DEC PTS 50 Guide d'installation

Dietrich Engineering Consultants sa

Z. I. Larges Pièces A · Chemin du Dévent · P. O. Box 9 · 1024 Ecublens · Switzerland

Tel +41 21/694 20 40 · Fax +41 21/694 20 59 · info@dec-group.ch

MAN-PTS-GB, Revision 9, BSC, 15-FEB-2017

INSTALLATION, OPERATING AND MAINTENANCE

MANUAL

POWDER TRANSFER SYSTEM

PTS 50 - 400

MAN-PTS-GB, Revision 9, BSC, 15-FEB-2017 2/46

MAN-PTS-GB, Revision 9, BSC, 15-FEB-2017 3/46

TABLE OF CONTENTS

1Safety ........................................................................................................................................................6

1.1 Symbols............................................................................................................................................6

1.2 Operators and maintenance personnel...................................................................................6

1.3 Risk analysis.....................................................................................................................................6

1.4 Powder characteristics.................................................................................................................7

1.5 Inspection........................................................................................................................................7

1.6 Residual risks....................................................................................................................................7

2General description ...............................................................................................................................8

2.1 Warranty..........................................................................................................................................8

2.2 Application.....................................................................................................................................8

2.3 Patents.............................................................................................................................................8

2.4 Process description........................................................................................................................8

2.5 Major advantages.......................................................................................................................10

2.6 Choice of PTS................................................................................................................................10

2.7 Options ..........................................................................................................................................11

2.7.1 PTS Mobile.................................................................................................................................11

2.7.2 Dual pressure............................................................................................................................11

2.7.3 CIP ..............................................................................................................................................11

2.8 Technical Data.............................................................................................................................14

2.8.1 Dimensions................................................................................................................................14

2.8.2 Power supply/Media...............................................................................................................14

2.8.3 Environmental Conditions......................................................................................................14

2.8.4 Noise Emissions.........................................................................................................................14

2.8.5 Cleaning Agents......................................................................................................................14

3Construction and operation...............................................................................................................15

4Transport and storage..........................................................................................................................18

4.1 Inspection after transport...........................................................................................................18

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4.2 Transport and lifting.....................................................................................................................18

4.3 Storage ..........................................................................................................................................18

5Assembly, connections and first commissioning ............................................................................20

5.1 Mechanical assembly.................................................................................................................20

5.2 Installation.....................................................................................................................................20

5.3 Commissioning.............................................................................................................................23

5.3.1 Safety check ............................................................................................................................24

5.3.2 Adjustments..............................................................................................................................24

5.4 Daily start-up.................................................................................................................................25

6Operation, Maintenance and Repair ..............................................................................................26

6.1 Normal operation........................................................................................................................26

6.2 Operation with solvent wet powder........................................................................................26

6.3 Installation shut down.................................................................................................................26

6.4 Maintenance................................................................................................................................27

6.5 Repairs ...........................................................................................................................................28

7Cleaning.................................................................................................................................................29

7.1 Hand cleaning.............................................................................................................................29

7.2 Cleaning in place (CIP)..............................................................................................................30

7.3 Drying.............................................................................................................................................31

7.4 Filter change.................................................................................................................................31

7.5 Filter assembly ..............................................................................................................................33

7.5.1 Option with 1 O-Ring and screw ..........................................................................................33

7.5.2 Option with 1 O-Ring and groove........................................................................................34

7.5.3 Option with 3 O-Rings and groove for triclamp version...................................................35

8Operating problems and their solutions...........................................................................................36

9Appendix................................................................................................................................................46

9.1 Additional data............................................................................................................................46

9.2 List of spare parts.........................................................................................................................46

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9.3 Manufacturer documentation..................................................................................................46

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1SAFETY

For safe handling of the system, it is imperative that you strictly follow these instructions. Pay

particular attention to the instructions marked with the following symbols.

Please also note the safety instructions from the vendor documentation.

