LIAG-LÄUFER International AG

Documentation
DMV Pigging System in 2,5"

Customer: Instalaciones y Mantenimiento del Bajío Sa de C.V.

Delivery: Octobre 2020
INDEX General
1.1
1.2
Datasheet
Safety information
1
1.3 Manufacturer's Declaration
1.4 General terms and conditions (Form 162 und Form 162)

Components DMV Pigging System

2.1 Scope of Delivery
2.2
2.3
Arc valves / pigging valves
Actuators for arc valves and pigging valves
2
not relevant 2.4 Peripheral valves outside the pigging line
(e.g. pressure inlet- and outlet valves, CIP-in- and outlet)
not relevant 2.5 Actuators for peripheral valves
2.6 DMV Pigging stations
2.7 DMV lip pig
2.8 Sensors

Operation manual DMV Pigging system

3.1 Flow Chart
3.2 Functional Description / Signal list

Assembling and Installation Instructions

3
4.1 General information
4.2 Loading and De-loading the DMV Lip Pig
not relevant 4.3 Assistance first time

Certificates
4
5.1 3-A Certificate
not relevant 5.2 Material Certificate according EN10204
5.3 FDA Certificate of DMV Silicone Lip Pig
not relevant 5.4 ATEX Certificates

Author:
5
LIAG® LÄUFER International AG

Am Wasserstall 12
88682 Salem Distribution of this technical documentation is not
Tel.: +49 7553/59089-0 allowed without notification to LIAG!
 1. General

1.1 Datasheet of Project DMV Pigging System

1
Nominal Diameter of DMV System: 2,5"
Functionality of DMV System: Two Way System with Turningstations
Product: Coca Cola
Pushing Medium: Water/Air
Pressure Level: PN10
Materials:
in contact with product: 1.4404
not in contact with product: 1.4301
gaskets: EPDM
DMV Silicone lip pig: Silicone
Surface in contact with product: Ra ≤ 0,8µm

Customer: IMBSA
Purchase Order: 100/331
Order Date: 26.08.2020
Customer Contact: Mr. Garcia
Delivery Address Instalaciones y Mantenimiento del Bajio
Av. Campo Militar 25. Int. B7-La Sierrita
MEX-76137 Querétaro / Mexico

Conditions:
According our general terms and conditions form 161 and 162
Compliance with special Formalities:
The compliance of existing or future building and industry formalities, the operation authorisation
and the attention to relevant safty at work formalities to operate the system
are objectives of the buyer.

Delivery date October 2020

Contact Person Deliverer Mr. Meesmann
Internal Order Number: LVAB019703
Date and Name technical Documentation: 21.10.2020 / Meesmann
 1. General

1.2 Safety Instructions for DMV Pigging System

Designated use
1
The DMV pigging system is designed exclusively for the purposes described below. Using the DMV
pigging system for purposes other than those mentioned is considered contrary to its designated use.
LIAG cannot be held liable for any damage resulting from such use; the risk of such misuse lies entirely
with the user. The prerequisite for the reliable and safe operation of the DMV pigging system is proper
transportation and storage as well as competent installation and assembly. Operating the DMV pigging
system within the limits of its designated use also involves observing the operating, inspection and
maintenance instructions.
Especially following subjects are to be observed:
a) The pigging line has to be suitable for DMV Silicone lip pig, i.e.:
- Inside pipe diameter and ovality has to be within the range of use of the DMV pig.
- Radius of used bends should not be smaller than 1,5xD.
- Welding seams of the pigging line have not to be sharp to avoid damages to the DMV pig.
- Possible shoulder of pipe connections have to be within the range of use of the DMV pig.
b) Mechanical Damages due to wrong valve operation, not suitable pigging line or
too high pushing pressure are not part of our warranty.
c) For pushing the DMV lip pig through the pigging line, a pressure of 2 to 3 bar is needed.
d) Before welding, valves have to be disassambled to avoid damages.
e) All assembling and handling instructions have to be observed.

Personnel
Personnel entrusted with the operation and maintenance of the pig cleaning station must have the
suitable qualification to carry out their tasks. They must be informed about possible dangers and must
understand and observe the safety instructions given in the relevant manual. Only allow qualified
personnel to make electrical connections.

