2: Rinsing / sterilisation after transfer
CIP cleaning with seat lift
If seat lifting is activated for a CIP cleaning (preferably in cycles) no process must
be running in the opposite line. Furthermore, the outlet valve of the sterile
chamber to drain the CIP medium must be open.
Safety
Intended use
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Fig.3: Seat cleaning valve disk Fig.4: Seat cleaning double disk
The medium should preferably flow in the opening direction of the valve disk to
avoid pipe hammers when the valve is opened or closed. Should this not be
possible due to technical reasons related to the plant or process, it is
recommended to switch the valve without pressure. Both measures prevent
pressure hammers when the valve is opened or closed.
The valve is monitored, controlled and operated by the customer's installation.
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: Directive 2014/68/EG. They are
classified according to Annex II, article 4, section 3. 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.
Safety
Intended use
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2.1.4 Improper operating conditions
The operational reliability of the valve cannot be ensured under improper
operating conditions. Therefore avoid improper operating conditions.
Operating the valve 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 valve.
•Damage has been detected on the valve.
•Maintenance intervals have been exceeded.
•the position of the side valves is not adjusted to the process steps
Hint!
Negative pressure and switching under negative pressure in the
pipeline can lead to damage to the membrane.
2.2 Operator’s Duty of Care
In your capacity as operator of the facility you bear a particular responsibility for
the proper and safe handling of the valve in your facility. Only use the valve when
it is in perfect condition to prevent danger to persons and property.
These Operating Instructions contain the information you and your staff need for
the safe and reliable operation during the entire service life of the valve. 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 allow qualified staff to work on the valve.
•The operator must authorize the staff to carry out the relevant tasks.
•Working areas and the entire environment of the valve must be neat and
clean.
•The staff must wear suitable work clothing and personal protective equipment.
As the operator of the facility make sure that work clothing and personal
protective equipment are used.
•Instruct the staff with regard to any properties of the product which might pose
a health risk and the preventative measures to be taken.
•Have a qualified first-aider on call during the operation, who can initiate the
necessary first-aid measures in case of an emergency.
•Clearly define processes, lines of authority and responsibilities associated
with the valve. Everybody must know what to do in case of an emergency.
Instruct the staff in this respect at regular intervals.
•The signs relating to the valve must always be complete and legible. Check,
clean and replace the signs as necessary at regular intervals.
Safety
Operator’s Duty of Care
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