Installation, Operation & Maintenance Manual

Transcription

1 Original Instructions Installation, Operation & Maintenance Manual Sentry IsoPure Sampler Aseptic Samplers S-LS-IOM

2 Table of Contents Safety Information... 3 General Safety Precautions... 4 General Description Specifications Installation Operation Maintenance Standard Warranty Customer Support Design Drawing Copyright Do not install, maintain, or operate this equipment without reading, understanding, and following the appropriate Sentry Equipment Corp instructions. Otherwise, injury, damage, or both may result by Sentry Equipment Corp. All rights reserved. All product and company names are property of their respective owners. This document contains proprietary information. No part of this document may be photocopied or reproduced without the prior written consent of Sentry Equipment Corp. Limit of Liability Sentry Equipment Corp, its employees, agents, and the authors and contributors to this document specifically disclaim all liabilities and warranties, express or implied (including warranties of merchantability and fitness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information contained herein and/or for the fitness for any particular use and/or for the performance of any material and/or equipment selected in whole or part with the user of/or in reliance upon information contained herein. Selection of materials and/or equipment is at the sole risk of the user of this publication. Note The information contained in this document is subject to change without notice. 2 Sentry Equipment Corp

3 Safety Information Please read the entire manual before attempting to unpack, set up, or operate this product. Pay careful attention to all Warnings, Cautions, and Notes. Failure to do so could result in serious personal injury and/or equipment damage. Use of Hazard Information If multiple hazards exist, the signal word corresponding to the greatest hazard shall be used. Definitions DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. NOTE Information that requires special emphasis. TIP Alternate techniques or clarifying information. SHALL: This word is understood to be mandatory. SHOULD: This word is understood to be advisory. Sentry IsoPure Sampler 3

4 General Safety Precautions Product Selection, Installation, and Use Improper selection, installation, or use can cause personal injury or property damage. It is solely the responsibility of users, through their own analysis and testing, to select products suitable for their specific application requirements, ensure they are properly maintained, and limit their use to their intended purpose. Follow proper local, state, and federal regulations for proper installation and operational requirements. Always use caution and common sense when working with any chemical. Read the product label and Material Safety Data Sheets (MSDS) carefully and follow the instructions exactly. Potential Equipment Hazards Hot surfaces! This equipment may have very hot surfaces. If an operator contacts a hot surface, injury may occur. Use protective clothing to prevent injury. If other equipment comes in contact with a hot surface, damage to the equipment may occur. Ensure the area around this equipment is kept clear to prevent this damage from occurring. High pressures! This equipment may contain fluids at very high pressures. Prior to installing, removing, or maintaining this equipment, ensure that the equipment is isolated from all connecting piping, the equipment is depressurized, the contents have been drained, and the equipment is cool. Basic safety measures When operating the sampler, the user must be familiar with the operating instructions and all applicable occupational safety, trade association, and accident prevention regulations on the correct and safe handling of the sampler. All persons instructed to commission, operate, maintain, or repair the sampler must first read and observe the operating instructions, especially the safety instructions, prior to operation. Operation is prohibited for persons under the influence of drugs. Danger of scalding and chemical burns to person from media or cleaning fluids leaking from the sampling connection and the purging connections. As such, visual checks must always be carried out. If leaks occur while the sampler is closed, the bellows must be replaced. Independent modifications to the construction of the sampler will affect its intended function, and are prohibited. 4 Sentry Equipment Corp

5 Safety at the sampler Wear safety goggles. Wear protective clothing. Wear safety boots. The following are prohibited: wearing loose hair and jewelery, including rings. modifying or disabling safety equipment, e.g., the leak drainage system. painting over or removing signs, notices, etc. operation of the sampler by unauthorized persons without proper professional qualifications. operation of the sampler when components are damaged, e.g., when the leak tell-tale indicates seal damage. The safety of the sampler may be impaired if: the sampler is converted or modified. additional equipment other than that specified or authorized by the manufacturer is used on the sampler. replacement parts other than those specified by the manufacturer are used. Basic safety measures for maintenance and servicing Maintenance on the sampler may only be performed when the sampler is cool. Clean the sampler before performing any maintenance work. All supply lines must be depressurized. Compliance with environmental protection regulations Environmental regulations regarding the prevention of waste and proper recycling/disposal must be observed during all work on and with the sampler. Sentry IsoPure Sampler 5

