SIMPLEX™ SAMPLING VALVE

D O N ’ T G A M B L E W I T H Y O U R S A M P L E ™

SIMPLEX™ SAMPLING VALVE

User ManUal

DOCUMENT VERSION LOG

The table below lists previous versions of this User Manual and states the major changes between versions.This version list is introduced in November 2015.

Version # Version date Major changes from previous versions1 April 2016 Latest version without version log

INTRODUCTION: MANUFACTURER: KeofittA/S Kullinggade 31 5700Svendborg,Denmark

TYPE: SIMPLEX™SAMPLINGVALVE YEAR OF INTRODUCTION: 2007 YEAR OF REVISED DESIGN: 2014 MANUAL LAST UPDATED: Apr. 2016

TheEnglishversionofthisManualisthegoverningversionanditistheonlyauthorizedversion.Consequently,KEOFITTcannot be held liable for other versions including translations of this Manual.

CONTENTS1. PRESENTATION .............................................................................................................................7

1.1Definitionofterms ............................................................................................................................71.2Quickstart ........................................................................................................................................9

2. CLEANING – DISINFECTION – STERILISATION ..........................................................................102.1Clean-In-Place(CIP) ....................................................................................................................... 102.2Disinfection.................................................................................................................................... 10

3. VALVE FUNCTION ........................................................................................................................12

4. EVERYDAY USE OF THE VALVE ...................................................................................................134.1Pre-productiontreatment ............................................................................................................. 134.2Chemicalcleaning(CIP)anddisinfection .................................................................................... 134.3Sampling ......................................................................................................................................... 135. valve .................................................................................................................................................. 145.1 Material ........................................................................................................................................... 145.2Certificate ....................................................................................................................................... 145.3Pressure(max.) .............................................................................................................................. 145.4Surfacefinish ................................................................................................................................. 145.5Viscosity: ......................................................................................................................................... 145.6Flow ................................................................................................................................................ 15

6. VALVES .........................................................................................................................................17

7. PARTS & ACCESSORIES ..............................................................................................................18

8.MOUNTING INSTRUCTIONS ..........................................................................................................198.1 Location .......................................................................................................................................... 198.2 Before welding ............................................................................................................................... 19

9. WELDING INSTRUCTIONS ............................................................................................................209.1 Welding method ............................................................................................................................. 209.2Guidelineweldingvalues ............................................................................................................... 20

10. BLOCK DIAGRAMS .....................................................................................................................2110.1KeofittvalvetypeT(tank) ............................................................................................................ 2110.2KeofittvalvetypeP(pipe) ............................................................................................................ 2110.3Keofittvalvetypeclampconnection ........................................................................................... 2210.4KeofittvalvetypeVarivent® ........................................................................................................ 22

11. MAINTENANCE ...........................................................................................................................2311.1Sparepartslist ............................................................................................................................. 2311.2Assemblyofvalvebodyandhead .............................................................................................. 2411.3Disassemblyofvalvehead ......................................................................................................... 25

12. INSTRUCTIONS ON REPLACING PTFE MEMBRANE .................................................................26

13. UPGRADE FROM SILICONE/EPDM TO PTFE MEMBRANE ........................................................2713.1FormanuallyoperatedvalveheadstypeH,KandQ ............................................................... 27

14. MEMBRANES .............................................................................................................................2814.1Siliconemembrane-art.no.600051 ........................................................................................ 2814.2EPDMmembrane-art.no.600052 .......................................................................................... 2914.3FFKMmembrane-art.no.600053 ........................................................................................... 3014.4PTFEmembrane-art.no.850055 ............................................................................................ 31

K E O F I T T U S E R M A N U A L P A G E 7

1. PRESENTATIONTheKeofittSimplexsamplingvalveisavalve,whichcanbereadilysanitizedandwhichmeetsbothhygienicandprocessdesignrequirements.Thismeansthataneffectivecleaningofthesamplingvalvecanbecarriedoutbetweenproductionbatches.TheKeofittSimplexvalveisEHEDGTypeELauthorised.TheEHEDGTypeELcertificationisaEuropeanstandardanditincludesadditionaltestsofbacterialingressoncomponentsthatareindirectcontactwiththesampleaftertheCIPprocess.Thevalveisusedinawiderangeofprocessingindustries,suchasbreweries,dairies,andthepharmaceutical and biotechnological industries.

1.1 Definition of termsInordertoeasethereadingofthismanualandtoavoidanymisunderstanding,pleaserefertothedefinitionoftermsinthetablebelow:

TERM DEFINITION

3-ASanitaryStandard 3-ASSIisanindependent,not-for-profitUScorporationdedicatedtoadvancinghygienicequipmentdesignforthefood,beverageandpharmaceutical industries.

