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GEA VARICOVER
®

HYGIENIC PRODUCT
RECOVERY SYSTEMS
 3

Legal notice
Publication date: March 2023

The publication of specifications, technical data and information

in written or electronic form does not release the user from
the responsibility of checking for themselves all products
delivered by us for suitability for the application(s) intended.
These may be subject to change without prior notification.
Errors and printing errors excepted ­– we assume no liability for
the correctness of specifications given.

The general terms and conditions of delivery apply.

All rights reserved – copyright on all contents. The ® symbol in

this catalog identifies a trademark registered in certain countries.

GEA Tuchenhagen GmbH

Am Industriepark 2 – 10, 21514 Büchen, Germany
 5

CONTENTS
06 Introduction 70 GEA Valve Automation – Control and Feedback Systems

06 Hygienic Valve Technology 70 Overview

08 Hygienic Components – for Special Process Functions 75 Appendix

10 Technical Characteristics 75 GEA Service for Hygienic Valve Technology

14 Selection Matrix 76 Description of Certificates

16 VARICOVER® Product Recovery Systems 77 Abbreviations and Terms

17 Overview 80 CAD Files

22 Pig Selection Matrix 81 General Sales Terms and Condition of Delivery

24 Overview VARICOVER® Pig Components

31 VARIVENT® Type L

32 VARICOVER® Pig Cleaning Station

34 VARICOVER® Pig Cleaning Station ATEX

36 VARICOVER® Pig Catching Pipe/Pig Catching Station

38 Pig Driving Medium Valves with VARINLINE® Housing

40 VARICOVER® Pig Stopper

42 VARICOVER® Pig Stopper ATEX

44 VARICOVER® Pig T-Piece

46 VARICOVER® Pig Type PK

48 VARICOVER® EMI/1

49 VARICOVER® EMII/1

50 VARICOVER® DM/1

52 VARICOVER® SP1/SP2

53 VARICOVER® MP1/MP2

54 Options

56 Questionnaire

58 Options

59 Available Options

60 Surface Qualities

61 Connection Fittings

65 Additional Options

69 General
6 Introduction | Hygienic Valve Technology

GEA VARIVENT® GEA GEA VARIVENT®

Hygienic Hygienic Hygienic special
seat valves butterfly valves application valves

GEA VARICOMP®
Hygienic expansion
compensators

GEA VARINLINE® GEA VARITOP®

Hygienic process Hygienic tank
connections safety systems
 Introduction | Hygienic Valve Technology 7

GEA VARICOVER® GEA VARIVENT®

Hygienic product Hygienic valves
recovery systems for the U.S. dairy market

Hygienic Valve
Technology
Efficiency delivering perfect results Regardless of the sector, the application or production spec-
Hygienic valves from GEA form the core component of ifications: Our hygienic valve technology is sure to meet the
matrix-piped process plants. Thanks to a pioneering valve demands of our users.
concept that sets standards for its flexibility, as well as the
latest control and automation functions, our valves offer man- Hygienic solutions for every task
ufacturers maximum product safety and process reliability. Additional components in our portfolio are available to optimize
the design of any process plant – from pigging systems for
All GEA hygienic valves are designed to be efficient and the recovery of valuable products, process connections, and
cost­effective for their particular applications, leading to sus- expansion compensators for offsetting thermal stress, to tank
tainable operation and considerable savings potential. safety systems for securing and cleaning tanks and containers.

GEA valve technology controls flow processes Supported by our Research and Development Department we
Our hygienic valve technology ensures safe, efficient processes regularly launch new, technologically mature products on the
wherever sensitive liquid products are manufactured. In food markets. Our customers have high standards, which we con­
production, the classic application areas range from milk pro- tinuously and systematically meet.
cessing (milk, yogurt, cheese ...) to liquid foods (sauces and
pastes, instant products, baby food ...) and on to the brewing
of beer and production of beverages. Further significant areas
are biotechnology and pharmaceuticals, as well as care products
and cleaning agents / detergents.
Hygienic Components –
for Special Process Functions
Special components, free of dead spaces, for your process
Every process operator who processes valuable or sensitive were developed on the basis of the groundbreaking and proven
liquids benefits from our hygienic, 100 % drainable components GEA VARIVENT® design and guarantee extraordinary reliability
for important special functions in the process. All components and functionality for trouble-free, efficient processes.

GEA VARINLINE® Process Connections

The trademark VARINLINE® includes control and measuring
instruments that meet the requirement of being CIP/SIP-able,
thus enabling cleaning and sterilization without the need for
dismantling. The instruments can be cleaned and sterilized
without any residue in automatic cleaning and sterilizing
process cycles. The core piece of the in-line control and
measurement technology is the process connection fitting,
the VARINLINE® housing. It is mainly an in-line housing with
double vertical ports with two process connections.

The process connections in the VARINLINE® housing allow up

to two control / measuring instruments, e.g. a sight glass with
opposite illumination unit or different measuring mountings.
They are available for all pipe sizes, with the VARIVENT®
process connection designed for the nominal width of the
respective components to be installed. VARINLINE® housings are
self draining – also in the horizontal installation orientation – and
thus permit instrumentation free of dead zones. VARINLINE®
housings are 3A approved, according to the DGRL and are
EHEDG-certified.
Introduction | Hygienic Components – for Special Process Functions 9

GEA VARICOMP® Expansion Compensators

VARICOMP® expansion compensators compensate for expansions
and tensions in pipeline systems that result from temperature
differences. Due to the dead-zone free design, they are able
to be used in hygienic and aseptic processes.

GEA VARITOP® Tank Safety Systems

The VARITOP® tank safety system consists of a modular system
and thereby forms a functional unit designed individually
according to the customer’s requests.

The diverse applications of the VARITOP® system range from tank

cleaning to protecting tanks against high and low pressures to
gassing and degassing of tanks.

GEA VARICOVER® Product Recovery Systems

VARICOVER® product recovery systems are designed for use in
fully automatic operations with maximum cleaning demands.
They are used to recover valuable products from pipelines – an
important consideration to optimize the economic efficiency
of a process system. Pigging pushes the product from the
pipes and returns it to the production cycle.

A VARICOVER® product recovery system usually comprises of

a pig cleaning station, a pig catching station with propellant
medium valves and a pig.
10 Introduction | Technical Characteristics

Technical Characteristics

Available nominal widths for valve series

DN 25 40 50 65 80 100
Nominal width
OD 1" 1 ½" 2" 2 ½" 3" 4"

Valve type

VARICOVER® product recovery system • • • • • •

Pipe classes
The dimensions of the welding ends comply with the following standards:

Metric Inch

Outside diameter
Outside diameter
OD based on
DIN according to
IPS ASME-BPE-a-2004,
DIN 11866, series A
DIN 11866, series C
25 29.0 × 1.50 1" 25.4 × 1.65
40 41.0 × 1.50 1 ½" 38.1 × 1.65
50 53.0 × 1.50 2" 50.8 × 1.65
65 70.0 × 2.00 2 ½" 63.5 × 1.65
80 85.0 × 2.00 3" 76.2 × 1.65
100 104.0 × 2.00 4" 101.6 × 2.11
 Introduction | Technical Characteristics 11

Surfaces Seal materials

The standard for surfaces in contact with the product depends Seals in contact with the product are EPDM (standard), HNBR
on the particular nominal width standard: and FKM. NBR material is used for seals not in contact with
• Metric, inch OD, ISO: Ra ≤ 0.8 μm the product.

Surfaces not in contact with the product (housing) are matt The mixing constituents of our seal materials conform to the
blasted or metal ground as standard. Detailed information on USP class VI and are contained in the FDA White List. In this
surface designs can be taken from the respective sections. the sealings fulfill FOOD and DRUG (FDA) guidelines 21 CFR
Part 177.2600 or 21 CFR 177.1550: “Rubber articles intended
Materials for repeated use”.
Components in contact with the product are produced from
1.4404 (AISI 316L), while those not in contact with the product The resistance of the seal material depends on the type and
use 1.4301 (AISI 304). Other materials, e.g. for use when handling temperature of the product being transported. The contact
aggressive fluids, are available on request. time with certain products can negatively affect the service
life of seals.
For detailed information about the properties of the materials,
refer to the material properties table. For detailed information about the seal material properties,
refer to the seal material properties table.
Test report and inspection certificate
Optionally, the valve housings and product wetted parts can
be supplied with a test report 2.2 or an inspection certificate 3.1
according to EN 10204.

If 3.1 inspection certificates are required, please notify us of

this when you place the order.
12 Introduction | Technical Characteristicss

Technical Characteristics

Ambient conditions Feedback

In the control top
See catalog GEA Valve Automation
Ambient temperatures

VARICOVER® 0 °C to 45 °C Proximity switch holder (INA)

32 °F to 113 °F Proximity switches of size M12 × 1 can indicate the positions
“open” and/or “closed”.

The components can also be used outdoors. However, in For detecting the end positions by proximity switches in these
these application areas they must be protected against icing, valves, it is recommended to use the proximity switch holder
or else de-iced before switching or lifting. In addition, the par- (INA) on the actuator (see catalog GEA Valve Automation).
ticular requirements on the control and feedback system must
be taken into account in this case. Certificates
Components for special process applications in the GEA
The product or operating temperature depends on the seal Hygienic Valve Technology portfolio meet the requirements
material and can be seen in the seal material properties table. of the European Hygienic Engineering and Design Group
(EHEDG) as well as those of 3-A Sanitary Standards, Inc. (3-A
Air supply SSI). Numerous components have been demonstrated to offer
The actuators are configured for operation with min. 4 bar and trouble-free and efficient cleaning ability not only in accor-
max. 8 bar air pressure. The standard actuator sizes are con- dance with the above guidelines, but also in independent and
figured for an air supply pressure of min. 6 bar (with a product standardized cleaning tests.
pressure of 5 bar). The quality of the air supply must meet the
requirements of ISO 8573-1:2010. ATEX certificates and other additional certificates are available
on request for many components in the GEA Hygienic Valve
Technology portfolio.
ISO 8573-1:2010

Solid content Quality class 6

Particle size max. 5 μm
Particle density max. 5 mg/m³
Water content Quality class 4
Max. dew point 3 °C
A correspondingly different dew point is
required for applications at high altitude or
with low ambient temperatures.
Oil content Quality class 3
Max. 1 mg oil per 1 m³ air, preferably oil-free
 Introduction | Technical Characteristics 13

Material properties

Main alloy elements in % by mass

Material Cr Ni Mo C max.
Short name Similar materials PREN***
number (Chrome) (Nickel) (Molybdenum) (Carbon)
1.4301* X5CrNi18-10 AISI 304 BS 304S15 SS2332 18 17.5 – 19.5 8.0 – 10.5 – 0.07
1.4404** X2 CrNiMo 17-12-2 AISI 316L BS 316S11 SS2348 25 16.5 – 18.5 10.0 – 13.0 2.0 – 2.5 0.03

* Standard material for components not in contact with the product

** Standard material for components in contact with the product (other materials available on request)
*** Pitting Resistance Equivalent Number = % Cr + 3.3 × (% Mo + 0.5 W) + 20 N

Seal material properties

Seal material EPDM FKM HNBR

−40 to 135 °C −10 to 200 °C −25 to 140 °C

General application temperature*
−40 to 275 °F 14 to 392 °F −13 to 284 °F
At permitted
Medium Concentration
operating temperature
Alkali ≤ 3% up to 80 °C + ○
+
≤ 5% up to 40 °C + ○ ○

≤ 5% up to 80 °C + − −

> 5%  ○ − −
Inorganic acid** ≤ 3% up to 80 °C + + +
≤ 5% up to 80 °C ○
+ ○

> 5% up to 100 °C − + −

up to 80 °C + + +
Water
up to 100 °C + + +
Steam up to 135 °C + ○ ○

Steam, approx. 30 min up to 150 °C + ○ −

Hydrocarbons / fuels − + ○

Products containing ≤ 35 % + + +
grease
> 35 % − + +
Oils − + +

Other applications on request + = Good resistance

* Depending on the installation situation = Reduced service life
** Inorganic acids are, for example, hydrochloric acid, nitric acid, sulphuric acid − = Not resistant
14 Introduction | Selection Matrix

Selection Matrix

Catalogs GEA VARIVENT®

Hygienic Valve Technology seat valves

Catalogs
GEA butterfly valves
Hygienic Pump Technology

Catalogs GEA VARIVENT®

Aseptic Valve Technology special application valves

Catalogs GEA VARIVENT®

Cleaning Technology valves for the U.S. dairy market

GEA VARITOP®
tank safety systems

GEA VARINLINE® / GEA VARICOMP®

process connections and
expansion compensators

GEA VARICOVER®
product recovery systems

GEA Service
for hygienic valve technology

GEA valve automation

control and feedback systems
 Introduction | Selection Matrix 15

VARICOVER®
product recovery systems 1
Options
2
16 VARICOVER® Product Recovery Systems | Overview

1
VARICOVER®
Product
recovery
systems
 17

Overview
VARICOVER® product recovery systems
Product recovery systems optimize the economic efficiency
of a process system by recovering the valuable products
from pipelines.

