Project Engineering Handbook: P&ID Guidelines

PROJECT ENGINEERING
HANDBOOK
P&ID Guidelines
Version: 01
Date: 2017.11.28
Author: Saniago Villafane Trabajo
Department: Cross-Application EMEA South

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Document Description:
P&ID Guidelines
CONTENT
1 Sound Engineering Practice (SEP) ....................................................................................................5
1.1 SEP for Varivent, Ecovent, Butterfly and Control Valves from GEA .........................................5
1.2 SEP for Overflow (Type Q) Valves from GEA...........................................................................6
1.3 SEP for Vacuum Relief (Type V) Valves from GEA ..................................................................7
1.4 SEP for Safety Relief (Type 488 and 483 Stericom) Valves from GEA....................................8
1.5 SEP for Centrifugal Pumps (Type TP) from GEA .....................................................................9
1.6 SEP for Piping Systems from GEA .........................................................................................10
2 Selection of Appropriate Pump Types .............................................................................................12
2.1 Overview of Pump Types, and Reference Material ................................................................12
2.2 Centrifugal Type – Where to Use it .........................................................................................14
2.3 Self-Priming Centrifugal Type – Where to Use it ....................................................................15
2.4 All centrifugal pumps from GEA Hilge.....................................................................................16
2.5 Rotary Lobe Positive Displacement Type – Where to Use it ..................................................17
2.6 Peristaltic Type – Where to Use it ...........................................................................................18
2.7 Piston Type – Where to Use it ................................................................................................19
2.8 Screw Type – Where to Use it ................................................................................................20
2.9 Twin screw Type – Where to Use it ........................................................................................21
2.10 Diaphragm Metering Type – Where to Use it .........................................................................22
2.11 Mechanical Seals ....................................................................................................................23
2.12 Design Rules for Pumps and Fail-Safe Features ...................................................................24
2.12.1 Flow ...........................................................................................................................24
2.12.2 No Flow ......................................................................................................................24
2.12.3 Reverse Flow .............................................................................................................24
2.12.4 High Pressure ............................................................................................................25
2.12.5 Low Pressure .............................................................................................................25
3 Selection of Appropriate Valve Types ..............................................................................................26
3.1 Introduction of Hygienic Design Criteria for Valves ................................................................26
3.2 Overview of Valve Configurations ...........................................................................................30
3.2.1 Overview of Valve Housing Configurations ...............................................................31
3.3 VARIVENT® Valve Selection Scheme ...................................................................................33
3.3.1 Single Seat Shut-Off Valves: Flow Stoppage ............................................................34
3.3.2 Single Seat Shuttle Valves: Changing Flow Direction ...............................................35
3.3.3 Double Seat Shut-Off Valves: Hygienic Mix-Proof Separation of Media ...................36
3.3.4 When Product Recovery (“Pigging”) is Required.......................................................47
3.4 Modulating Control Valves ......................................................................................................48
3.5 Overflow Valves ......................................................................................................................50
3.6 Safety Relief Valve ..................................................................................................................51
3.7 Vacuum Valve .........................................................................................................................52
3.8 Sampling Valves .....................................................................................................................53
3.8.1 Varivent Sample Valve Type I ...................................................................................53
3.8.2 Varivent Sample Valve Type TSVN/U .......................................................................53
3.9 Butterfly Valves .......................................................................................................................54
3.10 Mixproof butterfly valves (Type 988): ......................................................................................55
3.11 Aseptomag Valves ..................................................................................................................56
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4 Dynamic and Static Behaviour of Valves in Pipe Systems ..............................................................58

4.1 When Liquid is in Motion .........................................................................................................58
4.2 When Liquid is at Rest ............................................................................................................59
4.3 Dynamic and Static Behaviour of Valves in Pipe Systems .....................................................60
5 Appearance and Scaling of Major Equipment on the Drawing ........................................................61
5.1 Orientation of Tanks and Associated Valves ..........................................................................61
6 Chapter Summary ............................................................................................................................62
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DOCUMENT HISTORY
Date Revision Change Author
2017.11.22 0.0 Update Corporate Design document Santiago
Villafñe
2017.11.28 0.1 Review and eliminate references (if proceed), Santiago
update pictures, Villafañe
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1 SOUND ENGINEERING PRACTICE (SEP)
In the following sections, the recommended good practices for engineering are described. They are related to the
different equipment used for design installation (type of valves, centrifugal pumps and piping systems from GEA).
All equipment related to a project will be listed in a PID and/or in a equipment list.
1.1 SEP for Varivent, Ecovent, Butterfly and Control Valves from GEA
SEP 1 - function Classify all these types of valves in the project (from P&IDs or equipment list) into these types:
close-off flow (type –A, -B, -C, -L, any butterfly or shuttle valve W, X, Y) or mix (type –E), or
control flow.
SEP1.1 - close-off These valves are to close against flow (minimizes water hammer) (exception: valves on tank
emptying.
If liquid will be trapped between two close-off valves, check for risk of thermal expansion /
hydraulic lock and ensure one valve can relieve (expansion pressure can lift seat) or else add a
relieving valve (type Q or safety valve if required).
SEP1.2 - mixing Minimize dead-legs by placing stop valves close to the mixing valve (at downstream, dead-leg
side).
SEP1.3 - control Control valves do not provide full shut-off. If this is necessary, add an automatic close-off valve.
Use proper manual valves to size Kv value.
SEP 2 - mix- As a minimum, CIP and product operations must be separated by mix-proof or block and bleed
proofing valves.
SEP2.1 - K or D Select K type when separating CIP detergents or CIP water, otherwise use D type.
SEP2.2 - other mix- Type C has a double seal (a pressure spike could cause mixing of incompatible stream) but it is
proof types an economical alternative, e.g. on suction side of CIP stations). Type B, with balancer, protects
against pressure spikes. Type R has radial sealing to minimize losses in valve activation. Type
T is a tank bottom valve to minimize dead legs on tanks.
SEP2.3 - VSC Connect VSC to mix-proof valves (except type K). Allow one VSC per product line, maximum
15 valves per 1” VSC on a 1” line. (NOTE in process description: VSC not allowed activate if any
of connected valves activated).
Locate VSC upstream of CIP supply valve or downstream of CIP return valve, so that dead leg
to VSC is not exposed to product or process water.
SEP2.4 - Seat lift Use seat lift if the product is sticky such as sugar or yeast, and would adhere to the seal unless
it was cleaned.
SEP 3 - line size Size the valves to the local flow to check allowable product velocities and effect on pump duty.
SEP 4 - pressure Size the actuator to keep valve close against a pressure difference.
SEP 4 - hygiene All product valves must be on a CIP route. If there is no flow through the valve on CIP, put a
note on the P&ID “minimize dead-leg”.
Tank emptying valves should be top to bottom flow, for complete draining – this is allowed to
contravene SEP1.1 since pressures are normally < 0 barg.
SEP 5 - materials Select seals according to fluid. If client requires material certificates, note requirements on valve
list sheet in equipment list and in valve order.
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SEP 6 - electrical Configure control cap as double feed-back, AS-I connection, solenoid in valve cabinet, 24V dc,
unless client / site requirements are different. ATEX zoning affects the selection of feedback
switches and solenoids.
SEP 7 - access Valves must be located where they can be maintained, either at ground level or on a tank or
platform.
SEP 8 - noise Calculate Kv for control valves at normal flow duties. If the valve would operate < 20% of
selected Kv for the lowest normal flow, these is a danger of excessive noise.
1.2 SEP for Overflow (Type Q) Valves from GEA
SEP 1 - function Classify all these (Q) valves in the project (from P&IDs or equipment list) into these types: relieve
flow (type –B, -L) or bypass type (type –E), or control flow (-B).
SEP1.1 - relief For safety of personnel, (i.e. where liquid/gas is hazardous) or for cases where pressure relief
value is critical, use safety relief valve type 488 or equivalent instead; otherwise, Q type is
acceptable. Pipe relief line to ground or drain.
SEP1.2 - bypass Use at each positive pump (includes homogenizers) in process lines.
SEP1.3 - control Select a back-pressure to apply to product and note effect on pump. Note, it prevents back-flow,
and therefore acts as a non-return valve. Therefore also check for trapped liquid as per 1.1 of
Varivent valves.
SEP 2 - mix- N/A

proofing
SEP 3 - line size As for Varivent valves. For relief valves, the relief line and valve housing may be sized according
to the flow required to reduce the pressure in the system to safe levels.
SEP 4 - pressure Size the spring range according to the proper pressure.
SEP 4 - hygiene If it’s located on a product line, the valve must activate in CIP to clean the seats. For a relief line
allow for loss of CIP during pulsing operation.
SEP 5 - materials As for Varivent valves.
SEP 6 - electrical Select one feed-back in lantern.

