TECHNICAL DESIGN

MANUAL
Valve Block

Version: 1

Date: November 1, 2017

Author: Jing Sun

Department: Cross-Applications APAC China

CONTENT
1  Purpose .............................................................................................................................................. 3 
2  Applicability ........................................................................................................................................ 3 
3  Responsibilities .................................................................................................................................. 3 
4  Definition of Terms ............................................................................................................................. 3 
Terms: Valve Block ................................................................................................................... 3 
4.1  Design Types ............................................................................................................................ 4 
4.2  Elements in the Valve Block ..................................................................................................... 5 
5 Design specifications............................................................................................................................ 6 
5.1 General Date............................................................................................................................. 6 
5.2  Process Engineering Data ........................................................................................................ 6 
5.3  Components Specification ........................................................................................................ 7 
6  Design Regulations ............................................................................................................................ 8 
6.1  Valve Matrix .............................................................................................................................. 8 
6.2  Mounting Frame ...................................................................................................................... 26 
6.3  Leakage systems .................................................................................................................... 33 
6.4  Control..................................................................................................................................... 42 
6.5  Other components .................................................................................................................. 45 
7.6  Production of drawings ........................................................................................................... 50 
7  Documentation ................................................................................................................................. 54 
7.1  Approval drawings .................................................................................................................. 54 
7.2  Isometric pipe drawings .......................................................................................................... 55 
7.3  Material Certificates ................................................................................................................ 55 
7.4  Manufacturer’s declarations .................................................................................................... 56 
7.5  Welding seam documentation (weld logger)........................................................................... 56 
7.6  Digital photos .......................................................................................................................... 57 
8  Maintenance of the Procedure......................................................................................................... 57 
9 REVISION History ............................................................................................................................... 57 

2
1 PURPOSE
The purpose of this set of documents is to define a rule and a procedure to design a valve block.

2 APPLICABILITY
There is no standard procedure for making a design for a valve block, but different rules and design practices.

3 RESPONSIBILITIES
The Cross-Applications Execution NAM team

4 DEFINITION OF TERMS
Term: Valve Block
In a Valve Block, valves are combined to form an assembly. This assembly has a permanent and central place
of installation. Example: Filling and emptying valves for a tank group.

Illustration 1

Apart from the valves other components such as pumps, sight glasses, measuring instruments, solenoid valves,
etc. can be integrated in the valve block.

3
 Illustration 2

4.1 Design Types

Valve Block with Supporting Structure
On a valve block with supporting structure all elements are pre-assembled on a mounting frame.

Illustration 3
Valve block without supporting structure
A valve block without supporting structure is just the valve matrix (a drip pan can be fitted underneath the
matrix).
Valve cluster
A valve cluster consists of a number of valves and other devices welded together.

4
 Illustration 4

4.2 Elements in the Valve Block

The valve matrix is the main element in a valve block. A mounting frame, leakage system, control system and
other components can be added.

Matrix

- Pipe components (valves, in-line instruments, etc.)

- Pipes and pipe fittings
- Pipe connection elements

Mounting Frame

- Frame
- Holding fixtures
- Transport devices

Leakage Systems

- Drip pans
- Pipe system

Control System

- Valve and control cabinets

- Cable ducts and conduits
- Pneumatic and electrical lines other components (optional)
- Heat exchangers
- Tanks
- Pumps

5
5 DESIGN SPECIFICATIONS
Before a valve block can be designed, the following information and specifications must be obtained from the
customer.

5.1 General Date

Installation Conditions
- space available; conditions at the place of installation
- so-ordination with other suppliers
- positions of drains
- connection types, in-feed heights, connection dimensions
- operation side
- maintenance passages
Bringing-In Conditions
- size of the bringing-in port
- conveying means on site
- narrow passage due to equipment installed
Type of Transport
- road: suggested width dimension is 2.4m (including package); valve block wider than this dimension
must be cut two parts.
- sea freight
- air freight
Customer Regulations
- components regulations
- pipe classes
- other regulations relating to design
Automatic and Control Regulations
- control mode: PCS or valve island control
- square tube used for feeding compressed air

5.2 Process Engineering Data

PID with the Following Information
- supply boundaries
- connections between the components
- plant identification numbers
- pipe designations with reference to the pipe class
- flow directions
- nominal widths
- allocation of valve seat cleaning connections to the cleaning valve
- slopes
- information regarding the drawing of pipes