Pigging pushes the remaining product from the pipe and

returns it to the production cycle. The thin product film
is easy to remove by subsequent cleaning, so that the
pre-flushing time can be reduced.

Recover the value, reduce the waste!

Special features

Design with no dead zones

CIP/SIP-able
Reduced product loss
Reduced cleaning media and water consumption
Reduced waste water load
Reduced production downtimes
Simple maintenance
18 VARICOVER® Product Recovery Systems | Overview

Overview

Application ranges Types of product recovery systems

Product push-out The pigging process can be implemented with different degrees
Product recovery systems are used for the ejection of viscous / of automation. That is why the portfolio of GEA Tuchenhagen
flowing products from pipelines without mixing with any other offers three different product recovery systems:
media. This is especially required for high quality products in
the food and beverages industries, as well as, pharmaceutical 1. Automatic product recovery systems
and personal and health care industries. Due to the complete automation of the process, the pig can
push out and be cleaned without manual action. The entire
Product control process takes place solely in the pipeline.
In addition to pushing out of products from the pipelines,
product recovery systems are also used for gentle filling of 2. Semi-automatic product recovery systems
pipelines with sensitive and foaming products. Even vertical In contrast to the automatic product recovery systems, with the
pipelines can be easily filled by letting the product push the pig semi-automatic product recovery systems the pig is inserted
downwards in the pipe. and removed manually. Pushing out of product and returning
of the pig then takes place automatically.
Applications
Personal and health care industry 3. Manual product recovery systems
• body care In the manual product recovery system, the pig is manually
• shampoo, lotion, cream inserted into the pipeline and at the end removed manually.
• toothpaste The pig runs in only one direction.
• cleaning media, washing agents, softeners

Food industry Special features

• yogurt, quark, cheese Safe operation by closed pipe systems
• fruit juice No pig removal required in operation
• dough, vegetable oil Automatic function mode and thus fully verifiable processes
• sauce, ice cream Components certified to 3A (101-01)

Beverage industry
• concentrate
• syrup
 VARICOVER® Product Recovery Systems | Overview 19

2
Design of a product recovery system Features of VARICOVER® product recovery systems
A VARICOVER® product recovery system usually comprises VARICOVER® product recovery systems are characterized
of a pig cleaning station, a pig catching station with pro- by use in fully automatic operations at maximum cleaning
pellant medium valves, and a pig. The pig is placed in the demands. Safe operation is secured by a firmly installed
pig cleaning station during production and cleaning. In and closed pipe system so that no dismantling of the pig
the pig catching station, the pig is stopped mechanically cleaning station is required for operation and cleaning.
after successful product push-out and the propellant That is why the automatic function mode corresponds to
medium valves are used for propellant medium supply. a process that can be validated.

The pig components can be installed either in new systems Detection of the pig position via magnetically inductive
or integrated into already present process systems. proximity switch – from the outside of the pipeline – per-
mits automatic control and cleaning (CIP) of the product
recovery system.

The pig driving medium can be water, air, CO2 or N2.

Arrangement of the components Cross-section of the housing

in the product recovery system EMI/1 of the pig cleaning station
20 VARICOVER® Product Recovery Systems | Overview

Overview

Applications in process systems

Product recovery systems are used in different applications
to meet the various requirements in numerous industries and
processes:
• From product acceptance to pre-phase tanks
• From pre-phase tanks to mixers/process tanks
• From mixers/process tanks to storage tanks
• From storage tanks to filling machines

VARICOVER® Product Recovery System ATEX

Even in explosion endangered areas you are able to operate
GEA Product Recovery Systems. Our pigging components can
be used in ATEX-relevant areas in the following nominal sizes:
• DN 40; DN 50; DN 65
• OD 1 ½"; OD 2"; OD 2 ½"; OD 3"
• Authorized Ex zones inside of pipelines:
1; 2; 21; 22
• Authorized Ex zones outside of pipelines:
1; 2; 21; 22
• ATEX categories:
– II 2G Ex h IIB T3…T6 Gb X
– II 2D Ex h IIB T 135 °C Db X
• Suitable pig driving media:
– Water
– Nitrogen

Pig stopper with pig

 VARICOVER® Product Recovery Systems | Overview 21

Prerequisites for operating of product recovery systems Process system recommendations

• Fluid products suitable for pumping The pig speed control is important for the for successful
• Non-sedimenting products operation of a product recovery system. It must not exceed
• No installations protruding into the pipe in the section 0.5 m/s when reaching the pig station. If the arrival speed
to be pigged, such as measuring mountings is too high, there is the danger of damage to the pig.
• Only piggable valves matching the geometry of
the GEA Tuchenhagen double ball pig can be used When using compressible media, such as air, before and
• Same interior diameter throughout the pipe system behind the pig, the following applications must be avoided:
• No sharp-edged and strongly sagging welds • running the pig in a dry pipeline
• Connection fittings with transfers rounded on • returning the pig after pushing out water
the inside can be used
• No seals protruding into the pipe permitted If these applications are not observed, there is the
• Standard pipe bends with small middle radius can danger of a “stick-slip effect”. Here, the pig moves jerkily
be used – minimize number pf pipe bends through the pipeline and may reach too high of speeds.
• Use pipe bends with low ovality – Tolerances up An exception of this effect are with very slippery products
to ± 1.5% referring to the outside diameter across such as shampoo and vegetable oils that form a suffi-
the entire bend length cient lubricating film between the pig and the pipe wall.
22 VARICOVER® Product Recovery Systems | Pig Selection Matrix

Pig Selection Matrix

VARICOVER® VARICOVER®
product recovery systems pig components

VARICOVER®
product recovery systems
for automatic operation

VARICOVER®
product recovery systems
for semi-automatic operation

VARICOVER®
product recovery systems
for manual operation
 VARICOVER® Product Recovery Systems | Pig Selection Matrix 23

Pig cleaning station

1

2
Product recovery system Pig catching pipe/
EMI/1 pig catching station

Product recovery system Pig driving medium valves

EMII/1 with VARINLINE® housing

Product recovery system

Pig stopper
DM/1

SP1
Pig T-piece
(without ball valve)

SP2
Pig
(with ball valve)

MP1
Piggable double-seat valve
(without ball valves)

MP2
(with ball valves)
24 VARICOVER® Product Recovery Systems | Overview VARICOVER® Pig Components | Pig Cleaning Station

VARICOVER® Product Recovery Systems

Overview VARICOVER® Pig Components
Pig Cleaning Station

Function method of the pig cleaning station

The pig cleaning station, free of dead zones and completely
CIP-/SIP-able, is integrated into the product path and is flexible
for use as the launching or receiving station The pig retention
cylinders and guidance keeps the pig firmly in position in the
station during flooding with product or cleaning media. The
flow direction through the station is irrelevant.

When receiving or launching the pig, the pig gripper is pushed

forward. The pig is half gripped by the gripper rods, so that
it securely reaches the retracted position for production or
cleaning.

When the pig is flooded with product, there is a continuous

product exchange in the pig station housing. The product
is gently transported through the housing. This is possible
since the flow area around the pig corresponds to that of
the pipeline. Since the housing is free of dead zones without
domes and sumps, this ensures the best cleaning with complete
residual emptying.

Cleaning the pig in the pig cleaning station

During cleaning, the pig remains in the pig cleaning station.
Only there can it be flooded completely. This is possible
because the pig gripper moves forward and backward several
times by the control of the actuator so that a gap results
between the pig front and the metallic stop.
Complete cleaning
Furthermore, the pig can move between the gripper and the of the pig in the
guidance rods, so that the pig contract points to the rods are pig cleaning station
completely cleaned.
 VARICOVER® Product Recovery Systems | Overview VARICOVER® Pig Components | Pig Cleaning Station 25

2
1

2
Design of the pig cleaning station

1 Pig retention cylinder

The pig retention cylinders fasten the pig in the pig
cleaning station in their spring-to-close position and
release the pig after pneumatic activation. They are
controlled via the T.VIS® feedback system.
3
2 Pig station housing
Product and cleaning media flood the pig firmly held
in position in the pig station housing. Continuous
monitoring of the pig position from outside of the
housing is possible via the two magnetic sensors.
Different connection fittings are available optionally.
4

3 Pig gripper
The pig gripper takes the pig on one side so that
it will reach different positions safely.

4 Pig guidance
The pig is guided by straight rods within the pig
station housing and thus cannot take an inclined
position in the pig station housing which has a larger
diameter than the pig.

5 Lantern
The open design of the lantern separates the
actuator and product parts from one another.
5
It permits visual inspection of the stem seal, and is
also used for indicating any leakages. Furthermore,
a heat transfer between the pig station housing and
the pig actuator is prevented.

6 Pig actuator
The pig actuator consists of an air/air controlled
actuator used for moving the pig into the production/
cleaning position respectively into the launching/
6
receiving position.
26 VARICOVER® Product Recovery Systems | Overview VARICOVER® Pig Components | Pig Catching Pipe/Pig Catching Station

VARICOVER® Product Recovery Systems

Overview VARICOVER® Pig Components
Pig Catching Pipe/Pig Catching Station

Pig catching pipe/pig catching station

In the catching pipe, the pig is stopped mechanically. It cannot This arrangement ensures a complete cleaning of the NL shut-off
be flooded with cleaning media there and leaves the station valve. Furthermore, mixing between the product and the pig
right after arriving in most applications. The mechanical pig driving medium – in case of possible leaks – is prevented by
stop which is integrated in the catching pipe is cleaned during the open venting socket at the WK divert valve.
the pipe cleaning.
When air is used as the pig driving medium, an air throttle valve
The pig catching pipe can be used with or without pig driving is always installed at the inlet socket of the WK divert valve.
medium valves. The standard valve unit consists of two combined It sets the average pig speed by a hand-actuated adjustment
ECOVENT® valves of types NL and WK. The NL valve is used of the flow area.
for shut-off from the product pipe and the WK valve serves as
a divert valve between the inlet of the pig driving medium at
the upper housing and the connection to the vent at the lower
housing.

Pig catching pipe Cross section pig

Pig catching pipe with pig driving medium valves catching station
VARICOVER® Product Recovery Systems | Overview VARICOVER® Pig Components | Pig Driving Medium Valves with VARINLINE® Housing 27

VARICOVER® Product Recovery Systems

Overview VARICOVER® Pig Components
Pig Driving Medium Valves with VARINLINE® Housing

Pig driving medium valves with VARINLINE® housing

The VARINLINE® housing permits, aside from the con-
nection of the pig driving medium valves, the adaptation
of a pressure gauge, or a pressure transmitter, to record
the driving medium pressure during commissioning.

The standard valve unit also consists of two combined

ECOVENT® valves of types NL and WK. The NL valve is
VARINLINE® used for shut-off from the product pipe and the WK valve
housings serves as a divert valve between the inlet of the pig driving
medium at the upper housing and the connection to the
vent at the lower housing. This arrangement ensures a
complete cleaning of the NL shut-off valve. Furthermore,
mixing between the product and the pig driving medium –
in case of possible leaks – is prevented by the open venting
socket at the WK divert valve.

When air is used as the pig driving medium, an air throttle

valve is always installed at the inlet socket of the WK divert
valve. It sets the average pig speed by a hand-actuated
adjustment of the flow area.

