Steridose STERIVALVE 25 User's Installation And Operation Manual

Type
User's Installation And Operation Manual

This manual is also suitable for

STERIVALVE®
Installation and operation manual
(Including welding guideline)
Page 2 / 45
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---Table of Contents---
1. Introduction
1.1 Safety information
1.2 Scope and Purpose
1.3 Main Components
1.3.1 Valve housing
1.3.2 Actuators
1.3.3 Diaphragms
2. Assembly
2.1 General
2.1.1 Valve housing to actuator connection
2.1.2 Diaphragm connection
2.2 Assembly Procedure
2.2.1 Pneumatically operated valves
2.2.2 Manually operated valves
2.2.3 Additional procedures for installation of PTFE diaphragms
2.2.4 Position Indicators
2.2.4.1 Stainless Steel Pneumatic Actuators
2.2.4.2 Plastic Pneumatic Actuators
3. Operation
3.1 Pneumatically operated valves
3.2 Manually operated valves
3.3 Position Indicators
3.4 Cleaning
3.4.1 Internal cleaning
3.4.2 External cleaning
4. Maintenance/Service
4.1 Special tools required
4.2 Preventive Maintenance Schedule
4.3 Actuators
4.3.1 Manual Actuator
4.3.2 Pneumatic Actuator
4.4 Diaphragms
4.4.1 Interval of diaphragm inspection
4.4.2 Inspection procedure
5. Troubleshooting
6. Technical specifications
7. Spare parts list
8. Traceability and Conformity information
9. Contact information
APPENDIX A: Welding guide
APPENDIX B: Indicator systems
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1. INTRODUCTION
1.1 Safety information
DANGER! The equipment may be operated and maintained only when this maintenance manual
is thoroughly understood. Negligence to do so can result in personal injury and/or material
damage.
If the Sterivalve® is part of a piping system, please note:
DANGER! The system may be subject to overpressure, steam, hot water, vapors and
chemicals. Incorrect handling of the system may result in electrical shock and burn
injuries.
DANGER! When opening a valve to atmosphere or to a non-pressure vessel, always make sure
the pressure is 0 bar(g) (atmospheric pressure).
DANGER! Operation, maintenance and adjustment of the equipment may be performed by
authorized personnel only.
CAUTION! The valve inner surface is manufactured to a high polish and WILL get damaged if
tools are used improperly or without care.
1.2 Scope and Purpose
This document provides information regarding installation, normal operation, maintenance, and
troubleshooting of the valve, including safety aspects.
1.3 Main Components
The Sterivalve ® is a diaphragm valve especially designed for use in aseptic processes.
The valve consists of four major components:
Housing
Actuator manual or pneumatic*
Diaphragm
Clamp (Sterivalve® 51 (2”) and 76 (3”) do not feature a clamp. Instead, the housing and
actuator are bolted together).
*The pneumatic actuator can be fitted with electrical position switches indicating open/closed
position.
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Figure 1: Main Components
Sterivalve 12 (1/2”) to 38 (1.5”) Sterivalve 51(2”) and 76 (3”)
1.3.1 Valve housing
The valve housing is made as standard of stainless steel AISI 316L. Each valve housing is
marked with a respective lot number that links it with a specific material mill certificate.
Several housing configurations are available:
Process valves:
Standard process valves are available as shut-off, flow through, take-off, and divert. Refer to
figure 2. Other custom configurations are available upon request.
Bottom outlet valves:
Standard bottom outlet valves are available as single or double outlet, and double outlet with
steam integrated valve. Refer to figure 2. Outlet (s) can be provided as a straight weld-nose, or
elbow (90° or 45°) with or without TC connection. Other custom configurations are available
upon request.
Sampling valves:
Standard sampling valves are available as single or double outlet, for welding direct into a vessel
wall, or for mounting on a hygienic pad connection, such as Steriflange®. Refer to figure 3.
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Figure 2: Standard Valve Housing Configurations
Figure 3: Standard Sample Valve Housing Configurations
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1.3.2 Actuators
The valve is provided with the following actuator types:
Plastic Pneumatic Actuator 12 (1/2”) to 76 (3”)
The plastic pneumatic actuator is made of PPE (polyphenylene ether) polymer.
The actuators are sealed for life and are not serviceable.
The actuator is provided as spring to close/air to open (normally closed).