6
Pipe Classes with Information Regarding
- material
- sealing material
- DIN standards
- pipe part standards
- surface
- nominal pressure
- comments

5.3 Components Specification

FC Components
- specification acc. to FC catalogue
- product information
Purchased Parts (external component)
- manufacturer
- type information
- cataloguer sheet（if not available at VMO, please inquire）
- dimension sheet (if not available at catalog, please inquire）
- installation instruction (if not available at catalog, please inquire）

7
6 DESIGN REGULATIONS
The design regulations assist the designer with the following:

- Process engineering design aspects

- Manufacturing design aspects
- Using standardized parts
- Observance of standards

When planning and executing plants, legal regulations, standards and other regulations must be observed.
Deviations from legal regulations need, apart from the permission of the customer, approval of the relevant
authority. Workplace regulations and accident prevention must also be observed.

Following the regulations for the food industry and dairies (DIN 11481 equipment- pipes in dairies).

DIN 11481 is also applied for breweries.

Generally, food-grade stainless steels according to DIN 11850 must be used for these plants:

1.4301，1.4404，1.4571, 1.4541.

6.1 Valve Matrix

The valve matrix consists of components (FC components and non-FC parts) are configured in accordance with
the P&I diagram.

When designing the matrix, detachable connections and expansion components (depending on the
temperatures to be expected and maintenance aspects), fixing points, assembly clearances, position of valve
seat cleaning connections, etc. must be taken into account.

As a rule all types of double seat valves should be installed vertically for the following reasons:

- In order to ensure that cleaning liquids from the valve seat cleaning can drain and intermixing of product
and CIP solutions is safely excluded.
- Especially with balanced valves (Type B+R) the weight of the balancer may cause early wear of the
seals.

When laying the pipes, sufficient space must be left with regard to other pipes, to wall and ceiling. (Acc. to DIN
11481, the minimum distance of the pipes to one another and the wall is 100 mm, and 120 mm to the ceiling).

Attention must be paid to avoid dead zones in the valve matrix, that full clean ability is ensured and that pipes
can drain if necessary without leaving pools.

8
 Illustration 5
No formation of pools

Illustration 6
Avoid the dead zones

9
 Illustration 7
If spherical housings are rotated, pools may form

Illustration 8
Necessary installation access space
If possible, valves should close against the flow direction to avoid pipe hammers

10
 Illustration 9
Flow through a reducer in the specified direction, an air bubble may form where pollution may accumulate. This
area does not get clean during pipe cleaning. If the reducer is flooded in the opposite direction, no air bubble
forms.

Illustration 10

From the CIP process point of view, the flowing through a reducer in the direction is the most favorable. We use
to avoid this configuration because of possible pockets if installation needs to be drained.

Within the valve blocks, thermal stress can be generated by different media temperatures. If the limit is over
shot, expansion compensation must be provided.

11
 Illustration 11
Absorption of stress produced by the thermal elongation of heat conducting pipes is an essential requirement for
the safety of the pipes and components connected to them. When planning valve blocks, the probability of
thermal expansion occurring must be examine. Expansion compensators, for instance, can be used to absorb
thermal elongation within the valve block.

12
 Illustration 12
If a valve block is quite large, i.e. there are several rows of valve next to each other (length and width are more
than 2m), access (500mm wide) for maintenance purposes is insufficient. The block should then be divided into
two smaller valve blocks or maintenance passages should be provided. For this purpose, catwalks or platforms
can be arranged on the valve block. All the compress air square tube and cable tray should consider the access.

Illustration 13 Illustration 14

13
 Illustration 15
The maintenance passages should be assembled by foot plate on frame. More and more frames were produced
by the third party. If the maintenance passages weld on the frame, it would be cut in workshop.
Pipe Jumps
Jumps on the same level are compensated by means of 45°bends and fittings. Bend < 45°are only permitted it
the jumps is too small. If the height difference is very small, no bends are used and the pipes are directly
adjusted, or the difference is compensated by means of eccentric reducers (need to be avoided).

Illustration 16
45 degree bend and pipe adapter

14
 Illustration 17
Adjusted by pipe
Pipe jumps over two levels are established by means of a 90°bend and a 45°bend with fittings. If the height
difference is small, the same applies as stated in section 3.3.1.