VARINLINE®
housings
with pig driving
medium valves
28 VARICOVER® Product Recovery Systems | Overview VARICOVER® Pig Components | Pig Stopper

VARICOVER® Product Recovery Systems

Overview VARICOVER® Pig Components
Pig Stopper

Design pig stopper Function method pig stopper

In the spring-to-close position of the pig stopper, a rod travels The pig stopper is automatically operated and mostly used for
over the entire pipe cross section. In it, the pig is stopped two applications.
mechanically. Product or cleaning media can flow through the
free cross-section around the rod. Filling and emptying of tanks is often performed by tee-outlets
into pipelines. Pig stoppers can be placed before or behind
In contrast to the closed position, the stopper rod is retracted tee-outlets and serve as precise positioning of the pigs. When
in the air-to-open condition, so that the pig can pass the a pig reaches a stopper rod, it works as a shut-off element
stopper. and prevents further filling of the line.

The housing of the pig stopper is screwed to a VARIVENT® In the product recovery system EMII/1, the product is supplied
grooved flange on both sides and the pig stopper is welded through the lateral socket of the T-piece and the pig stopper
into the pipeline. prevents the pig from leaving the launching station if any
vacuum occurs.
Both the closed and the opened positions are monitored by
proximity switches.

Cross section pig stopper Cross section pig stopper Cross section pig stopper
Pig stopper with opened stopper rod with closed stopper rod with pig
 VARICOVER® Product Recovery Systems | Overview VARICOVER® Pig Components | Pig T-Piece 29

VARICOVER® Product Recovery Systems

Overview VARICOVER® Pig Components
Pig T-Piece

Pig T-piece
Special T-pieces in pigging lines are used as product inlet
and outlet.

For the pig to be guided well in the T-piece, the pull out
of the lateral socket is one nominal width smaller than
the main line. This prevents canting of the pig.

The pig T-piece is used to feed product and cleaning

media into the product recovery system EMII/1.

Arrangement of the components

Pig in T-piece in the product recovery system EMII/1
30 VARICOVER® Product Recovery Systems | Overview VARICOVER® Pig Components | Pig

VARICOVER® Product Recovery Systems

Overview VARICOVER® Pig Components
Pig

Pig
The pig is an inherently stable body made from wear- and Inside the pig, there are two stainless steel-encapsulated
temperature-resistant, product compatible material. Its con- permanent magnets that permit detection of the pig with
tours allow reliable cleaning of the entire surface. The double a magnetic sensor.
ball shape of the pig ensures an optimal passage through
small and large pipe bends as well as T-pieces with a reduced Available pig materials are Silicone and FKM (both FDA,
lateral pull out. Either running direction is possible. 3A (18-03) and EU VO 1935/2004 compliant).

Separation of two different media Both running directions possible

Separation of two different media Pigging pipe bends

 VARICOVER® Product Recovery Systems | VARIVENT® Type L | Piggable Double-seat Valve 31

VARICOVER® Product Recovery Systems

VARIVENT® Type L
Piggable Double-seat Valve

VARIVENT® double-seat valve type L

The piggable double-seat valve type L is used when dif-
ferent products must be separate from each other and
fully mixproof at pipeline junctions and the valve should
at the same time be piggable.

Only the lower valve housing with double horizontal

ports is piggable, while the upper housing can have one
or two horizontal ports. The upper and lower housings
are always welded to each other.

Similar to the double-seat valve type R, type L also has

the upper valve disc with an axial and the lower one with
a radial seal. The double-seat valve type L cannot be
equipped with a balancer in the lower housing to protect
against pressure hammers.

The double-seat valve type L can be installed in the

standing or suspended position. When suspended, the
valve opens with low switching leakage, while switching
leakage occurs in the standing position. The switching
leakage escapes from the additional emptying valve that
is between the housings.

The emptying valve pneumatically connected to the

actuator is opened while the valve is closed and closes
when activating the actuator.

In the standing installation orientation of the valve type L,

the cleaning media drains from two ports at the same
time – through the port above the housings and through
the emptying valve.

Application ranges

Piggable valve blocks

Piggable filling and emptying valves at product tanks

For more detailed information on the VARIVENT® valve

type L, see the catalog GEA VARIVENT® Hygienic Seat Valves.
32 VARICOVER® Product Recovery Systems | VARICOVER® Pig Cleaning Station

VARICOVER®
Pig Cleaning Station

Connection fitting
on port 1 / 7

VII

Technical data of the standard version

Material in contact with the product 1.4404

Seal material in contact with the product EPDM (FDA)
Ambient temperature 0 to 45 °C
Air supply pressure 4.8 bar (69.6 psi) to 8 bar (116 psi)
Max. product pressure DN 25 – DN 80
16 bar (232 psi)
OD 1" – OD 3"
DN 100
10 bar (145 psi)
OD 4"
Surface in contact with the product Ra ≤ 0.8 µm
External housing surface Matt blasted
Actuator type Pneumatic actuator air/air
Actuator type of the pig retention cylinders Pneumatic actuator air/spring
Connection fittings Welding end
Identification Adhesive ID tag
Certificates

Pipe Housing Dimensions General

Nominal Ø Ødi B C H1 H2 H3 X1* X2* Weight

width [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg]
DN 25 29.0 × 1.50 26.00 329 60 300.0 482.0 118.0 450.0 100 8.5
DN 40 41.0 × 1.50 38.00 339 90 353.0 521.0 135.0 503.0 100 14.5
DN 50 53.0 × 1.50 50.00 313 90 359.0 650.0 158.0 559.0 100 16.0
DN 65 70.0 × 2.00 66.00 323 90 367.0 692.0 170.0 597.0 100 17.0
DN 80 85.0 × 2.00 81.00 331 125 378.0 730.5 194.5 648.0 100 24.0
DN 100 104.0 × 2.00 100.00 340 125 462.0 829.0 215.0 762.0 100 37.0

OD 1" 25.4 × 1.65 22.10 329 60 298.0 477.0 115.0 448.0 100 8.5
OD 1 ½" 38.1 × 1.65 34.80 337 90 351.5 510.0 125.5 501.5 100 15.5
OD 2" 50.8 × 1.65 47.50 313 90 358.0 647.0 156.0 558.0 100 16.0
OD 2 ½" 63.5 × 1.65 60.20 320 90 364.0 689.0 170.0 594.0 100 18.0
OD 3" 76.2 × 1.65 72.90 326 125 374.0 721.0 192.0 634.0 100 22.5
OD 4" 101.6 × 2.11 97.38 340 125 461.0 829.0 216.0 761.0 100 36.0
*Clearance
 VARICOVER® Product Recovery Systems | VARICOVER® Pig Cleaning Station 33

Position

1
Description of the order code

Pig cleaning station

1
PIG/PCS Pig cleaning station MST 3A
2 Design

2
G Pig cleaning station complete
A Only actuator of the pig cleaning station
M Only pig retention cylinder for the pig cleaning station
3 Nominal width
DN 25 OD 1"
DN 40 OD 1 ½"
DN 50 OD 2"
DN 65 OD 2 ½"
DN 80 OD 3"
DN 100 OD 4"
4 Seal material
1 EPDM (FDA)
2 FKM (FDA)
3 HNBR (FDA)
5 Surface quality
2 Inside Ra ≤ 0.8 µm, outside matt blasted
3 Inside Ra ≤ 0.8 µm, outside ground
6 Pig retention cylinder
0 Without pig retention cylinder
2 With pig retention cylinder
7 Proximity switches at the pig actuator (for technical specifications, see catalog GEA Valve Automation)
0 Without proximity switches
2 With proximity switches
8 Magnetic sensors at the pig station housing (for technical specifications, see catalog GEA Valve Automation)
0 Without magnetic sensors
2 With magnetic sensors
9 Connection fittings Connection fitting on port 1 / 7
VARIVENT® flange connection complete,
N Without connection fittings TK
grooved flange on housing
VARIVENT® grooved flange complete,
J With connection fittings TN
incl. O-ring and connecting parts

TF VARIVENT® plain flange

CO Clamp connection

10 Accessories
/52 Adhesive ID tag
+
11-16 Air connection/control and feedback system
00000M Metric for air hose Ø 6/4 mm
00000Z Inch for air hose Ø OD ¼" (6.35/4.35 mm)
XXXXX Order code for different control and feedback systems see catalog GEA Valve Automation

The code is composed as following, depending on the chosen configuration:

Position 1 2 3 4 5 6 7 8 9 10 11 to 16
Code PIG/PCS - - - - / /52 +
For order codes differing from the standard version, please refer to section 2.
34 VARICOVER® Product Recovery Systems | VARICOVER® Pig Cleaning Station ATEX

VARICOVER®
Pig Cleaning Station ATEX

Connection fitting
on port 1 / 7

VII

Technical data of the standard version

Material in contact with the product 1.4404

Seal material in contact with the product EPDM (FDA)
Ambient temperature 0 to 45 °C
Air supply pressure 4.8 bar (69.6 psi) to 8 bar (116 psi)
Max. product pressure DN 40 – DN 65
16 bar (232 psi)
OD 1 ½" – OD 3"
Surface in contact with the product Ra ≤ 0.8 µm
External housing surface Matt blasted
Actuator type Pneumatic actuator air/air
Actuator type of the pig retention cylinders Pneumatic actuator air/spring
Connection fittings Welding end
Identification Adhesive ID tag
Certificates

Pipe Housing Dimensions General

Nominal Ø Ødi B C H1 H2 H3 X1* X2* Weight

width [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg]
DN 40 41.0 × 1.50 38.00 339 90 353.0 521.0 135.0 503.0 100 14.5
DN 50 53.0 × 1.50 50.00 313 90 359.0 650.0 158.0 559.0 100 16.0
DN 65 70.0 × 2.00 66.00 323 90 367.0 692.0 170.0 597.0 100 17.0

OD 1 ½" 38.1 × 1.65 34.80 337 90 351.5 510.0 125.5 501.5 100 15.5
OD 2" 50.8 × 1.65 47.50 313 90 358.0 647.0 156.0 558.0 100 16.0
OD 2 ½" 63.5 × 1.65 60.20 320 90 364.0 689.0 170.0 594.0 100 18.0
OD 3" 76.2 × 1.65 72.90 326 125 374.0 721.0 192.0 634.0 100 22.5
*Clearance
 VARICOVER® Product Recovery Systems | VARICOVER® Pig Cleaning Station ATEX 35

Position Description of the order code

1 Pig cleaning station

1
PIG/PCS Pig cleaning station MST ATEX
2 Design
G Pig cleaning station complete
A Only actuator of the pig cleaning station
M Only pig retention cylinder for the pig cleaning station

2
3 Nominal width
DN 40 OD 1 ½"
DN 50 OD 2"
DN 65 OD 2 ½"
OD 3"
4 Seal material
1 EPDM (FDA)
2 FKM (FDA)
3 HNBR (FDA)
5 Surface quality
2 Inside Ra ≤ 0.8 µm, outside matt blasted
3 Inside Ra ≤ 0.8 µm, outside ground
6 Pig retention cylinder
0 Without pig retention cylinder
2 With pig retention cylinder
7 Proximity switches at the pig actuator (for technical specifications, see catalog GEA Valve Automation)
0 Without proximity switches
2 With proximity switches
8 Magnetic sensors at the pig station housing (for technical specifications, see catalog GEA Valve Automation)
0 Without magnetic sensors
2 With magnetic sensors
9 Ex-zone surrounding area Ex-zone pipework
1 Gases, zone 1 1 Gases, zone 1
2 Gases, zone 2 2 Gases, zone 2
21 Dust, zone 21 21 Dust, zone 21
22 Dust, zone 22 22 Dust, zone 22
10 Connection fittings Connection fitting on port 1 / 7
VARIVENT® flange connection complete,
N Without connection fittings TK
grooved flange on housing
VARIVENT® grooved flange complete,
J With connection fittings TN
incl. O-ring and connecting parts

TF VARIVENT® plain flange

CO Clamp connection

11 Accessories
/52 Adhesive ID tag
+
12-16 Air connection/control and feedback system
00000M Metric for air hose Ø 6/4 mm
00000Z Inch for air hose Ø OD ¼" (6.35/4.35 mm)
XXXXX Order code for different control and feedback systems see catalog GEA Valve Automation

The code is composed as following, depending on the chosen configuration:

Position 1 2 3 4 5 6 7 8 9 10 11 12 to 16
Code PIG/PCS - - - - - / /52 +
For order codes differing from the standard version, please refer to section 2.
36 VARICOVER® Product Recovery Systems | VARICOVER® Pig Catching Pipe/Pig Catching Station