Figure 4: Plastic Pneumatic Actuators
Stainless Steel Pneumatic Actuator 12 (1/2”), 25 (1”), and 38 (1 ½”)
The pneumatically operated actuator for Sterivalve® has a stainless steel cover but it is not
autoclavable. The actuator is mounted on the housing with a clamp.
The stainless steel pneumatic actuator is available in two versions:
S-A, where the designation S-A indicates: Spring closed, Air open
A-A, where the designation A-A indicates: Air closed, Air open
Figure 5: Stainless Steel Pneumatic Actuator 12 (1/2"), 25 (1"), & 38 (1-1/2")
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Stainless Steel Pneumatic Actuator 51 (2”) & 76 (3”)
The stainless steel pneumatic actuator for valves 51 (2”) and 76 (3”) is sealed and not serviceable.
The actuator is bolted to the housing.
The pneumatic actuator is provided already pre-assembled with the adapter and adapter plate (see
figure 6).
The pneumatic actuator is spring/air. The cylinder is reversible and can be set-up as either spring
to close/air to open (normally closed), or spring to open/air to close (normally open).
Figure 6: Stainless Steel Pneumatic Actuator 51 (2") & 76 (3")
Manual Actuator 12 (1/2”) to 76 (3”)
The manually operated actuator is manufactured in stainless steel and is autoclavable. The
actuator is mounted in the same manner as with the pneumatic actuators.
An extended handle manual actuator is also available for bottom outlet valves. This option
makes the handle more accessible to the operator. See figure 8.
Figure 7: Manual Actuator 12 (1/2") to 76 (3") Figure 8: Extended Manual Handle
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1.3.3 Diaphragms
The valve has three different diaphragm material options. Consult Steridose for availability of
each material for any particular valve size.
Diaphragm material selection is a function of chemical compatibility with the process fluid (s),
including CIP solutions/steam, operational temperature and number of cycles.
The following materials are offered:
-Platinum cured Silicone, USP <88> Class VI.
-EPDM, USP <88> Class VI.
-Modified PTFE (TFM), USP <88> Class VI.
All diaphragms can be traced by their lot number. The lot number is marked in the packaging.
Additionally, silicone and EPDM diaphragms have markings on the back providing the
manufacturing date. See section 10 for more details.
Figure 9: Diaphragm Materials
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2. Assembly
2.1 General
When installing the valve sufficient clearance to remove/assemble the actuator must be
considered. The amount of space required depends on valve size and actuator configuration.
In order to ensure self draining, the valve must be installed in the correct position. See figures 10
and 11:
Figure 10: Self draining positions for process valves
The housing is self draining in these positions,
but NOT in this position.
Figure 11: Self draining position for bottom outlet valves
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2.1.1 Valve housing to actuator connection
The valve housing and actuator are connected with either a hygienic clamp union or bolts, as
indicated below:
Size 12 (1/2”): TC CLAMP 1"/ 1.5"
Size 25 (1”): TC CLAMP 2.5"
Size 38 (1 ½”): TC CLAMP 2.5"
Size 51 (2”): M8x16mm. ( 4pcs.)
Size 76 (3”): M8x16mm. ( 4pcs.)
2.1.2 Diaphragm connection
The diaphragm connection to the actuator stem is made by means of a pressure plate or threaded
connection depending on valve size and diaphragm material.
For valves 12 (1/2”), 25 (1”), and 38 (1 1/2”), with EPDM and Silicone diaphragms, the
diaphragm is attached by means of a pressure plate installed in the stem, type 1 or 2. As a
standard, the actuators are supplied with a type 1 pressure plate. When using type 1, the
diaphragm is pressed into the plate. The type 2 pressure plate is provided as an option and
recommended when it is expected that the valve would remain in the closed position for prolong
periods of time and would also be subject to steaming. The diaphragm screws into the type 2
pressure plate.
The pressure plates are interchangeable. Refer to Figure 13 for details on how to replace a type 1
for a type 2.
Figure 12: Diaphragm Connection Types
No Pressure Plate Pressure Plate Type 1 Pressure Plate Type 2
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Figure 13: Replacement of pressure plate type 1 for type 2
For valves 12 (1/2”) to 76 (3”), with PTFE diaphragm, no pressure plate is required in the valve
stem. The PTFE diaphragm is provided with a threaded stud that will screw direct to the valve
stem.
