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DON’T GAMBLE WITH YOUR SAMPLE™

SESAME

™ 

SAMPLING VALVE

User Manual

Содержание SESAME series

Страница 1: ...DON T GAMBLE WITH YOUR SAMPLE SESAME SAMPLING VALVE User Manual ...

Страница 2: ...mp changed in 6 4 Added pressure graphs in 6 7 Spare parts list in 13 1 15 2 and 15 4 deleted as not applicable 3 February 2017 Steel plugs added in 6 3 Chapter 7 Valve Bodies added Chapter 8 Valve Heads added Chapter 9 Parts Accessories added 4 September 2017 More detailed certificate specifications Expanded temperature ranges Modified drawings for Clamp and Varivent connections Failure Mode sect...

Страница 3: ...ALVE PATENTS DK 175721 B1 CN 100501219C EP 1 690 038 B1 US 7 658 201 B2 YEAR OF INTRODUCTION 2016 MANUAL LAST UPDATED September 2017 The English version of this Manual is the governing version and it is the only authorized version Consequently KEOFITT cannot be held liable for other versions including translations of this Manual ...

Страница 4: ...SESAME USER MANUAL V 4 PAGE 4 ...

Страница 5: ...7 Parts and Accessories 15 3 8 Pressure and vacuum 15 3 9 Valve cleaning disinfection sterilisation 16 4 EVERYDAY USE OF THE VALVE 17 4 1 Batch change cleaning 17 4 2 Chemical cleaning CIP 17 4 3 Chemical Disinfection 18 4 4 Steam sterilisation 18 5 VALVE OPERATIONS 19 5 1 Chemical CIP 19 5 2 Chemical disinfection 20 5 3 Steam sterilisation 22 5 4 Sampling 24 6 TECHNICAL DATA 25 6 1 Material 25 6 ...

Страница 6: ...35 13 1 Maintainance 35 13 2 Spare parts list 35 13 3 Disassembly and assembly of valve body and head 36 13 4 Replacing a rubber membrane 36 13 5 Instructions on replacing a PTFE membrane 37 13 6 Cleaning valve head 38 14 FAILURE MODES 39 14 1 Broken membrane tip 39 14 2 Broken membrane side 39 14 3 Broken integrated o ring 39 14 4 Cleaning the valve after a failure 39 15 MEMBRANES 40 15 1 Silicon...

Страница 7: ... food beverage and pharmaceutical industries Acids An acid is a chemical substance whose aqueous solutions are characterized by a sour taste and the ability to react with bases and certain metals like calcium to form salts Aqueous solutions of acids have a pH of less than 7 A lower pH means a higher acidity and thus a higher concentration of positive hydrogen ions in the solution Removes limestone...

Страница 8: ...rrosion Resistance Exposure time Period in a sterilisation disinfection process during which the item is exposed to the sterilant disinfectant at the specific sterilisation disinfection parameters Flow path The path the sample flows from the tank or process equipment to the sample recipient Germicidal The property of an agent to destroy microorganisms Microbial load The number and types of viable ...

Страница 9: ...all forms of viable microorganisms In a sterilisation process the presence of microorganisms is expressed in terms of probability Although this probability can be reduced to a very low number it can never be reduced to zero Sterility Assurance Level The probability of a viable microorganism being present on an item after sterilisation Usually expressed as 10 n a SAL of 10 6 means 1 1 million chanc...

Страница 10: ...to remove Minerals Acids Complexing agent Often seen as lime scale Biofilm Alkali and Chlorine Peracetic acid possibly Enzymes Biofilm is an accumulated mass of microorganisms that is tightly adhered to a surface and cannot be easily removed Starch Alkali and Chlorine 2 2 Disinfection Although CIP removes all visible residues of the process media the valve surfaces will still be contaminated on a ...