VARICOVER®
Pig Catching Pipe/
Pig Catching Station

Connection fitting
on port 1 / 2

I II

Technical data of the standard version

Material in contact with the product 1.4404

Seal material in contact with the product EPDM (FDA)
Ambient temperature 0 to 45 °C
Max. product pressure DN 25 – DN 65
16 bar (232 psi)
OD 1" – OD 2 ½"
DN 80 – DN 100
10 bar (145 psi)
OD 3" – OD 4"
Surface in contact with the product Ra ≤ 0.8 µm
External housing surface Matt blasted
Connection fittings Welding end
Identification Adhesive ID tag
Certificates

Pig catching pipe

Pipe Dimension

Nominal Ø Ødi L L1* L2** H

width [mm] [mm] [mm] [mm] [mm] [mm]
DN 25 29.0 × 1.50 26.00 155 205 198 95
DN 40 41.0 × 1.50 38.00 176 226 219 101
DN 50 53.0 × 1.50 50.00 181 231 224 107
DN 65 70.0 × 2.00 66.00 206 256 262 115
DN 80 85.0 × 2.00 81.00 246 296 302 123
DN 100 104.0 × 2.00 100.00 271 321 327 132

OD 1" 25.4 × 1.65 22.10 150 200 193 93

OD 1 ½" 38.1 × 1.65 34.80 166 216 209 99
OD 2" 50.8 × 1.65 47.50 176 226 219 105
OD 2 ½" 63.5 × 1.65 60.20 196 246 252 112
OD 3" 76.2 × 1.65 72.90 226 276 282 118
OD 4" 101.6 × 2.11 97.38 261 311 317 131
* with VARIVENT® grooved flange ** with clamp connection
 VARICOVER® Product Recovery Systems | VARICOVER® Pig Catching Pipe/Pig Catching Station 37

Pig catching station

Housing Valve Dimensions

Nominal A B C F H1 X*
width [mm] [mm] [mm] [mm] [mm] [mm]
DN 15 47.0 40 65 180 298 348

1
DN 25 50.0 31 90 230 338 498
DN 40 62.0 39 90 230 372 532
DN 50 74.0 41 90 230 378 538

OD 1" 46.0 29 90 230 336 496

2
OD 1 ½" 59.0 39 90 230 370 530
OD 2" 71.5 42 90 230 377 537
*Clearance

Position Description of the order code

1 Pig catching pipe

PIG/PCP Pig catching pipe
2 Nominal width of the pigging line
DN 25 OD 1"
DN 40 OD 1 ½"
DN 50 OD 2"
DN 65 OD 2 ½"
DN 80 OD 3"
DN 100 OD 4"
3 Nominal width of the driving medium valves*
0 Without driving medium valves
DN 15
DN 25 OD 1"

* The order codes of the driving medium valves can be taken from the catalog GEA VARIVENT® Hygienic Seat Valves.
DN 40 OD 1 ½"
DN 50 OD 2"
4 Magnetic sensors (for technical specifications, see catalog GEA Valve Automation)
0 Without magnetic sensor
1 With magnetic sensor
5 Seal material
1 EPDM (FDA)
2 FKM (FDA)

Please indicate in your request that you need valves for product recovery systems.
3 HNBR (FDA)
6 Surface quality
2 Inside Ra ≤ 0.8 µm, outside matt blasted
3 Inside Ra ≤ 0.8 µm, outside ground
7 Connection fittings Connection fitting on port 1 / 2
VARIVENT® flange connection complete,
N Without connection fittings TK
grooved flange on housing
VARIVENT® grooved flange complete,
J With connection fittings TN
incl. O-ring and connecting parts

TF VARIVENT® plain flange

CO Clamp connection

8 Accessories
/52 Adhesive ID tag

The code is composed as following, depending on the chosen configuration:

Position 1 2 3 4 5 6 7 8
Code PIG/PCP - - - - / /52
For order codes differing from the standard version, please refer to section 2.
38 VARICOVER® Product Recovery Systems | Pig Driving Medium Valves with VARINLINE® Housing

Pig Driving Medium Valves

with VARINLINE® Housing

Connection fitting
on port 1 / 2

I II

Technical data of the standard version

Material in contact with the product 1.4404

Seal material EPDM (FDA)
Ambient temperature 0 to 45 °C
Max. Product pressure DN 25 – DN 65
16 bar (232 psi)
OD 1" – OD 2 ½"
DN 80 – DN 100
10 bar (145 psi)
OD 3" – OD 4"
Surface in contact with the product Ra ≤ 0.8 µm
External housing surface Matt blasted
Connection fittings Welding end
Identification Adhesive ID tag
Certificates

VARINLINE® housings

Pipe

Nominal Ø Ødi L L1* L2**

width [mm] [mm] [mm] [mm] [mm]
DN 25 29.0 × 1.50 26.00 180 230 223
DN 40 41.0 × 1.50 38.00 180 230 223
DN 50 53.0 × 1.50 50.00 180 230 223
DN 65 70.0 × 2.00 66.00 250 300 306
DN 80 85.0 × 2.00 81.00 250 300 306
DN 100 104.0 × 2.00 100.00 250 300 306

OD 1" 25.4 × 1.65 22.10 180 230 223

OD 1 ½" 38.1 × 1.65 34.80 180 230 223
OD 2" 50.8 × 1.65 47.50 180 230 223
OD 2 ½" 63.5 × 1.65 60.20 250 300 306
OD 3" 76.2 × 1.65 72.90 250 300 306
OD 4" 101.6 × 2.11 97.38 250 300 306
* with VARIVENT® grooved flange ** with clamp connection
 VARICOVER® Product Recovery Systems | Pig Driving Medium Valves with VARINLINE® Housing 39

Pig driving medium valves

Housing Valve Dimensions

Nominal A B C F H X*
width [mm] [mm] [mm] [mm] [mm] [mm]
DN 15 47.0 40 65 180 298 348

1
DN 25 50.0 31 90 230 338 498
DN 40 62.0 39 90 230 372 532
DN 50 74.0 41 90 230 378 538

OD 1" 46.0 29 90 230 336 496

2
OD 1 ½" 59.0 39 90 230 370 530
OD 2" 71.5 42 90 230 377 537
*Clearance

Position Description of the order code

1 Pig catching pipe

PIG/T Inline housings
2 Nominal width
DN 25 OD 1"
DN 40 OD 1 ½"
DN 50 OD 2"
DN 65 OD 2 ½"
DN 80 OD 3"
DN 100 OD 4"
3 Nominal width of the driving medium valves*
0 Without driving medium valves
DN 15
DN 25 OD 1"

* The order codes of the driving medium valves can be taken from the catalog GEA VARIVENT® Hygienic Seat Valves.
DN 40 OD 1 ½"
DN 50 OD 2"
4 Seal material
1 EPDM (FDA)
2 FKM (FDA)
3 HNBR (FDA)
5 Surface quality
2 Inside Ra ≤ 0.8 μm, outside matt blasted

Please indicate in your request that you need valves for product recovery systems.
3 Inside Ra ≤ 0.8 μm, outside ground
6 Certificates
K Without Z Inspection certificate 3.1
W Test report 2.2 A Inspection certificate 3.1 and 2.2
7 Connection fittings Connection fitting on port 1 / 2
VARIVENT® flange connection complete,
N Without connection fittings TK
grooved flange on housing
VARIVENT® grooved flange complete,
J With connection fittings TN
incl. O-ring and connecting parts

TF VARIVENT® plain flange

CO Clamp connection

8 Material in contact with the product

1.4404 1.4404 (AISI 316L)

The code is composed as following, depending on the chosen configuration:

Position 1 2 3 4 5 6 7 8
Code PIG/T - - - - / 1.4404
For order codes differing from the standard version, please refer to section 2.
40 VARICOVER® Product Recovery Systems | VARICOVER® Pig Stopper

VARICOVER®
Pig Stopper

Connection fitting
on port 1 / 2

I II

Technical data of the standard version

Material in contact with the product 1.4404

Seal material in contact with the product EPDM (FDA)
Ambient temperature 0 to 45 °C
Air supply pressure 4.2 bar (61 psi) to 8 bar (116 psi)
Max. product pressure DN 25 – DN 65
16 bar (232 psi)
OD 1" – OD 2 ½"
DN 80 – DN 100
10 bar (145 psi)
OD 3" – OD 4"
Surface in contact with the product Ra ≤ 0.8 µm
External housing surface Ground
Actuator type Pneumatic actuator air/spring
Connection fittings VARIVENT® grooved flange (welding end)
Identification Adhesive ID tag
Certificates

Pipe Housing Actuator Dimension General

Nominal Ø Ødi B L1 L2 D1 H X* Weight Stroke

width [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] [mm]
DN 25 29.0 × 1.50 26.00 37.0 75 125 68 328 358 6.0 32.0
DN 40 41.0 × 1.50 38.00 41.0 75 125 68 334 364 6.5 44.0
DN 50 53.0 × 1.50 50.00 51.0 75 125 139 377 407 11.0 59.0
DN 65 70.0 × 2.00 66.00 58.0 75 125 139 385 415 12.0 75.0
DN 80 85.0 × 2.00 81.00 65.0 75 125 139 392 422 12.5 90.0
DN 100 104.0 × 2.00 100.00 79.5 75 125 139 402 432 14.5 109.0

OD 1" 25.4 × 1.65 22.10 35.0 75 125 68 326 356 6.0 28.0
OD 1 ½" 38.1 × 1.65 34.80 39.5 75 125 68 333 368 6.5 41.0
OD 2" 50.8 × 1.65 47.50 49.5 75 125 139 376 406 11.0 56.5
OD 2 ½" 63.5 × 1.65 60.20 55.0 75 125 139 382 412 11.5 69.0
OD 3" 76.2 × 1.65 72.90 61.0 75 125 139 388 418 12.0 82.0
OD 4" 101.6 × 2.11 97.38 78.0 75 125 139 401 431 14.0 106.5
*Clearance
 VARICOVER® Product Recovery Systems | VARICOVER® Pig Stopper 41

Position Description of the order code

1 Pig stopper
PIG/PS Pig stopper
2 Nominal width
DN 25 OD 1"
DN 40 OD 1 ½"
DN 50 OD 2"
DN 65 OD 2 ½"
DN 80 OD 3"
DN 100 OD 4"
3 Proximity switches at the actuator (for technical specifications, see catalog GEA Valve Automation)
0 Without proximity switches
2 With proximity switches
4 Design
S Pig stopper (complete)
A Actuator as spare part
5 Seal material
1 EPDM (FDA)
2 FKM (FDA)
3 HNBR (FDA)
6 Surface quality
3 Inside Ra ≤ 0.8 µm, outside ground
7 Connection fittings Connection fitting on port 1 / 2
VARIVENT® grooved flange complete,
N Without connection fittings TN
incl. O-ring and connecting parts

J With connection fittings

8 Accessories
/52 Adhesive ID tag
+
9-14 Air connection/control and feedback system
00000M Metric for air hose Ø 6/4 mm
00000Z Inch for air hose Ø OD ¼" (6.35/4.35 mm)
XXXXX Order code for different control and feedback systems see catalog GEA Valve Automation

The code is composed as following, depending on the chosen configuration:

Position 1 2 3 4 5 6 7 8 9 to 14
Code PIG/PS - - - 3 - / /52 +
For order codes differing from the standard version, please refer to section 2.
42 VARICOVER® Product Recovery Systems | VARICOVER® Pig Stopper ATEX

VARICOVER®
Pig Stopper ATEX

Connection fitting
on port 1 / 2

I II

Technical data of the standard version

Material in contact with the product 1.4404

Seal material in contact with the product EPDM (FDA)
Ambient temperature 0 to 45 °C
Air supply pressure 4.2 bar (61 psi) to 8 bar (116 psi)
Max. product pressure DN 40 – DN 65
16 bar (232 psi)
OD 1 ½" – OD 2 ½"
OD 3" 10 bar (145 psi)
Surface in contact with the product Ra ≤ 0.8 µm
External housing surface Ground
Actuator type Pneumatic actuator air/spring
Connection fittings VARIVENT® grooved flange (welding end)
Identification Adhesive ID tag
Certificates

Pipe Housing Actuator Dimension General

Nominal Ø Ødi B L1 L2 D1 H X* Weight Stroke

width [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] [mm]
DN 40 41.0 × 1.50 38.00 41.0 75 125 68 334 364 6.5 44.0
DN 50 53.0 × 1.50 50.00 51.0 75 125 139 377 407 11.0 59.0
DN 65 70.0 × 2.00 66.00 58.0 75 125 139 385 415 12.0 75.0