In the event of replacing a silicone or EPDM diaphragm for a PTFE diaphragm on an existing
installation, the pressure plate type 1 or 2 must be removed from the stem. The pressure plates
are glued to the stem. Caution should be taken that all residual glue is carefully removed from
the threads in the stem, so that the PTFE diaphragm can screw all the way into the stem. Failure
to do so may result in diaphragm damage. A tap can be run on the stem threads to ensure
removal of all residual glue.
NOTE: When replacing silicone or EPDM diaphragms for PTFE diaphragms on valves that
have been in operation for some years, ensure that the valve is tested for leaking prior to put
back into service. Small scratches, misaligments, etc that may be present in the valve housing
may not affect the sealing capability of silicone or EPDM, but may affect PTFE.
For valves 51 (2) and 76 (3”), the diaphragm is provided with a threaded insert that screws
directly into the valve stem.
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2.2 Assembly Procedure
2.2.1 Pneumatically operated valves
In order to install the pneumatic actuator to the valve, follow these steps:
1-Attach diaphragm to actuator stem, or screw the valve diaphragm to the actuator stem. Refer
to section 2.1.
2-Actuate the actuator to the open position. If the actuator is set-up as normally closed, actuate
the actuator to the open position. If the actuator is set-up as normally open, continue to step 3.
3-Insert actuator with diaphragm into valve housing.
4-Secure clamp around actuator and valve body. For 51 (2”) and 76 (3”) secure the 4 bolts that
attach the actuator to the valve body. Tighten the bolts.
5-Actuate the actuator to the closed position.
6- For valves with PTFE diaphragms make sure support gasket/o-rings are installed with the
diaphragm. See figure 14. See additional installation procedures for PTFE diaphragms in section
2.2.3.
Figure 14: PTFE diaphragm o-rings (left) and support gasket (right)
2.2.2 Manually operated valves
In order to install the manual actuator to the valve, follow these steps:
1- Turn the actuator hand wheel clockwise (closed).
2- Attach diaphragm to actuator stem or, screw the valve diaphragm to the actuator stem. Refer
to section 2.1.2.
3- Turn the actuator hand wheel counterclockwise (open).
4- Insert actuator with diaphragm into valve body.
O-ring
Support
gasket
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5- Secure clamp around actuator and valve body. For 51 (2”) and 76 (3”) secure the 4 bolts that
attach the actuator to the valve body. Tighten the bolts by using a wrench.
6-Actuate the manual actuator to the closed position by turning the wheel in the opposite
direction.
7- For valves with PTFE diaphragms make sure support gasket/o-rings are installed with the
diaphragm. See figure 14. See additional installation procedures for PTFE diaphragms in section
2.2.3.
2.2.3 Additional Procedure for Installation of PTFE Diaphragms
In order to ensure proper sealing of PTFE diaphragms, it is recommended to heat-treat them
before use. Follow these steps for the heat-treatment procedure:
1- Expose the installed diaphragm to steam at around 121° C for approximately 30 minutes. The
valve should be in the closed position, or closed directly after exposure. Alternatively, the
installed diaphragm can be exposed to hot air at around 100° C for approximately one hour.
2- Re-tighten the clamp (1/2”-1.5” sizes) or bolts (2” and 3” sizes), after the valve has cooled
down to ambient temperature.
3- Repeat this process each time the valve insert (actuator and diaphragm) is disassembled and
reassembled.
2.2.4 Position Indicators
An assortment of models and styles of instrumentation are available to sense the actuator
position. Listed below are some of the most common. Please consult Steridose to determine
the best solution to your particular application.
2.2.4.1 Stainless Steel Pneumatic Actuators
For valves 12 (1/2”), 25 (1”), and 38 (1-1/2”)
To accommodate a wide variety of position indicator solutions various adapters may need to be
used on particular assemblies. Please consult with Steridose representatives to determine overall
dimensions and specifications.
The sensors available are:
Open, micro-switch
Open/Close, micro-switch
Open, inductive proximity switch
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In order to assemble open micro-switches follow these steps:
1. Add/remove any required adapters or sensors from top of actuator.
2. Screw the electrical position indicator in and adjust so that when the actuator is open the
sensor switch is activated.