1.1 SYMBOLS

The following symbols and instructions are used for safety instructions. They warn of possible

personal injury or property damage, and give advice to facilitate working with the system.

Indicates a hazardous situation which will result in death or serious injury.

Indicates a hazardous situation which could result in death or serious injury.

Indicates a hazardous situation which could result in minor or moderate injury.

Indicates a hazardous situation which could result in material damage or

environmental damage.

Indicates additional and useful information for operating the device.

1.2 OPERATORS AND MAINTENANCE PERSONNEL

Only trained personnel should carry out the first commissioning of the PTS system. Particularly

personnel working with pneumatic components must be specifically qualified for such work.

Work on electrical components must be performed only by qualified and certified personnel.

The initial adjustments are carried out at the time of the first start-up. The unit operates

automatically and requires during normal operation only a simple supervision by the operator.

Only authorized and trained personnel can be used for cleaning and maintenance work. The

instructions given in this manual must be strictly followed.

1.3 RISK ANALYSIS

A risk analysis was carried out on the PTS system according to directives 2006/42/EC (Machinery)

and 2014/34/EU (ATEX).

The result of the analysis confirm that the system belongs to group II , but does not fall within

categories 1, 2 or 3 of the ATEX directive (report issued by IBExU, Institut für Sicherheitstechnik

GmbH, Freiberg, dated February 6th 2002.

A separate analysis must be carried out by the user according to directive 1999/92/EC (ATEX

137) in order to ensure the safe use of the equipment. The analysis must also include a study of

the risk relating to the products to be transferred (explosive, toxic etc.).

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In addition, the user is responsible to earth the equipment and to carry out periodic checks

ensuring the continuity of power supply.

1.4 POWDER CHARACTERISTICS

This instruction manual refers only to the operation and use of the PTS system. Specific risks related

to the powders are not part of this manual and must be treated separately. Dec takes no

responsibility in the case of accidents resulting from incorrect handling of the products to be

transferred. The production manager must point out the dangers and safety measures

concerning the powders to transfer in his own operation manual. The operators must strictly

respect the safety instructions.

1.5 INSPECTION

The PTS system is designed and inspected by the manufacturer in accordance with the

applicable national standards and the pressure equipment directive 2014/68/EU. Should a PTS

system be mounted on an installation,the certification of the entire installation is the responsibility

of the operator.

If necessary, the operator will have to inspect the installation before the first commissioning and

undertake further cyclic inspections of the equipment according to the applicable national

standards.

Any change or repair to the system carried out by a third party is subject to the prior written

permission of the manufacturer and must conform to the applicable standards, especiallyto the

pressure equipment directive 2014/68/EU.

1.6 RESIDUAL RISKS

Residual risks are unpredictable risks, which cannot be excluded during the operation of a pow-

der handling system, even with a safe design. These residual risks are not obvious to detect and

could be a possible source of injury or a danger to health (see European norm EN ISO 12100).

In case such a risk is present, the installation should be stopped immediately and the production

manager should be informed. He must then undertake all possible actions to definitively

eliminate this risk. If necessary, he should inform and consult the manufacturer.

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2GENERAL DESCRIPTION

The PTS technology, developed and patented by Dec, is a proven technology which allows the

transfer and dosing of powder. Due to its unique concept, it is possible to solve various and

complex problems in industrial applications and pilot plants. This manual describes mainly the

standard models used in industrial applications.

Dimensions, choice of materials, etc. of the PTS can be selected according to your needs. In

case you have chosen a special execution, you will find in the technical documentation the

specific data and certificates for your system.

2.1 WARRANTY

The PTS system is guaranteed by the manufacturer as described in the General Sales Conditions,

which are made available at the conclusion of a sales contract.

The instructions and warnings included in this manual must be strictly followed. The performance

guarantee and the manufacturer responsibility become void if the system is not used according

to this instruction manual as well as in cases of misuse, insufficient or inadequate maintenance.

The operator must protect the system against the risk of overpressure.

