Keofitt W9 User manual

SOME PEOPLE WOULDN’T GAMBLE WITH THEIR SAMPLETM
User ManUal
W9™ SAMPLING VALVE
www.sks-online.com
www.sks-webshop.com

www.sks-online.com
www.sks-webshop.com

INTRODUCTION:
MANUFACTURER: Keott a/s,
Lumbyvej 11H
5000 Odense C
Denmark
TYPE:
W9 SAMPLING VALVE
PATENTS:
U.S. PAT. 5,246,204 • E.P. 0468957
YEAR OF INTRODUCTION: 1998
YEAR OF REVISED DESIGN: 2003
www.sks-online.com
www.sks-webshop.com

www.sks-online.com
www.sks-webshop.com

CONTENTS
Presentation...................................................................................................................................................................7
Valve function.................................................................................................................................................................7
Everyday use of the valve ..............................................................................................................................................8
Sterilisation .......................................................................................................................................................................... 8
Sampling .............................................................................................................................................................................. 8
Technical Data ...............................................................................................................................................................9
Material ............................................................................................................................................................................. 9
Certicate............................................................................................................................................................................. 9
Pressure - max. ................................................................................................................................................................. 9
Temperature - max. .......................................................................................................................................................... 9
Surface nish Ra ................................................................................................................................................................. 9
Viscosity: .............................................................................................................................................................................. 9
Valve bodies W9.......................................................................................................................................................... 10
Valve Heads for W9..................................................................................................................................................... 12
Parts and accessories for W9.................................................................................................................................... 13
Mounting instructions................................................................................................................................................ 14
Location:.............................................................................................................................................................................14
Before welding: ..................................................................................................................................................................14
Welding instructions: ................................................................................................................................................. 14
Block diagram for welding to pipe and tank ............................................................................................................ 15
Keott valve type P (pipe): ................................................................................................................................................15
Keott valve type T (tank): ................................................................................................................................................15
Keott valve type P (pipe connection vertical) Inline: .....................................................................................................15
Block diagram for installation with Clamp,Varivent® and Thread ......................................................................... 16
Keott valve type Clamp connection:...............................................................................................................................16
Keott valve type Varivent®:.............................................................................................................................................16
Keott valve type Thread:..................................................................................................................................................16
Maintenance ............................................................................................................................................................... 17
Spare parts list .................................................................................................................................................................. 17
Disassembly and assembly of valve body and head....................................................................................................... 17
Instructions on replacing PTFE membrane .............................................................................................................. 18
Upgrade from silicone to PTFE membrane............................................................................................................... 19
Upgrade from silicone to PTFE membrane............................................................................................................... 20
www.sks-online.com
www.sks-webshop.com

www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 7
PRESENTATION
The Keott W9™ sampling valve is a valve which can be readily sterilised and which meets both hygienic and process design
requirements. This means that an effective cleaning and sterilisation of the sampling valve can be carried out between random
samples independently of the course of the production process without compromising the same.
The W9 valve is 3-A and EHEDG Type El authorised. 3-A Sanitary Standard is an American standard which is normative for a
component’s ease of cleaning and sterilisation. The standard ensures optimum conditions for food products which may come
into contact with the component in question. The EHEDG Type El certication is a European standard and it includes additional
tests of bacterial increase on components that are in direct contact with the sample after the CIP process.
The valve is used in a wide range of processing industries, such as breweries, dairies, and the pharmaceutical and biotechno-
logical industries.
VALVE FUNCTION
The valve is designed to regularly take representative random samples in the production process. The valve is therefore de-
signed such that effective cleaning, sterilisation and sampling can be carried out regularly without interrupting the production
process.
Sterilisation is carried out by supplying steam through the upper of the valve’s two hose pieces. It is the perfect, hygienic design
and surface nish of the inner part of the valve which enables absolute sterilisation in a closed state. According to an EHEDG-
based test carried out by the Biotechnological Institute in Denmark, the valve is sterilised after just 1 minute’s supply of steam
at a pressure of 2 bar(g) (121°C).
Following sterilisation, but prior to sampling, a sterile plug of rubber or stainless steel is tted to the top hose piece. When the
valve is opened the liquid will run out of the lower hose piece.