3. Wire the sensor per manufacturer recommendations.
In order to assemble open/close micro-switches follow these steps:
1. Set the actuator open.
2. Screw in/remove adapters as necessary.
3. Screw in instrumentation bushing.
4. Set stroke limiter.
5. Fix nut against actuator top.
6. Unscrew screw on actuator top lid and remove.
7. Loosen set screw on body.
8. Slip on instrumentation body into correct position.
9. Lock into place with set screw.
10. Reassemble to lid with screw.
In order to assemble open, inductive proximity switches follow these steps:
1. Set the actuator open.
2. Screw the indicator into the tapped hole on top of the actuator, until it stops.
3. Loosen the indicator one turn and fix the indicator against the actuator by screwing the lock-
nut down against the top of the actuator.
4. Compare the measurement A against the chart. Check that measurement A and B are achieved
during operation. The switch can be adjusted by turning it.
5. Secure the switch with the lock-nut.
Chart Sterivalve® 12 (1/2”), 25 (1”), and 38 (1 ½”)
Size / Measures A B
Sterivalve® 12 41 69
Sterivlave® 25 28 56
Sterivlave® 38 29 57
Figure 15: Installation of position indicators for valves 12 (1/2"), 25 (1"), and 38 (1.5")
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For valves 51 (2”) and 76 (3”)
The stainless steel pneumatic actuator for 51(2”) and 76 (3”) valves can be provided with
inductive switches for sensing open and closed position. The same actuator is used with or
without switches. A plastic sensor holder is added to the actuator and the sensors are screwed to
each mounting bracket as shown on figure 16.
The sensors available are:
Open, inductive proximity switch
Open/close, inductive proximity switch
In order to adjust the sensor position, follow these steps:
1. Place the actuator in either the open or closed position.
2. Loosen the vertical adjustment screw on the corresponding mounting bracket and adjust
the position until the switch LED signal light is activated. By carefully moving the
mounting bracket up and down vertically, position the switch in the middle of the sensor
range and then tighten down.
3. Move the actuator to the other position and repeat step 2 for the remaining switch.
Figure 16: Installation of position switches for valves 51 (2") and 76 (3")
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2.2.4.2 Plastic Pneumatic Actuators
For valves 12 (1/2”), 25 (1”), 38 (1-1/2”), 51 (2”), and 76 (3”)
The sensors available are:
Open, micro-switch
Open/Close, micro-switch
Open, inductive proximity switch
Open/close, inductive proximity switch
In order to assemble switches follow these steps:
1. Loosen set screw on instrumentation body.
2. Remove duplication system from instrumentation body.
3. Check that seals are properly seated and undamaged.
4. Unscrew and remove transparent plastic cap on top of actuator.
5. Apply air to position actuator rod to the top position.
6. Unscrew and remove yellow visual indicator.
7. Screw duplication system into actuator rod.
8. Tighten adapter until contact is made with top of the actuator.
9. Fully tighten duplication system rod on actuator rod with screwdriver.
10. Depressurize actuator to return to default position.
11. Insert instrumentation body onto duplication system, making sure not to damage contact
levers on switches.
12. Tighten set screw on instrumentation body
13. Wire according to manufacturer instructions.
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3. OPERATION
3.1 Pneumatically operated Valve
The pneumatically operated actuator type S-A is opened when pressurized and closed otherwise.
The pneumatically operated actuator type A-A is opened when the lower connection is
pressurized and closed when the upper connection is pressurized.
DANGER! Always make sure that the surrounding system is de-pressurized before opening a
valve to atmosphere or non-pressure vessels. Negligence can result in personal injuries or
material damages.
3.2 Manually operated Valve
The handle is turned counterclockwise to open the valve and clockwise to close. The valve is not
suitable as a regulating valve, and should therefore not be set half-way open. Degree of opening
is visually displayed on the side of the handle.
When closing the valve be sure not to over tighten the handle.
The manually actuator with extension handled is opened by turning the handle counter-clockwise
and closed by turning it clockwise.
DANGER! Always make sure that surrounding system is de-pressurized before opening a valve
to atmosphere or non-pressure vessels. Negligence can result in personal injuries or material
damages.
WARNING! The handle will become hot if the valve is cleaned with hot liquid or sterilized with
steam or water. Use glove if the valve must be opened when the valve is hot.