The guarantee automatically becomes null and void if filters other than those supplied or

expressly authorized by Dec are used.

2.2 APPLICATION

The PTS system has been developed solely for the transfer and dosage of powders. It is not

designed for any other application.

2.3 PATENTS

The PTS technology is patented. All violations thereof (copies, reproductions, transmission of

drawings to a third party, instigation to replicate the system etc.), will be legally prosecuted.

2.4 PROCESS DESCRIPTION

The PTS system is an exceptionally effective and reliable method of transferring and dispensing

both dry and wet powders and granules. Its unique filtration concept with a flat membrane

makes it the only vacuum dense-phase system available on the market today. There are

currently over 4000 Powder Transfer Systems operational worldwide.

The PTS challenges convention, using both vacuum and pressure to move powders as if they

were liquid, dispensing with the need for gravity charging, making multi floor processes a

requirement of the past. The system is a significant enhancement to any process, providing total

containment where necessary, but always speeding up production whilst improving safety and

hygiene. Batch time can be substantially reduced and existing process steps can be linked to

each other.

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The PTS consists of a cylindrical chamber with a tangential inlet and a filtration membrane at the

top. The system is equipped with 4 pneumatic valves (inlet valve V1, outlet valve V2, vacuum

valve V3, and pressure valve V4) connected to a pneumatic or electro-pneumatic control

cabinet.

The operating principle is as simple as it is efficient. The PTS chamber is filled and emptied in a

cyclic manner by alternating a source of vacuum and pressure. A flat filtration membrane,

installed inthe upper part of the system, prevents fine particles from entering the vacuum system.

In order to guarantee its suction capacity from the beginning to the end of the transfer, the

membrane is cleaned with each emptying cycle in a countercurrent fashion by compressed air

or inert gas.

Powder is sucked in by opening the inlet valve V1 and the vacuum valve V3 connected to a

vacuum source (vacuum pump). The PTS chamber is emptied by opening the outlet valve V2

and the pressure valve V4 (compressed air or nitrogen).

VACUUM

PUMP

NITROGEN

POWDER

1. PTS BODY

2. PTS MEMBRANE

3. PTS COVER

4. POWDER OUTLET VALVE

5. POWDER INLET VALVE

6. VACUUM VALVE

7. NITROGEN VALVE

Valve open

VACUUM

PUMP

NITROGEN

POWDER

SHUT-DOWN SUCTION PHASE

VACUUM

PUMP

NITROGEN

EMPTYING PHASE

Valve closed

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2.5 MAJOR ADVANTAGES

•Empties or fills all process equipment (including reactors, dryers and centrifuges)

•Transfers all powders (sticky, fine, non-free flowing, hygroscopic, humid, etc.)

•Safe transport of toxic < 1μg/m3 or dust explosive powders < 1mJ

•Charges directly into closed vessels under vacuum or pressure

•Prevents dust creation

•Removes oxygen from powder before entering into the process

•Charges in the presence of solvents

•No product retention

•No particle damages

•Total containment

•Easy to clean – CIP system

•GMP compliant design, ATEX compliant

2.6 CHOICE OF PTS

PTS models (PTS 50to PTS 400)are standard installations designed for industrial applications.Other

models are also available, depending on the problem to solve. Furthermore, it is also possible to

transfer almost continuously by using two PTS chambers which work alternately or to provide a

second input for an additional product.

The choice of the PTS size depends on the powder type, the transfer distance and the transfer

capacity to be reached. Depending on the application (e.g. transfer of corrosive products), the

PTS can be manufactured in various materials or with special anticorrosive coatings which are

resistant to chemicals (Hastelloy C22, glass-lined, Halar®, PVDF coating, etc.).

The material in which the PTS is to be manufactured must be specified by the

operator. The material and its resistance to corrosion will be defined by the nature

of the products to be transferred. It is the operator's responsibility to verify that the

system is compatible with the products to be transferred.

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