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KAT-B 1914 Edition1 10-01-2018 Operation and Maintenance Instructions VAG BEV Venting Set
KAT-B 1914 Edition1 10-01-2018
Operation and Maintenance Instructions
VAG BEV Venting Set
VAG reserves the right to make technical changes and use materials of similar or better quality without express notice. Pictures are non-binding.
Content
1 General 3
1.1 Safety 3
1.2 Proper use 3
1.3 Identification 3
2 Transport and Storage 3
2.1 Transport 3
2.2 Storage 3
3 Product features 4
3.1 Features and function description 4
3.2 Applications 4
3.3 Performance limits 4
3.3.1 Minimum pressure 4
3.3.2 Air inflow performance data 4
3.3.3 Air release performance data 5
3.3.4 Venting during operation performance data 5
4 Installation in the pipeline 5
4.1 Conditions required on site 5
4.2 Installation location 5
4.3 Installation position 5
4.4 Installation instructions 6
4.4.1 Discharge of venting water 6
4.4.2 Assembly instructions and fittings 6
5 Set-up and operation of the valve 6
5.1 Visual inspection and preparation 6
5.2 Function check and pressure test 6
6 Maintenance and repair 6
6.1 General safety instructions 6
6.2 Inspection and operation intervals 7
6.3 Disassembly and assembly 7
6.4 Automatic shut-off during disassembly 7
6.5 Maintenance work and replacement of parts, VAG DUOJET® Automatic Air Valve 7
6.5.1 Design of the VAG DUOJET® Automatic Air Valve 8
6.5.2 Recommendations for the replacement of parts 8
6.5.3 Bolt tightening torques 9
7 Program expansions 9
7.1 Flushing device 9
7.2 Shortenable installation equipment 10
8 Troubleshooting 10
9 How to contact us 10
VAG Operation and Maintenance Instructions • 3
1 General
1.1 SafetyThese Operation and Maintenance Instructions must be observed and applied at all times along with the general “VAG Installation and Operation Instructions for Valves” (see www.vag-group.com / Category: Ins-tallation and Operation Instructions).
Unauthorized changes to this product or to the attachment parts which are delivered together with it are prohibited. We reject any warranty claims based on consequential damage which may re-sult from the failure to observe this rule.
When using this valve, the generally acknowledged rules of tech-nology (e.g. German DIN standards, DVGW (German association for gas and water) instruction sheets W 334 (Ventilation of water transportation and distribution systems, W 392 (pipeline network inspection) and the VDI guidelines (Association of German Engi-neers) must be observed.
Installation may only be carried out by qualified staff (see also Section 6.1, General safety instructions). For further technical in-formation such as dimensions, materials or applications, please refer to the respective documentation, (KAT 1914-A).
VAG valves are designed and manufactured according to the highest technological standards and their safety of operation is generally ensured. However, valves may be potentially dangerous if they are operated improperly or installed for a use which devia-tes from their intended use.
Each person who works as an operator with the assembly, di-sassembly, operation, maintenance and repair of the valves must have read and understood the complete Operating and Mainte-nance Instructions (UVV (Accident prevention regulations), VBG1 Sect. 14 et seq.).
Before removing any protective devices and/or performing any work on the valves, depressurize the pipeline section and ensure it is free of hazards. Unauthorized, unintentional and unexpected activation must be prevented, as well as any hazardous move-ments caused by stored energy (pressurized air, pressurized wa-ter etc.).
For equipment that must be monitored and inspected, all relevant laws and regulations, such as the Industrial Code, the Accident Prevention Regulations, the Ordinance of Steam Boilers and inst-ructional pamphlets issued by the Pressure Vessels Study Group must be complied with. In addition, local accident prevention re-gulations must be observed.
1.2 Proper useThe VAG BEV Venting Set is a valve for flanging to the pipeline (DN 80). Alternatively, a design with a BAIO® DN 80 spigot end for a plug-type socket connection to the VAG BAIO®plus System is available.
VAG BEV Venting Sets are designed to vent water supply sys-tems.
For the respective technical application ranges (e.g. operating pressure, medium, temperature, etc.), please refer to the product-related documentation (KAT 1914-A).
For any alternative operating conditions and applications, the manufacturer’s written approval must be obtained!
These Installation and Operation Instructions contain important information on the safe and reliable operation of the VAG BEV Automatic Air Valve.