Note! The membrane functions both as a dynamic packing in the valve seat and as a hygienic, static packing against the valve
body.
WARNING!
• During sterilisation with steam the valve will become hot, and care should thus be taken when handling the valve.
• The valve is designed for use in working conditions of up to 6 bar(g) pressure and temperatures of up to 121°C. It
is therefore important to be aware that the rubber plug (designed for max. 3 bar(g)) or the steel plug (designed for
max. 10 bar(g)) can be forced out at high speed if not seated correctly.
• Always remember to use safety goggles when taking samples because of the risk to the eyes.
IMPORTANT!
• The valve cannot be used for vacuum since the membrane will be sucked hard into the seat.
• The membranes are available in three different qualities: silicone, EPDM and PTFE.
• The silicone membrane has the advantage that it in general can stand higher temperatures, but it cannot tolerate
moisture condensation resulting from steam sterilisation.
• The EPDM membrane is better able to cope with condensation in the steam, and at the same time can be used
with a majority of CIP uids.
• The PTFE membrane resists most CIP uids and very high steam temperatures.
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 8
EVERYDAY USE OF THE VALVE
Sterilisation
Sterilisation takes place with valve closed.
1. Remove the plugs.
2. Connect the steam hose to the valve’s upper hose piece.
3. Open the steam supply and let it ow through the valve for sterilisation. 1 min. at 121°C (2 bar(g)).
4. Close the steam supply.
WARNING!
• During sterilisation with steam the valve will become hot, and care should thus be taken when handling the valve.
• The valve is designed for use in working conditions of up to 6 bar(g) and temperatures of up to 121°C. It is
therefore important to be aware that the rubber plug (designed for max. 3 bar(g)) or the steel plug (designed for
max. 10 bar(g)) can be forced out at high speed if not seated correctly. Therefore always remember to use safety
goggles when taking samples because of the risk to the eyes.
• For valve heads allowed for Group IIGD, Category 2 (zone 1) both handle and top of valve heads N and Q must be
cleaned before use.
• Use saturated steam without condensation at max. 2 bar(g). At higher pressures the membrane can be
damaged/split. In most cases the coaxial design ensures absolute cleanliness without the use of CIP or similar. If
CIP is used, please refer to enclosed data sheet. If in doubt, contact Keott.
IMPORTANT!
• To reach 121ºC a pressure of 2 bar(g) is needed. This can only be reached by use of a pressure release valve, or
other counter pressure device mounted on the outlet connection.
• Let steam hose be in place to prevent air contamination during sampling. If removal of steam hose is required, t
a sterile rubber or stainless steel plug onto the upper hose piece.
Sampling
1. Open the valve and take the sample.
2. Shut the valve after the sample has been taken.
3. Clean the valve with steam and/or hot water, cf. ’sterilisation’, points 1-4.
Sterilisation Sampling
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 9
TECHNICAL DATA
Material
Valve body: AISI 316L (1.4404)
Valve head: AISI 316L (1.4404)
Membrane: Silicone (grey)
EPDM (black)
PTFE (white)
Certicate
Valve body: 3.1 ®
Membrane silicone acc. to FDA & BGA
Membrane EPDM acc. to FDA & BGA
Membrane PTFE acc. to FDA & BGA
* A 6-digit code is marked on the valve body. This code refers to a 3.1 certicate which accompanies every
consignment of valve bodies.
Pressure - max.
Working pressure: 6 bar(g) / 87 psi(g)
Rubber plug 3 bar(g) / 44 psi(g)
Steel plug 10 bar(g) / 145 psi(g)
Temperature - max.
Sterilisation temp.: 121°C / 249,80°F **
** It is important that the steam is saturated, but dry, as condensation can damage the membrane. (Dry steam
at max. 2 bar(g)).
Surface nish
Internal: Ra <0,5 µm/20 µinch
External: Electropolished
Every valve is Ra measured.
A serial number identies each valve body. A surface nish certicate copy is available on www.keot.dk
Viscosity:
Viscosity range: 0-1000cP, with particles up to 3mm in diameter.