6 General Description The Sentry IsoPure sampler allows easy and safe sampling of liquids from closed systems such as vessels and pipelines. The aseptic, compact design provides a permanent valve integration into aseptic and hygienic production lines, eliminating the need for costly consumables. The IsoPure sampler has a dead-space-free design that can be easily cleaned and sterilized via clean-in-place (CIP) or sterilize-in-place (SIP). The PTFE bellows guarantee hermetic sealing against the environment to prevent process contamination. Specifications The following information can be found on the sampler: Part Number: IP (example) Serial number: SN (determined on delivery) 3-A marking Technical data Dimensions: Refer to Design Drawing on page 15 Weight: 2 lb (1 kg) Product-contact materials: AISI 316L Non-product contact materials: AISI 304 Product-contact seals: PTFE Pressure rating: max. 145 psi (10 bar) Continuous operating temperature: 250 F (121 C) Sterilization temperature: 275 F (135 C) for short periods (approx. 20 min.) Ambient temperature: minimum 40 F (4 C) to maximum 140 F (60 C) Product-contact surface finish: Ra 32 μin (0.8 µm) Non-product contact surface finish: : Ra 64 μin (1.6 µm) Sampler functions When the sampler opens, the PTFE bellows opens the sampler seat. When the sampler closes, the PTFE bellows seals in the sampler seat. Handwheel: Open the sampler by turning the handwheel counterclockwise. Close the sampler by turning the handwheel clockwise. Lever: Open the sampler by lifting the lever. Close the sampler by pushing the lever down. Pneumatic: The sampler is normally closed. Open the sampler by applying air to the pneumatic actuator. 6 Sentry Equipment Corp

7 Installation Read these instructions completely before proceeding to assemble, install or operate this sampler. This sampler should be installed, operated and serviced by qualified individuals. Follow proper local, state and federal regulations for proper installation and operational requirements. Sampler must not be installed, disassembled or removed from line until line is free of product, is at atmospheric pressure, all components are at a safe temperature, and all services have been shut off. Unpacking After carefully removing the sampler from its shipping carton, inspect it for any damage. If damage is evident, please contact Sentry Equipment immediately. Sampler orientation The sampler can be installed in a variety of orientations, as shown in the illustrations. Take care that the leakage port (L) is turned to the lowest point. Instructions for installing the sampler Install the sampler in a manner consistent with the design and technical specifications of both the sampler and the system in which it will be used. Ensure that there is sufficient space to install the sampler in the proper orientation. Refer to the dimensional drawings for the appropriate dimensions. Ensure that there is sufficient space for both operation and servicing of the sampler. Ensure that there is no tensile or compressive stress on the sampler body. Make sure that the flange and pipeline connections are tight. Tri-clamp Attach the sampler to the ferrule with a tri-clamp. Sentry IsoPure Sampler 7

8 Weld The actuator assembly must be removed from the sampler body prior to welding work. 1. Place the sampler in the open position and loosen the housing nut from the housing assembly. 2. Remove the entire actuator assembly with spindle and PTFE bellows from the housing, taking care not to damage the bellows. 3. To protect the sampler from distortion, install the sampler body using industry code procedures when welding. Major distortion cannot be corrected and will prevent correct operation of the sampler. 4. Reinstall the actuator assembly. 5. Actuate the sampler to ensure that it operates smoothly. Leak testing Leak test the sampler before commissioning, after any maintenance work, and during ongoing operation: 1. Check visually to confirm that the sampler is not leaking; defective seals must be replaced 2. Check the body for damage 3. Confirm all the screw fittings are fastened tightly, free of leaks, and that the pipes and screw fittings are permitted for use in the intended pressure range If the sampler leaks, check the PTFE bellows. Replace the bellows if it is defective or worn. If faults cannot be remedied by the operator, contact Sentry Equipment. Do not exceed the pressure rating indicated in the Specification section of this manual. Operation Failure to observe this warning can cause bodily risk. Before commissioning, confirm: all the screw fittings are fastened tightly and free of leaks. all the pipes and hose connections are attached. the piping and screw fittings are approved for the intended pressure range. electrical installations are protected sufficiently against potential leakage. the maximum pressure does not exceed the pressure rating indicated in the Specification section of this manual. 8 Sentry Equipment Corp

9 System cleaning is required before the product s initial run. Mode of operation Sampling 1. Clean or sterilize the sampler to plant standards Cleaning or sterilization is carried out with the sampler closed If your sampler has two connectors, attach the steam or disinfectant solution to the upper connector and allow it to flow through the sampler for one to three minutes 2. Actuate the sampler to obtain a sample 3. After sampling, clean or sterilize the sampler to plant standards Flow Coefficients Stroke % Stroke mm C V value 10% % % % % % % % % % Maintenance Maintenance and servicing schedule For proper operation of the sampler, perform cleaning and maintenance at regular intervals. Once servicing is complete, ensure that all the individual parts are re-installed properly. Only authorized, qualified personnel are permitted to work on the sampler and perform maintenance and service work. Sentry IsoPure Sampler 9

10 Independent conversions and modifications are prohibited, as they place the safety of the operating personnel and the sampler at risk. Replacement parts must meet the technical requirements of the machine manufacturer. Always use original parts. The manufacturer accepts no liability for damage resulting from the use of parts acquired from other sources. Action Person Interval Cleaning and sterilizing the sampler Operator After each product passage Entire sampler (visual check for damage) Operator Before initial use Checking hoses and their connections for Operator Before initial use damage Checking seals for deformities Operator During maintenance Replacing seals Operator When bellows fails to seal Removing the actuator for cleaning and maintenance work Sampler must not be installed, disassembled or removed from line until line is free of product, line is at atmospheric pressure, all components are at a safe temperature, and all services have been shut off. Figure 1. Figure 2. Figure 3. Figure Open the sampler. Loosen the actuator assembly using an open-end 34 mm wrench (Figure 1) 2. Unscrew the housing nut from the sampler body. (Figure 2) 3. Keep the actuator assembly from twisting by inserting a metal pin (red arrow) in the leakage port. (Figure 3) Turn handwheel clockwise until the end of travel 4. Unscrew the bellows by hand. Remove the disk (3), wave spring (2) and pressure plate (1) (Figure 4) 10 Sentry Equipment Corp