Observing these Installation and Operation Instructions helps you to:
• Prevent hazards
• Reduce repair costs and down-time of the valve and/or the en-tire equipment
• Improve the operational safety and useful life of the equipment.
1.3 IdentificationIn accordance with DIN EN 19, all valves bear an identification label specifying the nominal diameter (DN), nominal pressure (PN), body material and the manufacturer’s logo.
A rating plate is attached to the body and contains at least the following information:
VAG Manufacturer’s name
Valve type
DN Nominal diameter of the valve
PN Pressure level of the valve
Date of manufacture
2 Transport and Storage
2.1 TransportFor transportation to its installation site, the valve must be packed in stable packaging material suitable for the size of the valve. It must be ensured that the valve is protected against atmospheric influences and external
damage. When the valve is shipped under specific climatic condi-tions (e.g. overseas transport), it must be specially protected and wrapped in plastic film and a desiccant must be added.
Picture 1: Factory transportation pallet
The factory-applied corrosion protection and any assemblies must be protected against damage by external influences during transport and storage.
The VAG BEV Venting Set must be transported and stored in a secure transport position. It is advisable to leave the valve in the factory transportation pallet until its installation.
2.2 StorageThe elastomeric parts (seals) must be protected against direct sunlight and/or UV light as otherwise their long-term sealing func-tion cannot be guaranteed. Store the valve in a dry and well-aera-ted place and avoid direct heat. Any assembly components ne-cessary for the proper function of the valve are factory-protected against dust and other external pollution by suitable covers.
VAG Operation and Maintenance Instructions • 4
3 Product features
3.1 Features and function description
The VAG BEV Venting Set is a two-stage valve for the automatic venting of pipelines.
Picture 3: VAG Venting Set with flange connection
Do not remove the protective caps on the connections / flanges and the packaging materials until immediately prior to installation.
The valve can be stored at ambient temperatures ranging from
-20 °C to + 50 °C (protected by adequate covers). If the valve is stored at temperatures below 0 °C, it should be warmed up to at least +5° C before installation and before it is put into operation.
Cross - sectional view Spigot end connectionFlange connection
3.2 ApplicationsThe VAG BEV Venting Set can be used with the following media:
• Water
• Raw and cooling water
The VAG BEV Venting Set is not suitable for seawater, sewage or waste water.
For information about the corresponding temperature limits, ple-ase refer to the product-related technical documentation (KAT-A 1914).
For other operating conditions and applications, please consult the manufacturer.
3.3 Performance limits
3.3.1 Minimum pressureThe minimum pressure for sealing the venting areas is 0.3 bar.
3.3.2 Air inflow performance dataThe large venting area is for aerating with large amounts of air when switching off the pumping station.
Rat
e o
f ai
r in
flow
Q [
m³/
s]
Internal pressure p [bar - absolute]
Picture 4: Air inflow – large cross-section
The VAG BEV Venting Set consists of a sturdy anti-rust protective jacket pipe for direct buried installation. The buried installation of VAG BEV Venting Set can take place in two different ways, as de-scribed in Figure 2.
In this procedure, the protective jacket pipe performs the function of the pit. The functional unit of the VAG BEV Venting Set consists of a VAG DUOJET® Automatic Air Valve DN 50 or DN 80.
This valve performs the following venting functions:
• Large ventilation area for venting large amounts of air (air inflow) while emptying the system
• Large ventilation area for venting large amounts of air (air re-lease) while filling the system
• Small ventilation area for venting small amounts of air (air re-lease) during operation
VAG BEV Venting Sets are available in the following standard ty-pes (see Figure 3):
• with DN 80 flange connection and DN 50 VAG DUOJET® Auto-matic Air Valve
• with DN 80 flange connection and DN 80 VAG DUOJET® Auto-matic Air Valve
• with BAIO® DN 80 spigot end and VAG DUOJET® DN 50 Auto-matic Air Valve
Possible installation depth in meters:
• Underground installation: 1.00; 1.25; 1.50; 1.75
• Above-ground installation: 0.75; 1.00; 1.25; 1.50
Above-ground installationUnderground installation in a special surface box
Picture 2: VAG Venting Set, buried installation
VAG Operation and Maintenance Instructions • 5
Picture 6: Air release – small cross-section
Venting sets should be installed as close as possible to the pipe being vented to prevent long supply lines from collecting stagna-ting water (hygienic problems, higher costs, regular flushing). In addition, long supply lines may result in limited venting function as well as contribute to the risk of freezing (the supply line or the air valve itself).