Illustration 18
45 degree bend and pipe is adapter
A change of direction with or without height offset is implemented using two 90°bends and a pipe fitting.

15
 Illustration 19
90 degree bend and pipe is adapter
Reducers
Reducers are adapter elements between two nominal widths.
If reducers are needed directly in between two clusters, they must all be of the same length (±0.1 mm) and must
be plane-parallel.

Illustration 20
Eccentric reducers are expensive and time-consuming to process, so that they should only be used if it is
absolutely necessary. When it is horizontal pipe with liquid, it requires eccentric reducers. When it is vertical
pipe with liquid or horizontal pipe with dry air (Didn’t include steam and compressed air.), concentric reducer is
available.

16
Orbital Welding
If the pipe is welded using an automatic welding machine, sufficient space must be allowed for applying the
welding tongs. The tongs are 200 mm wide and 83 mm thick. Due to these dimensions, a minimum distance of
140 must be provided between the pipe center and other components.

Pipe to be welded
DN 40 50 65 80 100 125 150 6“ IPS
40 161 161 161 161 161 161 161 161
Benachbartes Rohres

50 167 167 167 167 167 167 167 167

65 175 175 175 175 175 175 175 175
80 183 183 183 183 183 183 183 183
100 192 192 192 192 192 192 192 192
125 205 205 205 205 205 205 205 205
150 217 217 217 217 217 217 217 217
6“ IPS 225 225 225 225 225 225 225 225

Table 1

To allow the welding tong (welding head) to be applied to a pipe, a minimum gap between the pipes must be
provided; see Table 2

Pull-Outs
Tees should be avoided in pipe systems. Pull-outs are better from a hygienic point of view(less welding seams)
and can be produced at lower costs on the appropriate machines, in particular of large nominal widths.

Illustration 21
Dimension “depends on “DN A “and “DN B“. It is given in Tables 2-4

17
 Height H for the collar of the pull-out
Nominal width of pull-out A
DN 15 20 25 32 40 50 65 80 100 125 150 162
15 - - - - - - - - - - - -
20 - - - - - - - - - - - -
25 - - 0 - - - - - - - - -
32 - - 0 0 - - - - - - - -
40 3 3 1 1 0 - - - - - - -
50 3 3 3 3 3 3 - - - - - -
65 3 3 3 3 3 3 3 - - - - -
80 3 3 3 3 3 3 3 3 - - - -
100 3 3 3 3 3 3 3 3 3 - - -
125 3 3 3 3 3 3 3 3 3 3 - -
Nominal width of pipe B

150 3 3 3 3 3 3 3 3 3 3 3 -
162 3 3 3 6 6 6 6 6 6 6 3
200 3 3 3 3 3 3 3 3 3 3 3 3
250 3 3 3 3 3 3 3 3 3 3 3 3
350 - - - 6 6 6 6 6 6 6 6 6

Table 2

18
 Height H for the collar of the pull-out
Nominal width of pull-out A
OD 1“ 1.5“ 2“ 2.5“ 3“ 4“ 6“
1“ 0 - - - - - -
1.5“ 1 3 - - - - -
Nominal width of pipe B

2“ 3 3 3 - - - -
2.5“ 3 3 3 - - - -
3“ 3 3 3 3 - - -
4“ 3 3 3 3 3 - -
6“ - 6 6 6 6 6 6

Table 3

Height H for the collar of the pull-out

Nominal width of pull-out A
Nominal width of pipe B

IPS 2“ 3“ 4“ 6“
2“ 3 - - -
3“ 3 3 - -
4“ 3 3 3 -
6“ 6 3 3 3

Table 4
Depending on the type of pull-out machine, a minimum clamping length of 100 mm and a gap of 60 mm
between two pull-outs on the same level must be provided.

Illustration 22 Illustration 23

Min 100 later shortening is possible in special cases only.

Radial offset of two pull-outs by 90°on a circumference is only possible if the pull-outs are smaller than the pipe
by two nominal widths. If the pull-outs are offset by 180°, they can have the same nominal width as the pipe.