Acids Anacidisachemicalsubstancewhoseaqueoussolutionsarecharacterizedbyasourtasteandtheabilitytoreactwithbasesandcertainmetals(likecalcium)toformsalts.AqueoussolutionsofacidshaveapHoflessthan7.AlowerpHmeansahigheracidity,andthusahigherconcentrationofpositivehydrogenionsinthesolution.Removeslimestoneandmostmineraldeposits.

Alkali Alkalisareallbases,whichformhydroxideions(OH-)whendissolvedinwater.Theterms“base”and“alkali”areoftenusedinterchangeably.AlkalishaveapHvalueabove7.Alkalisdissolvesfatandoil,destroysproteinandattackslightmetal.

Aseptic sampling Theprocessofwithdrawingasamplefromtheproductionequipmentthroughaclosedcircuit,whichhasbeensterilisedandkeptsterilewithnoexposuretotheambientduringthesamplingprocess.

Bioload SeeMicrobialload.Bioburden SeeMicrobialload.ChemicalSterilant Afewdisinfectantswillkillsporeswithprolongedexposuretimes(3–12

hours);thesearecalledchemicalsterilants.Chlorine ChlorineisachemicalelementwithsymbolClandatomicnumber17.It

belongstothehalogengrouptogetherwithforinstanceiodine.Itisastrongoxidizingagentandreactswithmanysubstances.Thesepropertiesmakechlorinecompoundsefficientdisinfectants.

CIP AbbreviationofClean-In-Place.Theprocessofcleaningaprocesscomponent(likeasamplingvalve)withoutremovingitfromtheproductionline.

Cleaning Removal,usuallywithdetergentandwaterorenzymecleanerandwater,ofadherent visible soil on a surface.

Complexingagent Asubstancecapableofformingacomplexcompoundwithanothermaterialinsolution.Improvesthecleaningpropertiesofadetergent.

Contacttime The time span during which the item is in contact with the detergent or the disinfectant.


Enzymes Molecules,whichareaddedtocleaningagentstoeasetheremovalofspecificorganicmaterial.Assuressamecleaningeffectatalowertemperature.

Disinfectant Usuallyachemicalagentthatdestroysharmfulmicroorganismsbutmightnotkillbacterialspores.

Disinfection Thermalorchemicaldestructionofmicroorganisms.Disinfectionislesslethalthansterilisation,becauseitdestroysmostrecognisedmicroorganismsbutnotnecessarilyallmicrobialforms(e.g.bacterialspores).

Detergent Acleaningagentthathasnoantimicrobialeffect,butindilutedsolutionsgood cleaning properties.

EHEDG AbbreviationfortheEuropeanHygieneEngineeringandDesignGroup.EHEDGisaconsortiumofequipmentmanufacturers,foodindustries,research institutes as well as public health authorities promoting safe foodbyimprovinghygienicengineeringanddesigninallaspectsoffoodmanufacture.

Electropolishing Electropolishingisanelectrochemicalprocessbywhichthehighpointswithinthemicroscopicsurfacetextureareremovedandthecornersrounded.ThisresultsinReducedProductAdhesion,EaseofCleaningandImprovedCorrosionResistance.

Exposuretime Periodinasterilisation/disinfectionprocessduringwhichtheitemisexposedtothesterilant/disinfectantatthespecificsterilisation/disinfectionparameters.

Flowpath Thepaththesampleflowsfromthetankorprocessequipmenttothesample recipient.

Germicidal Thepropertyofanagenttodestroymicroorganisms.Microbial load Thenumberandtypesofviablemicroorganismswithwhichanitemis

contaminated;alsocalledbioloadorbioburden.Microorganisms Animalsorplantsofmicroscopicsize.Asusedinfoodandpharmaceutical

industries,generallyreferstobacteria,fungi,virusesandbacterialspores.Peraceticacid Acommonlyuseddisinfectant,whichisefficientatlowtemperatureand

shortcontacttime.Relativelyharmlessasitdecomposesintocarbondioxide(CO2)andwater(H2O).

Processmedia Theproductintheprocessequipmentandtheproductfromwhichasampleistaken.

Representativesample Asamplewhichwhenitreachesthelaboratoryisstillidenticaltotheprocessmedia.Asamplewhichisinnowaycontaminatedoralteredduringneitherthesamplingprocessnorthetransporttothelaboratory.

Sanitization The application of a chemical agent that reduces the number of bacterial contaminantstoasafelevelasjudgedbythepublichealthauthorities.Theofficialsanitizerprotocolindicatesthat99.999%ofthespecifictestbacteriabekilledin30secondsundertheconditionsofthetest.

SIP AbbreviationforSterilise-In-Place.Theprocessofrenderingaprocesscomponent(likeasamplingvalve)sterilewithoutremovingitfromtheproduction line.

