INTEGRATED AUTOCLAVE WITH SHREDDER

MWI-150

Installaঞon Instrucঞons
Please read this manual carefully before installing and using the product

Please keep this manual for future reference

Gient Heaঞng Industry Co., Ltd

 GIENT HEATING INDUSTRY CO., LTD.

Catalogue
1 Scope............................................................................................................................................... 1
2 Brief introduction............................................................................................................................ 1
3 System composition........................................................................................................................ 1
3.1 Basic conditions ..................................................................................................................................... 1
3.2 Requirements for operating environment............................................................................................... 2
4 Main Specifications ........................................................................................................................ 2
5 System installation instruction........................................................................................................ 2
5.1 Preparatory work before installation ...................................................................................................... 2
5.2 Hoisting and assembling ........................................................................................................................ 3
5.2.1 MWI-150 ....................................................................................................................................... 3
5.2.2 Installation of the Steam Pipeline .................................................................................................. 4
5.3 Hydrostatic test of the integrated unit .................................................................................................... 5
6 Inspection after installation............................................................................................................. 5
6.1 Inspection after installation of mechanical parts .................................................................................... 5
6.2 Inspection after installation of electrical parts ....................................................................................... 6
6.3 Inspection after installation of pipelines ................................................................................................ 6
7 Use and management ...................................................................................................................... 6
8 Safe operation ................................................................................................................................. 6
8.1 Preparations before operation ................................................................................................................ 6
8.1.1 Inspection of the integrated autoclave with shredder..................................................................... 6
8.1.2 Vacuum pump inspection .............................................................................................................. 8
8.1.3 Process pipeline inspection............................................................................................................ 8
8.2 Inspection before operation.................................................................................................................... 8
8.3 Operating program ................................................................................................................................. 8

1
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

1 Scope
This system is suitable for treatment of infectious waste and sharps, but not suitable
for treatment of pharmaceutical and chemical waste, or for treatment of medical waste
with high levels of mercury and volatile organic compounds.
The detail standard of classification of the medical waste is as per the related regulation
in the country where the system is applied or that issued by WHO or EU.
https://www.healthcare-waste.org/basics/categories/
The steam autoclave is a pressure vessel. To ensure proper use of the equipment,
please read this instruction carefully before installation and operation, and appoint special
personnel to be responsible for operation.

2 Brief introduction
The shredder and autoclave in this system in integrated and all the medical waste
process procedures are carried out in a closed vessel.
Working procedures: Open the top door, put the medical waste into the loading
chamber, then close the top door. The medical waste will be shredded and fall into the
sterilization chamber. After sterilizing, cooling and de-odor, open the bottom door to
discharge the sterilized waste and transported to municipal waste treatment system.

3 System composition
The integrated medical waste is composited with built-in shredder, autoclave, vacuum
pump, valves and instruments, operating platform as well as electrical control system.

3.1 Basic conditions

Water supply: 0.35MPa~0.5Mpa,3~5m3/min

Compressed air supply: 0.6~0.8MPa, flow:80L/min
Power supply: 3N~380V/220V/50Hz (or according to the local power supply condition)
Steam pressure: 0.5~0.7MPa
Safety valve calibrate pressure: 0.28MPa
Waste water and exhaust treatment facilities should conform to local laws and
regulations.
Lubricant oil VG320, dosage: no less than 7 L.

4 1
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

3.2 Requirements for operating environment

A specialized workshop with hard concrete floor is a must for the autoclave unit, where
power, steam source, water source, drainage, ventilate facility as well as specialized
grounding devices are applied.
The place, where the autoclave is installed should be well ventilated and there should be
enough space for installation and maintenance;
For the safety valve on the autoclave, its discharge outlet should extend to outdoor and
square to the wall, meanwhile weather proof measurements should be made at the outlet.
The height of the outlet to the ground should conform to the local regulation or laws.
Specialized power distributors for power input is a must.
For safety usage, there should be pressure gages and relevant manual valves for water
source and steam source.

4 Main Specifications
Name and model Parameter and unit Value
Working press. 0.3(-0.06) MPa
Rated press. 0.4(-0.1) MPa
Rated temp. 152°C
MWI-150 Working temp. 134°C
Cycle capacity 150 L
Cycle time 60 min/cycle
Power of shredder 5.5 kW
Auxiliary engine Power of vac. pump 0.81 kW

5 System installation instruction

This system is skid mounted for transportation, and some pipes should be installed
onsite, please carefully read the following information before installation.