NOTE for process description – if the valve lifts, it should not put the program into error (exclude
from generic V/M errors), just give an alarm message.
SEP 7 - access As for Varivent valves.
SEP 8 - noise Select spring range so that the normal duty is mid-range on spring. If the valve would operate at
lowest spring tension, there is a danger of excessive noise.
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1.3 SEP for Vacuum Relief (Type V) Valves from GEA
SEP 1 - function Exclusively for vacuum protection of enclosed tanks. Must be protected against freezing, and
restrictions to air inflow.
SEP1.1 - relief Activates at minimum vacuum of 25mm water gauge of -2.5mbar. Normally not suitable on its
own for protection against collapse of hot CIP vapour.
SEP 2 - mix- N/A

proofing
SEP 3 - line size Size according to air inflow required against vacuum rating allowed for tank.
SEP 4 - pressure No protection against over-pressure. Self-acting on vacuum < -2.5mbar.
SEP 4 - hygiene If it’s located on a product tank, the valve must activate in CIP to clean the seat. Specify the
pneumatic lifting actuator (needs 5 bar air to open against maximum 3b in tank).
CIP fluid is collected in an integral drip pan. Size depends on size of valve to be collected in
funnel and drain pipe.
Allow for loss of CIP during pulsing operation.
SEP 6 - electrical Optional feed-back under drip pan.

NOTE for process description – if the valve lifts, it should not put the program into error, just give
an alarm message.

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1.4 SEP for Safety Relief (Type 488 and 483 Varivent ®) Valves from GEA
SEP 1 - function Protection of personnel from rupture of pipes or vessels containing hazardous fluids or gases,
or protection of equipment when pressure setting is critical.
Stericom types contain bellows-type seal, suitable for pharmaceutical application. Type 483 is
for tanks or valves. Type 484 is for dead-space free tank connection only.
Varivent type 488 is for dairy, food, beverage and brewing applications.
SEP1.1 - relief Run vent pipe to external or safe area (not linked to other vents). Observe installation guidelines
in manual to avoid a pipe layout that would allow liquid to accumulate over the lifting disk.
SEP 2 - mix- N/A

proofing
SEP 3 - line size Stericom Type 483 sized according to table in Components catalogue 3.2/4 (57); Stericom type
484 sized to 3.2/7 (57); Varivent type 488 sized to 3.2/11 (57).
SEP 4 - pressure Specify the pressure at which the valve must lift. This cannot be varied on site.
SEP 4 - hygiene If it’s located on a product line, the valve must activate in CIP to clean the seats. Specify the
pneumatic lifting device H8.
Allow for loss of CIP during pulsing operation.
SEP 6 - electrical Option – proximity switch for H8.

NOTE for process description – if the valve lifts, it should not put the program into error (exclude
from generic V/M errors), just give an alarm message.

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1.5 SEP for Centrifugal Pumps (Type TP) from GEA
SEP 1 - function These pumps add a differential pressure to liquids in a flow range 1 to 200m3/h, maximum 90m
flow head. It is for sanitary applications where the liquid is less than 500cP. The pump will operate
at a point determined by the system back pressure and the “pump curve” for the selected impeller
/ model. See SEP 2 below.
SEP1.1 - direction These pumps do not block liquid flow in either direction.
If reverse flow is a possibility, and it is fitted with a speed drive, a specific set-up configuration is
required to avoid errors in speed drive.
SEP1.2 - starting Rated for up to 15 starts per hour. It is not suitable for pulse operation.
SEP1.3 - control Pump operating flow can be controlled by speed drive or by control valve on discharge.
SEP 2 - sizing Use a pressure drop calculation tool to calculate the duty of the pump. Warning levels should be
taken in consideration where NPSH is low (redesign system / select special pump) or liquid
velocity is high (check client requirements).
Specify the duty to the pump supplier / manufacturer, who is given the responsibility to select the
correct model / impeller / motor based on this data. Check the pump type proposed by the
manufacturer – it is to be mid-range on curve and ideally be one impeller size below maximum
allowed in housing.
SEP2.1 - routes If the flow can increase due to changes in routing or operating requirements (CIP, or options),
make a separate calculation for this duty and provide all relevant information to the supplier.
SEP2.2 - motor Consider the requirements for over-sizing the motor if operating conditions allowed for “run-out”,
i.e. the pump operating at the end of the pump curve due to absence of system back-pressure.
Consider the number of starts per hour, especially for CIP supply pumps and pumps operating
to maintain a level or pressure.
SEP2.3 - sealing The seal protects the motor from the liquid in the housing; it allows part of the fluid to lubricate
the seal surface. NEVER run the pump without liquid in the line – the seal will overheat and
break.
Consider the posibility of flushed seals for CIP supply pumps and pumps where product is at
temperature >60°C, or is likely to crystallize or harden when the pump is inactive. Double or
balanced seal sets are used to prevent leakage of the fluid to the atmosphere, or for high suction
pressure.
SEP 3 - pressure Find the maximum dead-head pressure that the selected pump can generate, and check the
pressure rating of the connected piping system.
SEP 4 - hygiene Pump must be on a CIP route. Check if pump needs to operate in CIP, if not, put a note on the
process description / activation table to “jog” pump a limited number of times in CIP. If pump
housing needs to be drained (usual in pharmaceutical applications) then specify VTP drain valve)
SEP 5 - materials Select seals according to fluid media. If client requires material certificates, note requirements
on pump sheet in equipment list and in pump order.
SEP 6 - electrical Configure pump as the available Hz and voltage. Please, always verify hertz and voltage.
Standard IEC motor, with thermistors if necessary, unless client / site requirements are different.
Select stainless steel shroud. ATEX zoning affects the selection of motors, thermistors, cable
and glands.
SEP 7 - access Pump must be located where it can be maintained. There is approx. 80mm clearance under the
motor. If more is required, fit the pump to a box section frame.
SEP 8 - noise See SEP 2 (NPSH) above.

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1.6 SEP for Piping Systems from GEA
SEP 1 - function Classify all these systems (from P&IDs) into these types: hygienic, hazardous fluids, utilities.
Note that “tubing” is the correct description for the typical stainless steel “pipe” we use in our
installations, and that “pipes” are defined by reference to schedules of pipe thicknesses.
SEP1.1 - hygienic Consider CIP as the prime requirement. CIP flow to be a minimum of 1.5m/s in any part of
hygienic pipe system.
Avoid or minimize dead-legs (Length / Diameter <= 0.5).
SEP1.2 - hazard Specify earthing at each pipe connection to dissipate static charge for hazardous fluids or
powders with risk of explosion or fire.
Concentrated detergents are hazards and must be carried in Sch. 5 pipe or double pipe, to
minimize dangers of leaks.
SEP1.3 - utilities Service pressure is outside our control; consider the available pressure and specify pressure
reducing sets, if required.
SEP 2 - line size Size the pipes to the local flow to check allowable product velocities and effect on pump duty.
SEP 3 - pressure Generally adopt 5b as the design pressure. This corresponds with the “standard” actuator
selection for GEA Flow Components valves with compressed air pressure of 6b.
Check the multiple of pipe diameter by design pressure (<5000 generally, or <2000 for
hazardous fluids).
SEP3.1 - hammer Consider any shut-off valve or positive displacement pump where liquid can suddenly stop due
to normal or fail operation of valve or pump.
Ensure valves close against flow. If no fail-safe relief is possible (given the valves as required
or used in the process), specify a Q-type valve discharging safely to drain. Specify Q-type
valves at positive displacement pumps so that discharge-line pressure can lift seat to relieve
to upstream side.
Note in process description / activation matrix – on-delay of pumps, off-delay of valves.
SEP3.2 - vacuum If due to siphoning, or collapse of vapor after CIP, or water hammer, vacuum can be created
in the system, provide vacuum break valves so as to allow the pipes to drain out.
SEP3.3 - expansion Stainless tube will expand approximately 1.7mm per meter when heated from 0°C to 100°C.
In lengths < 5m where elbows are free to move, compensation for this expansion is usually not
necessary.
The mechanical installation specification makes it the contractor’s responsibility to cater for
expansion by sliding supports, pipe loops, or compensators. It must be noted, on layout or
otherwise, the fixed points in each pipe >5m straight length (usually at equipment, or where
passing through a wall, or as designated).
SEP3.4 - safety (Pressure) Consider if the pressure can exceed the design pressure and find the weakest
equipment or tubing in the system. If this equipment or tubing is of a lower rating that the
possible maximum pressure in a system, protect the equipment with a rated safety valve.
(Temperature) If the pipe surface temperature is generally at a temperature of >60°C and is
within normal reach of operators, check the possibility of insulate the pipe, it must be marked
on the P&ID as requiring insulation.
SEP3.5 - venting / Line must be capable of being filled and emptied.