Страница 11: ... 6 means that the probability or risk of a single viable microorganism being present on the valve interior afterwards is only 1 in 1 000 000 which is a generally accepted level for calling an item sterile Although the probability can be reduced to a very low number it can never be reduced to zero Sterility may in practise only be obtained by steaming Disinfectants exist that in high concentrations...

Страница 12: ...fitt Quick Coupling Mini Tri clamp Thread M16x1 5 Welding ends to weld steel tubing on All welding connector options are available with Hose Piece ports For the other port configurations only some combinations are standard but all non standard combinations are likely to be available On request All valve bodies with their various ports are machined in one piece of steel thus avoiding all crevices a...

Страница 13: ... and thus be operational under higher pressure and temperature Furthermore the steel plugs may be autoclaved For further information please consult www keofitt dk 3 5 Sampling coil When sampling beer the rapid pressure drop from inside the tank CO2 pressure of 2 3 bar to the open pressure less sample recipient causes excessive foaming even when opening the valve very slowly and very little This ph...

Страница 14: ...ne is better able to cope with the condensation in the steam and at the same time it can be used with a majority of CIP fluids and disinfectants in normal concentrations The PTFE membrane resists all CIP fluids and disinfectants except highly oxidising acids in high concentrations The FFKM covers the highest temperature range and has excellent chemical resistance to virtually any chemical compound...

Страница 15: ...cuum ratings On installations where vacuum will occur rubber membranes EPDM FFKM Silicone are at risk of being sucked hard into the valve seat whereby the valve might not open properly However the additional closing force from the vacuum corresponding to max 1 bar g or 0 bar abs is rather small 10 compared the force exerted by the spring corresponding to at least 10 bar g so there is no risk of da...

Страница 16: ...chemical detergent through the inlet port while in Clean position results in cleaning the valve CIP It is the perfect hygienic design and surface finish of the inner part of the valve which enables easy efficient and reliable cleaning in a closed state of the valve Supplying steam at the steam INLET port and setting the valve at Clean results in cleaning and sterilisation It is the perfect hygieni...

Страница 17: ...ank and clean the valve chamber and the valve seat The valve body end surface will be spray cleaned together with the tank interior PIPE to CIP return pipe Pipe mounted This cleaning method is suitable if the valve is connected to a pipe with sufficient pressure to cause an adequate flow through the valve Set the valve in Sample position and connect a hose from the outlet port to a CIP return pipe...

Страница 18: ...4 Disinfection Apply an appropriate disinfectant targeting one or more or all microorganisms 5 Final rinse Rinse with cleaned water to remove all traces of the disinfectant 4 4 Steam sterilisation Steaming has the advantage that it does flushing cleaning and sterilisation in one operation However the heat from the steam will cause sugary substances to caramelise and substances containing protein t...

Страница 19: ...mpling valve with a turn knob However the instructions also apply to pneumatic valves and valves with a handle 5 1 Chemical CIP The CIP takes place with the valve remaining in its closed position Perform the following steps n PROCESS MEDIA n CIP LIQUID n CLEAN WATER n STEAM DISINFECTANT 1 Remove the plugs if any from the INLET and OUTLET ports In the case of a valve with clamp connections there ar...

Страница 20: ...CIP perform the disinfection if required The disinfection takes place with the valve remaining in its closed position There are 2 recommended ways to carry out the disinfection A by letting the disinfectant flow through the valve chamber B by filling the valve chamber with the disinfectant advantage smaller volume of disinfectant needed and quicker and more reliable disinfection Steps to perform w...

Страница 21: ...ny hoses from the INLET and OUTLET 2 Plug the lower hose piece with a rubber plug or a steel plug In case of a valve with mini clamp connections the closing of the outlet may be obtained by using a tri clamp blind cap or by squeezing an attached piece of tubing or by any other appropriate means 3 Set the valve in its Clean position and fill the valve chamber with the disinfectant through the INLET...