Spores Relativelywater-poorrestingcellssurroundedbyanimperviouscellwall,whichmakesthemrelativelyresistanttodisinfectantsandsterilants.Theyaredangerousastheycansurviveinadverseconditionsandre-emergeaslive bacteria at a later stage.


Sporicidal Thepropertyofanagentthatkillsspores.Steaming The process of using saturated steam under pressure as the sterilising

agent.Sterile Stateofbeingfreefromalllivingmicroorganisms.Inpractice,usually

describedasaprobabilityfunction,e.g.,astheprobabilityofanymicroorganism surviving sterilisation being one in one million.

Sterilant Afewdisinfectantswillkillsporeswithprolongedexposuretimes(3–12hours);thesearecalledchemicalsterilants.

Sterilisation Validatedprocessusedtorenderanitemfreeofallformsofviablemicroorganisms.Inasterilisationprocess,thepresenceofmicroorganismsisexpressedintermsofprobability.Althoughthisprobabilitycanbereducedtoaverylownumber,itcanneverbereducedtozero.

SterilityAssuranceLevel

Theprobabilityofaviablemicroorganismbeingpresentonanitemaftersterilisation.Usuallyexpressedas10–n;aSALof10-6means<1/1millionchance that a single viable microorganism is present on a sterilised item.

Tensides A tenside is a surfactant that reduces the surface tension of water and assures a faster and better contact between the detergent and the soil.

1.2 Quick startThetablebelowgivesyouanoverviewoftherelevantchapterstoreaddependingontheoperationsyouwanttoperformtoobtaintherequiredhygieniclevel.

Required hygienic level

4.1Pre-

prod

uctio

n tre

atm

ent

4.2Chemical

cleaningCIP

4.3Chemical

disi

nfec

tion

4.4Steam

ing

5.1Chemical

CIP

5.2Chemical

disi

nfec

tion

5.3Steam

st

erili

satio

n

5.4Sam

pling

Cleaning

Disinfection

Sterilisation

K E O F I T T U S E R M A N U A L P A G E 1 0

2. CLEANING – DISINFECTION – STERILISATION

2.1 Clean-In-Place (CIP)Thoroughcleaningofthevalveisaprerequisiteforproperdisinfectionorsterilisation.Cleaningofthevalveistheremovalofanyvisibleresidualproduct,itbeorganicorinorganic.Itmaybedoneusingeithersteam(continuoussteamwilleventuallyleadtosterility;SIP=Sterilise-In-Place)orasuitableliquiddetergent.Cleaningistheremovalofadheringsoilfromtheenvironmentandfromtheprevioussample(totheextentithasnotbeenremovedbytherecommendedpost-samplecleaning).Cleaningisusuallyperformedbyflushingwithwaterfollowedbyathoroughwashingwithanappropriatedetergentandfinishedoffwithathoroughrinsingwithwater.Dependingontheactualprocessmediatheproperdetergentmustbedeterminedincooperationwithyourusualsupplierofdetergents.ThecompanyNovadanApS,Kolding,Denmark-www.novadan.dk,hassuppliedthegenerictablebelowforyourconvenience.

What to clean for Generic cleaning agents Comments

Fat AlkaliandTensides Heatwillfacilitatethecleaningprocessas the fat melts

Protein Alkali,Acids,TensidesandChlorine Coagulationandburningwhenheated,whichmakestheproducthardtoremove.

Sugar,Salt Waterisusuallysufficientastheproduct is water soluble

Sugarcarameliseswhenheated,turningintoahardstickysubstance,whichisdifficulttoremove

Minerals Acids,Complexingagent OftenseenaslimescaleBiofilm AlkaliandChlorine,Peraceticacid,

possiblyEnzymesBiofilmisanaccumulatedmassofmicroorganismsthatistightlyadheredtoasurfaceandcannotbeeasilyremoved.

Starch AlkaliandChlorine

2.2 DisinfectionAlthoughCIPremovesallvisibleresiduesoftheprocessmediathevalvesurfaceswillstillbecontaminatedonamicroscopiclevel.Dependingonyouractualprocessmediaitwillbenecessarytocarryoutadisinfectionoperationinordertoa)reducethemicrobialloadtoanacceptablelevel(alsoreferredtoasSanitization)orb)destroycriticalmicroorganisms,butnotnecessarilyallmicrobialforms(e.g.bacterialspores).Thedisinfectionprocessmaybecarriedoutinoneoftwowaysandtodifferentlevelsofdisinfectiondependingona)theinitialmicrobialloaddistribution,b)therequiredhygieniclevelandc)thetype,exposuretimeandconcentrationofthechemicalsused(ifusingachemicaldisinfectant):

• Bysteaming(inacontinuedprocessaftersteamcleaning)• Byapplyingoneormoresuitableliquidchemicaldisinfectants

Thereareanumberofchemicaldisinfectants.Itisimportanttochoosetherightone,therightconcentrationandcontacttimeandtherightmethodforyourcurrentapplication.Yourusualsupplierofchemicaldisinfectantscansupportyouinchoosingtherightdisinfectantforyourprocessmediaandthespecificgroupofmicroorganismsyouareaimingat.ThecompanyNovadanApS,Kolding,Denmarkhassuppliedthetablebelow,asapreliminaryindicationofwhichtypeofdisinfectanttouse:


Disinfectant

Microbes to inactivate

Halogenes(Clorine)

Peroxides(hydrogenperoxid&peraceticacid)

Alcohol(70%)

Gram-negbacteriaSalmonellaCampylobacterE.Coliandothers...