19
Radial offset of two pull-outs by 90 degrees
Pipe diameter
DN 40 50 65 80 100 125 150 162
Nominal width of pull-out pipe

25 o o o o o o o o
40 o o o o o o
50 o o o o o
65 o o o o
80 o o o
100 o o
125 o

Table 5
The applicable tolerances for the pull-outs can be taken from the general tolerances (acc. to DIN 7168 Part 1),
middle tolerance class. The general tolerances are shown in the title block of a drawing.
If a pipe is to be shortened at a later stage, the required clamping lengths must be given in the parts lists as cut-
off pipe section can no longer be used.
Application example: Valve seat cleaning valve on a CIP pipe

Illustration 24
Pull-out DN25

20
Valve Seat Cleaning

Illustration 25

Nominal width of cleaning Nominal with of cleaning Max number of valves Nominal width of
valve NW-V pipe d connected A detergent supply line D
15 15 5 25
25 25 15 40
40 40 40 65
50 50 60 100

Table 6

Illustration 26
Nominal width of the detergent covering pipe D

21
Configuration
The pipes should be placed in the vicinity of the lantern. The pipe union should point downwards.

Illustration 27
The Teflon hoses are approx. 500mm long and are placed as shown.
The pipe for valve seat cleaning to be placed at lantern level, if possible.
Welded unions to be centrally placed, pointing downwards, between the valve rows.

22
 Illustration 28
The connection between the valve seat cleaning pipe and the valve is established with a Teflon hose. The hose
must be long enough to allow for the valve stroke (min.500 mm). The hose diameter depends on the valve size
(DN 40 to 100 Φ8×1，DN 127 to 162 Φ10×1).
The allocation of the valves to be cleaned to the associated valve seat cleaning valve can be taken from an
allocation list or a P&I diagram.

Example of an allocation List

RV1 RV2 RV3 RV4 RV5
DT1V1 DT2V1 DT3V1 DT4V1 DT5V1
DT1V2 DT2V2 DT3V2 DT4V2 DT5V2
DT1V3 DT2V3 DT3V3 DT4V3 DT5V3
DT1V4 DT2V4 DT3V4 DT4V4 DT5V4
DT1V5 DT2V5 DT3V5 DT4V5 DT5V5
Table 7

23
 Illustration 29
The last connection to the valve seat cleaning pipe (DN25) must be placed at the end to avoid producing a dead
zone.

Illustration 30

24
The valve seat cleaning valves are connected to the CIP pipe via a pull-out. The valve should be welded on
directly, without extending the socket, since the long lever arm could cause a break of the seam if vibrations are
produced during transport. Therefore it is also necessary to fit a support near the valve.

Illustration 31 Illustration 32

Illustration 33

25
6.2 Mounting Frame

Illustration 34 (if ASi bus is installed)

The frame must be designed so that it supports the matrix and all the other components. Transport within and
outside the factory must be possible without causing any damage to the block. It must also be ensured that
individual valves in the block can be removed.
Frame
For building the mounting frame, two types of square tube profiles are available:
Square tubes of 100×50×3/80X40X3 mm can be used to assemble ground. All the other pipes can be made of
50×50×3/40X40X2.5 mm square tubes. If some square tubes are applied for compressed air, it will be
40X40X2.5.
Up to a frame height of 500 mm no struts are required between the feet. From a height of 500 mm onwards,
cross-struts should be fitted.

26
Illustration 35

27
 Illustration 36
The mounting frames stand on adjustable calotte type feet (see 3.2.2). The number of legs to be fitted to a
frame depends on the number of valves and the nominal width.
If a control cabinet is to be fitted, a seat is provided on the mounting frame (see III.21 and 41). Cable ducts are
welded onto the mounting frame using plates. Lifting lugs with a maximum load of 2000 Kg per lug must be
provided for transport within and outside the factory.

28
 Illustration 37

Feet and Vibration Elements

- Rubber quality with FDA approval
- Polished stainless steel cap
- 2000 Kg carrying power per foot
- 5-8°floor slope can be compensated
- With floor plate for 50×50 mm square tube

Illustration 38

Fixing Devices
Pipe clamps are used to fix the valve matrix to the mounting frame. Once the valve block has been installed, the
clamps should be released so that thermal expansion in the valve matrix is not transferred to the mounting
frame.
The number of fixing devices to be used depends on the nominal width of the valves.