draining
On closed loops (e.g. circulating water for heat exchangers), ensure high points can be vented,
and low points can be drained, with the addition of manual valves (for first filling).
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SEP 4 - hygiene Line must be on a CIP route. If there is no flow through the line on CIP, put a note on the P&ID
“minimize dead-leg”.
Line must be free-draining to atmosphere. If a non-draining section (U-section) in the pipe
layout is unavoidable, add an automatic drain valve for use in CIP (and add a note to the
process description).
Specify line filters (M&S angular type), mesh 1.5mm, on delivery side of CIP pumps to trap
residual dirt or particles.
Product filters may be specified by client. Check the pressure drop, and if a proprietary filter is
specified (e.g. bag-type) note that many are not CIP cleanable and may have dead-legs. Advise
client of any breaches in hygiene or CIP due to the client specification. The responsibility for
manual cleaning will be with the client.
SEP 5 - materials Select seals according to fluid media. If client requires material certificates, note requirements
on mechanical installation specification and in contract / order.
Tubing to be AISI 316L or 304 to a defined standard (DIN 11850, or ASTM A270R.) for
pharmaceutical or high quality hygienic systems.
SEP 6 - insulation For thermal efficiency, steam, condensate, chilled water and hot water pipes must be insulated
– refer to mechanical installation specification.
SEP 7 - access Equipment must be located where it can be maintained, either at ground level or on a tank or
platform. Pipes can be carried in overhead racks.
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2 SELECTION OF APPROPRIATE PUMP TYPES
2.1 Overview of Pump Types, and Reference Material
Pumps are commonly grouped into 2 classes; those which produce pressure by accelerating the liquid (roto-
dynamic or centrifugal type), and those which move volume (positive displacement type).
Fig 2.1.A: Pump Types

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The operating characteristics of each type of pump is illustrated below. A centrifugal pump has a characteristic
flat curve with the pressure (representing pressure added by the pump) decreasing with flow, whereas a positive
displacement pump typically moves the same volume flow regardless of pressure.
Fig 2.1.B: Comparison of Pump Responses
The “dead head” represents the pressure added by a centrifugal pump when the outlet is closed.
The “System” represents the pressure drop in the piping and equipment downstream of the pump. As flow and
velocity increase, the system pressure increases. The pressure drop at zero flow represents the static head, or
the pressure required to lift the liquid to the discharge point.
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2.2 Centrifugal Type – Where to Use it
A centrifugal pump takes a liquid in at the center of a rotating impeller and accelerates it by moving it along the
vanes to the discharge neck at the top right of the impeller housing. The fast moving liquid is suddenly slowed
down to pass through the outlet. This is what generates the pressure at the discharge point. Looking from the
motor side, the motor and the impeller move in a clockwise direction.
Key features:
1 Impeller A Mechanical seal

3 Pump cover 7 Shaft
55 Key to join motor stub shaft to shaft 7
Fig 2.2.A: Centrifugal Pump
Centrifugal pumps have very wide applications in our business. They are cheaper than similarly sized positive
displacement pumps, are easy to clean, and many types have EHEDG certification.
They are not good for cases where the suction pipe is not flooded (CIP return from a tank), or for low flow-rates
(under 5m3/h requires a careful selection) or media which is sensitive to shear (because of the acceleration caused
by the impeller) or media which have a viscosity greater than 300cP (note some manufacturers will supply
centrifugal pumps for higher viscosities).
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2.3 Self-Priming Centrifugal Type – Where to Use it
A self-priming centrifugal pump is a mechanical modification of the impeller housing so as to tackle one
fundamental weakness of centrifugal pumps – the requirement for flooded suction. Each manufacturer has a
different approach.
Alfa Laval developed a cartwheel type impeller to create a wide liquid ring. APV (Ws+) use an inducer (a “pre-
impeller”) to create a liquid ring, plus a small pilot pipe refilling the suction from the discharge to create a very
effective and efficient self-priming pump.
Some manufacturers put a reservoir on the outlet (to maintain prime). Fristam and Hilge have liquid ring pumps
which depend on a gradually deepening channel behind the impeller to create an enhanced suction.
Appart of Hilge, GEA have released a self-priming centrifugal based on the TP pump which has a good chance
of being the first EHEDG certified self-priming pump. It is efficient (40% compared to a typical 25% for a
conventional liquid ring pump), it uses an inducer which is eccentrically mounted to maintain a liquid “well” while
it creates a liquid ring, and does not need a pipe connection from the discharge to the suction. It does need to be
piped to be at a low point.
Fig 2.3.A: Self-Priming Centrifugal Pump
TPS Self-priming centrifugal pumps are almost always used ONLY for CIP return from tanks. Most types are not
designed in a hygienic way and would therefore be unsuitable for product.
Even other pumps manufacturers and the more recent GEA models (TPS and Hilge) are less efficient than
standard centrifugal motors and therefore have a high power requirement. They are not suitable for generating
high pressure – the usual limit is 4bar for “conventional”.
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2.4 All centrifugal pumps from GEA Hilge
Fig 2.4.A: Centrifugal Pumps from GEA Hilge

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2.5 Rotary Lobe Positive Displacement Type – Where to Use it
A rotary lobe pump draws liquid into a central inlet between two counter rotating lobes, and, as the lobes rotate,
each carries a fixed pocket of liquid around until they meet on the opposite side, where they are squeezed together
and “escape” through the centrally mounted outlet.
Note that the pump creates enough suction to prime itself, and that the flow is necessarily “pulsed” because of
the time interval between suction and delivery. Increasing the number of lobes reduces the effect of pulsation. (A
bi-lobe or scimitar type is worst for pulsation but can be selected for the most shear-sensitive products.
Conventionally we use a tri-lobe. There are 4-lobes available also, which is best at reducing pulsation).
In a lobe pump there is clearance between the lobes and the impeller casing which allows a certain amount of the
liquid to be carried back to the suction. This is called slippage and it is a consequence of having a clearance for
the lobes. Slippage decreases as viscosity increases. Pumps which are designed for viscous materials are very
poor at pumping water or CIP.
Fig 2.5.A: Rotary Lobe Pump Operation
Rotary lobe pumps are used for liquids with a viscosity higher than 300cP, or for shear-sensitive liquids. They are
typically used for cold cream, flavors, colors, food oils and yeast. The Alfa Laval SRU, and the Waukesha
Universal II series are among several rotary lobe pumps with EHEDG certification.
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2.6 Peristaltic Type – Where to Use it
A peristaltic pump is the simplest type of pump as it does not have any valve, ring or anything susceptible to
obstruction or corrosion. The fluid is just in contact with the internal wall of the hose, eliminating the risk of
contamination of the fluid from the pump or vice versa. This type of pump can run dry without any problem.
The hose is compressed by a roller against a semi-circular track. As the roller move along the track, the fluid
keeps moving until the track finishes. New fluid enters the hose and the same operation is repeated.
The material hose has to be selected according to the fluid media to be pumped.
Clean the hose may be difficult in some cases. The hose may be smaller or the pressure in the hose for cip may
be higher than the pressure design hose.
Check always the hose material and the cleanability possibilities.
Fig 2.6.A: Peristaltic Pump Operation
A: hose of the pump / B: housing / C: rotor / D: shoe / E:housing cover

F: breathing window / G: supports / H: reducer / I: electrical motor
Peristaltic pumps are ideals for most types of fluids, even the ones with a high viscosity, the shear-sentives, the
corrosive and the abrasive ones, or those which have suspended solids.
They are especially useful in pumping applications where hygiene is very important. These pumps are
recommended for different applications: measuring, dosing and dispensing. They are easy to install, easy to
operate and cheap to maintain.
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2.7 Piston Type – Where to Use it