If work which is done around the valve is likely to cause soiling or dirtying (e.g. painting, bricklaying, working with concrete etc.), the valve must be protected by adequate covering.
For assembly, suitable sealing materials, lubricants and process materials must be used which are approved for use in drinking water pipelines.
Before putting the valve into operation, clean and flush the corre-sponding pipeline sections. Observe DVGW (German association for gas and water) instruction sheets W 291 and W 346.
4.2 Installation location
To ensure the trouble-free function and long service life of the val-ve, several factors have to be taken into account when positioning the valve.
VAG BEV Venting Sets are buried. It is possible to install them as an underground installation with a special surface box or as above-ground installation (without surface box).
4.3 Installation position
The VAG BEV Venting Set must always be installed in an upright position. If installed in any other position, the manu-facturer can-not ensure that the system will function correctly (see Figure 7).
Picture 5: Air release – large cross-section
Rat
e o
f ai
r in
flow
Q [
m³/
s]
Internal pressure p [bar - absolute]
3.3.4 Venting during operation performance dataThe small venting area is for venting small amounts of air during
operation under full internal overpressure.
Rat
e o
f ai
r re
leas
e Q
[m
³/h]
Working pressure p [bar]
3.3.3 Air release performance data
The large venting area is for venting large amounts of air when starting up the pumping station.
permissible
impermissible
upright instal-lation position
Picture 7: Installation position of the venting set
90°
<> 90°
4 Installation in the pipeline
4.1 Conditions required on siteWhen installing the pipeline flange, it must be horizontal, plane parallel and in true alignment.
VAG Operation and Maintenance Instructions • 6
4.4 Installation instructionsObserve the following special installation instructions in ac-cordance with the plant conditions and installation positions.
4.4.1 Discharge of venting water
Water accumulating in the venting set due to
• Maintenance work
• Water which is carried in during vent air outflow
must be discharged to the exterior.
This can be done using either a
a) Drainage pit or
b) Drain pipe.
At the base body of the valve, a commercially-available PE hose of od 20 mm can be installed onto a clamped fitting as a drainage pipe.
The accumulating water can be discharged at any low-lying point.
Picture 8: Installation position for splashing or surge water
Drainage pipe
Clamped fitting
4.4.2 Assembly instructions and fittingsCheck the valve prior to installation for possible damage that it may have suffered during transport and storage. Protect the valve against dirt caused on the construction site by adequate covering until installation. Thoroughly clean the surface of the flange gasket prior to installation.
VAG does not assume any liability for consequential damage caused by dirt, shot-blasting gravel residue etc.
The functional parts should be checked for proper operation prior to installation.
Should the valves be repainted later on, the functional parts must not be painted over. The identification plates must not be painted over either. If the equipment is sand-blasted for cleaning prior to installation, these parts must be adequately covered. If solvents are used for cleaning, it must be ensured that the solvents do not destroy the seals of the pipeline or the valve.
For the assembly of the VAG BEV Venting Set, it must be ensured that proper load suspension devices as well as means of transport and lifting devices are available.
When connecting the valve with the pipeline flanges, hexagon bolts and nuts with washers from flange to flange must be used in the through holes.
The bolts and nuts selected by the operator must be appropriate for the pressure, temperature, flange material and the gasket. For connections that contain at least one cast-iron flange, it is advisa-ble to use bolts with a yield strength not exceeding 240 N/mm².
Fasten the bolts evenly and diagonally to prevent unnecessary tension which may result in cracks or breaks.
We recommend using steel-reinforced rubber seals which corres-pond to DIN EN 1514-1, Shape IBC. If you use raised face flanges, these seals are mandatory.
5 Set-up and operation of the valve
5.1 Visual inspection and preparationBefore putting the valve and the equipment into operation, per-form a visual inspection of all functional parts. Check whether all bolted connections have been properly fastened.
If there is an upstream shut-off valve, it must be set to the open position so that the VAG BEV Venting Set can function satisfac-torily.
5.2 Function check and pressure testWarning: The pressure exerted on the closed valve must not ex-ceed its nominal pressure (see technical data sheet KAT-A 1912).
Newly installed pipeline systems should first be thoroughly flushed to remove all foreign particles. If residue or dirt particles are pre-sent in the pipeline, they may clog the installations while the pipe-line is being flushed. This may impair the function of the valve or even block it.
In particular after repair work or when commissioning new equip-ment, the pipeline system is to be flushed again. If detergents or disinfectants are used, it must be ensured that they do not attack the valve materials.