OD 1 ½" 38.1 × 1.65 34.80 39.5 75 125 68 333 368 6.5 41.0
OD 2" 50.8 × 1.65 47.50 49.5 75 125 139 376 406 11.0 56.5
OD 2 ½" 63.5 × 1.65 60.20 55.0 75 125 139 382 412 11.5 69.0
OD 3" 76.2 × 1.65 72.90 61.0 75 125 139 388 418 12.0 82.0
*Clearance
 VARICOVER® Product Recovery Systems | VARICOVER® Pig Stopper ATEX 43

2
Position Description of the order code

1 Pig stopper
PIG/PS Pig stopper ATEX
2 Nominal width
DN 40 OD 1 ½"
DN 50 OD 2"
DN 65 OD 2 ½"
OD 3"
3 Proximity switches at the actuator (for technical specifications, see catalog GEA Valve Automation)
0 Without proximity switches
2 With proximity switches
4 Design
S Pig stopper (complete)
A Actuator as spare part
5 Seal material
1 EPDM (FDA)
2 FKM (FDA)
3 HNBR (FDA)
6 Surface quality
3 Inside Ra ≤ 0.8 µm, outside ground
7 Ex-zone surrounding area Ex-zone pipework
1 Gases, zone 1 1 Gases, zone 1
2 Gases, zone 2 2 Gases, zone 2
21 Dust, zone 21 21 Dust, zone 21
22 Dust, zone 22 22 Dust, zone 22
8 Connection fittings Connection fitting on port 1 / 2
VARIVENT® grooved flange complete,
N Without connection fittings TN
incl. O-ring and connecting parts

J With connection fittings

9 Accessories
/52 Adhesive ID tag
+
10-15 Air connection/control and feedback system
00000M Metric for air hose Ø 6/4 mm
00000Z Inch for air hose Ø OD ¼" (6.35/4.35 mm)
XXXXX Order code for different control and feedback systems see catalog GEA Valve Automation

The code is composed as following, depending on the chosen configuration:

Position 1 2 3 4 5 6 7 8 9 10 to 15
Code PIG/PS - - - 3 - - / /52 +
For order codes differing from the standard version, please refer to section 2.
44 VARICOVER® Product Recovery Systems | VARICOVER® Pig T-Piece

VARICOVER®
Pig T-Piece

Connection fitting
on port 1 / 2 / 7

VII

I II

Technical data of the standard version

Material in contact with the product 1.4404

Seal material in contact with the product EPDM (FDA)
Ambient temperature 0 to 45 °C
Air supply pressure 4.2 bar (61 psi) to 8 bar (116 psi)
Max. product pressure DN 25 – DN 65
16 bar (232 psi)
OD 1" – OD 2 ½"
DN 80 – DN 100
10 bar (145 psi)
OD 3" – OD 4"
Surface in contact with the product Ra ≤ 0.8 µm
External housing surface Matt based
Connection fittings welding end
Identification Adhesive ID tag
Certificates

Pipe Dimension

Nominal Ø Ødi L L1* L2** H H1** H2

width [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
DN 25 29.0 × 1.50 26.00 100 150 143 31.5 56.5 53.0
DN 40 41.0 × 1.50 38.00 120 170 163 39.5 64.5 61.0
DN 50 53.0 × 1.50 50.00 140 190 183 51.5 76.5 73.0
DN 65 70.0 × 2.00 66.00 160 210 216 61.5 86.5 89.5
DN 80 85.0 × 2.00 81.00 180 230 236 72.5 97.5 100.5
DN 100 104.0 × 2.00 100.00 200 250 256 89.0 114.0 117.0

OD 1" 25.4 × 1.65 22.10 100 150 143 29.7 54.7 51.2
OD 1 ½" 38.1 × 1.65 34.80 120 170 163 41.1 66.1 62.6
OD 2" 50.8 × 1.65 47.50 140 190 183 48.4 73.4 69.9
OD 2 ½" 63.5 × 1.65 60.20 160 210 216 58.8 83.8 86.8
OD 3" 76.2 × 1.65 72.90 180 230 236 64.1 89.1 92.1
OD 4" 101.6 × 2.11 97.38 200 250 256 89.3 114.3 117.3
* with VARIVENT® grooved flange ** with clamp connection
 VARICOVER® Product Recovery Systems | VARICOVER® Pig T-Piece 45

Position Description of the order code

1 Pig T-piece
PIG/TEE Pig T-piece
2 Nominal width
DN 25 OD 1"
DN 40 OD 1 ½"
DN 50 OD 2"
DN 65 OD 2 ½"
DN 80 OD 3"
DN 100 OD 4"
3 Seal material
1 EPDM (FDA)
2 FKM (FDA)
3 HNBR (FDA)
4 Surface quality
2 Inside Ra ≤ 0.8 μm, outside matt blasted
3 Inside Ra ≤ 0.8 μm, outside ground
5 Connection fittings Connection fitting on port 1 / 2 / 7
VARIVENT® flange connection complete,
N Without connection fittings TK
grooved flange on housing
VARIVENT® grooved flange complete,
J With connection fittings TN
incl. O-ring and connecting parts

TF VARIVENT® plain flange

CO Clamp connection

6 Accessories
/52 Adhesive ID tag

The code is composed as following, depending on the chosen configuration:

Position 1 2 3 4 5 6
Code PIG/TEE - - - / / /52
For order codes differing from the standard version, please refer to section 2.
46 VARICOVER® Product Recovery Systems | VARICOVER® Pig Type PK

VARICOVER®
Pig Type PK

Technical data of the standard version

Pig material in contact with the product VMQ , FKM

Ambient temperature -5 to 130 °C
Certificates

Dimensions Article number

Nominal L1 L2 ØD Material
width [mm] [mm] [mm] VMQ FKM
DN 25 On request On request On request On request On request
DN 40 80 42 > 38.00 228-163.24 228-163.23
DN 50 99 48 > 50.00 228-163.27 228-163.26
DN 65 127 60 > 66.00 228-163.30 228-163.29
DN 80 158 76 > 81.00 228-163.33 228-163.32
DN 100 192 91 > 100.00 228-163.36 228-163.35

OD 1" On request On request On request On request On request

OD 1 ½" 67 32 > 34.80 228-263.12 228-263.11
OD 2" 93 45 > 47.50 228-263.03 228-263.02
OD 2 ½" 119 58 > 60.20 228-263.15 228-263.14
OD 3" 144 70 > 72.90 228-263.18 228-263.17
OD 4" 181 83 > 97.38 228-263.06 228-263.05
 47

2
48 VARICOVER® Product Recovery Systems | VARICOVER® EMI/1 | Automatic Product Recovery Systems

VARICOVER® Product Recovery Systems

VARICOVER® EMI/1
Automatic Product Recovery Systems

Launching station

Pig driving medium

Product/CIP

Receiving station

Pig driving medium

Product/CIP

Functional description Selection criteria for the product recovery system EMI/1
Production The product recovery system is automatically operated and
The pig is firmly held in position in the launching station and the pig is cleaned in the launching station. The pig is removed
flooded with product. from the pipeline for inspection.

Product push-out Preferred combination of the pig driving media

The pig is pushed through the pipeline by means of the driving Launching station: Water
medium and pushes the residual product towards the receiving Receiving station: Air
station. At least one liquid medium is before or behind the pig in each
pig run.
Pig return
When reaching the receiving station, the pig is immediately Combination of the pig driving media
returned to the launching station. Launching station: Air
Receiving station: Air
Cleaning This is only possible with very slippery products such as sham-
The pig stations are cleaned during the pipe cleaning. The pig poo and vegetable oils that form a sufficient lubricating film
is fully flooded in the launching station and cleaned. between the pig and the pipe wall. Not applicable for products
that do not lubricate, so to avoid the “Stick-slip effect”.

The pipeline can be fully self-drained after cleaning.

 VARICOVER® Product Recovery Systems | VARICOVER® EMII/1 | Automatic Product Recovery Systems 49

VARICOVER® Product Recovery Systems

VARICOVER® EMII/1
Automatic Product Recovery Systems

Launching station 1
Pig driving medium

2
CIP

Product/CIP

Receiving station

Pig driving medium

Product/CIP

Functional description Selection criteria for the product recovery system EMII/1
Production The product recovery system is automatically operated
The pig is firmly held in position in the pig catching pipe and the pig is cleaned in its specific receiving station.
of the launching station and the product enters the The pig is removed from the pipeline for inspection.
system via the lateral socket of the special T-piece. The
pig stopper prevents the pig from exiting the system if a Preferred combination of the pig driving media
vacuum occurs. Launching station: Air
Receiving station: Air
Product push-out One liquid medium is located before the pig in each pig run.
The pig is pushed through the pipeline by means of the
driving medium and pushes the residual product towards Applicable for products with low lubrication properties.
the receiving station. For subsequent cleaning, the pig
remains in the receiving station. Applicable for pipelines that do not self-drain. The pig
pushes the water from the last cleaning step out towards
Cleaning the launching station.
The pig stations are cleaned during the pipe cleaning.
The pig is fully flooded in the receiving station and The pipeline is not sterilized with steam.
cleaned. The system must not be sterilized with steam,
because the pig cannot be driven back along a dry line.

Pig return
At the end of the cleaning, the pig is driven back to the
launching station by a gaseous driving medium. On its
way back, the pig is pushing out the final rinsing water
from the pipeline.
50 VARICOVER® Product Recovery Systems | VARICOVER® DM/1 | Automatic Product Recovery Systems

VARICOVER® Product Recovery Systems

VARICOVER® DM/1
Automatic Product Recovery Systems

Pig station S1

Pig driving medium

Product/CIP

Pig station S2

Pig driving medium

Product/CIP

Functional description
1. Product push-out optionally in two directions 2. Product filling with slope
If the product is filled into empty and descending pipelines,
Production product and air may mix and produce foam.
The pig stations have one pig firmly held in position each. Both
are flooded with product in their stations. This incident can be avoided using the product recovery
system DM/1. For this purpose, pig S2 is driven against pig
Product push-out S1 prior to production start. Afterwards pig S2 is pushed
After the production end, the residual product may be pushed back with product into its station and serves as a separator
out in the desired direction using the driving medium. The pig between product and air. All further process steps are the
moves to the opposite pig of the receiving station for this. same as described before under section 1.

Pig return 3. Operation with one pig

When reaching the receiving station, the pig is immediately
returned to the launching station. Only one pig is used in the system. The function method is the
same as for the product recovery system EMII/1. In contrast to
Cleaning the EMII/1, no T-piece is used for product infeed. The prod-
The pig stations are cleaned during the pipe cleaning. uct enters directly via the launching station and floods the pig
The pigs are fully flooded in their specific stations and cleaned. firmly held in position.
 VARICOVER® Product Recovery Systems | VARICOVER® DM/1 | Automatic Product Recovery Systems 51

Selection criteria for the product recovery system DM/1

The product recovery system is automatically operated
and the pigs are cleaned in the pig station. The pigs are
removed from the pipeline for inspection.

Three possible applications:

• Product push-out optionally in two directions
• Product filling with slope
– particularly when having foaming products
• Operation with one pig
–b enefit as compared to EMII/1: Product infeed
without T-piece

All combinations of driving media can be used if at least

one liquid medium is located before or behind the pig in
each pig run.
52 VARICOVER® Product Recovery Systems | VARICOVER® SP1/SP2 | Semi-automatic Product Recovery Systems

VARICOVER® Product Recovery Systems

VARICOVER® SP1/SP2
Semi-automatic Product Recovery Systems

Receiving station

SP2: Position ball valve

Pig driving medium

Product/CIP

Launching station

Product/CIP

Pig driving medium/CIP

Functional description Selection criteria for the product recovery system SP1/SP2
Production The product recovery system is semi-automatically operated,
Before starting production, the pig is manually inserted in since the pig runs automatically and cleaning of the pig takes
the launching station. The pipe bend is removed for this and place manually.
then installed again. Product infeed takes place via the lateral
socket of the T-piece. SP1: without ball valve
SP2: with ball valve
Product push-out The ball valve increases operational safety when inserting and
The pig is pushed through the pipeline by means of the driving removing the pig.
medium and pushes the residual product towards the receiv-
ing station. Preferred combination of the pig driving media
Launching station: Water
Pig return Receiving station: Air
When reaching the receiving station, the pig is immediately At least one liquid medium is located before or behind the pig
returned to the launching station. in each pig run.