Страница 22: ...pling WARNING Carefully follow the guidelines given for the chemicals involved Always remember to use safety goggles when steaming CIPping taking samples and all other operations of the sampling valve 5 3 Steam sterilisation Chemical CIP and chemical disinfection are not needed when using steam as steam does it all An exception from this is with sugary substances which caramelise and with substanc...

Страница 23: ...r valve heads allowed under ATEX for Group IIGD Category 2 zone 1 both handle and top of valve heads N and Q must be cleaned before use Always remember to wear safety goggles when steaming CIPping taking samples or any other operations of the sampling valve IMPORTANT Don t attach a steam trap to the hose from the valve steam outlet lower hose piece as it will impede the flow of steam and hence the...

Страница 24: ...o close the valve 3 Perform a post sample cleaning by flushing the valve with steam detergent or water whatever is required by the process medium Connect a hose to the outlet port in order to lead the steam detergent water to the drain Turn the turnknob or the handle anti clockwise towards Clean and flush for a sufficient time to clean the valve chamber of any sample residues usually 10 to 30 seco...

Страница 25: ...FE acc to EU10 EU1935 EU2023 FDA USP Class VI FFKM acc to FDA USP Class IV EC1935 EC2023 For more details please see the individual certificates 6 3 Pressure max Process pressure 10 bar g 145 psi g CIP SIP 6 bar g 87 psi g Rubber plug 3 bar g 44 psi g Steel plug 15 bar g 218 psi g 6 4 Temperature Steam Sterilisation using dry saturated steam at 121 C 250 F and 1 bar g Dry saturated steam at temper...

Страница 26: ...ific surface roughness certificate is supplied with every valve A general surface finish certificate copy is available on www keofitt dk 6 6 Viscosity Viscosity range 0 1000cP with particles up to 3mm in diameter Higher viscosity liquids may be sampled only will the sampling take longer 6 7 Flow The graphs below illustrate for water at 20 C 68 F the following Pressure drop across valve as a functi...

Страница 27: ...ss the valve equals the process pressure tank pressure or line pressure The volume flow through a valve is given by kv Q 1000x p ρ Symbol Unit Description kv m3 h Flow in m3 h through a valve at a pressure drop of 1 bar as defined in VDE VDI norm 2173 Q m3 h Volume flow through the valve ρ kg dm3 Density of the fluid For Water it is 1 Δp bar Pressure drop across valve As the gauge pressure at the ...

Страница 28: ...039 890022 890025 890026 890005 O n r e q u e s t O n r e q u e s t Thread M16x1 5 O n r e q u e s t 890015 O n r e q u e s t 890016 O n r e q u e s t O n r e q u e s t O n r e q u e s t O n r e q u e s t 890024 O n r e q u e s t O n r e q u e s t O n r e q u e s t Welding Ends 890007 O n r e q u e s t 890019 O n r e q u e s t O n r e q u e s t O n r e q u e s t O n r e q u e s t O n r e q u e s t...

Страница 29: ... H Turn knob 0 10bar Type Q Lever handle 0 10bar Type N Pneumatic 0 6bar Silicone 890041 890043 890044 EPDM 890041E 890043E 890044E FFKM 890041F 890043F 890044F PTFE 895541 895543 895544 For further product information material dimensions etc please refer to the specific datasheet at www keofitt dk ...

Страница 30: ...QC W9 M4 HP 550057 ADAPTER 600062 RUBBER CAP For mini tri clamp For valve heads 600170 Q HANDLE TYPE N 880255 TOOL REFLEX PTFE 890170 Q HANDLE TYPE Q Misc 890064 DOUBLE ST ST CHAIN 550002 2 PTFE W QC TC O 5M 550003 2 PTFE W QC TC 1M 900091 GASKET 1 900086 CLAMP 1 900189 CLAMP DN 10 20 900075 CLAMP 800014 MINIC 1 CLAMP 900096 ADAPTER W9 TC 900013 MINICLAMP SPIKE 550005 PTFE W TC 1 0M 550004 PTFE W ...