6 Maintenance and repair
6.1 General safety instructions
Prior to starting maintenance work, we recommend depressuri-zing the service pipeline.
After completing the maintenance work and before resuming ope-ration, check all connections for proper fastening and tightness. Perform the steps described for initial set-up as described under Section 5, “Set-up and operation”.
Statutory and local provisions as well as the safety and accident prevention regulations must be observed and complied with at all times.
VAG Operation and Maintenance Instructions • 7
Picture 9: Disassembly of VAG DUOJET Automatic Air Valve
1
2
3
Servicing, maintenance and inspection work as well as the repla-cement of spare parts must only be carried out by qualified staff. The plant operator is responsible for determining the suitability of the staff or for ensuring the relevant qualifications.
In case the operator’s employees do not have the qualifications re-quired, they need to attend a training course. This training course can be held by e.g. VAG Service employees.
In addition to this, the plant operator needs to ensure that all em-ployees have understood these Installation and Operation Instruc-tions as well as all further instructions referred to in them.
Protective equipment such as safety boots, safety helmets, gogg-les, protective gloves etc. must be worn during all work requiring such protective equipment or for which such protective equip-ment is prescribed.
Improper or wrong use of the valve should be avoided. Prior to performing any work on the valve and equipment, it must be en-sured that the relevant pipeline section has been depressurized and/or de-energized.
6.2 Inspection and operation intervals
The VAG BEV Venting Set is virtually maintenance-free.
Nevertheless, the integrated VAG DUOJET® Automatic Air Valve should still be inspected at least once per year (DVGW, German association for gas and water, instruction sheet W392).
Under extreme operating conditions, inspections should be car-ried out more frequently.
The valve can be disassembled, inspected and, if necessary, ser-viced on site and under full working pressure. If needed, work may also be done in the workshop.
The required maintenance work on the VAG Automatic Air Valve can be done easily by one person.
6.3 Disassembly and assembly• 1: Open surface box (visible inscription which reads „VAG Ven-
ting Set“). Loosen the fastening bolt (M8, SW13) and remove the dome-shaped cover (cf. Figure 9).
• 2: Unscrew pressure stem (Tool: Socket SW22 / 12-side) until the VAG DUOJET® Automatic Air Valve with spindle is pushed through the seal by the internal pressure of the pipe system (cf. Figure 9).
• 3: Lift out the VAG DUOJET® Automatic Air Valve at the pressu-re tube. The rubber-lined floating ball will close off the system automatically (see chapter 6.4) (cf. Figure 9).
Install the VAG DUOJET® Automatic Air Valve into the protective pipe by following the steps in the reverse order.
6.4 Automatic shut-off during disassemblyIllustration A in Figure 10 shows the integrated VAG DUOJET® Automatic Air Valve while venting during operation. The rubber-lined floating ball is held in the lower operational position by the thrust piece.
If the functional unit is expanded upwards (illustration B), the floa-ting ball is moved up by the buoyant force and seals off the sys-
tem automatically. Sealing takes place before the O-ring seal of the VAG DUOJET® Automatic Air Valve leaves the sealing bush.
Assembly takes place in the reverse order.
The highest level of functional reliability is ensured in this area, which is prone to dirtying, by the use of red brass as a corrosion- and wear-resistant material of the thrust piece and the seating bush.
The use of the rubber-lined floating ball with pressure-resistant aluminum core ensures reliable automatic sealing thanks to its simple and sturdy design.
6.5 Maintenance work and replacement of parts, VAG DUOJET® Automatic Air ValveMaintenance work includes:
•Cleaning
• Removing sedimentation
VAG Operation and Maintenance Instructions • 8
Picture 10: Automatic shut-off
A
Thrust piece
Sealing bush
Item Name Piece Material
1 Body 1 EN-JS 1030
2 Cover 1 EN-JS 1030
3.1 Float 1DN 50 plastic / DN 80 stainless steel 1.4571
3.2 Seal 1 EPDM
4 Shell body 1 1.4541
5 Shut-off device 1 1.4541
6 Lead screw 1 1.4305
7 Supporting Disc 1 1.4541
8 Flatsealing 1 EPDM
9 Cylinder screw 1 A4-70
13 Thrust piece 1 red brass
14 O-ring 1 NBR
7
2
1
8
6
14
3.2
5
9
3.1
13
4
Picture 11: Design
• Renewing corrosion protection (if necessary)
• Changing seals (if necessary)
• Changing operational venting (if necessary)
and inspections of:
• Damage and corrosion
• Mobility of shut-off device float
• Tightness
• Proper function
• Unobstructedness of nozzles
• Visible sedimentation on floating elements and guiding ele-ments
6.5.1 Design of the VAG DUOJET® Automatic Air ValveThe design view in Figure 11 is a partial overview of the following descriptions of the work procedures. Spare parts with associated part numbers are available in our document VAG KAT-E 1912.