5.1 Preparatory work before installation

Carefully read the drawings and installation instruction.

Note: The installation should be carried out as per the layout plan and adjusted to the
onsite condition.
Check if the accessories are complete.

5 1
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Send the safety valve of the autoclave to calibrate locally and set the active pressures
respectively at 0.33MPa.

4 1
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Note: Because the autoclave is a pressure vessel, the installation should be carried out
by qualified specialist or company.

5.2 Hoisting and assembling

Select a proper hoisting machine based on the weight of the equipment, fasten the
hangers or slings on the lifting lugs of the equipment reliably and make sure no damage
will be caused to the equipment when hoisting.
Note:
1. The max. lifting height is 2200mm, while the max. lifting weight is 2500kg.
2. Be sure to check if the hoist devices are solid and reliable enough.

5.2.1 MWI-150

Note: The exhaust pipe should be extended to outdoor and discharges upwards with
necessary waterproof measures. Exhaust pipe outlet cannot face to pedestrian passages.

3 3
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

5.2.2 Installation of the Steam Pipeline

4 4
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

The steam pipeline must be installed by qualified specialist.

After welding, internal of the pipes should be blow by compressed air and ensure there

5 5
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

is no welding slag or rust.

The installation direction of the valves should as per the flow direction of the medium.
Reverse installation is strictly forbidden.
The steam pipeline should be paint with antirust paint and cover with thermal insulation
layer, which thickness should be no less than 60mm.
Steam pipe welding should be performed by qualified specialist.
Hydraulic test for leakage test should be performed after finishing installation.
The steam pipeline shall be fixed as required to prevent its gravity acting on the
equipment, and prevent the pipeline pushing or pulling the equipment.

5.3 Hydrostatic test of the integrated unit

After the equipment is assembled and set in place, plug the ports for safety valve and
thermometer without they being installed, and close all valves for the hydrostatic test. The
content of chloride ions of the water for hydrostatic testing shall no exceed 25mg/L. After
passing the test, it is required to immediately drain water and blow the inside dry.
Procedures of hydrostatic test:
a. Fill the chamber with water through the pipe of cooling water at top;
b. Boost the pressure slowly to 50% of the working pressure (i.e. 0.13MPa), and
maintain the pressure for 10 minutes under observation;
c. When it is confirmed normal, continue boosting the pressure to 75% of the working
pressure (i.e. 0.19MPa) slowly, and maintain the pressure for 10 minutes under
observation;
d. When it is confirmed normal, continue boosting to the design pressure (i.e.
0.3MPa); if no leakage occurs, continue boosting to the test pressure (i.e. 0.38MPa), and
maintain the pressure for 30 minutes;
e. Then depressurize to the rated pressure (i.e. 0.42MPa), and maintain the pressure
for 30 minutes and check if the pressure remains constant. If no leakage, seepage, visible
deformation or abnormal noise of the chamber occurs, it shall be deemed that conformity
is verified through the pressure test. Finally, slowly depressurize to the atmosphere
pressure; drain and dry the container.
Note: The hydraulic test can also be performed as per local regulation.

6 Inspection after installation

6.1 Inspection after installation of mechanical parts

6 6
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Check all connecting bolts for tightness and tighten if being loose;

7 7
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Check the equipment for firmness; track down the causes and eliminate the problem if
any shake;
Check if the safety interlock system is locked and reliable;
Lubricate to the relative moving parts. Refill lubricant for the reducer;

6.2 Inspection after installation of electrical parts

Check electric devices for good grounding;

Check control signal for correctness;
Check the motor for correct rotating direction;
Check wirings against any looseness or short circuit;

6.3 Inspection after installation of pipelines

Check valves as per correct flow direction;

Check valves for opening and closing;
Check pipelines and valves against leakage.

7 Use and management

The equipment must be operated and maintained as per local regulation; it shall be
operated in strict accordance of the technical parameters. No over-temperature or
overpressure in operation is allowed;
Personnel responsible for management, operation and maintenance of the equipment
must be trained and examined to be qualified.
The user shall formulate Procedures for Safe Operation, and operate strictly in
compliance with the Procedures;

8 Safe operation
8.1 Preparations before operation

8.1.1 Inspection of the integrated autoclave with shredder

Check if the top and bottom autoclave doors are open and close correctly;
Check if the seal rings are well installed and no foreign matter that affects the sealing;
Inching the shredder to check if it rotates forward and reverse correctly in manual mode,
or if there is any abnormal noise, scratch or clamp.