Страница 31: ...unctional This is obtained by the dual valve function that keeps the CIP port closed in neutral position and during sampling IMPORTANT The tank side of the valve body must be positioned flush with the inside of the tank or the pipe in order to avoid any dead space 2 3 4 5 Confidential Property of Keofitt A S Not to be handed over to copied or used by third party 2D 3D reproduction of con Title 10 ...

Страница 32: ...g result will be best if the following method is used A collar is made on the pipe section so that the valve has a flat contact face This flaring must look like a T piece as shown in the example below A A 1 2 1 1 2 2 3 3 4 4 A B C D 14 09 2016 Confidential Property of Keofitt A S Not to be handed over to copied or used by third party 2D 3D reproduction of contents to be authorized by Keofitt A S T...

Страница 33: ...L V 4 PAGE 33 12 BLOCK DIAGRAMS 12 1 Keofitt valve type T tank 2 3 4 5 6 Confidential Property of Keofitt A S Not to be handed over to copied or used by third party 2D Title 12 2 Keofitt valve type P pipe 1 2 3 4 B C D ...

Страница 34: ... 4 PAGE 34 12 3 Keofitt valve type clamp connection I order to minimise dead space the length of the connecting piece must be smaller than the internal diameter of the connecting piece A B 12 4 Keofitt valve type Varivent ...

Страница 35: ...starting with short intervals and continuously extend the time in use until one reaches the limit of the membrane s durability Based on the desired safety margin the user then decides on the replacement interval to adapt In each individual case a standard operating procedure including maintance intervals should be endorsed based on experience For disassembly of valve body and valve head see instru...

Страница 36: ...usually with Off pointing at INLET UP on the valve body 3 Mount the clamp and tighten it using a small spanner don t apply excessive force but make sure the flanges come in full mechanical contact 4 Reestablish steam or detergent disinfectant supply WARNING When replacing the membrane set the valve head in the CLEAN position during disassembly and assembly Omitting to do so may cause damage to the...

Страница 37: ...to the valve head 6 Set the valve head to OFF position 7 Place the new membrane on valve head and press the new membrane against the steel shoulder in order to allow the membrane to lock into the groove 8 For PTFE membranes Press the tip of the membrane hard against a table or similar until it clicks indicating the membrane locking into the valve stem For rubber membranes If necessary push the tip...

Страница 38: ...ompression force press the Split Pin out it is advised this job to be done by two persons 5 Release the compression force slowly until the Membrane Anchor comes loose together with a spring behind it 6 Clean and rinse all detached parts 7 Clean and rinse the Valve Head Housing and its remaining assembly 8 Allow parts to dry completely Perform assembly by following these steps 1 Align Turn Knob wit...

Страница 39: ...o take many rounds of samplings due to the short sampling time and the very low pressure on the external side of the membrane 14 3 Broken integrated o ring The even more rare incident of a broken integrated o ring will cause leakage along the inside wall of the part of the valve body on to which the valve head is clamped The integrated o ring seals between the steam CIP compartment of the valve an...

Страница 40: ...SESAME USER MANUAL V 4 PAGE 40 15 MEMBRANES 15 1 Silicone membrane art no 890051 ...

Страница 41: ...SESAME USER MANUAL V 4 PAGE 41 15 2 EPDM membrane art no 890052 ...

Страница 42: ...SESAME USER MANUAL V 4 PAGE 42 15 3 PTFE membrane art no 890055 52 mm 2 4 8 O D m m 8 0 I D mm ...

Страница 43: ...SESAME USER MANUAL V 4 PAGE 43 ...

Страница 44: ...vendborg Denmark Phone 45 6316 7080 Fax 45 6316 7081 info keofitt dk www keofitt dk Keofitt reserves the right to change technical data without notice For complete set of updated data sheets and manuals for Keofitt products please refer to our web page www keofitt dk ...

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