6.5.2 Recommendations for the replacement of parts
All parts should be changed as needed. The interval is oriented towards servicing requirements.
For the seals (parts 3.2 and 8), replacement is recommended eve-ry 5 years.
6.5.3 Replacement of the seals (3.2 and 8)
• Unfasten the cylindrical screws (9) crosswise
• Lift off cover (2) of the valve
• The seals, float, shell and shut-off device can now be removed
• The seal (3.2) is attached to the float (part 3.1) with cyanoacryla-te adhesive (rapid set adhesive). When replacing the seal, pull it
B
VAG Operation and Maintenance Instructions • 9
Cylinder screw (9)
M 12 M 16
30 Nm 10 Nm
Table 1: Cylinder screw tightening torques
off the float and then glue the new seal to the float.
• For subsequent reassembly, place the shell into the body. Placethe float into the shell, insert the seal (part 8) as well as theretaining washer (part 7) into the cover and centre it. Insert theshut-off device into the guide screw (part 6) and place the coveronto the body. Fasten the hexagon socket screws crosswise.
6.5.3 Bolt tightening torques
7.1 Flushing deviceVAG flushing devices for cleaning the protective jacket pipe are available in the following designs:
Installation depth in meters: 1.00; 1.25; 1.50, 1.75
Ball valve 1 ½“ nickel-plated brass
Pipe 1 ½“galvanized
Connection with fe-
male thread G 1 ½“
Separation point: the flushing device consists of
two parts when delivered
Installation depth Rd [m] Face-to-face length H [mm] Height L [mm] Height N [mm]
1,00 1350 500 610
1,25 1600 750 610
1,50 1850 1000 610
1,75 2100 1250 610
Table 2: Dimensions of flushing device
Picture 12: Flushing device
7 Program expansions
VAG Operation and Maintenance Instructions • 10
7.2 Shortenable installation equipmentThe jacket pipe may be shortened by 100 mm at the construction site.
Assembly, Stage 1
Two additional elongated holes (red) closed with plugs (elasto-mer).
1. Draw a mark at 100 mm
2. Shorten the jacket pipe by 100 mm
3. Remove plugs
Assembly, Stage 2
Additional bore hole in pressure tube
1. Loosen the screw at the construction site
2. Shorten the pressure tube by 100 mm
3. Mount the screw in the second bore hole
Assembly, Stage 3
Re-assemble the BEV equipment
100 mm
Separation cut (at construction site)
Separation cut (at construction site)
100 mm
Picture 13: Shortenable installation equipment
1
2
For all repair and maintenance work, please observe the general
safety instructions described in Section 6.1!Kontaktdaten
8 Troubleshooting
Problem Cause Remedial action
Leaky main air valve
Foreign matter stuck in seat area
Flush valve, disassemble, if necessary, and remove foreign matter
Internal pressure too lowTo achieve tightness, internal pressure must be at least 3 m water column. Replace gasket with a low pressure gasket (0.1 - 1 bar)
Deposits from medium on the seat Open cover, clean seat section
Seal damaged Replace seal (recommendation: replacement after a maximum of 5 years) see 6.3.3
Improper installation position Change installation position
Leaky air release
Foreign matter stuck in air release orifice
Flush valve, disassemble, if necessary, and remove foreign matter
Seal defective Replace seal (recommendation: replacement after a maximum of 5 years) see 6.3.3
Air release rate too small Operational characteristics were changed
Check layout and operational characteristics; if neces-sary, install special air release with larger release bore
Outlet clogged Insect infestation Clean valve and attach insect protection
9 How to contact us
Head office VAG GmbH Carl-Reuther-Str. 1 68305 Mannheim Germany Telephone: +49 (621) 749-0 Fax: +49 (621) 749-2153 [email protected] http://www.vag-group.com
Service
Our service hotline can be reached 24/7 worldwide. In case of emergency, please contact us by phone.
Service hotline: +49 621 - 749 2222 Service per email: [email protected]