29
Types of fixing devices
- Up to 50 mm shaft height: round bar Φ20 mm
- From 50 to 300 mm: After reducer(DN20XDN40), drawn-in tube 40×1.5
- From 300 mm: square tube 50×50×3 with end plate and drawn-in tube

Illustration 39
Arrangement of fixing devices.
Do not use more fixing devices than necessary!
When placing the fixing devices, ensure that the clusters can be removed easily for maintenance purposes; this
applies in particular to valves with detachable housings as the sealing ring between the housings must be
replaced on those valves.

Illustration 40
Avoid if possible Recommend to fix on lower housing
Fit the fixing device preferably to the lower housing!
On shuttle valves, the fixing device should be fitted to the center housing if possible.
Placing fixing devices on welding seams is only allowed if both parts are cylindrical (i.e. not on a flange, bend,
reducer, etc.)

30
The fixing devices should be fitted so that not more than one component protrudes unsupported. If this cannot
be avoided in single cases, a flange connection should be provided to allow the unsupported valves to be
removed for transport.

Illustration 41 Illustration 42 Illustration 43

Set on lower housing Fixed on middle housing

If connected with pipe, fixed on welding part

31
 Illustration 44
Special types
Two-tier holders: are only used to support valve seat cleaning pipes, protection tubes, and air lines and
actuators or horizontal valves.

It may be necessary to weld the clamps within a 90°offset.

Illustration 45

32
Brackets
Brackets are edged sheets that support equipment (pumps, heat exchangers, etc.) on the mounting frame (see
illustration 44-47). The equipment can be easily aligned and fixed, including vibration dampeners as required, by
providing holes during assembly after arrival of the components.
Wall and Ceiling Fixtures
Valve blocks can also be fixed to a wall or ceiling. For this purpose, rectangular flanges with gusset plates are
welded to the mounting frame. Strut to be designed for a weight of 4000 Kg each. To stablish the frame, it is
also strengthen with gusset plates on the underside.

Illustration 46 Illustration 47

6.3 Leakage systems

Leakage systems are provided to centrally discharge switch-over leakage produced by mix proof valves.

Drip Pan (seat valve with lift)

The drip pan must be big enough so that the volume of liquid produced during valve seat cleaning can reliably
be collected and discharge without the pan overflowing. This means that the minimum edge height at the
shallowest point is 60 mm. Furthermore, a slope towards the outlet of at least 3% must be provided, since the
pan would otherwise not drain completely. If the valve block contain the lift seat valve, the slope and depth
should be as big as possible to avoid the backwash.

33
 Illustration 48

For pan dimensions please observe:

- Dimensions A and B can be selected in steps of 50 mm from 195 mm to 2995 mm. If the width of pan is
over 3000 mm, it will be separated into two parts.
- Dimension C can be rounding.
- Dimension D is determined by the slope. It will be more than 200 mm to connect with main drain; if the
deodorant bend is made on the ground, D should be more than 230 mm.
- Dimension E is 70 mm.
- Nominal width DN 50 for the outlet (alternatively DN80).
- Connection F (e.g. Varivent flange, union, welding end). General in APC Dairy, it will use clamp. In PC
project, it will use union.
- Ensuring the depth of drain pan, the height of the outlet of tanks should be more than 1200 mm.

34
Draw out pan:

Illustration 49

In the case of horizontal K valves (gas fittings), the leakage is discharged via a spill duct. The leakage pipe
projects 10 mm into the spill duct. The duct must be wide enough to allow for the stroke of the horizontal valve.

Integrated Drip Pan with the structure:

When the valve block is over a platform, integrated drip pan will be considered.

Illustration 50 Illustration 51

35
 Illustration 52
For vertical K valves, the leakage pipes must project deep enough into the spill duct so that they will not slip out
of the drip pan even when performing a full stroke.

Illustration 53
Special case: The pan can be fixed to a pipe (no frame).
It is held by clamps type C and flat bars.

36
 Illustration 54
Leakage Pipe Systems
The leakage pipe system is a system of pipes and collecting funnels.

Illustration 55

37
 Illustration 56

To collect the leakage from vertical K valves, a leakage collecting pipe with pull-outs can be used. The leakage
pipes on the K valves project into these pull-outs. In this case, the leakage is not visible. Length the pipe should
project into the pull-out = valve stroke plus 5 mm.