3.3 Position indicators
When installed, the position indicators will indicate if the valve is closed or open by means of
sending an electric signal to a control panel. In some models, a red LED light will also provide a
visual indication that the valve is in the open position.
3.4 Cleaning
3.4.1 Internal cleaning
The valve is designed for Cleaning In Place (CIP) but can also be cleaned manually by
disassembling the parts and manually cleaning housing and diaphragm.
3.4.2 External cleaning
External cleaning is made according the customers standard procedures, designed for the selected
materials of the equipment.
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4. MAINTENANCE / SERVICE
4.1 Special tools required
No special tools are required for operation and ordinary maintenance of the valve.
For maintenance of the pneumatic actuator 12 (1/2”), 25 (1”) and 38 (1 ½”) a special tool and
instruction are needed. It is recommended that the pneumatic actuators 12 (1/2”), 25 (1”) and 38
(1 ½”) are returned to Steridose for repair. Pneumatic actuators 51 (2”) and 76 (3”) are sealed
and not serviceable. All plastic Pneumatic actuators and manual stainless steel actuators are also
sealed and not serviceable.
4.2 Preventive Maintenance Schedule
Table 1 shows the recommended intervals for inspection of the valve components:
Table 1: Intervals of inspection
Preventive maintenance
Section in
manual for
reference
Interval
Leakage inspection
4.2
Daily
Sterivalve diaphragm inspection
4.4
see 4.4.1
Sterivalve pneumatic actuator inspection
4.3.2
12 months
Sterivalve housing inspection
4.2
12 months
Pneumatic tubing
4.3.2
12 months
Electrical cables
4.3.2
12 months
Clamps frequently opened should be greased at the thread with “Molykote 111” regularly.
Negligence may result in damage to threads.
The wetted surfaces of the valve housing should be checked for signs of corrosion and
discoloration.
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4.3 Actuators
4.3.1 Manual Actuator
The manual actuator does not need any maintenance or service. Visual inspection every 12
months is recommended.
4.3.2 Pneumatic Actuator
General
The pneumatic actuator requires inspection every 12 months. The following components shall
be inspected:
1- Inspect pneumatic tubing and replace if damaged. Assure that the pneumatic hose is not in
contact with hot piping etc.
2- Inspect electrical cables and replace if damaged. Assure that the electric cable is not in contact
with hot piping etc.
3- Inspect overall function of the actuator. Any noises that may indicate air leakage would result
in loss of pressure and could result in an inoperative actuator.
Additional service procedures for stainless steel actuators 12 (1/2”), 25 (1”) and 38 (1.5”)
The stainless steel pneumatic actuators 12 through 38 are serviceable and a repair kit is available
for each size. Refer to tables 2-4. The repair kits include all O-rings and gaskets in the actuator
assembly. Special tools are required. See section 4.1.
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STERIVALVE 12
Table 2: Sterivalve 12 (1/2") S-A
STERIVALVE 12 (1/2”) S-A
Part # 104156
Pos:
Qty:
Description:
Dimension:
Note:
1
1
O-ring
16.1x1.6
2
1
X-ring
9.25x1.78
3
1
Compact seal
32
4
1
O-ring
34.65x1.78
5
1
O-ring
3.1x1.6
6
1
Pressure plate
STERIVALVE 25
Table 3: Sterivalve 25 (1") S-A
STERIVALVE 38
Table 4: Sterivalve 38 (1-1/2") S-A
STERIVALVE 38 (1 ½”) S-A
Part # 104158
Pos:
Qty:
Description:
Material:
Dimension:
Note:
1
1
O-ring
Viton
17.17x1.78
2
1
X-ring
Viton
9.25x1.78
3
1
Compact seal
Nitril
80
4
1
O-ring
Viton
74.2x5.7
5
1
O-ring
Nitril
4.3x2.4
STERIVALVE 25 (1”) S-A
Part # 104157
Pos:
Qty:
Description:
Material:
Dimension:
Note:
1
1
O-ring
Viton
17.17x1.78
2
1
X-ring
Viton
9.25x1.78
3
1
X-ring
Viton
56.75x3.53
4
1
O-ring
Viton
59.2x5.7
5
1
O-ring
Viton
12x2
6
1
O-ring
Nitril
4.3x2.4
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Steridose STERIVALVE 25 User's Installation And Operation Manual

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