Modifications, spare parts, accessories

Unauthorized modifications, additions or conversions which affect the safety of the pig cleaning station
are not permitted. Safety devices must not be bypassed, removed or made inactive.
Only use original spare parts and accessories recommended by the manufacturer.

General instructions
The user is obliged to operate the pig cleaning station only when it is in good working order. In addition
to the instructions given in the operating manual, please observe the following:
- relevant accident prevention regulations
- generally accepted safety regulations
- regulations effective in the country of installation
- working and safety instructions effective in the user's plant.

Commissioning
System guarantee can only be given if the commissioning is done by LIAG personnel!
 1. General

1.3 Declaration of Incorporation

according to EC directive 2006/42/EC on machinery (Annex II B)

1

Manufacturer LIAG® LÄUFER International AG

Am Wasserstall 12
D - 88682 Salem / Germany

Herewith we declare, that the partly completed machineries described below:

Product Denomination: DMV Product Recovery System 2,5" with Turning Stations
Model / Type: L19703SMS63
Machinery / Serial Number: 19703
Year of manufacture: 2020

is complying with all essential requirements of the Machinery Directive 2006/42/EC, as far as the
scope of delivery allows. Additional we declare that the relevant technical documentation is compiled
in accordance with part B of Annex VII. In addition the partly completed machinery is in conformity
with the EC Pressure Equipment Directive 97/23/EC.

We commit to transmit, in response to a reasoned request by the market surveillance authorities,

relevant documents on the partly completed machinery by our documentation department.
The partly completed machinery must not be put into service until the final machinery into which it is
to be incorporated has been declared in conformity with the provisions of Directive 2006/42/EC on
Machinery, where appropriate, and until the EC Declaration of Conformity according to Annex II A is
issued.

The person authorized to compile the relevant technical documentation (must be established within EU):

LIAG-Läufer International AG, Am Wasserstall 12, 88682 Salem

__________________________________________________________________________
Salem, 21.10.2020, Michael Laeufer (Executive Director)
 1. General

1.4 General Terms and Conditions LIAG – LÄUFER International AG

1
1. General

1
1. General

1
 2. Components DMV Pigging System

2.1. Scope of Delivery

LIAG®-DMV Pigging system 2,5" 2-Way System with Turning Stations

Item Tag Article-No. Description Qty

1.0 Pig 000801 LIAG® 63-65DMV SILICON PIG WITH MAGNET (BLUE) 2

2.0
2.1
DMVWS
004665
LIAG®-DMV Pig Launching Turning Station 2,5" Namur 3A
12" SCH 5 C41003-E TriClamp gasket EPDM
2
4
2
2.2 MS1 003432 38-100MSB12 MAGNET SENSOR M12, 24 V/DC for Plug (Pig Detection) 2
2.3 002683 25-102M55 Double Sensor 24V/DC, plugable 2
2.4 B1 Water Supply Valve 2" 0
2.5 B2 Water/CIP Valve 2" Outlet 0
2.6 B3 CIP Valve 2" Inlet 0

3.0 V1 000605 63C530A21 3-WAY ARC VALVE Clamp ends, 3A 2

3.1 003333 25-102M55BSt Inductive proximity switch M12, metal, 24V DC 4

4.0 DMVFS LIAG®-DMV Product Filling Station 2,5" Namur 2

4.1 MS2 003432 38-100MSB12 MAGNET SENSOR M12, 24 V/DC for Plug (Pig Detection) 2

5.0 V2 000599 63C520A21 2-WAY ARC VALVE Clamp ends, 3A 2

5.1 003333 25-102M55BSt Inductive proximity switch M12, metal, 24V DC 4

6.0 DMVWS LIAG®-DMV Pig Receiving Turning Station 2,5" Namur 3A 2

6.1 004665 12" SCH 5 C41003-E TriClamp gasket EPDM 4
6.2 MS3 003432 38-100MSB12 MAGNET SENSOR M12, 24 V/DC for Plug (Pig Detection) 2
6.3 002683 25-102M55 Double Sensor 24V/DC, plugable 2
6.4 B5 Air Supply Valve 2" 0
6.5 B6 Water/CIP Valve 2" Outlet 0
 2. Components DMV Pigging System

