33-08841 Rev.

F
ISO 9001 Certified Firm








VAREC
Vapor Control Inc.

221 Series
Emergency Pressure Relief
Manway Cover

INSTRUCTION, OPERATION AND MAINTENANCE MANUAL












!
221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
2
TABLE OF CONTENTS


DISCLAIMER OF WARRANTIES................................................................................................................................. 3

LIMITATIONS OF SELLER'S LIABILITY ................................................................................................................... 3

SAFETY PRECAUTIONS............................................................................................................................................... 3

1. Safety Precautions Definitions..................................................................................................................................... 4

GENERAL........................................................................................................................................................................ 5

CONSTRUCTION............................................................................................................................................................ 5

OPERATION.................................................................................................................................................................... 5

INSTALLATION.............................................................................................................................................................. 5

CALIBRATION................................................................................................................................................................ 6

MAINTENANCE ............................................................................................................................................................. 6

REPLACEMENT PARTS ................................................................................................................................................13


LIST OF FIGURES

Figure 1 - 221P Assembly................................................................................................................................................. 8

Figure 2 - 221PV Assembly..............................................................................................................................................10


LIST OF TABLES

Table 1 221P Materials .................................................................................................................................................. 9

Table 2 221PV Materials ...............................................................................................................................................11

Table 3 221P & 221PV Soft Goods ...............................................................................................................................12

Table 4 221P & 221PV Flange Drilling.........................................................................................................................12

Table 5 221P Replacement Parts ...................................................................................................................................13

Table 6 221PV Replacement Parts.................................................................................................................................13
221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
3
Disclaimer of Warranties
The contract between the Seller and the Buyer states the entire obligation of the Seller. The contents of
this instruction manual shall not become part of or modify any prior or existing agreement, commitment
or relationship between the Seller and Buyer. There are no express or implied warranties set out in this
instruction manual. The only warranties that apply are those in the existing contract between the Seller
and Buyer.
The Varec 221 Series Emergency Pressure Relief Manway Cover has not been tested by Varec under all
possible operational conditions, and Varec does not have all the data relative to your application. The
information in this instruction manual is not all inclusive and does not and cannot take into account all
unique situations Consequently, you should review this product literature in view of your application.
If you have any further questions, please contact Varec for assistance.
Limitations of Seller's Liability
In the event that a court holds that this instruction manual created some new warranties, Seller's liability
shall be limited to repair or replacement under the standard warranty clause. In no case shall Seller's
liability exceed that stated as Limitations of Remedy in the contract between the Seller and Buyer.
Use of parts that are not manufactured or supplied by Varec voids any Varec warranty and relieves
Varec of any obligation to service the product under warranty. Varec recommends the use of only
Varec manufactured or supplied parts to maintain or service Varec 221 Series Emergency Pressure
Relief Manway Covers.
This document, or any part of, may not be reproduced by any means without written permission of
Varec, Inc.
Safety Precautions
READ AND UNDERSTAND THIS INSTRUCTION MANUAL BEFORE INSTALLING,
OPERATING OR PERFORMING MAINTENANCE ON VAREC 221 SERIES EMERGENCY
PRESSURE RELIEF MANWAY COVERS. FOLLOW ALL PRECAUTIONS AND
WARNINGS NOTED HEREIN WHEN INSTALLING, OPERATING OR PERFORMING
MAINTENANCE ON THIS EQUIPMENT.









221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
4
Safety Precautions Definitions


CAUTION
Damage to equipment may result if this precaution is disregarded.

WARNING
Direct injury to personnel or damage to equipment which can cause injury to personnel may result if this
precaution is not followed.

WARNING
Allow any pressure to vent slowly when opening manhole by carefully raising cover.
Wear appropriate gloves and/or breathing apparatus if hazardous vapors are present.




















