GEA VARICOVER MST 3A Operating Instruction Download

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Hygienic components

Operating instruction (Translation from the original language)
430BAL009974EN_3

GEA VARI

COVER

Pig Cleaning Station MST

Summary of Contents for VARICOVER MST 3A

Page 1: ...Hygienic components Operating instruction Translation from the original language 430BAL009974EN_3 GEA VARICOVER Pig Cleaning Station MST 3A...

Page 2: ...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...

Page 3: ...ign 19 3 2 Functional description 20 3 2 1 Pig cleaning station 20 Production 20 Sending the pig 20 Receiving the pig 22 Cleaning the pig cleaning station 23 3 2 2 Pig retainer control tops 24 4 Trans...

Page 4: ...hreads 51 10 9 Installation 52 10 9 1 Assembling the pig actuator 52 Aligning the throttle check valve 52 Inserting the pig clamp 52 Assembling the cylinder pipe for pig cleaning station 4 OD 53 Adjus...

Page 5: ...N100 1 5 OD 4 OD 82 22 Dimension sheet Pig Cleaning Station MST 3A sizes DN25 and 1 OD 84 23 Dimension sheet free cross sectional area on pig station housing 86 24 Appendix 88 24 1 Lists 88 24 1 1 Abb...

Page 6: ...430BAL009974EN_3 6 23 07 2019...

Page 7: ...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 the...

Page 8: ...n 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...

Page 9: ...iples 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 ac...

Page 10: ...ce 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...

Page 11: ...o 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 t...

Page 12: ...e process plants have been emptied and depressurised Observe the accident prevention regulations and all local regulations 2 4 2 Environmental Protection Harm to the environment can be avoided by safe...

Page 13: ...alified electrician supervise the work The following minimum qualifications are required Training as a specialist for working independently on the component Adequate instruction to work on the compone...

Page 14: ...he following areas Mechanical equipment Electrical equipment Pneumatic system Authorization with regard to safety engineering standards to carry out the following tasks Setting devices into operation...

Page 15: ...to life Inadvertent switch on of the valve Effectively disconnect all components effectively prevent switch on Electric power Observe the following safety rules 1 Isolate from the power supply 2 Take...

Page 16: ...e cover panels during the operation Never reach into openings As a precautionary measure wear personal protective equipment in the vicinity of the valve Protective gloves Safety shoes Environmental da...

Page 17: ...g actuator Please observe the following notes In the event of malfunctions shut down the pig cleaning station disconnect from the power and air supply and secure it against being used Never reach into...

Page 18: ...n a second person who can operate the main switch in case of an emergency The housing sockets have very sharp edges Wear suitable protective gloves when transporting and installing the pig cleaning st...

Page 19: ...ription 3 1 Design Fig 6 Design No Designation A Pig C Pig retainer air opening spring closing Q Control top 3 Lantern 7 Pig station housing V3 Pig actuator Description Design 430BAL009974EN_3 23 07 2...

Page 20: ...leaning agent can flow around it The pig position is continually monitored by a magnetic switch E1 1 Product can flow through the pig cleaning station from A to B and vice versa Fig 7 3 2 1 2 Sending...

Page 21: ...1 Activate V4 1 and V4 2 Fig 9 Pig retainer is opened Position feedbacks V4 1 and V4 2 active 2 Activate V3 1 Pig leaves position E1 1 and magnetic switch E1 1 is inactive Pig detection via E1 2 is a...

Page 22: ...tuator there is an adjustable throttle check valve for reducing the inflowing air throughput Carry out the following steps 1 Deactivate V3 1 2 Activate V3 2 Pig leaves position E1 2 Magnetic switch E1...

Page 23: ...the pig cleaning station are in rest position The pig is held in place in its position in the pig station housing where cleaning agent can flow around it The pig position is continually monitored by...