Gram-posbacteriaListeriaBacillus cereusClostridiumandothers...

Bacteria sporesBacillus cereus and others...

BacteriophageYeastFungiVirus

Legend: Efficient Limited effect Little/Noeffect

NOTE!Thefinalchoiceofdetergent,disinfectantandmethodlieswiththeuser,supportedbythesupplieroftheCIPfluidsanddisinfectants,asitisverymuchdependantonindividualconcernsand circumstances.


3. VALVE FUNCTIONThevalveisdesignedtoregularlytakerepresentativenon-sterilerandomsamplesintheproductionprocess. The valve is therefore designed such that effective cleaning and sampling can be carried out. Forsterilesampling,pleaserefertootherKeofittsamplingvalvessuchasKeofittW9orKeofittReflex.CleaningiscarriedoutbysimplyopeningthevalveduringtheCIPprocessallowingthecleaningagentstoflowthroughthevalveanditsoutlet,whichshouldbeconnectedtoaby-passlooporotherclosedcircuittopreventtheoperatorfrombeingexposedtotheCIPliquid.

NOTE!Themembranefunctionsbothasadynamicpackinginthevalveseatandasahygienic,staticpackingagainstthevalvebody.

WARNING• Thevalveisdesignedforuseinworkingconditionsofupto6bar(g)pressureandtemperatures

ofupto121C.Itisthereforeimportanttobeawarethattherubberplug(designedformax.3bar(g))orthesteelplug(designedformax.10bar(g))maybeforcedoutathighspeed,ifnotseatedproperly

• AlwaysremembertousesafetygoggleswhenCIPping,takingsamplesandallotheroperationsof the sampling valve

IMPORTANT• IfvacuumoccursduringtheprocessitispreferabletousePTFEmembranesasrubber

membranesrisktobesuckedhardintotheseat.Neveropensamplingundervacuumconditionsduetothehighriskofcontaminatingtheprocess.

• Themembraneisavailablein3differentqualities:Silicone,EPDMandPTFE• TheSiliconemembranehastheadvantagethatitingeneralcanwithstandhightemperatures,

but it cannot tolerate moisture condensation resulting from steam sterilisation• TheEPDMmembraneisbetterabletocopewiththecondensationinthesteamandat

thesametimeitcanbeusedwithamajorityofCIPfluidsanddisinfectantsinnormalconcentrations

• ThePTFEmembraneresistsallCIPfluidsanddisinfectantsexcepthighlyoxidisingacidsinhighconcentrations


4. EVERYDAY USE OF THE VALVEThischaptergivesanintroductiontohowthesamplingvalveworksindifferentoperatingconditions.Forspecificoperatorinstructionspleaserefertothechapter“VALVEOPERATIONS”.

4.1 Pre-production treatmentBeforeeverynewproductionbatchthesamplingvalveiscleaned(andpossiblydisinfected)togetherwiththetankorvesselortheentireproductionline.MakesurethevalveisinitsopenpositionduringtheinitiallineCIPtoallowcleaningofthevalveseatand the membrane contact surface. ConnectareturnhosetothevalveoutletporttoleadtheCIPfluidbackintotheCIPcircuit.Remembertoclosethevalveafterthefinalrinseandpriortostartingupthenextproductionbatch.

4.2 Chemical cleaning (CIP) and disinfectionThevalvechamberandthevalveportmustbecleanedbothimmediatelyafterandbeforeeachsampling.Cleaningafterthesamplingistoremoveanyproductresiduesbeforetheysticktothevalveinterior.Cleaningbeforesamplingistoreducetheriskofcontaminatingthesample(andpossiblytheproductionbatch)byremovinganyairborneorothercontaminantsthatmighthavesettledonthevalvesincethelastsamplewastaken.Cleaningiscarriedoutbysquirtingajetofcleaningagentintothevalveport.Similarlydisinfectioniscarriedoutsquirtingadisinfectantintothevalveport.Rinsingisdoneinthesamewayusingcleanwaterorsimilar.

Just prior to sampling the valve port is cleaned

4.3 SamplingOncethecleaningisaccomplishedtakingasampleisdonebyopeningthevalveandclosingitagainwhentheriquiredsamplevolumeisobtained.