221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
5
GENERAL
The VAREC 221 Series Emergency Pressure Relief Manway Covers are installed on low pressure
storage tanks and vessels. They are designed to provide a relief opening when internal pressures exceed
tank breather vent capabilities. These covers also provide an access for tank inspection and
maintenance.
The Model 221P provides emergency pressure relief only. (See Figure 1)
The Model 221PV provides both emergency pressure relief and vacuum relief. Vacuum is relieved
through a spring loaded valve integral with the cover assembly. (See Figure 2)
CONSTRUCTION
The standard unit is constructed of a fabricated base with heavy cast cover and reinforced non-metallic
diaphragm.
For material selection, see Tables 1 and 2.
OPERATION
When excessive pressure builds up within the storage vessel the hinged cover opens at its predetermined
set point, relieving the excess pressure. After the over-pressure dissipates the cover closes and reseats
on the base. The vacuum element of the Model 221PV opens when a vacuum exceeding the pre-set
value occurs in the storage vessel. The integral spring closes the valve once the vacuum falls below the
pre-set value.
! Note
Emergency venting capacity requirements are dependent upon wetted surface area. Reference API
Standard 2000 for requirement information.
INSTALLATION
The VAREC 221 Series Emergency Pressure Relief Manway Cover is designed to be mounted on a
level and flat flanged roof nozzle. The standard 20-inch and 24-inch size units are drilled per API
Specification 650. The standard 18-inch design is drilled similar to this specification, though not an API
standard size. Mounting screws, nuts and a suitable gasket to be furnished by others.
1. Remove the unit from the shipping container or pallet. Remove all packing material. Ensure that
the cover pivots freely and seats flat and concentric on the base.
2. Place the flange gasket on the nozzle. Mount the VAREC 221 manway assembly on the nozzle.
Position the unit so that it is free to open without interference from any component on the tank roof.
221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
6
3. Install all mounting hardware initially hand tight. Then tighten uniformly around the flange in a
star pattern. Inspect and wipe seating before placing unit in service. Ensure that the flanged base
does not warp due to uneven tank surface. This will be a cause for leakage beyond specification.
! Note
As an optional feature, the manway cover can be restricted to opening only 60! from horizontal, thus
ensuring it to return closed after the over-pressure situation passes. A second hinge pin is installed
behind the hinge arm, secured in position by cotter pins. This Stop Pin can be quickly removed if
required to allow the cover to be opened pass vertical and therefore remain open.
WARNING
If the unit is painted or modified, ensure that the seating surface of the flanged base is flat within .002
inches across the diameter. It is not recommended to paint the seating.
CALIBRATION
The 221 Series Pressure Relief Covers are pre-set at the factory to relieve at the customer's specified
setting. Please contact Varec for adjustments to the preset settings. Vacuum setting can be adjusted a
follows:
Vacuum adjustment to Model 221 PV units. (Items in parenthesis correspond to Figure 2 and Table 2.)
Remove hood (110) and lead weight assembly (260-300) from posts (250). Tighten hex jam nut (240)
and compress spring (80) to increase vacuum setting, loosen nut and expand spring to decrease vacuum
setting. Replace hood assembly.
MAINTENANCE
Periodically lift cover and check for freeness of operation.
WARNING
Allow any pressure to vent slowly when opening manway by carefully raising lid.
Wear appropriate gloves and/or breathing apparatus if hazardous vapors are present.
Inspect and wipe seating surfaces. Replace damaged or worn components as noted in the following
procedures.

! Note
Place a temporary cover over the manway opening when performing the following procedures.

Model 221P Instructions
Items in parenthesis correspond to Figure 1 and Table 1.
221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
7
1. To replace diaphragm (20) and cover pads (40), remove cotter pins (120) and hinge pin (110) and
remove cover assembly (50 & 90) from base (10). Place temporary cover over base.
2. Disassemble screws (130) and nuts (140) to remove ring (30). Remove ring (30), diaphragm (20)
and pads (40) from cover (50). Clean surface of cover where pads were located.
3. Apply 3M Scotch Grip 2262 Plastic Adhesive or equal, and place new pad segments (40) in cover
(50) recess. Place new diaphragm (20) on cover with holes aligned. Replace ring (30) and install
screws (130) and nuts (140) initially hand tight. Tighten screws and nuts uniformly in a star pattern
to a torque of approximately 4 ft-lb.
4. Replace cover (50) and hinge arm assembly (90) on base (10). Replace hinge pin (110) and cotter
pins (120).
Model 221 PV Instructions
Items in parenthesis correspond to Figure 2 and Table 2.
1. Diaphragm (50) and cover pad (40) replacement:
a. Remove cotter pins (150) and hinge pin (170) and remove cover assembly (20 & 180) from base
(10). Place temporary cover over base.
b. Disassemble screws (200) and nuts (210) to remove ring (30). Remove ring (30), diaphragm
(50), and pads (40) from cover (20). Clean surface of cover where pads were located.
c. Apply 3M Scotch Grip 2262 Plastic Adhesive or equal on new pad segments (40), and press
them into cover (20) recess. Place new diaphragm (50) on cover (20) with holes aligned.
Replace ring (30) and install screws (200) and nuts (210) uniformly in a star pattern to a torque
of approximately 4ft-lb.
2. Vacuum pallet (120) or seat insert (140) replacement:
a. Remove cover assembly from base as described in 1.a above.
b. Remove nuts (230), hood (110) with attached lead weight (260-300) from cover (20).
Remove screen (60). Measure length of compressed spring (80).
c. Remove outer (lower) hex nut (240). Remove pallet (120), insert (140) and retainer (130).
Do not turn inner hex nut (240). Assemble new pallet (120), insert (140) and retainer (130)
on stem (100). Install outer hex nut (240) and tighten without changing compressed length of
spring (80).