Cleaning Combination of the pig driving media

The pig is removed manually before the start of cleaning at the Launching station: Air
launching station and manually cleaned outside of the system. Receiving station: Air
This is only possible with very slippery products such as
shampoo and vegetable oils that form a sufficient lubricating
film between the pig and the pipe wall.
 VARICOVER® Product Recovery Systems | VARICOVER® MP1/MP2 | Manual Product Recovery Systems 53

VARICOVER® Product Recovery Systems

VARICOVER® MP1/MP2
Manual Product Recovery Systems

1
MP2: Position ball valves
2

Launching station Receiving station

Product/CIP

Pig driving medium/CIP Product/CIP

Functional description Preferred pig driving medium at system MP1

Production Launching station: Air
Before starting production, the pig is manually inserted When using water, there is the danger of water escaping
in the launching station. The pipe bend is removed for when opening the pipe bend at the receiving station.
this and then installed again. Product infeed takes place
via the lateral socket of the T-piece. Preferred pig driving medium at system MP2
Launching station: Water
Product push-out Using water permits better adjustment of the pig speed
The pig is pushed through the pipeline by means of the than with the compressible medium of air. There is no
driving medium and pushes the residual product towards risk of water escaping since the ball valve before the
the receiving station. It is removed for subsequent cleaning receiving station is closed when opening the pipe bend.
there and not pushed back to the launching station.
Alternatively, the MP1 and MP2 systems can also be
Cleaning operated semi-automatically. For this, the valves are
The pig is manually cleaned outside of the system. equipped with pneumatic actuators. The pig run takes
place automatically and the pig is cleaned manually. As
Selection criteria for the product recovery system for the manual application, the pig is taken out at the
SP1/SP2 receiving station.semi-automatically. For this, the valves
The product recovery system is manually operated, are equipped with pneumatic actuators. The pig run
since both the pig runs and the cleaning of the pig take takes place automatically and the pig is cleaned manually.
place manually. As for the manual application, the pig is taken out at the
receiving station.
MP1: without ball valves
MP2: with ball valves
The ball valves increase operational safety when inserting
and removing the pig.
54 VARICOVER® Product Recovery Systems | Options

VARICOVER® Product Recovery Systems

Options

Pig detector
The pig detector serves to find an unmoving pig along the
pipeline or in a pig station. For this, the detector is manually
routed to the pipeline from the outside. Once it has entered
the area of the pig’s magnetic field, an indicator light comes
on. The design of the pig detector is comparable to that of
a pen. The detector is also approved for use in potentially
explosive atmospheres (ATEX and FM)

Article number

228-000358

Pig test material

Using pig test materials helps to determine the chemical
resistance of the pig material against products and/or cleaning
media in the planning stages.

This procedure is particularly recommended when the resis-

tance of the pig material is unknown. The test bodies have
a diameter of approx. 40 mm and a thickness of approx. 4 mm.
During resistance tests, deviations from the surface properties,
dimensions and weights can be found. Available materials:
Silicone and FKM.

Material Article number

FKM 228-000259
Silicone 228-000260
 VARICOVER® Product Recovery Systems | Options 55

Magnetic sensor with pipe bracket

Pigs are often detected along pipelines in the running
state to initiate measures to reduce the pig speed. For
this, magnetic sensors are attached to pipe brackets.
They can be fitted anywhere at the pipeline.

Pipe bracket for magnetic sensors

Nominal width Article number

DN 25 228-168.02
DN 40 228-168.04
DN 50 228-168.06
DN 65 228-168.08
DN 80 228-168.10
DN 100 228-168.12
OD 1" 228-168.01
OD 1 ½" 228-168.03
OD 2" 228-168.05
OD 2 ½" 228-168.07
OD 3" 228-168.09
OD 4" 228-168.11
* The magnetic sensors can be taken from the catalog GEA Valve Automation.
56 VARICOVER® Product Recovery Systems | Questionnaire | VARICOVER®

VARICOVER® Product Recovery Systems

Questionnaire
VARICOVER®

Customer

Company name /
customer number
Project
Contact
Phone
Email

Basic data (these parameters refer to the pipeline)

• The same pipe interior diameter across the entire pigging route.
• No sharp-edged and strongly sagging welds.
• No installations such as measuring mountings in the piggable area.
Prerequisites • Standard pipe bends with small middle radius can be used.
Recommendation: Minimize the number of pipe bends!
• Use pipe bends with low ovality.
Tolerance maximum ± 1.5 % referring to the outside diameter.

Pipeline □ Existing □ Planned

Nominal width
Pipe diameter Inside mm Outside mm
Material □ 1.4404 □ Others:
Seal material □ EPDM □ FKM □ HNBR
Piggable pipe lengths m
Height difference between
launching and receiving m □ Dropping □ Rising
stations
Outlets between launching
□ T-pieces □ Quantity
and receiving stations

Products

Designation Viscosity mPas Operating temperature °C Operating pressure barg Flow rate m³/h

1
2
3

Properties product 1 □ Foaming □ Lubricating □ Others:

Properties product 2 □ Foaming □ Lubricating □ Others:

Properties product 3 □ Foaming □ Lubricating □ Others:

Note: Please send us viscosity charts, viscosity [mPas] depending on the shear rate [s–1].

Pig driving medium

Compressed air (according

Air pressure min. barg Air pressure max. barg
to ISO 8573-1:2001)
Water Pressure barg

Other Pressure barg

□ Water can be used at the launching and air at the receiving station (preferred).

□ Water can be used at the launching and receiving stations.

□ Air can be used at the launching and water at the receiving station.

□ Air must be used at the launching and the receiving stations.

 VARICOVER® Product Recovery Systems | Questionnaire | VARICOVER® 57

Process

□ Pipeline is cleaned after each product push-out.

1
□ Pipeline must be emptied after each cleaning.

If so, □ the system is self draining.

□ The pipeline is sterilized with steam after cleaning. Temperature: °C

If so, □ the pig must push out the water.
2
How often is the product x x x
pushed out? per day per week per month

Cleaning

Cleaning media Concentration % Temperature °C

1.

2.

3.

Design

Explosion protected design □ No □ Yes

□ With control top

□ AS-interface-bus □ 24 V DC, 3-wire
□ With solenoid valve
□ Without solenoid valve
□ Others:
Control top

□ Without control top

□ With holding plate “INA” for proximity switches
□ With proximity switches
□ Without proximity switches

Note: Please send us a sketch of the planned installation position or a flow chart of the plant section into which the VARICOVER® product recovery system
is to be integrated.

Air supply pressure

(according to Air pressure min. barg Air pressure max. barg
ISO 8573-1:2001)

Use of ball valves

possible from a hygienic □ Yes □ No
point of view?

3-A certified □ Yes □ No

Comments
58 Options | Available Options

2 options
VARICOVER® Product Recovery Systems
 Options | Available Options 59

Available Options
60 Surface Qualities

60 Inner and Outer Surface of the Housings

61 Connection Fittings

61 Overview

62 VARIVENT® Flange Connection

64 Clamp Connection (Tri-Clamp)

65 Additional Options

65 Test Report and Inspection Certificate

66 ID Plates, TAG Numbers

68 3-A Symbol

69 General

69 Lubricant
60 Options | Surface Qualities | Inner and Outer Surface of the Housings

Options
Surface Qualities
Inner and Outer Surface of the Housings

Typical application and description

Deviating from the quality of the standard surface quality
(** DN / OD corresponding to Rₐ ≤ 0.8 μm), different surface
qualities are available up to a medium roughness for surfaces
in contact with the product of Rₐ ≤ 0.4 μm. The outer surface
of the housings is matt blasted as standard. Optionally, it can
also be supplied ground.

Housings that should comply with the 3-A standard are pro-
duced as standard with an inner surface of Rₐ ≤ 0.8 μm with
ground welds and a blasted outer surface. If a configuration
with a ground outer surface is required, it is necessary to
select not only option /3-A but also the corresponding
surface quality 3.

Incorporation of the option in the order code and example

Position Description of the order code for options

* Surface quality of the housing
2** Inside Rₐ ≤0.8 µm, outside matt blasted
3 Inside Rₐ ≤ 0.8 μm, outside ground

Position 1 2 3 4 5 6 7 8 9 10 11 to 16
Code PIG/PCS - G DN - 1 3 - 2 2 2 - N /52 + 0 0 0 0 0 M
80

* According to valve type

 Options | Connection Fittings | Overview 61

Options
Connection Fittings
Overview

Typical application and description

The valve housings can be specified with a welded-on con-
nection fitting. To find which connection fittings are available,
please refer to the list on the following pages.

If the vertical ports within a valve do have different configu-

rations, please inform us of the designation for the particular
housing port including the required connection fitting (as in the
example below). The seal which may be included corresponds to
the sealing material of the valve.

Connection fittings

VARIVENT® flange connection,

TK
groove flange on housing
VARIVENT® groove flange incl. O-ring
TN
and connecting parts

TF VARIVENT® flange

Clamp connection / TRI-Clamp,

CO
DIN 32676 (DN) / ISO 2852 (OD)

Incorporation of the option in the order code and example

Position Description of the order code for options

Connection fittings
J Component with connection fittings (required connection fitting according to list above, please state separately)

Position 1 2 3 4 5 6 7 8 9 10 11 to 16
Code PIG/PCS - G - DN - 1 2 - 2 2 2 - J /52 + 0 0 0 0 0 M
80
62 Options | Connection Fittings | VARIVENT® Flange Connection

Options
Connection Fittings
VARIVENT® Flange Connection

Complete connection
including bolts and
nuts (TK)

Groove flange (TN),

including connecting
elements and
seal ring

Flange (TF)

Typical application and description

An O-ring is used for sealing the VARIVENT® flange connec-
tion, and is given a defined compression by a metal stop. The
O-ring is also protected by the special geometry of the recess
from being pulled out at high flow rates.

The VARIVENT® flange connection (TK) can be ordered either

as a complete connection including bolts and nuts (TK) or a
groove flange (TN)/flange (TF) as a connection fitting on a
vertical port. If a complete connection is ordered as the con-
nection fitting, the groove flange is welded onto the housing.
The groove flange (TN) contains not only the O-ring but also
the required connecting elements.
 Options | Connection Fittings | VARIVENT® Flange Connection 63

1
TK = VARIVENT® flange connection

Available nominal widths

2
Metric DN 25–100
Inch OD OD 1" – 4"

Technical data TN = VARIVENT® groove flange

Material 1.4404
Surface in contact with the product Ra ≤ 0.8 µm
Certificates 3.1/AD2000W2
Max. pressure DN 25 – DN 65
16 bar
OD 1" – OD 2 ½"
DN 80 – DN 100
10 bar
OD 3" – OD 4"
Seal materials EPDM (FDA), FKM (FDA), HNBR (FDA) TF = VARIVENT® flange

Dimension O-Ring

Nominal D1 D2 D3 D4 d L L1
[mm] PS
width [mm] [mm] [mm] [mm] [mm] [mm] [mm]
DN 25 70 30.0 26.0 53 4×Ø9 50 25 25.0 × 5.0 16
DN 40 82 42.0 38.0 65 4×Ø9 50 25 36.0 × 5.0 16
DN 50 94 54.0 50.0 77 4×Ø9 50 25 47.0 × 5.0 16
DN 65 113 70.0 66.0 95 8×Ø9 50 25 62.0 × 5.0 16
DN 80 128 85.0 81.0 110 8×Ø9 50 25 75.0 × 5.0 10
DN 100 159 104.0 100.0 137 8 × Ø 11 50 25 95.0 × 5.0 10

OD 1" 66 25.5 22.0 49 4×Ø9 50 25 25 × 5.0 16

OD 1 ½" 79 38.5 35.0 62 4×Ø9 50 25 36 × 5.0 16
OD 2" 91 51.0 47.5 74 4×Ø9 50 25 47 × 5.0 16
OD 2 ½" 106 63.5 60.0 88 8×Ø9 50 25 62 × 5.0 16
OD 3" 119 76.5 73.0 101 8×Ø9 50 25 75 × 5.0 10
OD 4" 156 102.0 97.5 134 8 × Ø 11 50 25 95 × 5.0 10

Incorporation of the option in the order code and example

Position Description of the order code for options

Connection fittings
J Component with connection fittings (please state option TK, TN or TF separately with reference to the connection)

Position 1 2 3 4 5 6 7 8 9 10 11 to 16
Code PIG/PCS - G DN - 1 2 - 2 2 2 - J /52 + 0 0 0 0 0 M
80
64 Options | Connection Fittings | Clamp Connection (Tri-Clamp)

Options
Connection Fittings
Clamp Connection (Tri-Clamp)

Clamp
connection (CO)

Typical application and description

The clamp connection acc. to DIN 32676 is a widely used con-
nection fitting, especially in North America. The connection
uses a symmetrically structured clamp connection with a seal
located in between it, and is secured by a clamp. The second
clamp connection, the seal and the clamp are not supplied.