This type is designed to produce regulated doses of fluid in an installation. The piston (D) drowns the fluid (B) in
the camera (C) when it moves downwards and discharges the fluid (E) when it moves upwards. It is necessary to
have a rotation of the conical valve (A) in a coordinated way so it can let the fluid enter the camera from B and
exit it by E.
Fig 2.7.A: Piston Pump Operation
The piston (D) has two rings (F) y (H), and the space created between them is called hydraulic barrier (G). This
allows the cleaning of the ring (F), which is in contact with the fluid and needs to be cleaned. During the production
phase, this ring forms a barrier between the product and the air external to the dispenser, which is contaminated,
by circulating good quality water with no pressure.
This pump is used in order to achieve a high precision injecting the fluid, for example, while packaging yogurt or
other viscous products, and it also allows to inject products with solids, like yogurt with pieces of fruit.
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2.8 Screw Type – Where to Use it

This type consist of a screw that moves the fluid along the screw axis as it turns. These pumps have a great
vacuum power and they are able to pump viscous fluids and generate very high pressures.
Fig 2.8.A: Screw Pump Operation
This pump is used for viscous fluids (like butter, cream, pulp fruitR) and high pressures.
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2.9 Twin screw Type – Where to Use it
This type consists of two screws which form chambers. These chambers are filled with the pumped fluid and, as
the pump rotate, the fluid is moved from the suction side of the pump to the higher pressure discharge side of the
pump.
While pumping there is no metal-to-metal contact within the pump housing. This allows good pumping
performance even with non-lubricating and corrosive and contaminating fluids.
Reverse flow is allowed by changing the shaft direction, so the suction becomes from discharge and vice versa.
Fig 2.9.A: Twin Screw Pump Operation (102)
This pump is also used for viscous fluids and high pressures, but it is more compact than the single screw type
and its pieces have a lower wear.
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2.10 Diaphragm Metering Type – Where to Use it
The diaphragm is actioned using compressed air, so the valves are operated by positive and negative pressure.
The fluid is sucked from the suction line into the process chamber. During the discharge, the suction valve is
closed and the discharge valve will open. The fluid is discharged from the process chamber into the discharge
line.
The diaphragm can be also actioned mechanically. In this case, they are used as dispensing pumps.
Fig 2.10.A: Diaphragm Metering Pump Operation
These pumps are mainly used for the transport of products, but not during processing. They are used for pumping
hot caustic and acid, and other products like fruit juices concentrates, jam, olives, honeyR
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2.11 Mechanical Seals
Most of the pumps showed need a Mechanical seal.
A mechanical seal is a device used to contain fluid within the pump, where a rotating shaft passes through its
stationary housing. The key is to allow the rotating shaft to enter the wet area of the pump without allowing the
pressurized fluid to escape. This is the reason why a mechanical seal is needed.
The most typical mechanical seals used are:
Fig 2.11.A: Mechanical seals
Single-acting (standard) mechanical seal.
It is used for non-critical substances and for low pressure

applications.
Single-acting, flushed (quench) mechanical seal.
It has a slide ring holder, a shaft sealing ring and a shaft

protection sleeve.
It is used for crystallizing and highly viscous products (>100

cP).
Double-acting mechanical seal.
It has a second slide ring and a counter ring on both sides.
It is used for hazardous, abrasive and dilatant fluids.

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2.12 Design Rules for Pumps and Fail-Safe Features

At the simplest level we are concerned with the following key words associated with pumps: flow, no flow, reverse
flow, high pressure and low pressure.
2.12.1 Flow
Ensure there is a supply of liquid to pumps before they start. Place them where there is a flow by gravity into the
suction of the pump, ensure by calculation that there will be adequate suction pressure, and control the operation
of the route so that the valves open (to allow liquid to flow) before the pump starts. Note even P.D. type pumps,
which can prime themselves, should still be governed by this rule.
2.12.2 No Flow
There are two cases; no flow due to blockage of the outlet line, and no flow because there is no liquid getting into
the pump. The control system needs to be designed to protect against these cases by generating a no flow error,
and in particular, by turning off pumps if there is a low level in the supply tank.
In the first case, there is no immediate danger for centrifugal pumps. The fluid will be heated by the pump and will
expand, and the motor will heat-up. The motor will normally NOT have a thermistor and can be damaged (usually
after more than 10 minutes) to the point of needing to be sent for rewinding.
The product, if the supply side route is open, generally will not cause damage due to expansion, but this needs to
be considered. However, there is a danger for positive displacement pumps, because the volume of liquid
displaced by the pump must go somewhere and it will rupture pipes or connections or equipment. Therefore we
must design a fail-safe protection for positive displacement pumps in the form of a pressure relief or overflow
valve.
In the second case, the pump will run dry which will cause the seal to heat up extremely quickly (a matter of
seconds). The pump must be protected by the control system!
2.12.3 Reverse Flow
For centrifugal pumps, even incorrect wiring (running backwards) does not cause reverse flow, just much lower
pressure. However, as the impeller housing has an open flow path, liquid can flow backwards through a centrifugal
pump if it is off. This can be a desired result (e.g. if you are washing two lines together, one in reverse flow) but if
it is not required, the best protection against it is a non-return valve.
For lobe type positive displacement pumps, incorrect wiring can cause reverse flow driven by the pump. If there
is liquid available (hence, per rule 1, always have the route open before starting the pump). However when the
pump is off, it is a blockage to flow (except for a small amount of slip). Therefore do NOT put a non-return valve
on the outlet of a P.D. pump.
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2.12.4 High Pressure
If high pressure can be generated outside the pump in question (for example by pumps in series), then pressure
on the suction side of (typically) 3 bar or greater can force open a mechanical seal, and cause excessive leakage.
Therefore, if putting pumps in series ensure that the second pump has a balanced (double) mechanical seal. The
control of such pumps must allow for a phasing in and out to avoid sudden pressure peaks or water hammer.
A pump generates a pressure wave when it starts, which can be higher than the dead head pressure; therefore
check the actuator sizing on valves that are close to the pump delivery and ensure there is a margin of safety on
the lifting pressure (2 bar suggested). Valves further away will not see the same level of pressure due to pressure
drops in the system.
Water hammer is a well-known phenomenon caused by the sudden closing of a valve in a flowing stream of liquid.
As a rule of thumb, sudden closures can cause a pressure spike of twice the operating pressure (if lines are more
that 100m long, this effect is exacerbated). The pressure spike may need to be calculated
The control system must protect against this by turning off pumps while the route valves are still open. This is a
phased shut-down. The designer must put in additional safety for positive displacement pumps.
For centrifugal pumps, the designer must consider where extra pressure would relieve to – for example in a normal
transfer line, the weak point may be the push-out to drain valve (typically a UA type) which will open to relieve
excess pressure. Furthermore, the control system should be designed to minimize pump re-starts (pulse/pausing
of pumps is not recommended!).
2.12.5 Low Pressure
It is very important to assure that there are no parts in the installation with a very low pressure because if the
pressure at any point of the circuit is lower than the vapour pressure of the liquid, cavitation will appear. This effect
will damage the pump and prevent it from priming.
In order to see if the installation is close to the effect of cavitation, the Net Positive Suction Head (NPSH) is used.
There are two types of NPSH:
- NPSHa (available): it measures how close the fluid is to cavitation
- NPSHr (required): limit value required at a specific point of the installation to avoid the cavitation of the
fluid.
The NPSHr has to be lower than the NPSHa of the centrifugal pump so that the cavitation effect does not exist
and the pump functions effectively.
There are rules of thumb regarding suction pipes sizes, for example the suction should be one size larger than
the delivery side – this may compromise the CIP velocity in each, so it is not always appropriate.
One very useful rule is to have as long as possible a straight suction pipe into the pump. This is especially relevant
for positive displacement pumps, because the pulsing flow creates an additional acceleration head (difficult to
calculate), that can affect cavitation.
Vacuum can also occur in piping if there is an intermediate high point between the pump and the outlet. This is a
risk associated with the pipe layout. If the pump stops, the liquid in the high point will drain both ways downwards,
and if BOTH sides are unable to drain out fully (thereby letting air into the line), then a vacuum break occurs. This
causes a problem on restart of water hammer and possibly even an overload on the pump (due to high initial
flow). In the piping design, select and specify routes that avoid intermediate rises with liquid trapped on both sides
– a continuous downward path on both sides is ideal.
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3 SELECTION OF APPROPRIATE VALVE TYPES