8 8
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Check if bolts for connecting the shredder with the cylinders are tight and properly
fastened;

9 9
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Check the connection bolts of the shredder against looseness and fasten them.
Check if the safety accessories are complete of safety valves, pressure gages,
thermometers, pressure sensors, temperature sensors and safety latches etc., and if the
accessories are reliably installed;
Check if the steam inlet, vacuum outlet, drainage and condensate drainage pipelines and
valve system are properly installed;
Check if all instruments and valves in the automatic control system are under working
conditions. Check whether the valves and joints and cylinders are connected correctly and
whether there is any leakage at the joints of pneumatic valves, cylinder pipes, etc.;
Adjust the relief pressure of the safety valve;
Adjust the pressure of steam and compressed air;
Adjust the stretching and retracting speed of the cylinders to meet the requirement of
equipment operation;
The operator shall prepare a Operation Record Notebook;
Prior to initial operation, the autoclave shall test run without load, during which the
safety valves shall be adjusted properly. Keep steam in the autoclave for 30 minutes at
its working temperature; conduct an overall inspection of the autoclave, particularly check
leakage, as well as operation of pressure gage, safety valve and the shredder. If any
abnormality is discovered, the autoclave shall be immediately stopped and inspected until
it can normally operate.
Latch inspection
a. This latch in the equipment is used in a dry environment and the ambient temperature
ranging between-10°C~60°C;
b. The latch adopts physical locking and electrical control. It is required to verify the
locking performance once a day and reliability of the electrical control system once a
week.
1) Latch calibration: Check if the latch could retract, extend out smoothly, and well
locked. Check against any deformation or damage, repair and replace in time.
2) Electrical control system calibration: check if the any loose of the wiring, short
circuit and compressed air pipe. Check whether signal switches are sensitive and reliable.
Check if the control program is correct as well as interlock is functional.

1 1
0 0
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Warning: If there is any flaw in the latch system, operation of the

1 1
1 1
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

equipment is strictly forbidden.

8.1.2 Vacuum pump inspection

Check if the manual valve of the inlet pipeline of the vacuum pump is open;
Check if the level of cooling water is applicable;
Inching the vacuum pump motor to check if rotation direction is correct. and if any
abnormal noise, scratch or clamp.

8.1.3 Process pipeline inspection

Check if the process pipeline is affected by any leakage or blocking;

Check the valves on the process pipeline for proper state (open/close) ready for
operation of the equipment;
Check the drainage pipeline is unblocked.

8.2 Inspection before operation

Trial run the machine before operation, switch off the shredder and close the drainage
valve before trial run.
Vacuum seal test
a) Vacuum seal test should be performed without load and in a dry environment. The
temperature difference between in and out of autoclave should be no more than 20℃.
Close all the valves (including the drainage valve and trap) when the pressure reaches to
-0.06MPa, wait for 5 minutes and start to write the time and the decrease value of vacuum
degree;
b) Continue testing for 10 minutes, if the vacuum degree decrease value less than
1.3KPa (10mm Hg), the vacuum seal test is qualified otherwise it is disqualified;
c) Notify to repair if there is any leakage, operate the autoclave with leakage is
strictly forbidden.

8.3 Operating program

Loading: Open the top autoclave door, and manually put the medical waste bags into
the loading chamber, close the top door after finish loading;
Shredding: Start the shredding procedure. Medical wastes will be shredded in the
shredding chamber and fall into the sterilization chamber;

1 1
2 2
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Sterilizing: Start the sterilization procedure, and the high-temperature steam will be
injected into the autoclave for sterilizing the shredded medical wastes;

1 1
3 3
 GIENT
GIENT
HEATING
HEATING
INDUSTRY
INDUSTRY
CO., CO.,
LTD.LTD.

Cooling: Inject cooling water into the autoclave to cool the sterilized medical wastes;
Drainage: Open the drainage valve to drain the cooling water from inside of autoclave;
Post-vacuum: Start the post-vacuum procedure to exhaust excessive gas and moisture
from the autoclave;
Vent: Open the vent valve to increase the pressure to 0 degree;
Re-drainage: Open the drainage valve again to drain out the water that generated
during the post vacuum process from the autoclave.
Discharge: Open the bottom door to unload the treated medical wastes.

1 1
4 4
Gient Heaঞng Industry Co., Ltd

T: 86-23-67383009
A: No.3 Gaobaohu East Rd, Konggang Industrial Zone,
Chongqing, 401120, China.
W: www.gient.net
E: info@gient.cn