2.2 Arc valves / Pigging valves

Parts list arc valve

Pos. qty Unit Designation Material Typ designation

1
2 1 St. Bearing cap 1.4404
3 1 St. Pivoted axle 1.4404
4 1 St. O-ring to the pivoted axle EPDM
5 1 St. Valve casing 1.4404
6 1 St. Shutter PTFE
7 1 St. Pinching nut with cone 1.4301
8 1 St. O-ring to the cone EPDM
9 1 St. Bearing bush POM
10 1 St. O-ring to the bearing cap EPDM

Date: 28.01.2020
LIAG® Arc Valve / Pigging Valve
Name: Meesmann
 2. Components DMV Pigging System

Disassembling of arc valves and pigging valves for maintenance

Attention! Valve must not be under line pressure

1. Loosen the fixing screws of the handle in order to remove the handle or actuator.
2. Loosen the fixing screw of the pinching nut.
3. Loosen the pinching nut with cone (7).
4. Remove the bearing cap (2), by first releasing the fixing screws.
5.
6.
Remove the shutter (6) from the valve casing (5).
Pull out the pivoted axle (3) from the bearing cap (2).
2
7. Remove all all O-Rings from the valve.

Maintenance:

1. Check the functional condition of the surface of the valve casing and clean it properly.
2. Replace O-ring (10) to the bearing cap.
3. Replace O-ring (4) and (8) (lubricated with food grade grease Molykote111).
4. Check the functional condition of the bearing bush (9), replace with new one if necessary.
5. Check the functional condition of the shutter (6), replace with new one if necessary.
6. The pinching nut with cone (7) is assembled together with the conical axle by factory.
Do not try to disassemble it !!
7. Follow assembling instructions on chapter 2.2.6

Suggested assembling direction of the shutter (6)

 2. Components DMV Pigging System

Assembling of inox arc valve after maintenance

1. Before assembling the valve check the cleanliness and good condition off all piece-parts.
2. Screw on the pinching nut with cone (7) to the bottom of the valve casing (5) until the cone contacts
the O-ring (8).
3. Reassemble the pivoted axle (3) to the bearing cap (2). Observe the sign (0) marked on the square shaft
of the pivoted axle (3) showing the side of the axle where the shutter (6) is situated inside the valve.
4. Insert the shutter (6) into the valve.
5. Mount the pivoted axle (3) together with the bearing cap (2), to the valve casing (5) as follows:
a) The arc plate of the pivoted axle (3) is shaped by factory in order to give an initial tightness to
2
the shutter (6) when assembled together.
b) When the shutter (6) is in the valve, place the bearing cap (2) to the valve as detail “A” shows.
c) The correct position is achieved when the arc plate is pressed against the shutter (3) and
on the detail “B” the cap (2) still has a clearance of 4-5 mm.
d) To avoid damages to the shutter (6), do not place the shutter (6) in front of
an exit during assembling.
e) Replace now the fixing screws of the bearing cap (2) and tighten crosswise until the cap (2) is
completely closed to the valve.
f) Fix the handle (1) in its right position. If the valve is pneumatic, skip to g) using a square head tool
to turn the stem by hand. Then reassemble actuator with the shutter (6) in the correct position.
g) Turn around the handle (1) a few times around to feel that the shutter (6) is tight.
6. Tighten finally the pinching nut (7) by hand (without using a tool) until the cone is pressing to the
arc plate Finish by turning an additional 90° clockwise with tool.
7. Tighten the fixing screw of the pinching nut (7)
 2. Components DMV Pigging System

Assembling / welding of the inox arc valve into the product line

Assembling:
For self draining the valve has to be installed so that one valve exit is
positioned vertical downwards.

Before welding process: (Valve disassembling --> see Chapter 2.2.3):

1. Loosen the fixing screw of the pinching nut with cone (7).
2
2. Loosen and disassemble the pinching nut with cone (7) using wrench.
3. Loosen fixing screws of the bearing cap (2) and remove the complete valve top assembling
(incl. the actuator or handle) from the valve casing (5). Attention should be given to
the O-ring (10) and the shutter (6).