This section explains the different VARIVENT® valve types, recommended uses and fail-safe design.
3.1 Introduction of Hygienic Design Criteria for Valves
The VARIVENT® Valve System is designed for process plants in which production quality, hygiene and
operational safety is a first priority. They are a classic example of “hygienic engineering” in which the principles of
“cleanability” and “drainability” are incorporated into the mechanical design.
There are certain features of the design of the VARIVENT® valves that differentiate them from other piston-type
valves, including:
- Leakage detection at the open valve lantern, which provides a hygienic design solution
- Geometry of the valve housings (no pockets, drainability, curved surfaces), which provides a hygienic
design solution.
- The seal / gasket design is such that no crevices exist where soil residues may be trapped and bacteria
can accumulate and multiply.
- The valve can be “cleaned in place“.
- Modularity / interchangeability of parts
- Standard “product contact” surface finishes of Ra </= 0.8µm, which provides better cleanability.
- The valves are EHEDG approved.
According to the EHEDG Requirement for “Leak detection”, the valve design must provide for rapid external
detection of leakage of seals between the product side and the atmosphere. In addition, it must not be possible
for fluid to transfer from actuators into product areas, and vice versa. VARIVENT® valves achieve this requirement
as follows:
- The lantern is opened, allowing the valve stem to be visible and providing immediate leak detection from
the outside.
- The opened lantern provides a break between the actuator and the valve housing, ensuring that there
can be no contamination from the actuator through to the product.
- The opened lantern also prevents temperature changes occurring in the actuator (as it is not subjected
to any changes in product temperature), thereby increasing the actuator’s lifetime.
Fig 3.1.A: Varivent Valve (lantern open)

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The VARIVENT® valve system satisfies the EHEDG Requirement for “Geometry and Drainability” as follows:
- The clear height of the housing always conforms exactly to the size of the sockets.
- There are no domes or sumps in the valve housings.
- The housings have excellent cleaning characteristics.
Fig 3.1.B: Geometry and Drainability
The VARIVENT® valve system satisfies the EHEDG Requirement for “Seals” as follows:
- The valves utilize a V-ring type seal in a groove, and a metallic stop which limits seal deformation and
avoids uncontrolled overstress.
- This avoids any dead space behind the seal, reduces the risk of contamination and increases the lifetime
of the seals.
Fig 3.1.C: Seals

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The EHEDG Requirement for “Cleaning in Place” lists the following methods for cleaning valve surfaces:
- Seat lifting to flush the seat, complete with a metallic stop, cavity and drain pipe.
- Cavity spray cleaning to reach the leakage chamber up to the seat seals and the drain pipe.
The VARIVENT® valve system achieves this requirement as follows:
- Cleaning by seat lifting optimizes cleaning of the cavity chamber and seal.
- The cavity outlet is small and easy to clean.
- There are no dead corners and a metallic throttling gap – no risk of contamination.
- Cleaning via the external connection achieves optimized cleaning by means of a spray nozzle.
Fig 3.1.D: CIP 1
Fig 3.1.E: CIP 2

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3.2 Overview of Valve Configurations
The VARIVENT® valve system is modular in nature, it means valve parts are interchangeable. The high flexibility
offers many advantages. With the ability to combine all basic elements with one another, the system offers a
broad range of possible applications. Existing valve systems in process installations can be modified or adapted
without changing the current system concept.
Fig 3.2.A: VARIVENT® valve parts
(1) Control and Feedback system
(2) Actuator
(3) Lantern
(4) Valve disk
(5) Valve housing

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3.2.1 Overview of Valve Housing Configurations
The height of the dead-zone-free housing exactly corresponds to the diameter of the connection pipeline.
This avoids domes and sumps with their negative effects such as oxidization damage or cleaning problmes. The
special ball shape of the housing offers the best flow profiles without flow separation.
All valves have exchanged modules, and design offers numerous housing combinations with either clamped or
welded seats.
Fig 3.2.A: For stop valves and mix-proof valves:
Fig 3.2.B: For shuttle valves:

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The two-letter code indicates the valve type (first letter) and the housing configuration (second letter) being used.
It is also possible to have a valve with a “mix-match” housing combination, where the upper housing is smaller
than the lower housing. In this case, the actuator size is based on the size of the upper housing. In some cases,
it is possible to have a larger housing on the upper side, e.g. the 3” / 2.5” combination, but this should always be
confirmed with Tuchenhagen prior to purchasing the valve.
• Note: Valves with mix-match housing combinations should also be considered for use in Valve Seat Cleaning
operations, in place of the more commonly used NL type valve, because there is no dead-leg associated with
its installation.
The following types of valves are manufactured within the VARIVENT® Valve System:
• Single Seat Shut-off Valves
• Single Seat Shuttle Valves
• Double Seal Valves
• Mix-proof Shut-off Valves
• Mix-proof Shuttle Valves
• Mix-proof Tank Bottom Valves
• Aseptic Valves
• Leakage Free Valves
Also covered in this section is Tuchenhagen’s range of:

• Sampling Valves
• Vacuum Valves
• Overflow Valves
• Control Valves
• Safety Valves
All valves will be describe along the rest of this chapter.

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3.3 VARIVENT® Valve Selection Scheme
The VARIVENT® Valve selection scheme is an aid to selecting the appropriate valve type for the particular
application. Please refer to the flow component catalogue for details.
When selecting the type of valve to use, it is important to bear in mind that different valve types have different
static and dynamic closing behaviours that must be taken into account when operating pipe systems.
In static pipe system conditions, it may be possible for a valve seat to open due to high pressure in the pipeline.
(Standard valve design allows the valve to be resistant to pressures of 5 bar or less).
Conversely, it may be possible for a valve seat to be “locked” into place (i.e. unable to open) if the pressure in the
pipe-line pressing down on the valve seat is greater than the compressed air pressure required to open the valve
(standard valves require 6 bar air pressure to open). Therefore, when selecting the valve type to use, it is important
to consider the orientation of the valve seats as well as the actuator size required.
In dynamic conditions, water hammer may be exacerbated during the closing action of the valve. Therefore it is
always important to ensure that the valve is installed so that its seat will close against the direction of flow of the
liquid. The diagram below shows a typical mix-proof valve, where the arrow indicates the recommended direction
of flow in order to prevent these pressure surges:
Fig 3.3.A: Typical Mix-Proof Valve

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3.3.1 Single Seat Shut-Off Valves: Flow Stoppage
• Valve types N and U provide single seat shut-off (flow stoppage) within a piping system.
• Typical applications include: Drain valve (type U), bypass valve, dosing valve and tank outlet valve
• The actuator is reversible, with the normal position being spring to open, air to close.
• The direction of flow dictates whether an N or a U valve is most appropriate – pressure surges during the
closing operation of the valve should be avoided. The valve should always shut against the direction of
hydraulic flow.
• If closing against the direction of flow is not possible (e.g. emptying of the system) the valve type U should
be used.
• There is also a smaller, more economical version of the N type valve available (ECOVENT) which has no
accessories and fewer housing combinations available.
Fig 3.3.B: Valve Types N and U
Type N Type U
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3.3.2 Single Seat Shuttle Valves: Changing Flow Direction
• Valve types W and X change the direction of flow within a piping system.
• The valve switch over should always take place against the direction of flow.
• Typical applications include: CIP supply piping, CIP return piping, collecting (converging) (Type W),
separating (diverging) (Type X).
• The actuator is reversible, with the normal position being spring to open, air to close.
• There is also a smaller, more economical version of the W type valve available (ECOVENT) which has
no accessories and fewer housing combinations available.
Fig 3.3.C: Valve Types W and X
Type W Type X
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3.3.3 Double Seat Shut-Off Valves: Hygienic Mix-Proof Separation of Media
3.3.3.1 Valve Type D
• The D type valve provides mix-proof separation at pipe junctions within pipe systems – stopping flow or
joining flow streams.
• Typical applications include: Valve blocks, tank outlets, units. For mix-proof separation of incompatible
media in rigid matrix-piped systems flowing through closed valve housings or for protecting already
cleaned pipes against contamination. This valve allows tanks in a common valve block to be washed
without putting the transfer operation at risk of contamination.
• The valve has an axial/axial gasket arrangement on the insert (which causes leakage of product during
switching from open to closed).
The lower seat moves up by about 2mm (allowing material in the bottom housing into the neutral area) to
join the upper seat and then both seats move up together
• The valve type D has a cleaning device for spray-cleaning of the leakage chamber. If valve seat cleaning
is required in connection with pipe cleaning, the valve must be equipped with a lifting actuator for lifting
the valve disk on the actuator side and/or on the opposite side for cleaning the leakage chamber.
• The valve should always shut against the direction of flow.
• Note: When ordering a D valve with a lifting actuator for independent seat lifting, it is very important to
specify that the standard cavity cleaning connection to the valve stem is also required.
To achieve full EHEDG requirements, it must be possible to clean the cavity of the valve; i.e. just cleaning
the seats is not enough because not enough flow velocity is present in the valve cavity to ensure that it is
cleaned properly. This should also be noted on the P&ID and in the FDS.
Fig 3.3.D: Valve Type D
Type D Seat Arrangement

