Steridose STERIVALVE 25 User's Installation And Operation Manual

STERIVALVE®

Installation and operation manual

(Including welding guideline)

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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:

Material:

Dimension:

Note:

1

O-ring

Viton

16.1x1.6

2

1

X-ring

Viton

9.25x1.78

3

1

Compact seal

Nitril

32

4

1

O-ring

Viton

34.65x1.78

5

1

O-ring

Viton

3.1x1.6

6

1

Pressure plate

316 L

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

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

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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