After welding process:

1. Clean the valve casing (5).
If necessary lubricate the O-rings with Klüber Paraliq GTE 703 Food Grade.
2. Assembling of Arc Valve --> see Chapter 2.2.6

Lubrication plan

O-ring gaskets getting in contact with product (material: EPDM / FPM oder FEP):

Klüber Paraliq GTE 703 Food Grade USDA H1 - Registration for the food industry

Lubrication of the inox fixing screws DIN 912 and DIN 933:

Klüberplex BEM 34-132

 2. Components DMV Pigging System

List of spare parts

Pos. Designation Material Type designation

4, 8, 10 O-Ring Set EPDM 63S502S21E
6 Shutter PTFE 63S501T
9 Bearing Bush POM 38-80SD503

Cleaning Instructions (CIP)

2
The valve has to be operated during the cleaning process.
For self-draining the valve has to be assembeld in that way, that one exit is vertical downwards.
 2. Components DMV Pigging System

2.3 Actuator for Arc Valve and Pigging Valve

Actuator for Pigging Valve

2
2. Components DMV Pigging System

2
2. Components DMV Pigging System

2
2. Components DMV Pigging System

2
2. Components DMV Pigging System

2
2. Components DMV Pigging System

2
2. Components DMV Pigging System

2
 2. Components DMV Pigging System

2.3 Actuator for Arc Valves

Vertical Actuator for Arc Valves

The pneumatic actuator is constructed with different cylinder diameters

in order to produce the optimum driving torque for every nominal width.
Standard: DN25/1" till DN40/1,5" Typ 002
DN50/2" till DN63/2,5" Typ 004
DN65/3" till DN100/4" Typ 006
It is activated by means of air pressure and/or spring power.
2
Typ L/F: (Air/Spring)
a) Closes by spring power and opens by means of pneumatic drive
b) Opens by spring power and closes by means of pneumatic drive
The standart spring is designed for 6 bar operating pressure.
It can, however, be adapted to suit other operating pressures if a customer so requires.
Individual parts are represented in the enclosed drawings.

Method of procedure when exchanging individual parts

Safety indication:
* Before commencing work it is absolutely necessary to ensure
that there is no medium and no pressure on the actuator.
* The accident prevention regulations are to be strictly observed
when working with dangerous materials.
* Repairs are only to be carried out by specially trained personnel.

1. Detach your actuator from the valve and clamp the casing at the lid
into the vice with aluminium mould followers.
2. Using suitable tolls (e.g. pliers and screw driver), remove the sealing ring.
3. The entire unit can now be removed from the casing (in order to assist
the dismantling process you can blow a little air very carefully into the top connection).
Caution: The spring is under high prestress.
4. In order to detach the piston and the spring we would recommend the use of a lathe.
Fix the lower part of the unit into the jaw chuck (soft mould followers) and press
the tailstock spindel against the pistons. Prestress the spring by aprox. 5mm.
5. Remove the sealing ring from the plug-type axle using suitable pliers.
Afterwards hit gently with a hammer in order to get the axle out of the bore hole with one blow.
6. Turn the tailstock spindle back until the spring becomes unstressed.
7. The individual parts of the actuator can now be taken apart.
8. In order to re-assemble the parts, follow the above procedure in reverse order.
 2. Components DMV Pigging System

Air consumption in litre by 6 bar

Typ 002 (D=89) Typ 004 (D=104) Typ 006 (D=129)

Öffnen / Opening 1,84 2,59 4,56
Schließen / Closing 2,52 3,63 7,95

Tourque accordance opening angle

Antrieb Luft öffnend

2
Actuator opens by air pressure
Asservissem ent overture par air
100
90
89er 4bar
80 89er 6bar
70
Drehmoment [Nm]

104er 6bar
60
Torque
Couple

50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90
Öffnungsw inkel [°]
Opening angle
Angle dóuverture

Antrieb Feder schließend

Actuator spring closed
Asservissement Fermeture par ressort
100
89er 4bar
90

80
89er 6bar
104er 6bar
Drehmoment [Nm]