Page 24: ...trol tops The pig retainers are fitted with a T VIS M 15 control top as standard Fig 13 Control Top T VIS M 15 The pig retainer actuator is spring closing It is closed in the rest position Identificat...

Page 25: ...age caused by impact or careless loading and unloading The outside synthetic materials are susceptible to breaking Control tops must be protected from animal and vegetable fats Only allow qualified st...

Page 26: ...04 EPDM FDA Control air pressure bar psi min 4 8 69 6 max 8 0 116 max product pressure bar psi 10 0 145 max temperature C F 135 275 5 2 Technical data Refer to the following tables for the key technic...

Page 27: ...si OD 4 10 bar 145 psi Flow speed max 3 m s Pig velocity of impact max 0 5 m s Technical data Ambient temperatures Designation Description Pig cleaning station 0 to 45 C 32 113 F standard 0 C 32 F use...

Page 28: ...of Sealing Materials The resistance of sealing materials depends on the type and temperature of the medium conveyed The exposure time can adversely affect the service life of the seals The sealing mat...

Page 29: ...100 C 212 F Water up to 80 C 176 F Steam up to 135 C 275 F o o Steam approx 30 min up to 150 C 302 F o Fuels hydrocarbons Product with a fat content of max 35 Product with a fat content of more than...

Page 30: ...825 1 25 4 1 65 22 1 x 1 5 38 1 1 65 34 8 x 2 50 8 1 65 47 5 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 5 5 Tools List of tools Tools Material no Open end spanner a f 8 10 408 032...

Page 31: ...al width DN Weight kg 25 on request 40 on request 50 16 65 17 80 22 5 100 36 Weight table for specifications in inch OD Nominal width inch OD Weight kg 1 on request 1 5 on request 2 16 2 5 17 3 24 4 3...

Page 32: ...ed against inadvertently being switched on 6 2 Notes on installation The installation position of the valve is upright Care must be taken to ensure that the valve housing and the pipe system can drain...

Page 33: ...nt dm3n stroke dm3n at 1 01325 bar at 0 C in accordance with DIN 1343 DN 25 to DN 100 1 to 4 OD 0 05 6 4 3 Establishing Hose Connections An air hose connection must be mounted leading from separate 3...

Page 34: ...off the compressed air supply 2 Use the hose cutter to cut the pneumatic hoses square 3 Air hoses in the plug connectors of the control tops and the actuators 4 Re open the compressed air supply Estab...

Page 35: ...f the magnetic switch and initiators Done Hint The proximity switches in the control top are factory set During transport and installation it can happen that the settings are changed so that readjustm...

Page 36: ...threads must be visible Done 6 5 3 Initiator cabling It must be possible to completely remove the pig actuator from the pig station housing without loosening the initiator cabling This means that the...

Page 37: ...ve are shown in the following table Assignment of initiators Actuation State D1 1 State D1 2 V3 1 assigned not assigned V3 2 not assigned assigned After actuation of V3 2 not assigned not assigned 6 5...

Page 38: ...ission the component Make sure that all connections are functioning properly The safety devices on the component must be completely installed in working order and function properly Check the function...

Page 39: ...ed on the surface of the pig the cause must be immediately identified and a solution must be found see Chapter 11 Page 56 Causes of damage on the pig surface Pig speed too fast Sag on welded seam too...

Page 40: ...ermitted Report any changes to the component immediately to the person in charge Always keep danger zones clear Do not leave any objects in the danger zone Only allow persons to enter the danger zone...

Page 41: ...amed it is recommended that you wait around half an hour before performing any pig runs The cleaning effect must be checked regularly by the operator Notice Cleaning agents can be very aggressive They...

Page 42: ...ng These factors can be combined in such a way as to make an optimal cleaning result probable 9 2 Passivation Before commissioning a plant passivation is commonly carried out for long pipes and tanks...

Page 43: ...to the maintenance or repair work going on Do not climb on the component Use suitable access aids and working platforms Wear suitable protective clothing Only use suitable and undamaged tools to carr...

