AWH DN100 User manual

ARMATURENWERK
HÖTENSLEBEN GmbH
ASSEMBLY INSTRUCTIONS
Pigging Systems / Components
Type: Launching and Receiving Station DN100
AWH Armaturenwerk Hötensleben GmbH
Schulstrasse 5 / 6
D-39393 Hötensleben
Telephone: + 49 - (0) 3 94 05 / 92 0
Telefax: + 49 - (0) 3 94 05 / 92 111
http: //www.awh.de
e- mail: [email protected]
Edition 12/ 2010
Translation of Original Operating Instructions

ADVICE
These assembly instructions represent an integral part of the
installation and must be accessible for the operators and maintenance
personnel at all times. The safety instructions contained therein must
be observed. In case the installation is resold, the assembly
instructions have to be joined to the delivery.
Translation
If delivered to a country of the European Economic Area, the
assembly instructions are to be translated into one of the official
languages of the European Community accepted by the manufacturer
of the machine / installation into which this pigging system is to be
integrated. In case of discrepancies in the text, the original assembly
instructions (in German) are to be consulted or the manufacturer is to
be contacted.
Copyright
The dissemination and duplication of this document, as well as the
use and transmission of its contents are prohibited unless expressly
permitted. Contraventions will result in claims for damages.
All rights reserved.

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1 Contents
1.1Table of contents
1 Contents 1-1
1.1 Table of contents 1-1
1.2 Manufacturer's Declaration - Launching and Receiving Station 1-3
2 Overview and proper use 2-4
2.1 Overview Launching and Receiving Station - Ill. 2-1 2-4
2.2 Proper use 2-5
2.3 Technical Data 2-6
2.3.1 Working data 2-6
2.3.2 Materials in contact with the media 2-6
2.3.3 Dimensions 2-6
2.3.4 General data 2-7
3 Safety / Dangers 3-1
3.1 Advice / Explanations 3-1
3.2 Characterization of the launching and receiving station 3-2
3.3 Safety measures (responsibility of the user) 3-2
4 Safety hints 4-1
4.1 Dangers 4-1
4.2 Dangers at the launching and receiving station 4-1
4.3 Installation of spare and wear parts 4-2
4.4 Shutdown procedures 4-2
5 Installation 5-1
5.1 Scope of delivery 5-1
5.2 Transport and packing 5-1
5.2.1 Delivery (applicable for spare and wear parts as well) 5-1
5.2.2 Intermediate storage 5-2
5.3 Installation 5-2
5.3.1 Incorporation of the launching and receiving station 5-3
5.3.2 Assembly of the connection fitting 5-3
5.3.3 Mounting the magnetic field sensor 5-4
6 Design and function 6-1
6.1 Launching and receiving station - Ill. 6-1 6-1
6.2 Connection fitting - Ill. 6-2 6-3
6.3 Inserting / Removing the pig in / from the launching and receiving
station 6-4
7 Maintenance 7-6
8 Malfunctions, Causes, Remedies 8-1

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9 Emergency 9-1
10 Disassembly / Disposal 10-1

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1.2 Manufacturer's Declaration - Launching and Receiving Station
AWH Armaturenwerk Hötensleben
Schulstrasse 5/6
D-39393 Hötensleben
Declaration of Incorporation
in accordance with
- EU Guideline: Pressure units 97/23/EG, Schedule II A
We herewith declare that the type of construction of
Designator: Launching and Receiving Station
Type: DN100 / PN10
in its supplied version is in conformity with the above guidelines and the below listed standards
(harmonized standards in accordance with the guidelines):
Guideline/
Standard Title Edition Remarks
DIN EN 62079 Establishment of instructions, structures, contents
and presentation 2001 Harmonized standard
97/23/EG EU Guideline
Pressure Units 2000
AD 2000
Techn. bulletins Regulations for pressure units (national standards)
DIN EN 12516-2 Industrial valves - housing rigidity - Part 2:
Calculation methods for pressurized housings
of fittings made of steel 04.04.2009
Harmonized standard
The Launching and Receiving Station has been designed for liquids of fluid group 1 and for gases of fluid group 2; as
such, it has been rated in accordance with article 3, paragraph 3.
In case of modifications of the launching and receiving station not cleared with us, this declaration becomes void.
Note:
A commissioning is prohibited until it has been determined that the overall installation is in
conformity with the regulations of the guidelines. Instructions on the proper use of the
fittings can be taken from the operating instructions.
Hötensleben, December 23, 2010 .............................................................
Thomas Erhorn / General Manager