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3.3.3.2 Valve Type B
• Higher pressure peaks over 25 barg in the pipe system beneath the valve seat may force the lower valve
seat open. The pressure peak is then relieved via the leakage outlet.
• The B type valve provides mix-proof separation at pipe junctions within pipe systems.
• Typical applications are similar to the D valve, except they are preferred for use with expensive products
in high pressure conditions.
• The valve comes with a balancer for the lower valve seat, which provides pressure hammer safety up to
25 bar.
• The valve has an axial/axial gasket arrangement on the insert (which causes leakage of product during
• Note: Due to its pressure resistance from the balancer, the valve has strong spring closing forces that
cause the valve to close much quicker than the valve type D without balancer. This may cause such
problems as water hammer in the piping system, or loss of feedback. The closing time of the valve can
be prolonged by throttling the exhaust air or by serial disconnection in the system via timer, first stopping
the liquid supply and then closing the valve1.
• The B type valve has the same housing combinations and sizes as the D type valve.
• Note: When ordering a B valve with a lifting actuator for independent seat lifting, it is very important to
the seats (with the lifting actuator) is not enough because not enough flow velocity is present in the valve
cavity to ensure that it is cleaned properly. This should also be noted on the P&ID and in the FDS.
Fig 3.3.E Valve Type B
Type B Seat Arrangement
Notes:
1. “In particular for valves (type R and type B) which are balanced under the valve seat against pressure surges, it is of
utmost importance that these valves are not closed abruptly against flowing in liquid. Otherwise high dynamic
pressure forms at the valve seat, high differential pressure at the discharge side and high flow velocity occur”.
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3.3.3.3 Working Principle: D and B Type Valves
Fig 3.3.F: Valve Type D and B
During opening, the lower seat moves up first, by about 2mm, to join the upper seat. This action allows liquid from
the lower pipeline to enter the neutral area of the valve. Then both seats move up together. During the closing
action of the valve, the liquid in the neutral area is discharged via the leakage port.
Fig 3.3.G: Effect of Balancer
Pressure acts equally in all directions. Also, pressure is inversely proportional to surface area. Therefore, the
addition of the balancer to the lower part of the valve insert, increases the surface area upon which the pressure
of the liquid can act. This counteracts the pressure which is acting on the valve seat, thereby “balancing” the effect
of the pressure surge.
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3.3.3.4 Valve Type R
• The R type valve provides mix-proof separation at pipe junctions within pipe systems.
• Typical applications are similar to the D and B valves, except they are preferred for use with expensive
products where no losses are desired.
• The valve has an axial/radial sealing arrangement on the insert (which means it is leakage free during
• The valve is fitted with a balancer which provides pressure hammer safety up to 30 bar.
• Due to its pressure resistance of 30 bar(g) and its quick-closing characteristic, the same conditions as
described for valve type B must be taken into account for the closing of the valve.
• Note: When ordering an R valve with a lifting actuator for independent seat lifting, it is very important to
the seats (with the lifting actuator) is not enough because not enough flow velocity is present in the valve
cavity to ensure that it is cleaned properly. This should also be noted on the P&ID and in the FDS.
Fig 3.3.H: Valve Type R
Type R Seat Arrangement

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3.3.3.5 Working Principle: R Type Valve
Fig 3.3.I: Valves with Axial-axial and Radial-axial Sealing
The radial sealing arrangement on the lower seat of the R valve means there is no leakage of product from the
neutral area during switching of the valve.
The axial-axial sealing arrangement means that the valve seal lifts as the lower part moves up, allowing liquid into
the neutral area. Whereas with the radial sealing arrangement, the seal is retained as the lower part moves up,
so that no liquid can enter the cavity.
Fig 3.3.J: Axial-axial Sealing

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• Cleaning can be achieved by means of a “valve seat cleaning” valve (typically an N type valve) which
supplies CIP solution via a flexible hose connection to the neutral area of the mix-proof valve.
• Cleaning can also be achieved through lifting (by fitting a lifting actuator onto the valve, which can lift the
individual valve seats independently of each other and of the main operation of the valve). This means:
o Optimised cleaning of cavity and gasket surfaces.
o Metallic throttling gap.
o No dead corners.
o Small and easily cleanable leakage outlet.
o No contamination risk.
Fig 73.3.K: Cavity Cleaning and Lift Positions
Cavity Cleaning Lift Positions

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3.3.3.6 Double Seat Shut-Off Valve: No Cleaning of the Neutral Area
• The K type valve provides mix-proof separation at pipe junctions within CIP or gas pipe systems – with
no cleaning of the neutral area.
• The valve type K is not designed for cleaning the leakage chamber. It is not suitable for applications in
hygienic product systems. It is preferably used in pipe systems that need not to be cleaned, but must
have mix-proof separation.
• Typical applications include mix-proof separation of CIP solutions or gas. They are also frequently used
on CIP Centres.
• The leakage chamber of the valve type K is not drained, neither in vertical nor horizontal installation
position of the valve. This should be taken into consideration when using this valve type. If draining of the
leakage chamber is required, then double-seat valves, type D, B or R should be used. The double-seal
valve, type C is also suitable for simple applications.
• The valve has an axial/axial gasket arrangement on the insert (which causes leakage of liquid during
• The K valve is an economic version of the D type valve, where hygiene might be less of a concern. It is
not available with a balancer.
Fig 3.3.L: Valve Type K
Type K
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3.3.3.7 Double Seat Shut-Off Valve
• The C type valve provides double-seal separation at pipe junctions within CIP or gas pipe systems –
stopping flow or joining flow streams.
• In all installation positions of the valve type C, the leakage chamber is drained via the lateral drain valves.
• If the valve is to be mounted in horizontal position, (e.g. Gas Block) the drain valve should always be at
the lower position to ensure drainage.
• This valve is not commonly used, although one possible use is in CIP Centres, instead of using a K type
valve (the advantage being that the seals/seats of the C valve can be cleaned).
• The C valve could be used as a more economical version of the D valve, but it should be noted that it is
not as reliable, because it does not have two independent seats. (If one seat lifts due to high pressure in
the line, so does the other).
• The valve has an axial-axial sealing arrangement.
• There is only one valve disk.
• The leakage cavity is cleanable, by means of 2 rinsing valves.
• On a product or Gas Block installation, one rinsing valve should be connected to a VSC supply and the
second rinsing valve should be piped to drain via 8mm tube.
• On a CIP Plant installation, only 1 rinsing valve is needed. (No VSC) This valve should be piped to drain
via 8mm tube. The Nozzle on the valve housing for the 2nd rinsing valve should be blanked off by using a
PTFE blanking plug. This plug is “flush” with the inside wall of the housing so there is no dirt pocket.
• Note: Make sure that both seals are in good condition, as otherwise only one seal is reliably sealing.
When changing the seals, both seals should always be replaced.
Fig 3.3.M: Valve Type C

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3.3.3.8 Double Seat Shut-Off Valve: Changing Flow Direction with Mix-Proof Protection
• The type Y valve changes flow direction with mix-proof separation of incompatible media.
• Typical applications include: Pasteurizers (pasteurised product against non-pasteurised product) and
tanks. Since the valve type Y is a mix-proof shuttle valve, it should be primarily used for flow diverging
applications.
• The Y valve is a combination of the shuttle valve X (lower part) & the mix-proof valve D (upper part).
• Note: Only the seat between the middle and upper ports is mix-proof. The lower seat, between the middle
and lower ports, is a single seat. This should be borne in mind when installing the valve and designing
the piping system.
• Cleaning of the “neutral area” is possible.
• A lifting actuator is available as an option.
• The valve should always switch against the direction of flow.
• Note: When ordering a Y valve with a lifting actuator for independent seat lifting, it is very important to
Fig 3.3.N: Valve Type Y
Type Y
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3.3.3.9 Mix-Proof Tank Bottom Valve
• The T type valve provides mix-proof tank outlet shut-off – stopping flow or joining flow streams.
• Typical applications include: Storage tanks (cream, milk, concentrate), process tanks (rennetting tanks,
ripening tanks, culture vessels, mixing tanks). E.g. mix-proof separation of product in the tank from CIP
in the line:
Fig 3.3.O: Mix-proof Separation of Product in Tank from CIP in the Line
• The valve has an axial-radial sealing arrangement, similar to the R valve (leakage free switching).
• It also has a balancer for the valve seat on the actuator side. This is because, after tank filling, the valve
closes with the direction of flow (contrary to our usual philosophy). The balancer on the actuator side
works against the tendency of pressure surges.
• The valve is mix-proof, and cleaning of neutral area is possible.
• A lifting actuator is available as an option.
• Horizontal installation is possible (ECO-MATRIX® principle).
• The leakage chamber of the bottom valve, type T_R is self-draining in the upside-down position only. In
case of vertical or horizontal installation position (e.g. ECO-MATRIX), the valve is equipped with an
additional drain valve.
• The valve provides a means of flush tank bottom shut-off.
• Note: When ordering a T valve with a lifting actuator for independent seat lifting, it is very important to
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Fig 3.3.P: Valve Type T
3.3.3.10 Mix-Proof Tank Bottom Valve
• The type NF or UF valves provide tank outlet shut-off.