Page 44: ...between the pig station housing and the pig actuator lantern O ring between the pig station housing and the pig actuator lantern O ring of the pipe connections Done 10 2 2 Pig Carry out the following...

Page 45: ...intervals To ensure maximum operational safety of the pig cleaning station the pig and all seals that come into contact with the product must be replaced at regular intervals The actual maintenance i...

Page 46: ...control air hoses off the pig actuator 5 Disconnect the power supply Done 10 4 2 Removing the pig Prerequisite Make sure that during maintenance and repair work no process is running or started in th...

Page 47: ...eaning station Prerequisite Make sure that during maintenance and repair work no process is running or started in the area concerned Caution Risk of burning due to hot cleaning agents and sterile stea...

Page 48: ...e following steps 1 Remove the air supply V3 1 and V3 2 to the actuator 2 Move the housing 7 when depressurised 3 Undo the hexagon nut 54 and remove the hinged clamp 53 If there is overpressure the ac...

Page 49: ...hinged clamp 50 7 Rotate the throttle check valve 28 for the air supply towards the piston 5 8 Separate the cylinder base 9 from the lantern 3 9 Remove the cylinder pipe 4 piston 5 and spacer 56 from...

Page 50: ...e the air supply V3 1 and V3 2 to the actuator 2 Move the housing 7 when depressurised 3 Loosen the hex head screws B2 and remove the pig retainer The gasket 1 is now freely accessible The pig retaine...

Page 51: ...aning station see Disassembling the pig actuator Section 10 6 Page 47 2 Carefully clean the individual parts 3 Carefully clean all the threads on the initiators and screws Done 10 8 2 Lubricating Seal...

Page 52: ...d from GEA Tuchenhagen if required A thin film of grease is required on the seals to ensure the proper function of the fittings It reduces friction and extends the service life of the seals This is ab...

Page 53: ...s the lantern 3 Done 10 9 1 4 Adjusting the initiators on the pig actuator To adjust the initiators on the pig actuator see Adjusting initiators on the pig actuator on page 35 10 9 1 5 Torques for the...

Page 54: ...e pig actuator with compressed air 2 Check the pig retainer stroke in accordance with Table Pig retainer stroke next page Done Strokes Depending on Size Pig retainer stroke Nominal width Stroke mm Met...

Page 55: ...olts M10 45 33 10 9 2 2 Checking the function of the pig retainer Setting the Stroke Prerequisite There must be no pig in the pig cleaning station Carry out the following steps 1 Actuate the pig retai...

Page 56: ...r tightness Fault in the electrical system Check actuation external controller and routing of electrical lines Solenoid valve defective Replace the solenoid valve Actuator moves too slowly O rings in...

Page 57: ...nt consists of the following materials Metals Synthetic materials Electronic parts Lubricants containing oil and grease Separate the different materials and dispose of them correctly sorted Also obser...

Page 58: ...13 Spare parts list pig cleaning station MST 3A Fig 26 Fig 27 Spare parts list pig cleaning station MST 3A 430BAL009974EN_3 58 23 07 2019...

Page 59: ...297 924 297 924 297 924 297 924 297 HNBR 924 312 924 312 924 312 924 312 924 312 20 Bearing disk N 1 4305 221 142 02 221 142 02 221 142 02 221 142 02 221 142 04 21 Hex head screw A2 70 901 350 901 350...

Page 60: ...017 D3 Nut 910 013 910 013 910 013 910 013 910 013 D4 Threaded bush 1 4301 228 000251 228 000251 228 000251 228 000251 228 000251 S Proximity switch holder magnet 1 4301 228 000357 228 000351 228 000...

Page 61: ...97 924 297 924 297 924 297 924 297 HNBR 924 312 924 312 924 312 924 312 924 312 20 Bearing disk N 1 4305 221 142 02 221 142 02 221 142 02 221 142 02 221 142 04 21 Hex head screw A2 70 901 350 901 350...