Kv: Valve capacity [m3/h]
Cv: Valve capacity [USgal/min]
Q: • Flow through valve seat [m3/h]
p: • Viscosity of uid [kg/m3]
p: • Presure drop across valve [bar]
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 10
VALVE BODIES W9
Hose piece Mini tri-clamp M16x1,5
Tank welding (type T) - process connection
850001 850006 850015
Key measurements
(Please refer to bottom page 11!)
B C D E B C D E B C D E
9 mm 8 mm
28 mm
68,22 mm
9 mm 8 mm
28 mm
122,1 mm
9 mm 8 mm
28 mm
69,1 mm
Pipe welding (type P) - process connection
850011 850010 850016
Key measurements
(Please refer to bottom page 11!)
B C D E B C D E B C D E
9 mm 8 mm
25 mm 68 mm
9 mm 8 mm
25 mm
122 mm
9 mm 8 mm
25 mm 69 mm
Pipe welding (type P) - NW25 - process connection
850014
Key measurements
(Please refer to bottom page 11!)
B C D E
9 mm 8 mm
28 mm 68 mm
Clamp - connection 1” - process connection
850021 850022 850024
Key measurements
(Please refer to bottom page 11!)
B C D E B C D E B C D E
9 mm 8 mm
50,4 mm
68 mm
9 mm 8 mm
50,4 mm
122 mm
9 mm 8 mm
50,4 mm
69 mm
Clamp - connection 2” - process connection
850003 850005
Key measurements
(Please refer to bottom page 11!)
B C D E B C D E
9 mm 8 mm
64 mm 68 mm
9 mm 8 mm
64 mm
122 mm
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 11
Hose piece Mini tri-clamp M16x1,5
Varivent® Ø50 - process connection OD Ø56 mm
850008
Key measurements
(Please refer to bottom page 11!)
B C D E
9 mm 8 mm
56 mm 68 mm
Varivent® Ø68 - process connection OD Ø68 mm
850009
Key measurements
(Please refer to bottom page 11!)
B C D E
9 mm 8 mm
68 mm 68 mm
Thread - Socket - process connection OD M28x1,5
850031
Key measurements
(Please refer to bottom page 11!)
B C D E
9 mm 8 mm
28x1,5 mm
68 mm
In-line - Vertical/Horizontal - OD12x1 - 1”
On request On request On request
Key measurements
(Please refer to bottom page 11!)
B C F* E B C F* E B C F* E
9 mm 8 mm
variable
68 mm
9 mm 8 mm
variable
122 mm
9 mm 8 mm
variable
69 mm
Dimension ’’A’’ varies according to the type of valve head mounted on the valve body. ’’A’’ is the same dimension for all valves except type N.
Patent: É.P.0468957 and U.S.Pat.5,246,204
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 12
VALVE HEADS FOR W9
Available with:
Valve head
item no.
Silicone 600051 Silicone 600251 EPDM 600052 EPDM 600252 PTFE 850055
Type H, manually
operated
600041
600041E
855541
Type K, manually
operated key version
600042
600042E
855542
Type Q, manually
operated with lever
600043
600043E
855543
Type N, pneumatically
activated
600044
600044E
855544
Type B, pressure
resistant up to 12
bar(g)
600047
600047E
855547
Type H, with Micro
Port
600048
600048E
÷
Type H, with Micro
Port and key
600049
600049E
÷
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 13
PARTS AND ACCESSORIES FOR W9
Item Material Ident no. Remark
Membrane EPDM black EPDM 600052
Membrane silicone grey Silicone 600051
Membrane EPDM black EPDM 600252 with Micro Port
Membrane silicone grey Silicone 600251 with Micro Port
Membrane teon Teon 850055
Key ring open right 600076
Double st.st. chain 600064
Rubber cap with knob 600062
Adjustable pressure relief
valve (0-3 Bar(g)) 850059
Quick coupling steel pipe 800070
Tommy bar 900018
Quick coupling for PTFE 800071
Quick coupling with 3/8”
Hose Barb 800082
Sampling coil with st.st.
cap 800058
Quick coupling with M4
hose piece 800086
Cap M16x1,5 800061
Bushing st.st. 600149
Hypodermic needle (long) 900022
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 14
MOUNTING INSTRUCTIONS
Location:
The valve should always be located with its centre line in a horizontal position, and with the two hose pieces in a vertical
position as shown in the diagram. The valve will then be selfdraining.