3. Spring replacement:
221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
8
a. Remove cover assembly from base as described in 1.a above.
b. Remove nuts (230), hood (110) with attached lead weight (260-300) from cover (20).
Remove screen (60). Measure length of compressed spring (80).
c. Remove hex nut (240) at top of pallet stem (100). Do not allow pallet assembly to drop
out of cover guide. Remove spring retainer (90) and spring (80).
d. Replace with new spring (80), ensuring that it is seated properly on cover guide. Replace
retainer (90) and hex nut (240). Tighten nut (240) to compress spring (80) to measured
length of original spring. Adjust length if necessary, using the calibration procedure
described in this manual.
e. Replace screen (60), hood (110) with weights (260-300) and four nuts (230).
f. Replace cover assembly on base. Replace hinge pin (170) and cotter pins (150).

FIGURE 1
MODEL 221P
* Counterweight assembly used only with pressure setting less than Minimum.

221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
9

PARTS LIST / MATERIALS
ITEM PART DESCRIPTION
MATERIAL CODE "1P0"
(STL BASE / ALUM COVER)
MATERIAL CODE "2P0"
(ALUM BASE / ALUM
COVER)
MATERIAL CODE "3P0"
(STL BASE / STL COVER)
MATERIAL CODE "4P0"
(SST BASE / SST COVER)
10 BASE ASSEMBLY STL ALUMINUM STL SST 316
20 DIAPHRAGM SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS
30 COVER RING ALUMINUM ALUMINUM STL SST 304
40 COVER PAD SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS
50 COVER ALUMINUM ALUMINUM STL SST 316
60 HANDLE ALUMINUM ALUMINUM ALUMINUM SST 304
70
HEX HEAD CAP
SCREW SST 304 SST 304 SST 304 SST 304
80 SLEEVE SST 304 SST 304 SST 304 SST 304
90 HINGE ARM ASSY STL STL STL SST 304
110 HINGE PIN SST 304 SST 304 SST 304 SST 304
120 COTTER PIN SST 304 SST 304 SST 304 SST 304
130
HEX HEAD CAP
SCREW SST 304 SST 304 SST 304 SST 304
140 HEX NUT SST 304 SST 304 SST 304 SST 304
150
HEX HEAD CAP
SCREW SST 304 SST 304 SST 304 SST 304
160.1 STUD SST 304 SST 304 SST 304 SST 304
160.2
HEX HEAD CAP
SCREW ALUMINUM ALUMINUM SST 304 SST 304
170 HEX NUT SST 304 SST 304 SST 304 SST 304
180 WASHER SST 304 SST 304 SST 304 SST 304
190 LOADING WEIGHT GRAY IRON GRAY IRON GRAY IRON GRAY IRON
200 COUNTER WEIGHT GRAY IRON GRAY IRON GRAY IRON GRAY IRON
210 SPACER, CTWT ALUMINUM ALUMINUM ALUMINUM ALUMINUM
220 PIN, CTWT ARM STL STL STL STL
230 ARM, CTWT STL STL STL STL
240
HEX HEAD CAP
SCREW ZN PL STL ZN PL STL ZN PL STL ZN PL STL
250 COTTER PIN SST 304 SST 304 SST 304 SST 304
TABLE 1
MODEL 221P
221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
10




FIGURE 2
MODEL 221PV

* Counterweight assembly used only with pressure setting less than Minimum.