•


5. VALVE

5.1 MaterialValvebody: AISI316L(1.4404)Valvehead: AISI316L(1.4404)Membrane: Silicone(grey)

EPDM(black) PTFE(white)

5.2 CertificateValvebody: 3.1Membrane: Silicone acc.toFDA&BGA

EPDM acc.toFDA&BGA PTFE acc.toFDA&BGA

*A6-digitcodeismarkedonthevalvebody.Thiscodereferstoa3.1certificatewhichaccompanieseveryconsignmentofvalvebodies.The3.1certificateisavailableattheKeofittOnlineServiceCenteronwww.keofitt.dk.ClickCertificatesandthen3.1.

5.3 Pressure (max.)Workingpressure: 6bar(g)/87psi(g)Rubberplug 3bar(g)/44psi(g)Steelplug 15bar(g)/218psi(g)

5.4 Surface finishInternal: Electropolished

Ra<=0.5µm/20µinch Ra(mean)=0.2µm/8µinch Ra(std.deviation)=0.08µm/3µinch

ValveswithinternalelectropolishingareidentifiedbyanEprecedingtheserialnumbere.g.E12345678

External: Electropolished The surface roughness is measured for each valve at 4 critical places. Aserialnumberidentifieseachvalvebody.Aspecificsurfaceroughnesscertificateissuppliedwitheveryvalve.Ageneralsurfacefinishcertificatecopyisavailableonwww.keofitt.dk

5.5 Viscosity:Viscosityrange: 0-1000cP,withparticlesupto3mmindiameter. Higherviscosityliquidsmaybesampled,onlywillthesamplingtakelonger.


5.6 FlowThegraphsbelowillustrate(forwaterat20°C/68°F)thefollowing:

• PressuredropacrossvalveasafunctionoftheflowfordifferentpositionsoftheturnknobBasedonthetankpressureandtherequestedsampleflowthegraphsmaybeusedtogetanindicationof to which degree the valve must be opened.

Thegenerallyacceptedsamplingtimeisaround10sec.forsmallsamplesandaround30sec.forlarg-ersamples.Asusualsamplesizesarebetween100mland1000mltheneededflowliesfrom600to2000ml/min.Asthepressureonthesamplesideusuallyis0bar(g)thepressuredropacrossthevalveequalstheprocesspressure(tankpressureorlinepressure).

Thevolumeflowthroughavalveisgivenby:

�

kv = Qρ

1000 × ∆p

Symbol Unit Description

�

kvm3/h Flowinm3/hthroughavalveatapressuredropof1barasdefinedinVDE/

VDInorm2173.

�

Q m3/h Volumeflowthroughthevalve

�

ρ kg/dm3 Densityofthefluid.ForWateritis1.

�

∆p bar Pressuredropacrossvalve.Asthegaugepressureatthevalveoutletusuallyis0bar(g)thepressuredropisoftenequaltothegaugepressureattheinput(theprocessside)


WARNING• Thevalveisdesignedforuseinworkingconditionsofupto6bar(g)pressureandtemperatures

ofupto121C.Itisthereforeimportanttobeawarethattherubberplug(designedformax.3bar(g))orthesteelplug(designedfor10bar(g))maybeforcedoutathighspeed,ifnotseatedproperly

• ForvalveheadsallowedunderATEXforGroupIIGD,Category2(zone1)bothhandleandtopofvalve heads N and Q must be cleaned before use

• Alwaysremembertowearsafetygoggleswhensteaming,CIPping,takingsamplesoranyotheroperations of the sampling valve

IMPORTANT• CIPfluidsarehazardous


6. VALVES

Forfurtherproductinformation-material,dimensionsetc.-pleaserefertothespecificdatasheetatwww.keofitt.dk


7. PARTS & ACCESSORIES

Forfurtherproductinformation-material,dimensionsetc.-pleaserefertothespecificdatasheetatwww.keofitt.dk


8.MOUNTING INSTRUCTIONS

8.1 LocationThevalveshouldalwaysbelocatedwithitscentrelineinahorizontalpositionandwiththehosepieceinaverticalpositionpointingdownwardsasshownonthefigure.Onlywiththisorientationthevalvewillbe self draining.

8.2 Before weldingRemembertodisassemblethevalvebodyandhead.Thevalvebodyandheadmustbeseparatedduringwelding.Rubberplugs,chainandmembranemustberemovedfromthevalvebody,asotherwiseheat from the welding process will damage them.