70

60
Torque
Couple

50

40

30

20

10

0
0 10 20 30 40 50 60 70 80 90

Öffnungswinkel [°]
opening angle
Angle dóuverture
 2. Components DMV Pigging System

Drawing and Piece Part List of vertical Actuator for Arc Valves

Pos. Article-No. Pieces Description Material

1 x0677-004-22 1 Welle mit Innenvierkant 1.4301
2 080 016,0 1 01 1 O-Ring 16x2,5 NBR
3 x0677-004-23 2 Buchse
4 DIN 7991 2 Senkschraube M6x16 1.4301
5 x0677-004-29 1 Flansch 1.4301
6 x0677-002-20 1 Führungsplatte 1.4301
7 080 094,0 1 01 2 O-Ring 94x3 NBR
8 080 008,0 1 01 2 O-Ring 8x2 NBR
9 x0677-004-27 1 Führungsstange 1.4301
10 x0678-001-01 1 Druckfeder 6bar 1.4301
10.1 x0678-001-02 1 Druckfeder 4bar 1.4301
11 x0677-003-24 1 Achse 1.4301
12 x0677-003-25 2 Laufrolle
13 DIN 6799-5 2 Sicherungsring 1.4301
14 x0677-002-30 1 Kolben
15 x0677-004-31 1 PKL DN100
16 080 014,00 2 01 2 O-Ring 14x2 NBR
17 x0677-002-11 1 Deckel 1.4301
18 x0677-002-10 1 Gehäuserohr 1.4301
19 x0677-004-26 1 Führungsstange 1.4301
20 080 022,00 2 01 1 O-Ring 22x2,5 NBR
 2. Components DMV Pigging System

2.6 DMV Pigging Stations

DMV Pig Launching Station

CIP inlet Magnetsensor

Water Inlet

2
CIP/Water Outlet
Line connection

Pig direction

DMV Product Filling Station

Magnetsensor

Product outlet Pig direction

DMV Pig Receiving Station

Air Inlet Magnetsensor

CIP/Water Outlet
Line connection

Pig direction
 2. Components DMV Pigging System

2.7 DMV Silicone Lip Pig with Magnet

Geometry

LIAG® DMV Silicone Lip Pig, specially designed for use of

hygienic LIAG® Arc Valves and LIAG® Pigging Valves

Technical Specification
2
Type Designation: 63-65DMV

Suitable for pipe inside diameter: 59 - 70 mm

Material: Silicone (FDA)

Features: Suitable for standard bends with R=1,5xD

Dimension:
L ØD
264 72

Cleaning: DMV 2-lipped silicone pigs can be easliy cleaned with soap and warm water.
Standard CIP solutions can also be used for cleaning.

Wearing: The DMV 2-lipped silicone pig has to be replaced when there is a cut through
the lipp and the pushing medium could pass.
It has also to be replaced when there is a cut in the round head of the pig.
 2. Components DMV Pigging System

2.8 Sensor

Double Sensor, 24V/DC, plugable

Dimension:

Type: 25-102M55
2
Electrical design : DC PNP
3-wire direct-current voltage
PNP normally open
Sensing range : 4 mm (non-flush mountable)
Output : normally open
Operating voltage [V] : 10 - 36 DC
Current rating [mA] : 250 mA
Short-circuit protection : existing
Reverse polarity protection / Overload protection : existing
Voltage drop [V] : < 2,5 DC
Current consumption [mA] :  15 mA (36 V)
Real sensing range [mm] : 4 ± 10 %
Operating distance [mm] : 0 - 3,25 mm
Switch-point drift [% / Sr] : -10 - +10
Hysteresis [% / Sr] : 1 - 15
Switching frequency [Hz] : 1300 Hz
Correction factors : mild steel = 1 / stainless steel approx. 0.7
brass approx. 0.4 / Al approx. 0.3
Cu approx. 0.2
Function display / Switching status : 2x yellow LED
Operating temperature [°C] : -25°C...+80°C
Protection : IP 67
EMC : EN 60947-5-2; EN 55011 class B
Housing material : Plastic PBTP
Connection : M12 connector