Available nominal widths

Metric DN 25–100
Inch OD OD 1" – 4"

Technical data

Material DN 1.4404 (AISI 316L)

OD AISI 316L
Standard DN DIN 32676
DIN 32676*;
OD
Length 28.5 mm**
Inner diameter DN DIN 11866 row A
OD DIN 11866 row C
Max. pressure DN 25 – DN 40
25 bar
OD 1" – OD 2 ½"
DN 50 – DN 65
16 bar
OD 2" – OD 3"
DN 80 – DN 100
10 bar
OD 4"
Certificates 3.1
*similar to ASME BPE B **OD 6" referred to DIN 32676

Incorporation of the option in the order code and example

Position Description of the order code for options

Connection fittings
J Component with connection fittings (required connection fitting, please state separately)

Position 1 2 3 4 5 6 7 8 9 10 11 to 16
Code PIG/PCS - G - DN - 1 2 - 2 2 2 - J /52 + 0 0 0 0 0 M
80
 Options | Additional Options | Test Report and Inspection Certificate 65

Options
Additional Options
Test Report and Inspection Certificate

Typical application and description

Optionally, the housings and connection fittings can be sup-
plied with a test report 2.2 and/or an inspection certificate
3.1 acc. to EN 10204.

European standard EN 10204 in its 2004 edition defines the

various types of test certificate that can be issued to the
ordering party in accordance with the agreements in the order
for delivery of metallic products.

Number Type of test certificate Content of the certificate Confirmation of the certificate by

Confirmation of compliance with the order,

2.2 Test report The manufacturer
specifying results of a non-specific test
Confirmation of compliance with the order, The manufacturer’s acceptance officer
3.1 Inspection certificate 3.1*
specifying results of a specific test independent of the production department
* Inspection certificates 3.1 can be selected either for the housing or for product wetted parts, incl. connection fittings or ADW2 (please specify when ordering).

Incorporation of the option in the order code and example

Position Description of the order code for options

Accessories
/41 Test report 2.2
/42 Inspection certificate 3.1 according to EN 10204
66 Options | Additional Options | ID Plates, TAG Numbers

Options
Additional Options
ID Plates, TAG Numbers

Typical application and description

If no alternative identification option is selected, the valves
are always provided with a nameplate for clear identification
(option /52). All key information required for clear allocation of
the component, as well as technical data, is specified on the
nameplate. The plate is glued onto the actuator. If the required
identification number is specified, this is allocated to the valve
by means of a separate sticker on the actuator.

Key data contained

Valve type
Serial number
Materials in contact with the product Metallic material / seal material
Air supply pressure Min./Max. [bar/psi]
Product pressure Housing 1/2/3 [bar/psi]
 Options | Additional Options | ID Plates, TAG Numbers 67

Option /50 – engraved labeling plate cpl. for system identi-

fication number
In addition to the nameplate, the option /50 consists of an
engraved labeling plate attached between the actuator and
lantern using a key ring on the clamp connection.

Option /51 – metal labeling plate US version cpl.

The engraved labeling plate is attached between the actuator
and lantern using a key ring on the clamp connection. Additional
information can be recorded as well as the TAG number, cus-
tomer designation and the valve type. In addition, the valve is
identified with a nameplate.

Incorporation of the option in the order code and example

Position Description of the order code for options

Accessories
/50 Engraved metal plate
/51 Metal plate (US version)
/52 Adhesive ID tag

Position 1 2 3 4 5 6 7 8 9 10 11 to 16
Code PIG/PCS - G - DN - 1 2 - 2 2 2 - N /50 + 0 0 0 0 0 M
80
68 Options | Additional Options | 3-A Symbol

Options
Additional Options
3-A Symbol

Typical application and description

3-A Sanitary Standards, Inc. is an independent, non-profit
corporation dedicated to advancing hygienic equipment design
for the food, beverage, and pharmaceutical industries. In
particular, it represents the interests of three stakeholder
groups in the US dairy industry with a common commitment
to promoting food safety and the public health – regulatory
sanitarians, equipment fabricators and processors. To achieve
this purpose, it has produced guidelines which define various
design requirements on components. Compliance with these
design specifications is examined by an independent expert
and confirmed by issuing a certificate.

If the 3-A option is selected, compliance with the require-

ments of the standard is confirmed by means of a sticker on
the component. Consequently, if this option is selected, it is
necessary to comply with the standard in terms of identifica-
tion as well.

Furthermore, when this option is selected, the welds of the port

connections are ground smooth. The standard does not specify
that this is mandatory, but it is in line with customers’ prefer-
ences in this market.

IMPORTANT: The standard surface when this option is selected

is “inside surface Rₐ ≤ 0.8 µm, outside matt”. Many customers
in this market ask for the alternative surface quality “inside
surface Rₐ ≤ 0.8 µm, outside ground”. If this is required, it must
be selected separately in the order code as a non-standard
surface.

Incorporation of the option in the order code and example

Position Description of the order code for options

Accessories
/3A Adhesive ID tag, configuration of the valve according to 3-A standard

Position 1 2 3 4 5 6 7 8 9 10 11 to 16
Code PIG/PCS - G - OD 3" - 1 2 - 2 2 2 - N/S /52/3A + 0 0 0 0 0 M
 Options | General | Lubricant 69

Options
General
Lubricant

Lubricant Article number

Rivolta F.L.G. MD-2 (1,000 g) 413-071

Rivolta F.L.G. MD-2 (100 g) 413-136
GEA Valve Automation –
Control and Feedback Systems
Valve automation for increased process reliability, efficiency the achievement of optimum system operation. This ensures
and flexibility adherence to a smooth process flow, while also achieving
GEA’s valve technology sets the standards for reliable, safe the utmost in product safety.
and permanently efficient liquid processes. Leading-edge
control and automation options enable operators to achieve Special priority is given to sustainability in intelligent valve
optimum control and monitoring of the valve – thereby realizing control: Thanks to the selectable LEFF® function integrated
state-of-the-art, highly flexible operating and automation in the T.VIS® A-15, up to 90 percent of cleaning agents can
concepts. be saved by an optimized and PLC-independent pulsing of
the valve discs during the cleaning process. The economical
The key component is the latest generation of GEA control air guidance in the control top and the integrated solenoid
tops with reliable, ground-breaking control and feedback valves with low power intake minimize energy consumption
technology. Mechanical valve components and a control top as well as the demand for compressed air and the number of
specified for the particular application together to form a finely hose connections.
tuned valve unit capable of realizing advanced system concepts
and enhancing process options. In addition, the control top offers the best protection to
components against adverse ambient conditions such as
The control top – integral part of the valve unit moisture, dust, liquids of any kind, vibrations and other
The control top facilitates optimized production and cleaning mechanical impact.
processes with less expenditure on staff, energy and time.
Valve functions can be automatically and continuously
monitored, recorded, evaluated and if necessary, corrected.
Detectable valve positions make a crucial contribution towards
 GEA Valve Automation – Control and Feedback Systems | Overview 71

Modern plant communication at the threshold to industry 4.0

The control tops in the current GEA range can be configured for
all common types of connection and control systems to make
future-oriented, pioneering automation functions possible.
For example, users can ensure early digital integration of
their system control setup in Industry 4.0 environments by
way of the modern IO-Link technology. Digital exchange of
data enables central setting of component parameters and
lossless information transfer.

Diagnostic data from the valve can be processed and displayed

in central control unit of the plant. The options even extend
to networking the system controller with the company’s ERP
system for optimized resource utilization.

Easy start-up The T.VIS® M-15 is fitted with manually adjustable sensors and
Thanks to pre-configurable system parameters and a fully is available for all established types of communication such as
automatic SETUP, the installation for digital valve control 24VDC, As-i and DeviceNet.
is easy even also without extensive technical knowledge.
Regional requirements, application-specific certificates (UL/ The T.VIS® A-15 offers extended functional scope and greater
CSA/PMO/ATEX) and other individual specifications can be ease of operation. Besides the established types of commu-
provided as needed. nication, this control top also features the groundbreaking
IO-Link technology, which allows users to set the parame-
As a true pioneer with decades of experience in the develop- ters for components centrally in the system via digital data
ment of valves and control tops for all processes, GEA offers exchange and transfer all process data loss-free. Thanks to
the perfect symbiosis of mechanical and electronic engineer- a fully automatic setup, commissioning can be quickly and
ing, largely with standardized components. Extensive tests easily carried out by means of the push buttons fitted on the
and countless valve units installed around the world have hood. Additional functions such as the selection of different
continuously proved the reliability and cost-effectiveness for tolerance bands, signal attenuation and the resource-saving
the user, always ensuring maximum safety of operation. LEFF® function round off the T.VIS® A-15.

Recommended control and feedback systems Attention must be paid to regional requirements for use
for GEA VARICOVER® product recovery systems in explosive areas. The SES meets the requirements of the
The T.VIS® M-15 offers an attractively priced basic version of European ATEX Directive and can be used in Zones 1 and 20.
control and feedback technology for GEA VARICOVER® prod- The T.VIS® A-15 is certified in accordance with the Directive
uct recovery systems with optimum adaptation to process Class 1 / Div. 2 in compliance with the regulations in place for
conditions. the North American market.
72 GEA Valve Automation – Control and Feedback Systems | Overview

GEA Valve Automation –

Control and Feedback Systems
Overview

Proximity switches
Technical data
External proximity switch M12 × 1 for position feedback at the
actuator of the pig cleaning station and the pig stopper. Nominal switching distance 10 mm
Protection class IP68
Operating voltage 10 – 30 V DC
Material GD-Zn, chrome-plated
Permitted ambient temperature −30 to +85 °C

Proximity switch M12×1 Article no.

3-wire PNP normally close

505-103
Electrical connection (plug connector 508-953)
by wiring in the
terminal chamber

Technical data

Nominal switching distance 2 mm

Protection class IP67
Operating voltage 10 – 30 V DC
Material Brass, chrome-plated / PA12
Permitted ambient temperature −25 to +70 °C
Marking EX II 2 G EEx ia IIC T6

Electrical connection Proximity switch M12 × 1

Article no.
by M12×1 connector for ATEX application
NAMUR (terminal chamber) 505-085
 GEA Valve Automation – Control and Feedback Systems | Overview 73

Magnetic sensors
Technical data
Magnetic-inductive proximity sensors monitor the position
of the permanent magnets in the pig from outside of the pig Nominal switching distance 90 mm
station housing or the pipeline. Protection class IP67
Operating voltage 10 – 65 V DC
Material GD-Zn, chrome-plated
Permitted ambient temperature −25 to +70 °C

Magnetic sensor
M12 × 1 for pig recognition – Article no.
normally open function
3-wire PNP normally close
505-081
Electrical connection (terminal chamber)
by wiring in the
terminal chamber

Technical data

Nominal switching distance 90 mm

Protection class IP67
Operating voltage 8.2 VDC
Material CuZn, chrome-plated / PA12-GF30
Permitted ambient temperature −25 to +70 °C

Magnetic sensor
M12 × 1 for pig recognition – Article no.
Electrical connection
ATEX category II 2 G, Ex zone 1
by M12×1 connector
NAMUR (plug connector 508-953) 505-078
 Appendix | GEA Service for Hygienic Valve Technology 75

Our service package for

dependable valve technology
With a tailored service concept, you can extend the service
life of your hygienic valve technology. Professional services
and original spare parts from GEA help to ensure maximum
system availability and security, smooth operation and precise
process execution.

Our service specialists are here to help you in every phase

of system utilization – from the initial process concept and
throughout the entire performance period to advising on your
best strategies for the future.