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2 Overview and proper use
2.1Overview Launching and Receiving Station - Ill. 2-1
The launching station consists of the following main components:
1 Plug-in chamber
2 Housing
3 Ball valve
4 Tee
5 Pigging connection groove-faced flange DIN
11864
6 Butterfly valve
7 Media branch DIN 11851
8 Connection fitting
9 Handle bar
10 Sensor support
11 Magnetic field sensor
1
2
3
4
6
7
8
9
11
12
5

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2.2 Proper use
The launching and receiving station was designed for their use in
installations of the foodstuffs, beverage and cosmetics industries.
Depending on its version, it serves to introduce, receive, remove, and
propel AWH lip or tangential pigs in piggable plant sections.
The pigging system permits the separation of products and the
cleaning of the pigging line. Suitable propelling media for the
launching and receiving station are water, air or nitrogen.
WARNING
The launching and receiving station was exclusively built for the above
described purpose. Any other or additional use or any modification of
the launching and receiving station without a prior written agreement
with the manufacturer is considered improper. The manufacturer will
not accept any liability resulting from this. The risk lies solely with the
user. The launching and receiving station must not be commissioned
before it has been assured that all safety systems are fully operational
and the installation into which this launching and receiving station is to
be incorporated is in conformity with the EU guidelines.
Proper use includes the observation of the operating instructions
prescribed by the manufacturer, as well as the instructions on
maintenance and repair.
The work described in this manual is described in such a way that
only a qualified person will be able to understand and complete it.
Qualified person
Any person who, based on his/her technical training, knowledge and
experience as well as his/her knowledge of the applicable standards,
is capable of judging the tasks he/she is entrusted with and can
recognize possible dangers.
The definition follows the contents of EN 60204-1.

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2.3 Technical Data
2.3.1 Working data
Nominal width DN100
Nominal pressure PN 10
Working temperature 100°C
2.3.2 Materials in contact with the media
refer to overview 2-1
Plug-in chamber 1.4404
Housing 1.4404/ 1.4301
Butterfly valve 1.4404
Ball valve 1.4404
Tee 1.4404
Seal material EPDM,
PTFE
silicone
Surfaces
External surface metallic bright
Interior surfaces in contact with the media Ra < 0,8 µm
2.3.3 Dimensions
Ill. 2-2
DN 100
D1 DN 25
D2 Rd 130x1/4“
D3 180
L1 645,5
L2 150
L3 140
H1 210
H2 193,5

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2.3.4 General data
Ambient temperature range
lower temperature limit + 5°C
upper temperature limit + 60°C
Mounting position horizontally

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3 Safety / Dangers
3.1 Advice / Explanations
DANGER
"DANGER" cautions about dangerous situations. Avoid all such
dangerous situations! Otherwise, death or serious bodily harm will
result.
WARNING
"WARNING" cautions about dangerous situations. Avoid all such
dangerous situations! Otherwise, death or serious bodily harm may
result.
CAUTION
"CAUTION" in combination with the warning sign cautions about
dangerous situations. Avoid all such dangerous situations! Otherwise,
slight or minor injuries may result.
ADVICE
"ADVICE" offers recommended procedures the disrespect of which
will not result in bodily harm. Follow the recommended procedures to
avoid material damage and trouble!
ADVICE
Assembly instructions are binding;
this is marked by the "book" sign.
DANGER
Risk of contusions is indicated by this pictogram.
DANGER
A risk of burns is indicated by this pictogram.