Connection:

black: BK
braun: BN
white: WH
blue: BU
 2. Components DMV Pigging System

2.8 Sensor

Inductive proximity switches M12 24V/DC, pluggable

Dimension:

2
Type Designation: 25-102M55BSt

Electrical design : DC PNP

3-wire direct-current voltage
PNP normally open
Sensing range : 4 mm
Output : normally open
Operating voltage [V] : 10 to 36 V/DC
Current rating [mA] : 100 mA
Short-circuit protection : existing
Reverse polarity protection / Overload protection : existing
Voltage drop [V] : < 2,5 V/DC
Current consumption [mA] : ≤ 10 mA (24V/DC)
Operating distance [mm] : 0 – 3,25 mm
Hysteresis [% / Sr] : 1 ‐ 20
Switching frequency [Hz] : 700 Hz
Correction factors : mild steel = 1 / stainless steel approx. 0.7
brass approx. 0.5 / Al approx. 0.4
Cu approx. 0.3
Function display / Switching status : yellow LED (4x90°)
Operating temperature [°C] : 0°C ...+100°C
Protection : IP 68 / IP 69K, II
Housing material : V4A (1.4571), active face: PEEK
Connection : M12 plug connection

Connection:
 2. Components DMV Pigging System

2.8 Sensor

Magnet Sensor M12, 24V/DC, pluggable

Dimension:

2
Type Designation: 38-102MSB12-90

Electrical design : DC PNP

3-wire „direct-current voltage“
PNP normally open
Sensing range with magnet M4.0 : 90 mm
Output function : normally open
Operating voltage [V] : 10 to 30 V/DC
Current rating [mA] : 200 mA
Short-circuit protection : existing
Reverse polarity protection / Overload protection : existing
Voltage drop [V] : <2V
Current consumption [mA] : ≤ 10 mA
Hysteresis [% / Sr] : 1 - 10
Repeatability [% / Sr] : 1% von Sr
Switching frequency [Hz] : 4 Hz (with ta=200ms)
Function display / Switching status : LED
Operating temperature [°C] : -25°C ...+75°C
Protection : IP 67
Housing material : nickel-plated brass; plastics
Connection : M12 connector
Signalduration : 200ms

Wiring:
 3. Function Description DMV Pigging System

3.1 Flow Chart

3
 3. Function Description DMV Pigging System

3.2 Functional Description / Signallist

3
 4. Assembling and Installation Instructions

4.1 General Instructions

Assembling of magnet sensor to the product filling station.

Magnetsensor

Product outlet 0,5m

Assemble the pipe clamp with magnet sensor to the pigging line in a distance of appr. 0,5m from
the product outlet.

Assembling of Pig Launching Turning Station

The launching turning station has
to be installed as shown with pig
inlet and outlet facing
downwards.

Pig inlet and outlet

Assembling of Pig Receiving Turning Station

The receiving turning station has
4
to be installed as shown with pig
inlet and outlet facing
downwards.

Pig inlet and outlet

 4. Assembling and Installation Instructions

4.2 Un-Loading / Loading the DMV Lip Pig

Fixing screw Axle with pig cage

Before laoding or un-loading the DMV lip pig into the launching turning station following must be checked:

* no running process (production, pigging, cleaning)

* no process can be startet (production, pigging, cleaning)
* the launching turning station is empty and without pressure
* pigging line and launching turning station must be depressurized

Functional steps for un- loading and loading the DMV lip pig into the launching turning station:
1. Observe the safty instructions
2. Loose the fixing screw of the clutch between actuator and turning station
3. Dismantle the backside blank ferrule with clamp ring and gasket
4. Mark the position of pig and axle with pig cage (for example take a photo)
5.
6.
Pull out the axle with pig cage and pig
Now you can take out the pig
4
7. Put back the pig into the cage with correct direction as marked before
8. Put back the axle with pig cage with correct position as marked before
9. Assemble the fixing screw of the clutch between actuator and turning station
10. Assemble the backside blank ferrule with clamp ring and gasket
11. Tighten the clamp ring properly
 5. Certificates

5.1 3-A Certificate for Arc Valves and pigging Valves

5
 5. Certificates

5.3 FDA Certificate of DMV Silicone Lip Pig