11 ÂÂ NOTE Always replace the PTFE bellows and wave spring at the same time. 5. To mount the bellows the sampler must be in the closed position. Apply a food grade anti-seize to the thread. Insert the spring washers combination (1-2-3). Thread the bellows on by hand. (Figure 4) Replace the metal pin. Turn handwheel counterclockwise to stop (Open). (Figure 3) When inserting the actuator assembly, take care to avoid damaging the PTFE bellows. 6. Insert the actuator assembly into the sampler body. Screw in the housing nut by hand (Figure 2) 7. Tighten the housing nut using an open-end 34 mm wrench with a torque of 44 ft-lb (60 Nm). (Figure 1) Cleaning Store cleaning agents in accordance with all applicable safety guidelines. When handling cleaning agents, observe the safety regulations on the cleaning manufacturer s data. Always wear rubber gloves and protective goggles during the cleaning process. Take care not to touch the sampler or the pipeline when processing warm media or during the sterilization procedure. Cleaning and CIP/SIP Before commissioning, flush the sampler with a suitable medium. Flush the inside of the sampler regularly using a suitable medium, e.g., during a product change, downtimes etc. These intervals are defined by the owner. Flush immediately once production is complete to stop the seals from sticking. This is particularly important when using sugary products. Observe the cleaning agent manufacturer s safety data. Only use cleaning agents that are not aggressive or abrasive to seals or stainless steel. The required cleaning times, temperatures, and concentrations of cleaning agent depend on the level of soiling and should be adjusted accordingly. Do not exceed the concentrations and temperatures recommended by the cleaning agent manufacturer. The Sentry Equipment warranty shall be deemed null and void in the case of damages resulting from a failure to observe these operating instructions, or unauthorized commissioning, handling, or interference from third parties. Sentry IsoPure Sampler 11

12 Permissible cleaning agents The following factors must be taken into account when selecting a cleaning agent: Do not use abrasive cleaning agents. Only use cleaning agents that do not react aggressively with the seals or stainless steel. Observe proper handling and disposal measures. Observe the safety data supplied by the cleaning agent manufacturer. When installed, the sampler must be cleaned together with the respective pipeline. The required cleaning times, temperatures, and cleaning agent concentrations depend on the level of soiling, and should be adjusted accordingly. The flow rate during cleaning must be at least 5 to 8 ft/sec (1.5 to 2.5 m/sec). Once cleaning is complete, the sampler can be sterilized using disinfectant or clean steam. Disposal The sampler is comprised of mainly steel and plastic parts, and must be disposed of in accordance with the applicable local regulations. Standard Warranty Sentry Equipment Corp ( Seller ) warrants products manufactured by it and supplied hereunder ( Products ) to be free from defects in workmanship and, to the extent materials are selected by Seller, to be free from defects in materials, in each case for a period as defined in the table below: Brand Product Line Warranty Period Sentry Steam & Water Sampling Products and Systems Solid & Powder Sampling Products and Systems Gas Sampling Products and Systems Liquid & Slurry Sampling Products and Systems Corrosion Monitoring Products Eighteen months from date of shipment or twelve months from startup (whichever occurs first) Waters Equipment Steam & Water Sampling Products and Systems To view the full warranty, go to Twelve months from date of shipment 12 Sentry Equipment Corp

13 Customer Support With proven sampling expertise since 1924, Sentry products and services provide business operations the critical insights to optimize process control and product quality. We deliver true representative sampling and analysis techniques to customers around the globe, empowering them to accurately monitor and measure processes for improved production efficiency, output, and safety. Standing behind our commitments, we are determined to tackle any application, anywhere. We know that running an efficient operation isn t easy. It requires thorough, careful analysis of controlled, real-time data achieved through reliable, accurate, and repeatable process monitoring and measuring. By effectively conditioning, sampling, and measuring gas, liquid, slurry, powder, solids, steam, or water within their production environments, our customers obtain the critical insights they need to control and optimize their processes. Yet, controlling your processes also means reliable customer support throughout the life cycle of your equipment. Customer Service General information, warranty claims, order management. Installation Service For systems that require specialized expertise upon installation. Technical Support Troubleshooting, training, and technical manuals. Field Service & Retrofits When a problem needs immediate attention. Replacements Parts & Consumables Order your replacement parts and consumables. Sentry ProShield Services Select from four ProShield Guardian service plans providing different levels of support to protect your large system investments with regularly scheduled maintenance. To learn more, go to Sentry IsoPure Sampler 13

14 Design Drawing 1 1/ / / / / / / / / / / / / / / Sentry Equipment Corp

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16 Serving customers in more than 50 countries across six continents worldwide. sentry-equip.com 966 Blue Ribbon Circle North, Oconomowoc, WI U.S.A