• The valves have an axial sealing arrangement, and are not mix-proof.
• Horizontal installation is possible.
• The valves are an economic solution, instead of the T type, where mix-proof protection is not required.
Fig 3.3.Q: Valve Type UF and Type NF
Type UF Type NF
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3.3.4 When Product Recovery (“Pigging”) is Required
• The L type valve stops flow or joins flow streams, with mix-proof separation of incompatible media, and
is suitable for pigging (product recovery) operations.
• Typical applications include tank filling and tank emptying, with pigging of the complete product pipe.
• The valve comes with an optional lifting actuator, individually switchable for upper and lower valve seats.
• Cleaning of “neutral area” with rinsing (valve seat cleaning) valves is also possible.
• The valve has a radial seal arrangement, similar to the R type valve.
• The valve can be installed in upright, horizontal or upside-down positions.
• Note: Product recovery is only possible in one housing (the housing furthest away from the actuator), as
the other housing contains the valve insert.
• Note: When ordering an L valve with a lifting actuator for independent seat lifting, it is very important to
To achieve full EHEDG requirements, it must be possible to clean the cavity of the valve as well as the
individual seats; i.e. just cleaning the seats is not enough because not enough flow velocity is present in
the valve cavity to ensure that it is cleaned properly. This should also be noted on the P&ID and in the
FDS
Fig 3.3.R: Valve Type L
Upside-down installation Upright installation Cavity Cleaning
Type L
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3.4 Modulating Control Valves
These valves are used to control conditions such as flow, pressure, temperature and liquid level by fully or partially
opening or closing in response to signals received from controllers that compare a “set-point” to a “process
variable” whose value is provided by sensors that monitor changes in such conditions.
The typical applications are:

Filling of tanks, pressure control of tanks, constant pressure of separators, overflow control, pasteurizers, heat
exchangers, dosing applications.
There are different valves that will be used from now on:
- Type P does not work as a regular modulating valve because it has different opening positions, so it is used
when just a complete opened or complete closed position of the valve is not what it is needed.
- Type S and A are used as a regular modulating valve. They have a fine adjustment, so they are useful for
cases where more precision is required.
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Fig 3.4.A: Valve Type S and Type P

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3.5 Overflow Valves
• The Q valve relieves excess pressure in pipes, but is NOT a safety device.
• Typical applications include: bypass valve after positive displacement pumps, drain valve, air exhaust
valve.
• The set pressure is adjustable by means of an actuator with an adjustable spring.
• An integrated pneumatic actuator (type M) is available as an option, in order to lift the valve seat for
cleaning purposes.
• There are 6 housing combinations available, according to the VARIVENT principle.
Fig 3.5.A: Valve Type Q
Type Q
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3.6 Safety Relief Valve
• The type 448 valve relieves excess pressure and is an approved safety device. The adjustment is factory
set and the adjustment mechanism is sealed.
• Approvals include TUV, ASME and ATEX.
• Typical application: tank pressure relief.
• Full-lift function.
• Response pressure: max. 10 bar.
• Pressure range: 0.2 to 16 bar (spring loaded actuator).
• Wetted components made of AISI 316L.
• Includes a cleanable housing, according to the VARIVENT principle.
• Manual lifting as standard, pneumatic seat lifting optional.
• Different connection types are available.
Fig 3.6.A: Valve Type 448
Type 448
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3.7 Vacuum Valve
• Valve type V relieves vacuum pressure.

• Typical application: tank vacuum protection.
• Suitable for vacuum of < / = 25 mm w.g. (2.5 mbar) (not to be used as tank protection during CIP,
when hot media is followed by cold).
• Pocket free designed housing, according to the VARIVENT principle, completely drainable and improved
protection against dirt particles.
• Special materials and surfaces for quick response.
• Integrated drip pan for cleaning media.
• Optional: heating rod, pneumatic lifting actuator, feedback.
Fig 3.7.A: Valve Type V
Type V
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3.8 Sampling Valves
There are three types of sampling valves available, as follows:
Fig 3.8.A: Valves Type IT, TSVU and TSVN
Type I Type TSVU and TSVN
3.8.1 Varivent Sample Valve Type I
• The type I sample valve is installed into the process system upright
• The actuator is dually configured so that the valve can be actuated pneumatically or manually.
• Due to the conical contour of the valve disc, smaller sample volumens can be tapped as well.
• It uses up to two proximity swithches, permiting the detection of the closed and/or opened positions.
3.8.2 Varivent Sample Valve Type TSVN/U
• The type TSVN/U valve stops flow at sample points.

• Typical application: drawing samples from product lines.
• Type TSVU: Safe from impact pressure.
• Type TSVN: For product recovery systems.
• Optionally, the valves are upgradable with metal bellows for aseptic sampling.
• Note: These valves should also be considered for use in Valve Seat Cleaning operations, in place of the
more commonly used NL type valve, because there is no dead-leg associated with its installation.
Note that the pipe diameter is smaller, so the maximum number of valves that can be connected should
be limited to 5 (10 in case of 1” NL).
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3.9 Butterfly Valves
• The function of the Ecovent butterfly valve is to stop flow.

• A butterfly valve opens and closes by rotating the flap. When closing the valve, the flap takes positions
between 0° and 90° in the direction of flow.
• The type 811 – weld end valve is the standard choice for applications where valve flanges can be easily
split to allow replacement of seals and bushes.
• The type 888 – intermediate flanged valve is the logical choice for applications where rigid pipe work
prevents easy removal of seals and bushes.
• Various connection types are available: flanged, weld-end, tri-clamp, and DIN union.
• Compact design.
• Vacuum resistant sealing.
• Possesses EHEDG certificate.
• One actuator mounting bracket; a selection of different actuators available. Control cap (T-VIS) also
available.
Fig 3.9.A: Valves Type 811x and Type 888x
Type 811 Type 888

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3.10 Mixproof butterfly valves (Type 988):

When the valve disk is closed, mixproof separation of the two product areas is achieved through two peripheral
sealing edges with the leakage cavity between them. This cavity is opened to the atmosphere so any leakage
becomes visible immediately.
Upon closing of the valve disk the drain ports are opened, and upon opening of the valve disk the drain ports
are automatically closed and reliably prevent product loss.
Fig 3.10.A: Valves Type 988

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3.11 Aseptomag Valves
• Aseptomag Bellows valves should be used for aseptic installations.

• Maximum operating pressures should not exceed 12bar
• If the valve closes with the direction of flow, it will cause serious damage to the Bellows.
• Different types of seal materials are available. –TEPASEP, PTFE, SILICONE, EPDM, VITON.
• Installations with Aseptomag valves which have Tefasep seals need to be Sterilized with steam to approx.
140degs for approx. 20mins, with all valves in the open position. The valves will then need to be closed
to embed the seal against the seat-ring to ensure a proper seal of up to 6bar.
Fig 3.11.A: Asptomag Valves
Damaged Bellows
The Aseptomag Bellows valves should be used for aseptic installations.
Advantage
• The Aseptomag Valve is hygienic. When the shaft of the valve insert moves, there is no contact with the
outside of the valve housing chamber. There is no risk of the product getting contaminated.
Disadvantage
• The Aseptomag valve Bellows is easily damaged. If the valve closes with the direction of flow, it will cause
serious damage to the Bellows.
• Replacement of the seals is not easy. They need to be melted off with a soldering iron.
• Replacement seals need to be heated in an oven.
• Tefasep seals need to be sterilized with steam to approx. 140degs for approx. 20mins, with all valves in
the open position. The valves will then need to be closed to embed the seal against the seat-ring to ensure
a proper seal of up to 6bar.
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Fig 3.11.B: Asptomag Valve Blocks
Typical Aseptomag Valve Block Typical Aseptomag Valve Block

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4 DYNAMIC AND STATIC BEHAVIOUR OF VALVES IN