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ADVICE
The Environmental sign
indicates measures to protect the environment.
3.2 Characterization of the launching and receiving station
The indications in these assembly instructions refer to the launching
and receiving station only, the type and version of which is indicated
on the title page. For all inquiries, we need the correct indication of:
- the nominal width
- the type of connection (DIN 11851, DIN 11864, welded on, etc.)
- manual operation
- version with ball valve
- accessory parts (feedback signal, etc.)
3.3 Safety measures
(responsibility of the user)
We would like to point out
- that the user has to train his maintenance personnel and to
supervise that the safety instructions are adhered to and the
mandated personal protective gear is worn
- that the user has to ensure that unauthorized people (no operators
or maintenance personnel) are prevented from accessing the
danger zone of the installation (into which the launching and
receiving station has been integrated)
- that the integration of the launching and receiving station, as well
as its service may be effected only after all pipes have been
emptied and depressurized.
- that the technical separation of energy sources is effected in such
a way as to ensure that the shutdown procedures as described
under 4.4. can be completed.
These assembly instructions are to be retained for future use. They
must be accessible close to the installation into which the launching
and receiving station has been integrated.
The indicated inspection and control measures must be observed.

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Assembly Instructions
4 Safety hints
4.1 Dangers
The safety systems and safety instructions in these assembly
instructions must be observed.
The installation is operated manually.
CAUTION
The launching and receiving station, the length and quality of the
pipes have to meet the requirements. The assembly is to be effected
by qualified personnel.
The parameters listed on the data sheet must be observed.
DANGER
A risk of burns exists during operation and maintenance, respectively,
in case the flow media reach temperatures exceeding 60 °C.
DANGER
When opening screw joints or removing the plug-in chamber while the
system is still pressurized, there is a risk of injuries caused by ejected
system components.
DANGER
For locating purposes, the pigs are equipped with powerful
permanent magnets capable of affecting sensitive, electronic
devices. People wearing a pacemaker have to keep a minimum
distance of 1 m from the installation.
4.2 Dangers at the launching and receiving station
The area around the launching and receiving station has to be kept
accessible to the operator.
CAUTION
For the operation and preparation, maintenance and repairs the
danger zone extends to 1 m around the launching and receiving

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Assembly Instructions
station. The pivoting range of opening switchbox doors has to be
taken into consideration as well. The operator has to ensure that any
access to the danger zone is prevented while parts of the installation
are in motion.
4.3 Installation of spare and wear parts
We expressly point out that spare and wear parts not supplied by
AWH have neither been checked nor approved by us. Consequently,
the installation and / or use of such products may adversely modify
structural characteristics of your installation.
Messrs. AWH GmbH will not accept any liability for damages caused
by the use of other than the original parts or accessories.
4.4 Shutdown procedures
WARNING
Before conducting any cleaning, maintenance work or repairs (by
qualified personnel only), the following shutdown procedure must be
observed.
1. Cut higher-level installation / machine / device off from the mains.
2. Block propelling medium / pneumatics
- close check valve
- Make sure the installation is depressurized
- Secure check valve against reopening.
3. Block off the media supply, depressurize the pipes and empty
same (exercise specific care in case of dangerous substances).
Verify that the media supply has been safely cut off and make
sure that the dummy disks are in position.
Make sure that in case of media temperatures exceeding 60°C a
cooling phase is observed.
In case of disrespect of the above, dangers for live and limb of the
personnel result!

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Assembly Instructions
5 Installation
5.1 Scope of delivery
ADVICE
The detailed scope of supply can be taken from the order
confirmation.
5.2 Transport and packing
Before being shipped, all products of Messrs. AWH Armaturenwerk
Hötensleben GmbH are carefully checked and packed; however,
damage to the products during transport cannot be ruled out
completely.
5.2.1 Delivery (applicable for spare and wear parts as well)
Receiving inspection:
- Check for completeness based on the information on the delivery
note!
In case of damage
-Check the shipment for damage (visual inspection)!
In case of complaints
If the shipment was damaged during transport:
- Immediately contact the last forwarding agent!
- Do not dispose of the packing material (for a possible inspection
by the forwarder or for the return transport).
Packing for return transport
For a possible return transport the machinery parts have to be packed
in such a way as to ensure that any damage during a proper transport
can be ruled out.
In case of questions in this context, please contact Messrs. AWH
Armaturenwerk Hötensleben GmbH.

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5.2.2 Intermediate storage
The packing of the machine and the spare and wear parts at the time
of delivery has been designed for a storage duration of up to 3
months.
Storage conditions
- Enclosed and dry area with an ambient temperature of + 10°C to
+ 45°C.
- The relative humidit must not exceed 60% (non-condensing).
5.3 Installation
ADVICE
The installation of the launching and receiving station is effected in
line with the structural design of the pipe systems and the technical
data of the connection variants.
The installation dimensions can be taken from the dimensional
drawings. The floor space required for the operation and
maintenance must be guaranteed.
Make sure that the flanged connections and pipe connections,
respectively, are tightly sealed.
Preclude any tensile or compression stress after installation.
Thanks to the design of the valves, a conversion from a manually
operated valve to a remote controlled valve with pneumatic drive can
be easily realized without having to disassemble the valves from the
pipe system.