Consulting and
Enhanced Operations

Together Getting you

with you started

Extended Beginning of
Life Services Life Services

Constantly Keeping it
improving running

Lifetime
Services

Beginning of life services Extended life services

We draw on our decades of experience to support you in When upgrades are available to enhance your system, you
configuring your system and providing extensive employee benefit from our continuing advances in hygienic valve
training. Our consultations and training sessions take place technology. We offer extensive advice and consultation.
in our Competence Centre in Büchen or, upon request,
at your premises. Consulting and enhanced operations
Working in partnership with you, we support your enduring
Lifetime services success and develop service strategies and Service Level
We optimize your spare parts logistics by using our modular Agreements for a profitable future operation.
component system and our extensive service network. Pre-
ventive maintenance programmes based on comprehensive
data, routine troubleshooting and efficient repair logistics
keep downtimes to a minimum.
76 Appendix | Description of Certificates

Description of Certificates

3-A 3-A Sanitary Standards, Inc. (3-A SSI) is an independent, non-profit corporation dedicated to
advancing hygienic equipment design for the food, beverage, and pharmaceutical industries.

24 / 7 PMO VALVE 2.0® 24 / 7 PMO VALVE® is a registered trade mark of GEA Tuchenhagen GmbH. It describes double-seat
NON-STOP PRODUCTION valves that have been authorized for use in PMO-regulated systems for carrying out the seat lift in
order to clean the leakage chamber while the other pipeline is carrying product. This grants system
operators the possibility of cleaning all valve components in contact with the product in parallel
with the production process. In this way, the valves permit uninterrupted production on a 24/7 basis.
AS-i Actuator Sensor interface. BUS system for the lowest field level.

ATEX Atmosphères Explosibles. ATEX comprises the directives of the European Union in the area of
explosion protection. For one thing, this is the ATEX equipment directive 2014/34/EU, for another,
the ATEX workplace directive 1999/92/EC.

cCSAus Test of a product by CSA according to applicable safety standards in Canada and the USA.

CE Conformité Européenne. By affixing the CE mark, the manufacturer confirms that the product
complies with the European directives 765/2008 applicable to the specific product.

CSA Canadian Standards Association. A non-governmental Canadian organization which issues

standards as well as checking and certifying the safety of products. It is now globally active.

cULus Test of a product by UL according to applicable safety standards in Canada and the USA.

DeviceNet BUS system of the ODVA organization for complex communication on various field levels.

EG 1935/2004* Materials in contact with the product used in valves from GEA Tuchenhagen GmbH are in accordance
with EC regulation 1935/2004. This defines a general framework for materials and objects
intended to come into contact with foodstuffs.

EHEDG European Hygienic Engineering & Design Group. European supervisory authority for foodstuffs and
pharmaceuticals. This authority issues approvals and certificates for products and materials that
are used in the foodstuffs and pharmaceuticals industries.

FDA Food and Drug Administration. US supervisory authority for foodstuffs and pharmaceuticals.
This authority issues approvals and certificates for products and materials that are used in the
foodstuffs and pharmaceuticals industries.

ODVA ODVA is a worldwide association comprising leading automation companies. It develops network
protocols and standards in the joint interests of its members, which are used for the international
interoperability of production systems.

TÜV Technischer Überwachungs-Verein. The German TÜV is a private company which carries out
technical safety checks as prescribed in national legislation or regulations.

UL Underwriters Laboratories. An organization founded in the USA for checking and certifying
products and their safety.

* not possible for HNBR

 Appendix | Abbreviations and Terms 77

Abbreviations and Terms

Abbreviation Explanation

°C Degrees Celsius, unit of measurement for temperature

°F Degrees Fahrenheit, unit of measurement for temperature
3-A Standard of 3-A Sanitary Standards, Incorporated (3-A SSI)
3D Three-dimensional
A Ampere, unit of measurement of current intensity or Output, term used in automation
AC Alternating Current
ADI free All elastomer compounds are free of animal-derived ingredients
AISI American Iron and Steel Institute, association of the American steel industry
ANSI American National Standards Institute, American body for standardizing industrial processes
approx. approximately
AS-i Actuator Sensor interface, standard for fieldbus communication
ASME American Society of Mechanical Engineers, professional association of mechanical engineers in the USA
ASME-BPE Standard of the ASME's – bioprocessing equipment association
ATEX Atmosphères Explosibles, synonymous with the directives of the European Union for potentially explosive areas
bar Unit of measurement for pressure. All pressure values [barg/psig] refer to positive pressure [barg / psig],
unless specifically stated otherwise.
barg Unit of measurement for pressure relative to atmospheric pressure
CAN Controller Area Network; asynchronous serial bus system
CE Conformité Européenne, administrative symbol for the free movement of industrial products
CIP Cleaning In Place, designates a process for cleaning technical process systems.
CRN The Canadian Registration Number is issued by a Canadian Jurisdiction and covers pressurized components.
The authorization is needed to operate these components in Canada.
CSA Canadian Standards Association, a non-governmental Canadian Standardization organization
dB Decibel, one tenth of a bel, named after Alexander Graham Bell and used for identifying levels and dimensions
DC Direct Current
DIN Deutsches Institut für Normung e. V. Standardization organization in the Federal Republic of Germany,
DIN = synonym for standards issued by the organization
DIP Dual Inline Package, design of a switch
DN Diameter Nominal, DIN nominal width
Device Net Network system used in the automation industry to interconnect control devices for data exchange
E Input, term used in automation
EAC Certification of technical confirmity from the customs union of Russia/Balarus/Kazakhstan
Pressure Equipment Directive of the European Parliament and the Council Directive for layout and conformity evaluation for pressure
Directive 2014/68/EU equipment and assemblies with a maximim pressure (PS) of more than 0.5 bars.
EG No. 1935/2004 Regulation of the European Parliament which lays down common rules for materials which come, or may come,
into contact with food, either directly or indirectly.
EHEDG European Hygienic Engineering and Design Group. Consortium of equipment manufacturers, food industries,
research institutes as well as public health authorities
EN European standard, rules of the European Committee for Standardization
EPDM Ethylene propylene diene rubber, acronym acc. to DIN / ISO 1629
Ex Synonym for ATEX
FDA Food and Drug Administration, official foodstuffs monitoring in the United States
FEM calculation Finite Element Method; calculation process for simulating solids
FKM Fluorinated rubber, acronym acc. to DIN / ISO 1629
H Henry, unit of measurement for inductance
HNBR Hydrated acrylonitrile butadiene rubber, acronym acc. to DIN / ISO 1629
Hz Hertz, unit of frequency named after Heinrich Hertz
I Formula symbol for electrical current
IEC International Electrotechnical Commission, international standardization organization for electrical and
electronic engineering
78 Appendix | Abbreviations and Terms

Abbreviations and Terms

Abbreviation Explanation

IP Ingress Protection / International Protection, index of protection class acc. to IEC 60529
IPS Iron Pipe Size, American pipe dimension
ISA International Society of Automation, international US organization of the automation industry
ISO International Organization for Standardization, international organization that produced international standards,
ISO = synonym for standards from the organization
kg Kilogram, unit of measurement for weight
Kv The Kv value corresponds to the water flow rate through a valve (in m³ / h) at a pressure differential of 0.98 bar
and a water temperature of 5 °C to 30 °C.
Kvs The Kv values of a valve at nominal stroke (100 % opening) is designated the Kvs value
L Conductive
LED Light-Emitting Diode
LEFF® Function of the T.VIS® valve informations system for cyclical pulsing during the lifting process; Low-Emission Flip Flop
mm Millimeter, unit of measurement for length
M Metric, system of units based on the meter or Mega, one million times a unit
m3/h Cubic meters per hour, unit of measurement for volumetric flow
max. Maximum
NAMUR Standardization working association for measuring and control technology in the chemical industry,
synonym for the interface type of the organization, especially for potentially explosive atmospheres
NC Normally Closed; valve or solenoid valve control which is closed in idle status
NO Normally Open; valve or solenoid valve control which is open in idle status
NOT-element Logic element, NOT gate
NPN Signal transmission against reference potential, current-consuming
NPT National Pipe Thread, US thread standard for self-sealing pipe fittings
OD Outside Diameter, pipe dimension
ODVA Open DeviceNet Vendor Association, global association for network standards
PA 12/L Polyamide
Pg Armoured thread
PMO Pasteurized Milk Ordinance
PN Nominal pressure for pipeline systems according to EN 1333, rated pressure in bar at room temperature (20 °C)
PNP Signal transmission against reference potential, current-supplying
PPO Polyphenylene oxide, thermoplastic material
PS Maximum permitted operating pressure at which the components can operate safely at maximum allowable
temperature (TS)
psi Unit of measurement for pressure, pound-force per square inch, 1 psi = 6894.75 Pa. All pressure values [bar/psi]
refer to positive pressure [barg / psig], unless specifically stated otherwise.
psig Unit of measurement for pressure relative to atmospheric pressure
PV Solenoid valve
Ra in μm Average roughness value, describes the roughness of a technical surface
RM Feedback
International Protection-Code Classifies and rates the degree of protection provided against intrusion dust, accidental contact, and water
IP67, IP66, IP69K
SES GEA Tuchenhagen control head for Ex areas, control top system of GEA Tuchenhagen
SET-UP Self-learning installation, the SET-UP procedure carries out all necessary settings for generating messages during
commissioning and maintenance.
SIP Sterilization in Place, refers to a process for cleaning technical process systems
SMS Svensk Mjölk Standard, Scandinavian pipe dimension
SW Indicates the size of a tool spanner, “Schlüsselweite”
 Appendix | Abbreviations and Terms 79

Abbreviation Explanation

TA-Luft If a product is certified according to TA Luft it meets the requirements for proof of high grade performance according
VDI 2440 to TA Luft of 1.0× 10-4 mbar x l / (s x m) at service conditions under the VDI guideline 2440. The product will hence
be tested for tightness.
TEFASEP® gold Brand name for GEA's proprietary valve seat seal (hard sealing)
T.VIS® GEA Tuchenhagen valve information system, control top system from GEA Tuchenhagen
TS Maximum permitted operating temperature
UL Underwriters Laboratories, a certification organization established in the USA
USP Class VI The United States Pharmacopeial Convention (USP) is a scientific nonprofit organization that sets standards to
help protecting public health. Class VI administer tests and impacts of material and their substances on animal and
human tissues.
UV Ultraviolet, ultraviolet radiation is a wavelength of light
V Volt, unit of measurement for voltage
VARICOMP® Pipe expansion compensator from GEA Tuchenhagen
VMQ High-polymer vinyl methyl polysiloxane, silicone rubber, MVQ = synonym
W Watt, unit of measurement for power
Y Control air connection for the working cylinder, designation from pneumatic systems
μ Micro, one millionth of a unit
Ω Ohm, the unit of electrical resistance named after Georg Simon Ohm
80 Appendix | CAD Files

CAD Files

Typical application and description

You can receive two-dimensional and/or three-dimensional
drawing files of our components for making your piping plan-
ning. For this purpose, please send us your specific request,
stating the particular order code and the required drawing
format. The required files will then be individually prepared
for you.

Available drawing formats:

Format Name

2D formats drw Native Pro / E

igs (2D) IGS file
dxf AutoCAD drawing exchange
pdf (2D) Adobe Acrobat document
tif TIFF (plot)
3D formats asm Native Pro / E
igs (3D) IGS file
pdf (3D) Adobe Acrobat document
stp STP file
bmp (3D) Bitmap image
jpg (3D) JPEG image
tif (3D) TIFF image
sat Standard ACIS
 Appendix | General Sales Terms and Condition of Delivery 81

General Sales Terms

and Condition of Delivery

Please note
All our sales and/or services are exclusively subject to our
valid terms and conditions of sale and/or service applicable in
the respective country of business, which can be found on our
internet platform: www.gea.com.

If not available or if you otherwise wish to receive such terms

and conditions directly from us, please contact us and we of
course will send you the applicable version of our terms and
conditions for the envisaged business.
82

VARICOVER®
Pig Catching Pipe/ VARICOVER® VARICOVER® VARICOVER®
Pig Catching Station Pig Cleaning Station Pig Stopper Pig T-Piece
GEA VARICOVER® Hygienic GEA VARICOVER® Hygienic GEA VARICOVER® Hygienic GEA VARICOVER® Hygienic
Product Recovery Systems Product Recovery Systems Product Recovery Systems Product Recovery Systems
83
 GEA.com

GEA Tuchenhagen GmbH

Am Industriepark 2 – 10,
21514 Büchen, Germany

gea.com/flowcomponents

VARICOVER® Hygienic Product Recovery Systems/EN-03-2023   © GEA Tuchenhagen GmbH. All rights reserved.   Subject to modifications. Printed in Germany.