Page 62: ...017 D3 Nut 910 013 910 013 910 013 910 013 910 013 D4 Threaded bush 1 4301 228 000251 228 000251 228 000251 228 000251 228 000251 S Proximity switch holder magnet 1 4301 228 000361 228 000248 228 0002...

Page 63: ...14 Parts list Pig Cleaning Station MST 3A DN 25 and 1 OD Fig 28 Fig 29 Parts list Pig Cleaning Station MST 3A DN 25 and 1 OD 430BAL009974EN_3 23 07 2019 63...

Page 64: ...ring Turcite T51 935 038 935 038 28 Screw in plug connection G1 8 6 4 Brass nickel plated 933 330 933 330 35 O ring NBR 930 302 930 302 36 O ring NBR 930 007 930 007 37 O ring NBR 930 050 930 050 38...

Page 65: ...r magnet 1 4301 228 000390 228 000389 E1 Magnetic switch 505 081 505 081 E2 Screw 901 012 901 012 E3 Threaded bush 1 4301 228 000252 228 000252 Q Control top See spare parts list for Control Top T VIS...

Page 66: ...15 Parts list Feedback for MST DK pig actuator DN 25 and 1 OD Fig 30 Parts list Feedback for MST DK pig actuator 430BAL009974EN_3 66 23 07 2019...

Page 67: ...505 088 505 088 6 Setting RM 228 000098 228 000098 7 Disk 1 4301 228 000099 228 000099 8 Hex head screw A2 70 901 317 901 317 9 Threaded bushing 1 4301 228 000251 228 000251 Dimensions in mm A for pi...

Page 68: ...16 Parts list Pigs DN and OD Fig 31 Parts list Pigs DN and OD 430BAL009974EN_3 68 23 07 2019...

Page 69: ...8 163 32 158 81 0 DN 100 228 163 36 192 100 0 228 163 35 192 100 0 1 OD 228 157 11 1 5 OD 228 263 12 67 34 8 228 263 11 67 34 8 2 OD 228 263 03 93 47 5 228 263 02 93 47 5 2 5 OD 228 263 15 119 60 2 22...

Page 70: ...17 Parts list Pig Retainer 3A with T VIS M 15 and A 15 Fig 32 Parts list Pig Retainer 3A with T VIS M 15 and A 15 430BAL009974EN_3 70 23 07 2019...

Page 71: ...plug connection metric 1 8 6 4 Ms CV 933 176 933 176 933 176 933 176 933 176 933 176 Screw in plug connection inch 1 8 6 35 Ms CV 933 173 933 173 933 173 933 173 933 173 933 173 98 O ring NBR 930 046...

Page 72: ...lug connection metric 1 8 6 4 Ms CV 933 176 933 176 933 176 933 176 933 176 933 176 Screw in plug connection inch 1 8 6 35 Ms CV 933 173 933 173 933 173 933 173 933 173 933 173 98 O ring NBR 930 046 9...

Page 73: ...18 Parts list Pig Retainer MSP 3A with T VIS M 15 and A 15 Fig 33 Parts list Pig Retainer MSP 3A with T VIS M 15 and A 15 430BAL009974EN_3 23 07 2019 73...

Page 74: ...173 933 173 933 173 70 Union nut 1 4571 933 456 933 456 933 456 933 456 71 Cutting ring 1 4571 933 455 933 455 933 455 933 455 72 Support sleeve 1 4571 933 382 933 382 933 382 933 382 98 O ring NBR 93...

Page 75: ...3 933 173 933 173 70 Union nut 1 4571 933 456 933 456 933 456 933 456 71 Cutting ring 1 4571 933 455 933 455 933 455 933 455 72 Support sleeve 1 4571 933 382 933 382 933 382 933 382 98 O ring NBR 930...