9. WELDING INSTRUCTIONS

Valvesforweldingareavailableintwotypes:T(tank)andP(pipe).1. FortypeT(tank)itisnecessarytodrillaholeø28mmintothetankwall,andthenfitthe

valveintothisholeflushwiththeinsideofthetank.Weldingshouldbecarriedoutasapenetration welding. Materialthicknesslessthan4mm:Weldfrominside.Materialthicknessgreaterthan4mm:Weld from both outside and inside. SincetypeThasasolidendpiece,thevalvewillnotbedamagedbypenetrationwelding.However,theuseofpurgegasintheformofeitherArgonorFormiergasisrecommendedinorder to give the best result.

2. FortypeP(pipe)penetrationweldingmustbecarriedoutfromoutside.Thevalveismachinedwitharecess-likeshoulderontheoutsideoftheendpiecewhichgivesapproximatelythesamematerialthickness(1.5mmmaterialthickness)asinthepipewall. Thismachinedshouldercanbemodifiedaccordingtothecustomer’swishes.

IMPORTANT!• Whengrinding/polishingtheinternalweld,thevalveseatmustnotbetouched.

9.1 Welding methodTheweldingresultwillbebestifthefollowingmethodisused:Acollarismadeonthepipesectionsothatthevalvehasaflatcontactface.ThisflaringmustlooklikeaT-piece,asshownintheexamplebelow.

• Thepipesectionandthevalve’shosepiecesaresealedwithspongerubberorsimilar.• PurgegassuchasArgonorFormiergasisfedthroughthevalvebodyintothepipesectionand

thesystemisnowfilledwith6timestheestimatedvolumeofthepipesection.AllO2 is thus expelledfromthesystemandweldingcancommence.

• Weldingmusttakeplaceonlywiththepurgegascontinuallyflowinginthesystem.• Thegasremainsinthesystemuntiltheitemislukewarm,afterwhichtheset-upcanbe

dismantled.

9.2 Guideline welding valuesSimplex™samplingvalveweldedontoa2mm3”dairypipe:50-60Amp.ItshouldbenotedthatKeofittcansupplyallPtypevalvesweldedontoapipesectionaccordingtocustomerspecifications.Flaringisthusavoidedandonlyagirthweldisrequired.


10. BLOCK DIAGRAMS

10.1 Keofitt valve type T (tank)

10.2 Keofitt valve type P (pipe)


10.3 Keofitt valve type clamp connection

10.4 Keofitt valve type Varivent®


11. MAINTENANCETherubbermembraneshouldbereplacedeveryothermonth.PTFEmembranesshouldbereplacedevery12months.Intheeventofintensivesterilisationandcleaningitmaybenecessarytoreplaceitmorefrequently.Theappropriatereplacementfrequencyshouldbedeterminedbytheuserbystartingwithshortintervalsandcontinuouslyextendthetimeinuseintilonereachesthelimitofthemembrane’sdurability.Basedonthedesiredsafetymargintheuserthendecidesonthereplacementinterval to adapt.Fordisassemblyofvalvebodyandvalvehead,seeinstructions.

11.1 Spare parts list

1. Valvebody2. MembraneSilicone(grey)MembraneEPDM(black)MembranePTFE(White)3. Lowerstem(slightlydifferentshapeforPTFEmembrane)4. Steelbushing5. Spring6. Turnknob7. Tommybar


11.2 Assembly of valve body and head

Inordertodissassembleandassemblethevalvebodyandvalveheadpleaseperformthefollowingoperations:

1. SetthevalveheadattheOPENposition.FortypesHandKthisisdonebyturningpos.6clockwise.

2. Removethevalveheadpos.8.DON’Tuseawrench.Atommybarpos.7shouldbeusedfordisassemblyandassembly.Thisiscarriedoutbyturningpos.8anti-clockwiseuntillooseand then pulling the valve head off.

3. Refitthevalvehead(intheOPENposition)oncethenecessarypartshavebeenreplaced.Careshouldbetakennottodamagethethreads.Usesuitablelubricant.

WARNING!• Whenreplacingthemembrane,setthevalveheadintheOPENpositionbeforeitisunscrewed

andpulledoutofthevalvebody.Omittingtodosomayresultintwistingandcuttingofthemembrane.

• Don’tcleanthevalveheadinanultrasonicbathorbyimmersingitinadegreasingliquid,asitwillimpedetheproperfunctioningofthescrewaction.Whenindoubt,contactyourlocalKeofittdealer


11.3 Disassembly of valve headOvertimetheturnknobmaybecomehardertoturn,whichmayberemediesbyregreasingthethreadedpartoftheturnknob.Performthefollowingstepstotakethevalveheadapartafterhavingseparateditforthevalvebodyasexplainedinchapter11.2:

• Setthevalveheadinclosedposition• Pulloffthemembrane• Removethebushing• Fixthelowersteminaviceusingsoftjaws• Unscrewthevalveheadtopusingthetommybar(holditbackwhenitgetsloose,asthespring

willpushitout)• Pullbytheknobtoseparateitfromtheunionnut• Unscrewtheupperstemfromtheturnknob• Lubricatetheupperstem’sthreadedpartincontactwiththeturnknob