PIPE SYSTEMS
4.1 When Liquid is in Motion
Liquid is not compressible, and in principle it must be assumed that incompressible liquids behave like a solid
body. If they are suddenly decelerated or abruptly brought to a halt, pressure surges can build up in closed pipes
(commonly known as “water hammer”) and can cause destruction (imagine a car being driven into a solid wall).
There are three ways to avoid this scenario:

(1) Always install the valve such that it closes against the direction of flow of the liquid; this alone will slow
down the closing action of the valve, as the valve seat forces itself against the pressure of the moving
liquid.
(2) If this installation is not possible (for example, on tank outlet headers, where a “free draining” line is
required), the closing action of the valve can be slowed down by throttling the exhaust air of the actuator.
(3) The liquid flow can be brought to a halt before the valve is closed (for example, ensure the supply pump
is stopped before closing the valve). This should be done as a matter of standard, and should be included
in all Program FDS.
In principle, these guidelines should be applied to all valves within the VARIVENT® range, particularly where the
valve has a “shut-off” or “direction-switching” function.
A special note relating to balanced valves:

In a balanced valve, the net force resisting the closing / downward action of the disk is much smaller than in a
standard (unbalanced) valve. (This is because the surface area of the balancer is acted on by the pressure in the
fluid to create a downward force. There is no such downward force in a standard valve).
Therefore, when the balanced valve closes against flow, it does so much quicker than a standard valve, almost
negating the advantage of closing against the flow. The result is a stronger water hammer and associated wear
on valve seals (in particular the radial seal in the valve type R, which is more susceptible than an axial seal).
To counteract this, balanced valves that close against flow must also have restrictors in the air exhaust,
in order to slow down the closing action.
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4.2 When Liquid is at Rest
The situation, where liquid may be trapped between 2 closed valves, must be avoided.
Liquid is not compressible, therefore it will not “give way” to allow the valve to open (or close) into it. The high
pressure build-up in the system means that the valve can no longer be opened by the control air pressure or that
it does not reach its non-actuated (closed) position.
Often, this high pressure build-up is caused by “thermal expansion” in the system when the liquid is at rest, i.e.
the temperature of the pipe-work, and the liquid in it, can increase over time, causing the liquid volume to expand.
There are a few ways to avoid this scenario:

(1) Evacuate the line before closing the route (e.g. carry out an air-blow of the pipe-line).
(2) Serial switching of the valves in the pipe system.
(3) Throttling of the closing stroke on certain valves to provide for compensation.
(4) Installation of expansion compensators or damping cylinders for the compensation of displacement
volumes.
How do butterfly valves behave under static conditions?

Liquid cannot be trapped in butterfly valves. Due to the rotating valve disk, the displaced volume on one side is
released on the other side of the rotating disk.
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4.3 Dynamic and Static Behaviour of Valves in Pipe Systems
• The C type valve can be used for double-seal separation at pipe junctions within CIP or gas pipe systems
instead of the K valve.
• Advantage
• The C valve is that the valve is cheaper than the D or K valve. It has only one disk. Less moving parts and
less seals.
• Disadvantage
• The C valve is not a true mix-proof, like the K or D valves, because it does not have two independent seats.
If one seat lifts due to high pressure in the line, so does the other.
Fig 4.1.A: C Valves
C Valves on a Gas Block VSC hose and 8mm drain line on a C Valve
Typical Gas Block with C Valves

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5 APPEARANCE AND SCALING OF MAJOR EQUIPMENT

ON THE DRAWING
The ideal arrangement is to have one process represented per P&ID, so for example, an intake line is a process,
and the storage tanks should be shown on a separate drawing. If there is a single intake line and a single storage
tank, then it makes sense to combine them.
Please avoid the more common situation where multiple intakes and a dispatch line are squeezed onto a P&ID
with numerous tanks laid out in a single line, making it impossible to correctly represent the orientation.
Note that tanks typically have three or more instruments attached, and may have an agitator, so the size of the
tank symbol must be large enough for all these foreseeable attachments.
5.1 Orientation of Tanks and Associated Valves
Although a P&ID is primarily schematic, it is often relied upon (even when layouts are available) as the guide for
placing and orienting tanks and valve blocks.
Mistakes are commonly made with valve block manufacture because the layout on the P&ID is notional and does
not reflect the actual orientation of the tanks and the valve block.
The key risks are: a tank is connected to the wrong valve row, or a valve block is constructed in the wrong
orientation, meaning pipes are crossing each other from tank to valve block. Therefore ALWAYS ensure the P&ID
reflects the planned layout of tanks and valve block.
Fig 5.1.A: Tank and Valve Block Layout
Explanatory Note
Note the equipment layout will

NOT follow these lines – they are
sketched here to SHOW:
o Space required between
tank rows.
o How tanks must be
linked to avoid lines
crossing.
The size this will occupy on the P&ID will be larger than a simplistic schematic layout, but this is a small price to
pay for accuracy of construction of valve block and accuracy in pipe to valve connections, with the attendant
benefits for wiring and process descriptions.
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6 CHAPTER SUMMARY
This chapter dealt with the design of the P&ID. The designer must be familiar with our Sound engineering
practice which provides a series of checks on the selection of valves and pumps.
Specific information is provided on common pump and valve types so that the appropriate type can be selected
from suppliers documentation and Tuchenhagen flow components.

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PROJECT ENGINEERING

Author: Saniago Villafane Trabajo

Department: Cross-Application EMEA South

4 Dynamic and Static Behaviour of Valves in Pipe Systems ..............................................................58

1 SOUND ENGINEERING PRACTICE (SEP)

1.2 SEP for Overflow (Type Q) Valves from GEA

SEP 2 - mix- N/A

SEP 5 - materials As for Varivent valves.

SEP 6 - electrical Select one feed-back in lantern.

SEP 7 - access As for Varivent valves.

1.3 SEP for Vacuum Relief (Type V) Valves from GEA

SEP 2 - mix- N/A

SEP 4 - pressure No protection against over-pressure. Self-acting on vacuum < -2.5mbar.

SEP 5 - materials As for Varivent valves.

SEP 6 - electrical Optional feed-back under drip pan.

SEP 7 - access As for Varivent valves.

SEP 2 - mix- N/A

SEP 5 - materials As for Varivent valves.

SEP 6 - electrical Option – proximity switch for H8.

SEP 7 - access As for Varivent valves.

1.5 SEP for Centrifugal Pumps (Type TP) from GEA

SEP 8 - noise See SEP 2 (NPSH) above.

1.6 SEP for Piping Systems from GEA

SEP3.5 - venting / Line must be capable of being filled and emptied.

2 SELECTION OF APPROPRIATE PUMP TYPES

2.1 Overview of Pump Types, and Reference Material

Fig 2.1.A: Pump Types

Fig 2.1.B: Comparison of Pump Responses

2.2 Centrifugal Type – Where to Use it

1 Impeller A Mechanical seal

Fig 2.2.A: Centrifugal Pump

2.3 Self-Priming Centrifugal Type – Where to Use it

Fig 2.3.A: Self-Priming Centrifugal Pump

2.4 All centrifugal pumps from GEA Hilge

Fig 2.4.A: Centrifugal Pumps from GEA Hilge

2.5 Rotary Lobe Positive Displacement Type – Where to Use it

Fig 2.5.A: Rotary Lobe Pump Operation

2.6 Peristaltic Type – Where to Use it

Fig 2.6.A: Peristaltic Pump Operation

A: hose of the pump / B: housing / C: rotor / D: shoe / E:housing cover

2.7 Piston Type – Where to Use it

Fig 2.7.A: Piston Pump Operation

2.8 Screw Type – Where to Use it

Fig 2.8.A: Screw Pump Operation

2.9 Twin screw Type – Where to Use it

Fig 2.9.A: Twin Screw Pump Operation (102)

2.10 Diaphragm Metering Type – Where to Use it

Fig 2.10.A: Diaphragm Metering Pump Operation

2.11 Mechanical Seals

Most of the pumps showed need a Mechanical seal.

The most typical mechanical seals used are:

Fig 2.11.A: Mechanical seals

Single-acting (standard) mechanical seal.

It is used for non-critical substances and for low pressure

Single-acting, flushed (quench) mechanical seal.

It has a slide ring holder, a shaft sealing ring and a shaft

It is used for crystallizing and highly viscous products (>100

Double-acting mechanical seal.

It has a second slide ring and a counter ring on both sides.

It is used for hazardous, abrasive and dilatant fluids.

2.12 Design Rules for Pumps and Fail-Safe Features

2.12.3 Reverse Flow

2.12.4 High Pressure