Leakage Protection
The leakage produced by individual mix proof valves that are not covered by the pan can be collected via a
leakage protection device. The leakage protection device is led via a hose connection into the nearest drip pan.
Leakage protection for valve block
Drain pipe of drip pan will be connected to main drain pipe or emission point. Start and end of pipe will weld
clamp connection. Clamp will be easy to disassemble and clean. (See Illustration 57).

Illustration 57 (Seat valve without lift function)

For the seat valve with lift function, the instantaneous drain liquid will be huge. To avoid the splash, sink should
be as deep as possible. The slop of sink will kept in 3 degree. If the vale is too high, dismountable plate should
be equipped to prevent splash (see Illustration 58).

38
 Illustration 58
For CIP return swing bend, all the liquid of sink can be connected into the swing bend sink (See Illustration 59).

Illustration 59
Leakage protection for single valve
Drain pipe of drip funnel will be connected to main drain pipe or emission point. Start and end of pipe will weld
clamp connection. Clamp will be easy to disassemble and clean.

39
If the drain is with pressure, the size should be adjusted according to pressure.
If the drain is with warm liquid, the length of straight reach should be more than 300mm (see Illustration 60).

Illustration 60

Leakage protection for valve row

For the tank CIP seat valve, it will be combined with a valve row. An independent sink will collect all the leakage
together (see Illustration 58).
Drain pipe of drip funnel will be connected to main drain pipe or emission point. Start and end of pipe will weld
clamp connection. Clamp will be easy to disassemble and clean.
Installation requirement: Sink should be installed with 3 degree slope to empty all the liquid; 100mm space
should be left on site for clean.
PE should offer the volume requirement, if not satisfied, sink will be widened or heighten.

40
 Illustration 61

Leakage protection for skid

When designer make the design for skid, drain pipe should be considered with the whole skid.

Illustration 62

Leakage protection for workshop

Project engineer will calculate the size and direction of drain. Then considering the civil situation, finish the
whole drain piping layout for the whole workshop.

41
6.4 Control
The control elements must be easy to access and arranged clearly. This applies in particular for sight glasses
and operating elements as well as for adjustment and setting work on actuators.

Switch and Control Cabinets

Switch and control cabinets are supported on the frame (made of 50×50×3 square tube) from the bottom and
are fixed with welding bolts to gusset plates at the back.

Illustration 63

Connections are fitted to the cabinets from the bottom. They must have a lateral clearance of min. 80 mm so
that they can be introduced into the central cable duct from the bottom with short loops.

42
 Illustration 64
Cable Ducts
Cable ducts are provided to carry the control, air and feedback lines. The ducts must be arranged in such a way
that the free lines to the components are as short as possible and that they do not obstruct access to the valves
during maintenance.
The maximum number of lines per cable duct as a total of the square line cross sections should not exceed 50%
of the ducts cross section.

Illustration 65

43
Conduits
In individual cases it can be necessary to run cables and/or air hoses in a conduit. This variant is only used in
connection with single valves with few cables. In this case, a tube is flanged and fixed to the matrix with clamps.
When cables and/or air hoses is in conduits, 30% empty space should be left.

Illustration 66
Bridge
When ASi bus is installed, electro-pneumatical wiring will be considered.
Network bridge will be fixed by square tube 40x40x2.5. The height should be left enough space for maintenance.
Generally, H= (OD+50) mm.
Inlet of compressed air is 1/2” adaptor. Outlet is 1/4” adaptor. The quantity of adaptor will depend on the
quantity of valves (bus control).

44
 Illustration 67
Valve Block

6.5 Other components

Other components can be integrated into a valve block, which are required from a process engineering point of
view. This could be pumps, heat exchangers, mixers, sieves, filters and tanks. Additional struts and feet can
then be required for static reasons and for supporting.
Pumps
Pumps are used to convey product and cleaning medium and to increase the pressure.
In order to support pumps on the frame, struts and/or pump brackets are required. The pump leg is either
screwed or pinned to the pump bracket or the pump is placed on the pump bracket on calotte-type feet.

45
 Illustration 68
It may be necessary (e.g.in the case of grey cast feet) to provide rubber pads between pump leg and bracket to
reduce vibration and corrosion.
Dosing pumps must be equipped with drip pans installed underneath.

Illustration 69 Illustration 70
Pipe bends must not be fitted directly in front of a pump. A supply line of 5 to 10 times the pipe diameter must be
allowed for.