221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
11

221PV PARTS LIST / MATERIALS
MATERIAL CODE 1PV1 MATERIAL CODE 1PV2 MATERIAL CODE 2PV1 MATERIAL CODE 2PV2 MATERIAL CODE 3PV2 MATERIAL CODE 4PV2
ITEM PART DESCRIPTION
STL BASE
ALUM COVER
ALUM VAC TRIM
STL BASE
ALUM COVER
ALUM VAC TRIM
ALUM BASE
ALUM COVER
ALUM VAC TRIM
ALUM BASE
ALUM COVER
SST VAC TRIM
STL BASE
STL COVER
SST VAC TRIM
SST 316 BASE
SST 316 COVER
SST VAC TRIM
10 BASE ASSEMBLY STL STL ALUMINUM ALUMINUM STL SST 316
20 COVER ALUMINUM ALUMINUM ALUMINUM ALUMINUM STL SST 316
30 COVER RING ALUMINUM ALUMINUM ALUMINUM ALUMINUM STL SST 304
40 COVER PAD SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS
50 DIAPHRAGM SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS
60 SCREEN H.D. POLYETHYLENE H.D. POLYETHYLENE H.D. POLYETHYLENE H.D. POLYETHYLENE H.D. POLYETHYLENE H.D. POLYETHYLENE
70 HANDLE ALUMINUM ALUMINUM ALUMINUM ALUMINUM ALUMINUM SST 304
80 SPRING ZN PL STL SST 304 ZN PL STL SST 304 SST 304 SST 304
90 SPRING RETAINER SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
100 STEM ALUMINUM SST 304 ALUMINUM SST 304 SST 304 SST 304
110 HOOD ALUMINUM ALUMINUM ALUMINUM ALUMINUM STL SST 304
120 VACUUM PALLET ALUMINUM SST 316 ALUMINUM SST 316 SST 316 SST 316
130 RETAINER ALUMINUM SST 316 ALUMINUM SST 316 SST 316 SST 316
140 VACUUM SEAT INSERT SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS SEE SOFT GOODS
150 COTTER PIN SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
160 SLEEVE SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
170 HINGE PIN SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
180 HINGE ARM ASSY STL STL STL STL STL SST 304
200 HEX HEAD CAP SCREW SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
210 HEX NUT SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
220 HEX HEAD CAP SCREW SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
230 HEX NUT SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
240 HEX JAM NUT SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
250 POST SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
260 LOADING WEIGHT GRAY IRON GRAY IRON GRAY IRON GRAY IRON GRAY IRON GRAY IRON
270 WEIGHT MTG. PLATE ASSY STL PLATE/SST 304 STUD STL PLATE/SST 304 STUD STL PLATE/SST 304 STUD STL PLATE/SST 304 STUD STL PLATE/SST 304 STUD STL PLATE/SST 304 STUD
290 HEX NUT SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
300 WASHER SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
310 HEX HEAD CAP SCREW SST 304 SST 304 SST 304 SST 304 SST 304 SST 304
320 COUNTER WEIGHT GRAY IRON GRAY IRON GRAY IRON GRAY IRON GRAY IRON GRAY IRON
330 SPACER, CTWT ALUMINUM ALUMINUM ALUMINUM ALUMINUM ALUMINUM ALUMINUM
340 PIN, CTWT ARM STL STL STL STL STL STL
350 ARM, CTWT STL STL STL STL STL STL
360 HEX HEAD CAP SCREW ZN PL STL ZN PL STL ZN PL STL ZN PL STL ZN PL STL ZN PL STL
370 COTTER PIN SST 304 SST 304 SST 304 SST 304 SST 304 SST 304

TABLE 2
MODEL 221PV


221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
12

221P & 221PV SOFT GOODS MATERIALS
SOFT GOODS
MATERIAL
CODE "B"
MATERIAL
CODE "T"
MATERIAL
CODE "V"
DIAPHRAGM
(221P & 221PV)
BUNA-N TEFLON VITON
COVER PAD
(221P & 221PV)
NEOPRENE NEOPRENE VITON
VACUUM SEAT
INSERT
(221PV ONLY)
BUNA-N TEFLON VITON

TABLE 3
MODEL 221P & 221PV





221P & 221PV FLANGE DRILLING DIMENSIONS
Nominal
Size
Flange
Drilling
Flange
Inside
Dia.
Flange
Outside
Dia.
Bolt
Circle
Dia.
Hole
Dia.
No. of
Holes
18
[450]
Varec
Std.
18.5
[470]
25.0
[635]
21.50
[546]
.63
[16]
16
20
[500]
API
650
20.5
[521]
26.0
[660]
23.50
[597]
.75
[19]
16
24
[600]
API
650
24.5
[622]
30.0
[762]
27.50
[699]
.75
[19]
20
18
[450]
ANSI
150#
18.5
[470]
25.0
[635]
22.75
[578]
1.25
[32]
16
20
[500]
ANSI
150#
20.5
[521]
27.5
[699]
25.00
[635]
1.25
[32]
20
24
[600]
ANSI
150#
24.5
[622]
32.0
[813]
29.50
[749]
1.38
[35]
20
Dimensions are inches. Dimensions in [ ] are millimeters.