5-3
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Assembly Instructions
5.3.1 Incorporation of the launching and receiving station
•Check all seals for possible damage and replace them, if necessary.
•Whenever components are being replaced, new seals have to be used.
•Clean the assembly area and conduct a check for possible damages.
•Attach the media supply and return lines.
•Insert the fastening bolts of the launching station into the flange
connection and fasten same in a criss-cross tightening sequence in
small steps. The bolts have to be tightened to such a degree as to
ensure that the joint remains leak-proof under the conditions to be
expected.
5.3.2 Assembly of the connection fitting
Assembly of the connection fitting
Ill. 5-1
Attach the connection fitting (13) with a seal
(14) and a clamp (15) to obtain a clamped
connection in accordance with DIN 32676
•Attach the propelling pressure supply / relief duct.
13
14
15

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5.3.3 Mounting the magnetic field sensor
Assembly pigging sensor
Ill. 5-2
Pre-assemble the sensor (12) with the clamp
(12a).
Ill. 5-3
Slide sensor onto the support (11).
Connect the sensor to the power supply.
Adjust the sensor by turning and sliding same.
(magnet recognized = the red LED at the
sensor lights up).
Fix the sensor in position by tightening the
screws (Allen key size 3).
12
12a
11
12

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6 Design and function
6.1 Launching and receiving station - Ill. 6-1

6-2
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Assembly Instructions
Pos. Qty. Designator Material
1 1 Slider chamber part 2 DN100 1.4404
2 1 PTFE ring 139x127x10 PTFE
3 1 Cross-tie 80.5x10x3 1.4404
4 2 O-ring FDA 102x5 EPDM EPDM
5 1 Groove-faced flange DIN 11864 DN100 1.4404
6 1 Lid 2 DN100 1.4404
7 3 Stud bolt DN100 Lipp 1.4301
8 1 Lid 1 DN100 1.4404
9 3 Cap nut A2
10 1 Pipe section 29x1,5x10 1.4404
11 1 Clamp nozzle DN25 1.4404
12 1 Ini support DN100 Lipp 1.4301
13 2 O-ring FDA 111x5 EPDM EPDM
14 1 Shell plate 1 DN100 Lipp 1.4301
15 1 Shell plate 2 DN100 Lipp 1.4301
16 1 Shell plate 3 DN100 Lipp. 1.4301
17 1 Schiebek. DN100 Lipp Teil1 geschw. 1.4404
18 1 Lip pig DN100 PTFE/ Silikon FDA
19 1 Red Tee, shortened 1.4404
20 1 Reducer DN100/80 exc. 1.4404
21 1 SV handle standard DN80-100 1.4301
22 1 Ball valve DN100 SS man. Operated 1.4404
23 1 Handle bar DN80/ 100 cpl 1.4301
24 4 Hexagon bolt M8x40 A2
25 1 Welded flange DN100 DIN 1.4404
26 4 Hexagon nut M8 A2
27 1 Threaded flange DN100 1.4404
28 1 Flap 1.4404
29 1 Plug GPN 300F112 blue PHT
30 1 SV middle seal DN100 Silikon FDA
31 2 SV bearing sleeve d14 DN80-100 PTFE
32 1 Magnetic field sensor BIM-AKT-AP6X-H1141/S235

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6.2 Connection fitting - Ill. 6-2
1 1 Clamp nozzle DN25 1.4404
2 1 Tee, short DN 25 1.4404
3 2 Welded flange DN 25 1.4404
4 2 Threaded flange DN 25 1.4404
5 4 SV bearing sleeve di=12 DN25-65 PTFE
6 2 Flap DN25 1.4404 1.4404
7 2 Plug GPN 300F5 blue PHT
8 8 Hexagon bolt M8x28 A2
9 8 Hexagon nut M8 A2
10 2 SV standard handle DN25-32 1.4301
11
2
Middle seal DN25
Silicone