Assemblyisthesameinreverseorder,butpleasenote:• Discardthemembraneandreplacewithanewone• Pushthemembraneandthebushingtogethersothatthemembraneissituatedagainstthe

shoulder of the bushing


12. INSTRUCTIONS ON REPLACING PTFE MEMBRANE Toremoveanoldmembranefromthevalvehead:

1. OPENthevalve(leverpositionasinillustrationA).2. Unscrewthevalveheadfromthevalvebodyasdescribedinchapter13.2.3. CLOSEvalvehead(illustrationA).4. Pushthemembraneandbushingapart(illustrationB)untilthetoolformembranefitsunder

it. 5. Inserttoolformembrane,betweenthemembraneandthebushing(illustrationB).6. OPENvalvehead(illustrationC).7. Now the membrane is loosened from the valve head and can be replaced.

Toattachanewmembranetothevalvehead:8. SetthevalveheadtoCLOSEDposition(leverpositionasinillustrationB).9. Placethenewmembraneonvalvehead.10. MountthemembranebushingwiththenewTeflonmembranebypressingthemembrane

withyourhanduntilitclicks.11. SetthevalveheadinOPENposition.12. Insertthevalveheadintothevalvebody.13. CLOSEvalvehead.

IMPORTANT

• Oncethemembranehasbeenremovedfromthevalveheadtheclicksysteminthemembranemight be damaged. Therefore the membrane might be unsafe for further use and it is recommended not to use the membrane again.

• Donotusehammerorothertoolthatmightscratchthesurfaceofthemembrane.

A. B. C.


13. UPGRADE FROM SILICONE/EPDM TO PTFE MEMBRANE

13.1 For manually operated valve heads type H, K and Q

1. Closevalve.2. Pulloffthesilicone/EPDMmembrane.3. Takethebushingoff.(page30,pos.5)4. Putthevalveheadinvice.5. Turnthehex-nutcounterclockwiceuntilthemembraneseatandspringareloose.Putthe

newlowerstemforPTFEmembraneinthevice.6. Fitthenewspringonthenewlowerstem.7. Inserttherestofthevalveheadinthepinandpressfirmly.8. Turnthehex-nutclockwiseuntilthelowerstemisfirmlyinplace.Careshouldbetakennotto

damage the threads.9. Putthebushingoverthespring,thenplacePTFEmembraneonthelowerstemandpress

firmlyuntilitclicksinplace.10. Putthevalveheadinopenposition.11. Putvalveheadinvalvebodyandtighten.

IMPORTANT• Thisisadelicateproceduretobeperformedbyskilledpersonnelonly.• Usevicewithaluminiumgrips,toavoidscratchinganddamagingthevalvehead.• UsethespringsuppliedwiththePTFEkit.PTFEmembranesrequireadifferenttypeofspring

thanEPDMandsiliconemembranes.• Donotusehammerorothertoolthatmightscratchthesurfaceofthemembrane.

Upgrade kit 854155 consisting of:

Ident no. Part name Material

600340 LowerstemforPTFE AISI316L(1.4404)

850055 MembraneforW9™&Simplex™ PTFE

600411 SpringH-Q-K12bar(g) St.St.


14. MEMBRANES

14.1 Silicone membrane - art. no. 600051

Last updated 22-01-2015*For further information please visit keofitt.dk

10 PC MEMBRANE W9/SIMPLEX SILICONE, GREY ART. NO. 600051

GENERAL

KEOFITT has the widest selection of spare parts and accessories to complete your sampling system

Compatible with all KEOFITT W9 & Simplex valve heads for silicone, EPDM & FFKM membrane


CERTIFICATION*FDA · USP · EU 1935/2004

TECHNICAL DATAType: Hardness (°Sha):Tensile strength (MPa):Elongation at break (%):Density (g/cm3): Range of temperature in dry atmospheric air (°C/°F):Compression set, DIN 53517, 24h/175°C (%): Wear resistance:Tear resistance:Resistance to Weather and Ozone:Resistance to Hydrolysis (water and steam):Resistance to Chemicals (acids/bases):Resistance to mineral oil and gas:Air and gas density:

Silicone (QBF-65 - grey)70 ±3Min. 8,5550 ±801,19 ±0,01 -60° - +200°C / -140° - +392° Max. 25 Less suitableVery goodExcellentGoodSuitableLess suitableNot suitable

Net Weight· Kg/lbs 0,030 kg /0,07 lbs

The patented membrane design is an essential part of the hygienic design of the KEOFITT sampling valves

It allows for optimal exposure to CIP and SIP media while also integrating the capacity to remove the membrane from the valve body without the use of tools