Illustration 71

46
 Illustration 72
2 elbow before suction will make the dead zone
A conical suction pipe (reducer) in front of a pump must be acutely conical to avoid formation of deposits.
OD of pressure pipe shouldn’t change suddenly, the reducer should be long enough.
A suction line in front of a pipe that is conical at the top can result in air bag formation and hence cause soiling
and cavitation.

47
 Illustration 73

The installation of pumps in pipe systems is described in DIN 24 295. The pump must be isolated against the
forces of the pipes by suitable means. Stress produced on the suction side and/or on the pressure side can
produce wear on the pump. The suction and pressure pipes must therefore be supported.

Illustration 74
 Never let the motor installed vertically.
 If the pump is installed outside of room, it should equipped with roof to protect the electrical element and
motor.

48
Tank
Due to their considerable weight when filled, tanks usually have legs and feet and are installed next to the valve
block. Small tanks can be integrated on the valve block if the frame can carry their weight by means of struts
and machine feet.
Heat Exchangers
Heat exchangers are usually placed on the process unit’s mounting frame. The weight of the heat exchanger
must be supported by additional cross-struts and feet. Brazing plate heat exchanger should be confirmed about
its insulation type. Enough space should be left for installation.

Illustration 75
The length of the plate package on a plate heat exchanger varies as plates can be retightened or replaced.
Therefore, the heat exchanger must be piped via joint bends.
During design, bend space should be considered. In the same time, 1200 mm space should be left for
maintenance.

Illustration 76

49
Filter

Illustration 77 Illustration 78

7.6 Production of drawings

A technical drawing is a means of communication between the customer and the individual departments of a
factory, e.g. the design, work scheduling, manufacturing and assembly team.

50
Manufacturing Drawing
In a technical drawing, the three-dimensional workpiece is shown by parallel projection onto the drawing plane
in the required views. The measures given clearly define the shape and the dimensions of the workpiece. In
addition, the technical drawing includes the necessary information about dimensional tolerances, surface quality
and materials so that the workpiece can be produced without queries being necessary.
The manufacturing drawing must have at least two views so that all the necessary information for the production
of a valve block is provided in conjunction with the parts list.

Illustration 79
The technical drawing is an international means of communication in technology so that the relevant standards
for producing drawings should be observer.
DIN 6 Views and sectional views
DIN 15 Lines in drawings
DIN 30 Simplified representation in drawings
DIN 406 Dimensioning in drawings, regulations
DIN 823 Sheet sizes
DIN 1912 Graphical representation of welded and soldered connections
DIN 6776 Standard ISO characters
DIN ISO 1101 Entering shape and position tolerances
DIN ISO 1302 Indicating the surface quality in drawings
DIN ISO 5455 Scales for technical drawings
DIN ISO 2162 Representation of springs
DIN ISO 6410 Representation of threads

51
Apart from the main dimensions, manufacturing-specific dimensions and connection dimensions(including the
type of connection), attention must be paid that individual pipe lengths are also specified so that the
manufacturing workers do not need to calculate them, unless a fitting is concerned(compare illustrations 90 to
11). The same applies for the support height from the upper edge of the frame and pull-outs.
Mounting Frame Drawing
If the valve block has a frame, this must be provided with the necessary dimension on the manufacturing
drawing. The dimensions can also be given on the manufacturing drawing on a separate isometric drawing (see
illustration 53 a) or on a separate frame drawing.

Illustration 80
Details
To show a workpiece clearly, details can be included in the drawing. These can be drawn to another scale than
the overall drawing.
Examples:
- Lifting lugs, see illustration 24
- Machine feet, see illustration 25
- Ceiling fixtures, see illustration 34 C
- Drip pan fixtures, see illustration 35
- Plates for fixing switch cabinets and cable ducts, see illustration 41 a
- Valve seat cleaning

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 Illustration 81
Part List
According to DIN 6771 T2, a parts list should be an inventory of all individual components and pipes of which a
product is made. It is used to exchange technical information within and outside a factory, in particular for
manufacturing scheduling. It is either included in the drawing above the title block or appended on a separate
DIN A4 sheet.