Valves centre line
Before welding:
Remember to disassemble the valve body and head. The valve body and head must be separated during welding. Rubber plugs,
chain and membrane must be removed from the valve body, as otherwise heat from the welding process will damage them.
WELDING INSTRUCTIONS
Valves for welding are available in two types: T (tank) and P (pipe).
1. For type T (tank) it is necessary to drill a hole ø28 mm into the tank wall, and then t the valve into this hole ush
with the inside of the tank. Welding should be carried out as a penetration welding.
Material thickness less than 4 mm: Weld from inside. Material thickness greater than 4 mm: Weld from both
outside and inside.
Since type T has a solid end piece, the valve will not be damaged by penetration welding. However, the use of
purge gas in the form of either Argon or Formier gas is recommended in order to give the best result.
2. For type P (pipe) penetration welding must be carried out from outside. The valve is machined with a recess-like
shoulder on the outside of the end piece which gives approximately the same material thickness (1.5mm material
thickness) as in the pipe wall.
This machined shoulder can be modied according to the customer’s wishes.
IMPORTANT!
• When grinding/polishing the internal weld, the valve seat must not be touched.
The welding result will be best if the following method is used:
A collar is made on the pipe section so that the valve has a at contact face. This aring must look like a T-piece, as shown in
the example below.
• The pipe section and the valve’s hose pieces are sealed with sponge rubber or similar.
• Purge gas such as Argon or Formier gas is fed through the valve body into the pipe section and the system is now
lled with 6 times the estimated volume of the pipe section. All O2 is thus expelled from the system and welding
can commence.
• Welding can take place with the purge gas continually owing in the system.
• The gas remains in the system until the item is lukewarm, after which the set-up can be dismantled.
Guideline welding values:
W9 valve welded onto a 2 mm 3” dairy pipe: 50-60 Amp.
It should be noted that Keott can supply all P type valves welded onto a pipe section according to
customer specications. Flaring is thus avoided and only a girth weld is required.
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 15
BLOCK DIAGRAM FOR WELDING TO PIPE AND TANK
Keott valve type P (pipe):
Keott valve type T (tank):
Keott valve type P (pipe connection vertical) Inline:
Welded to pipe
Welded to tank
outside
Welded to pipe
Welded to tank
inside
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 16
BLOCK DIAGRAM FOR INSTALLATION WITH CLAMP,VARIVENT® AND
THREAD
Keott valve type Clamp connection:
Keott valve type Varivent®:
Keott valve type Thread:
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 17
MAINTENANCE
The rubber membrane should be replaced every two months. PTFE membranes should be replaced every 12 months. In the
event of intensive sterilisation and cleaning it may be necessary to replace it more frequently. For valve heads with Micro
Port, approx. 5-10 samples may be drawn off per membrane at 5-2 bar(g) respectively. The rubber plug must be replaced at
least once every six months. 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 instructions.
Spare parts list
Pos. Item
1. Valve body
2. Membrane Silicone (grey)
Membrane EPDM (black)
Membrane PTFE (White)
3. Lower stem
4. Spring
5. Steel bushing
Disassembly and assembly of valve body and head
ORDER OF OPERATION:
Remember! When replacing the membrane, set the valve head in the open position before it is screwed loose and pulled out of
the valve body. Omitting to do so may result in twisting and cutting of the membrane.
1. Set the valve head at the open position. For types h and k this is done by turning pos. 6 clockwise.
2. Remove the valve head pos. 5. A Tommy bar pos. 8 should be used for disassembly and assembly. This is carried
out by turning pos. 5 anti-clockwise until loose and then pulling the valve head off.
3. Ret the valve head (in the open position) once the necessary parts have been replaced. Care should be taken
not to damage the threads.