FEATURES

SERVICE LIFE Average service life of a Silicone membrane is 2-3 months - actual life expectancy must be experimentally determined by the user. Temp. max.:Steam pressure:Process pressure:CIP:Samples:

121°C / 250°F0 - 2 bar (g) / 0 - 29 psi (g)0 - 6 bar (g) / 0 - 87 psi (g)NaOH or similar1-5 a day

27,0 mm

10,9

I. D. mm17,5

O. D.

mm 17,5

mm


14.2 EPDM membrane - art. no. 600052


10 PC MEMBRANE W9/SIMPLEX EPDM BLACK ART. NO. 600052

GENERAL





TECHNICAL DATAType: Hardness (°Sha):Tensile strength (MPa):Elongation at break (%):Density (g/cm3): Range of temperature in dry atmospheric air (°C/°F):Compression set, DIN 53517, 24h/175°C (%): Wear resistance:Tear resistance:Resistance to Weather and Ozone:Resistance to Hydrolysis (water and steam):Resistance to Chemicals (acids/bases):Resistance to mineral oil and gas:Air and gas density:

EPDM (EPL-60 - black)61 ±3Min. 16400 ±501,12 ±0,01 -40° - +140°C / -40° - +284° FMax. 16 Very goodVery goodExcellentExcellentVery goodNot suitableLess suitable




FEATURES

SERVICE LIFE Average service life of an EPDM membrane is 2-3 months - actual life expectancy must be experimentally determined by the user. Temp. max.:Steam pressure:Process pressure:CIP:Samples:

121°C / 250°F0 - 2 bar (g) / 0 - 29 psi (g)0 - 6 bar (g) / 0 - 87 psi (g)NaOH or similar1-5 a day

27,0 mm

17,5

mm

10,9

I. D. mm

17,5

O. D.

mm


14.3 FFKM membrane - art. no. 600053


MEMBRANE W9 & SIMPLEX FFKM, WHITE ART. NO. 600053

GENERAL





TECHNICAL DATAType: Hardness (°Sha):Tensile strength (MPa):Elongation at break (%):Density (g/cm3): Range of temperature in dry atmospheric air (°C/°F):Compression set, D395 70h/200°C (%): Wear resistance:Tear resistance:Resistance to Weather and Ozone:Resistance to Hydrolysis (water and steam):Resistance to Chemicals (acids/bases):Resistance to mineral oil and gas:Air and gas density:

FFKM (Perfluorelstomer)70 ±5131302,41 1° - +270°C / 34° - 518°F24 ExcellentExcellentExcellentExcellentExcellentExcellentExcellent




FEATURES

SERVICE LIFE Average service life of a FFKM membrane is 12 months (or more) - actual life expectancy must be experimentally determined by the user. Temp. max.:Steam pressure:Process pressure:CIP:Samples:

250° C / 482° F0 - 2 bar (g) / 0 - 29 psi (g)0 - 6 bar (g) / 0 - 87 psi (g)NaOH or similar1-5 a day

27,0 mm

17,5

mm

17,5

O. D. mm

10,9

I. D.

mm


14.4 PTFE membrane - art. no. 850055


MEMBRANE W9/SIMPLEX PTFE ART. NO. 850055

GENERAL


Compatible with all KEOFITT W9 & Simplex valve heads for PTFE membrane

Compatible with all KEOFITT W9 & Simplex valve heads for PTFE membrane


TECHNICAL DATAMaterial:Range of temperature in dry atmospheric air:Ball hardness (N/mm2):Tensile strength (DIN53455 - N/mm2):Elongation at break (DIN53455 - %): Density (DIN 53479 - g/cm3):Shore D (DIN 53505): Thermal conductivity (W/m.k DIN 52612):Expansion coefficient (DIN 53752 [K^-1]):Flammability:Chemical resistance:

PTFE (TFM 1600 - white)-200° - +200°C / -328° - +392°2935350 2,1757 0,2212-17x10^-5Inflammable UL 94Is not attacked by common chemicals with the exception of strongly oxidising acids




FEATURES

SERVICE LIFEAverage service life of a PTFE membrane is 12 months - actual life expectancy must be experimentally determined by the user.Temp. max.:Steam pressure:Process pressure:CIP:

1 - 150°C / 34 - 302° F0 - 2 bar (g) / 0 - 29 psi (g)0 - 6 bar (g) / 0 - 87 psi (g)NaOH or similar

32,0 mm

11,5I. D.

mm17,9

O. D. mm

KEOFITT A/SKullinggade 31DK-5700 SvendborgDenmark

Phone +45 6316 7080Fax +45 6316 7081

[email protected]

Keofittreservestherighttochangetechnicaldatawithoutnotice!ForcompletesetofupdateddatasheetsandmanualsforKeofittproductspleaserefertoourwebpagewww.keofitt.dk

SIMPLEX™ SAMPLING VALVE

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