Item Material
Description Size Length Standard Qty Unit Material
No. No.
Reducer Tee, DN11852, I
1 DN65-25 2 PCS SS304
short series
Reducer Tee, DN11852, I
2 DN65-40 1 PCS SS304
short series
DN11852, I
3 Reducer, Eccentric DN80-65 5 PCS SS304
series
4 Adapter R1/2" / 1 PCS SS304
5 Adapter R1/4" / 18 PCS SS304

Table 8

53
7 DOCUMENTATION
The following documentation can be offered to the customer:
- Approval drawings
- Isometric drawings of pipes
- Material certificates
- Manufacturer’s declarations
- Welding seam documentation
- Digital photos

7.1 Approval drawings

An approval drawing must clearly show the design, matrix configuration, main dimensions and connections (with
dimensions). It should not include any design details.

Illustration 82

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7.2 Isometric pipe drawings
An isometric pipe drawing is a three-dimensional, one-stroke representation of a pipe in a system of coordinates
whose X axis is drawn at an angle of 30°, whose Y axis is at an angle of 150°and whose Z axis is at an angle of
90°. According to DIN 2408, an isometric pipe drawing is a representation of a pipe or pipe section that is not
true to scale and that shows the course of the pipeline and the relevant dimensions via isometric projection.
It contains at least an unmistakable identification of the pipe, graphical symbols for pipe components, fittings,
instrumentation and pipe fixing devices, a flow direction, a north arrow, dimensions, insulation and heating as
required, references to connection points, follow-up drawings and a pipe parts list.

Illustration 83

7.3 Material Certificates

In order to guarantee material characteristics and for the quality assurance of plants, the following documents
can be supplied:
- Certificate acc. to DIN EN ISO 9001
- Certificate acc. to AD data sheet HP0/DIN EN 729-2
- Manufacturer’s declaration for components
- 3.1B certificate / marking-transfer certificate

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7.4 Manufacturer’s declarations
To allow the manufacturer to issue a manufacturer’s declaration, the regulations of the European standard EN
292 Parts 1 and 2 and of DIN 31 000/VDE 1000 must be observed during design and manufacturing.
For the components of GEA-Tuchenhagen the following manufacture’s declarations are available:
- Varivent valve
- VARIFLOW centrifugal pump
- Pumps
- IN-LINE housings
- Conductivity meter
- Flow switch
- Flowmeter
- Pressure gauge
- Pressure sensor
- Turbidity switch
- Turbidity detector
- Thermometer
- Temperature sensor
- Sight glass
- Rotating jet cleaner
- Cleaning lance
- Spray balls
- Cleaning devices
- Whirlpool cleaner
- Orbital cleaner, bunghole cleaner, vertical cleaner and Whirlpool cleaner
- Pigging system

7.5 Welding seam documentation (weld logger)

If welding seam documentation is required for the production of a valve block, the block is tacked together
cluster by cluster. Digital photos are taken of the tacked clusters or an isometric drawing is produced. While the
seams are welded a measuring instrument records
- Date of recording
- Instrument number of recording
- Batch number of recording
- Record number
- Start of recoding
- Duration of recording
- Average welding current
- Average welding voltage
Date Plant Batch Seam Time Duration I(A) U(V)
05.03.99 200398 1 1 10:36:50 00:00:26 196 24.9
05.03.99 200398 1 2 10:37:54 00:00:12 178 24.5
05.03.99 200398 1 3 10:40:11 00:00:15 188 24.9
05.03.99 200398 1 4 10:41:08 00:00:12 179 25.8
05.03.99 200398 1 5 10:42:05 00:00:16 84 22.9
18.16.99 200403 2 1 13:00:45 00:00:06 173 19.8
18.16.99 200403 2 2 13:01:10 00:00:09 167 22.2
Table 9

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After welding, the seams are stamped by the welder at the request of the customer. After evaluation of the
welding data, the seams on the digital photos are numbered consecutively and the relevant values supplied by
the measuring instrument and the name of the welder are allocated accordingly.
Tracking the welds back to the welding documentation and to the welder is always ensured.

7.6 Digital photos

Digital photos, which may also be processed, can be made available to the customers on diskette, CD or via
email.

8 MAINTENANCE OF THE PROCEDURE

9 REVISION HISTORY
This document is managed electronically in the NAM Process Engineering Handbook SharePoint Site. The
revision history is noted below and is also stored on the site.

Date Revision Change Author

2017.12.01 0.1 Update to standard template; translate Patty Blegen

language; format

57