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 18
INSTRUCTIONS ON REPLACING PTFE MEMBRANE
1. Open valve.
2. Remove the valve head from the valve body.
3. Push the membrane upwards until the tool for membrane  ts under it.
4. Insert tool for membrane, between the membrane and the bushing.
5. Close valve head.
6. Now the membrane is loosened from the valve head and can be replaced.
To attach new membrane to valve head.
7. Set the valve head to closed position.
8. Place the new membrane on valve head.
9. Mount the membrane bushing with the new Te on membrane by pressing the membrane with your hand until it
clicks.
10. Set the valve head in open position.
11. Insert the valve head into the valve body.
12. Close valve head.
IMPORTANT
• Once the membrane has been removed from the valve head the click system in the membrane might be
damaged. Therefore the membrane might be unsafe for further use and it is recommended not to use the
membrane again.
• Do not use hammer or other tool that might scratch the surface of the membrane.
Tool nr. Type of valve
300255 I40, I52 and W15
400255 M4
600255 W9
870255 W25
M4
INSTRUCTIONS ON REPLACING PTFE MEMBRANE
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 19
UPGRADE FROM SILICONE TO PTFE MEMBRANE
For manually operated valve heads type H, K and Q
1. Close valve.
2. Pull off the silicone / EPDM membrane.
3. Take the bushing off. (page 17, pos. 5)
4. Put the valve head in vice.
5. Turn the hex-nut counter clockwice until the membrane seat and spring are loose. Put the new lower stem for
PTFE membrane in the vice.
6. Fit the new spring on the new lower stem.
7. Insert the rest of the valve head in the pin and press rmly.
8. Turn the hex-nut clockwise until the lower stem is rmly in place. Care should be taken not to damage the
threads.
9. Put the bushing over the spring, then place PTFE membrane on the lower stem and press rmly until it clicks in
place.
10. Put the valve head in open position.
11. Put valve head in valve body and tighten.
IMPORTANT!
• This is a delicate procedure to be performed by skilled personell only.
• Use vice with aluminium grips, to avoid scratching and damaging the valve head.
• Use the spring supplied with the PTFE kit. PTFE membranes require a different type of spring than EPDM and
silicone membranes.
• Do not use hammer or other tool that might scratch the surface of the membrane.
UPGRADE KIT 854155 CONSISTING OF:
Ident no. Part name Material
600340 Lower stem for PTFE AISI 316L
850055 Membrane for W9 PTFE
600411 Spring H-Q-K 12 bar(g) St.St.
www.sks-online.com
www.sks-webshop.com

KEOFITT USER MANUAL PAGE 20
UPGRADE FROM SILICONE TO PTFE MEMBRANE
FOR PNEUMATICALLY ACTIVATED VALVE HEADS TYPE N:
1. Put the actuator in open position. Dismount the actuator by turning it anti-clockwise and pull it out. Dismount the
silicone membrane and the membrane bushing holding it. Dismount Lever/Q-handle.
2. Use a special tool in the two holes on the end cap and turn it anti-clockwise. Be aware of the pressure released
from the spring.
3. Pull out all parts. Inspect interior of actuator forloose parts or particles.
4. Install new valve stem for Teon. Before mounting, make sure to grease the seal on the entire surface (only use
mineral grease).
5. While mounting the valve stem turn it while pushing it down to avoid damaging the seal.
6. Remount the magnet, the magnet bushing and the spring.
7. Remount the end-cap by pushing it down turning it clockwise. Tighten it by use of the special tool. Care should be
taken not to damage the threads.
8. Mount the air-connection.
9. Mount the bushing with the new teon membrane installed by pressing the membrane with your hand until it
clicks in place.
10. Remount the lever/Q-handle on the actuator and put it in open position. Remount the actuator on the valve body
pushing while turning clockwise. Dismount lever/Q-handle. Tighten actuator by use of the tommy-ttt.
11. Re-connect the air hose to air tting on actuator.
IMPORTANT!
• Do not use a hammer or any other hard material to mount the membrane. This can damage the membrane seal.
UPGRADE KIT 854455 CONSISTING OF:
Ident no. Part name Material
600345 Stem for W9 AISI 316L
850055 Membrane for W9 PTFE
850820 O-ring ø32 EPDM
www.sks-online.com
www.sks-webshop.com