TABLE 4
MODEL 221P & 221PV

221 Series Emergency Pressure Relief Manway Covers
33-08841 Rev. F
13
REPLACEMENT PARTS
When ordering replacement parts, specify relief manhole cover by model number and flange size.
Identify replacement parts by part number and description where possible.

MODEL 221P
ITEM SIZE CODE 18 20 24
NOMINAL 18 IN. 20 IN. 24 IN.
PIPE SIZE 450 MM 500 MM 600 MM
DIAPHRAGM, BUNA-N B17608-074 B17606-074 B17604-074
2 DIAPHRAGM, TEFLON/GLASS B17608-094 B17606-094 B17604-094
DIAPHRAGM, VITON B17608-087 B17606-087 B17604-087
4 COVER PAD, NEOPRENE B10281-079 B7389-079 B8605-079
COVER PAD, VITON B10281-089 B7389-089 B8605-089

TABLE 5: 221P

MODEL 221PV
ITEM SIZE CODE 18 20 24
NOMINAL 18 IN. 20 IN. 24 IN.
PIPE SIZE 450 MM 500 MM 600 MM
4 COVER PAD, NEOPRENE B10281-079 B7389-079 B8605-079
COVER PAD, VITON B10281-089 B7389-089 B8605-089
DIAPHRAGM, BUNA-N B17608-074 B17606-074 B17604-074
5 DIAPHRAGM, TEFLON/GLASS B17608-094 B17606-094 B17604-094
DIAPHRAGM, VITON B17608-087 B17606-087 B17604-087
8 SPRING, ZN PL STEEL B17617-103 B17617-103 B17617-103
SPRING, 304 SST B17617-405 B17617-405 B17617-405
9 SPRING RETAINER B17615-005 B17615-005 B17615-005
10 STEM, ALUMINUM B17619-001 B17619-001 B17619-001
STEM, 316 SST B17619-005 B17619-005 B17619-005
12 VACUUM PALLET,
ALUMINUM
B14325-001 B14325-001 B14325-001
VACUUM PALLET, 316 SST B14325-006 B14325-006 B14325-006
13 RETAINER, ALUMINUM B14326-001 B14326-001 B14326-001
RETAINER, 316 SST B14326-006 B14326-006 B14326-006
VACUUM SEAT INSERT,
BUNA-N
B12743-074 B12743-074 B12743-074
14 VACUUM SEAT INSERT,
TEFLON
B12743-093 B12743-093 B12743-093
VACUUM SET INSERT, VITON B12743-087 B12743-087 B12743-087
24 HEX JAM NUT, 304 SST P31-304 P31-304 P31-304
29 HEX NUT, 304 SST P31-145 P31-145 P31-145
TABLE: 6: 221PV




VAREC



REVISIONS
REV. DESCRIPTION APPROVAL/DATE
C

ECN #01-1224 S.WILLIS 8-17-01
G.SETZER 8-20-01
D.WYANT 8-20-01
D

ECN #06-1311 S.WILLIS 8-25-06
D.WYANT 8-31-06
D.WYANT 8-31-06
A.GRAHMANN 9-06-06
E

ECN #06-1785
Revised entire report.
S.WILLIS 1-18-07
D.WYANT 2-07-07
J.CONLEY 2-07-07
F





















ECN #09-1510
Revised entire report.
S.WILLIS 12-03-09
D.WYANT 12-07-09
D.K.SHARMA 12-07-09

THIS PAGE IS FOR APPROVALS AND REVISION RECORDS OF THE DOCUMENT
IN THIS FOLDER. COPIES OF THIS PAGE ARE NOT TO BE DISTRIBUTED
WITH THE ASSOCIATED DOCUMENT.

EXCLUDING THIS PAGE, THIS DOCUMENT CONTAINS 13

DWN INSTRUCTION, OPERATION & MAINTENANCE
CHK MANUAL
APPR 221 SERIES
APPR EMERGENCY PRESSURE RELIEF MANWAY COVER
APPR SIZE REV.
APPR A 33-08841 F



FORM NO. 1500 REV. A 5/93