Page 76: ...19 Parts list Connection 0 and Proximity Switch Holder for Pig Retainer Fig 34 Fig 35 Parts list Connection 0 and Proximity Switch Holder for Pig Retainer 430BAL009974EN_3 76 23 07 2019...

Page 77: ...lack 221 004311 221 004311 221 004311 221 004311 221 004311 221 004311 59 Guide ring Turcite T51 935 050 935 050 935 050 935 050 935 050 935 050 61 Screw in plug connection metric 1 8 6 4 Ms CV 933 17...

Page 78: ...221 004311 221 004311 221 004311 221 004311 221 004311 221 004311 59 Guide ring Turcite T51 935 050 935 050 935 050 935 050 935 050 935 050 61 Screw in plug connection metric 1 8 6 4 Ms CV 933 176 93...

Page 79: ...20 Parts list Connection 0 Proximity Switch Holder for Pig Retainer MSP Fig 36 Fig 37 Parts list Connection 0 Proximity Switch Holder for Pig Retainer MSP 430BAL009974EN_3 23 07 2019 79...

Page 80: ...ng Turcite T51 935 050 935 050 935 050 935 050 61 Screw in plug connection metric 1 8 6 4 Ms CV 933 176 933 176 933 176 933 176 Screw in plug connection inch 1 8 6 35 Ms CV 933 173 933 173 933 173 933...

Page 81: ...g Turcite T51 935 050 935 050 935 050 935 050 61 Screw in plug connection metric 1 8 6 4 Ms CV 933 176 933 176 933 176 933 176 Screw in plug connection inch 1 8 6 35 Ms CV 933 173 933 173 933 173 933...

Page 82: ...21 Dimension sheet Pig Cleaning Station MST 3A DN40 DN100 1 5 OD 4 OD Fig 38 P clearance Dimension sheet Pig Cleaning Station MST 3A DN40 DN100 1 5 OD 4 OD 430BAL009974EN_3 82 23 07 2019...

Page 83: ...0 270 300 S 339 313 323 331 340 V 90 90 90 125 125 Dimension 1 5 OD 2 OD 2 5 OD 3 OD 4 OD C 33 133 155 155 152 L 125 5 156 170 192 216 M 351 5 358 364 374 461 P 150 200 230 260 300 S 337 313 320 326 3...

Page 84: ...22 Dimension sheet Pig Cleaning Station MST 3A sizes DN25 and 1 OD Fig 39 P clearance Dimension sheet Pig Cleaning Station MST 3A sizes DN25 and 1 OD 430BAL009974EN_3 84 23 07 2019...

Page 85: ...Dimension DN 25 1 OD C 64 64 L 118 115 M 300 298 P 150 150 S 329 329 V 60 60 Dimension sheet Pig Cleaning Station MST 3A sizes DN25 and 1 OD 430BAL009974EN_3 23 07 2019 85...

Page 86: ...n pig station housing Fig 40 The free cross sectional area A at the narrowest point in the pig station housing is 100 of the pipe cross sectional area Dimension sheet free cross sectional area on pig...

Page 87: ...rod 6 0 6 0 6 0 8 0 8 0 S gap 9 9 11 9 14 9 17 6 21 3 Dimension 1 5 OD 2 OD 2 5 OD 3 OD 4 OD D1 housing 53 0 72 0 86 5 105 5 140 5 D2 pipe 34 8 47 5 60 2 72 9 97 4 D3 pig 35 0 47 9 60 9 73 4 98 1 D4 r...

Page 88: ...Short designation according to DIN ISO 1629 Ethylene Propylene Diene Rubber F Unit of measurement of temperature degree Fahrenheit FKM Material designation short designation according to DIN ISO 1629...

Page 89: ...P Self learning installation During commissioning and maintenance the SET UP procedure carries out all the necessary settings for the generation of messages AF Specifications for the size of spanners...

Page 90: ......

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