MWI-150 Integrated Autoclave with Shredder

Installation and Operation Instructions

 Please read the Instructions carefully before installing and operating

 Please keep the Instructions in good custody for later reference

Chongqing Gient Heating Industry Co,. Ltd

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 Catalogue
1. Applicable scope .....................................................................................................................1

2. Brief introduction to the system (working principle) .............................................................1

3. Composition of the system.....................................................................................................1

4. Working environment and external conditions .....................................................................2

4.1 Basic conditions ............................................................................................................... 2

4.2 Environmental requirements .......................................................................................... 2

5. Main parameters ....................................................................................................................2

6. Instructions for installation and operation of the system......................................................3

6.1 Preparations before installation...................................................................................... 3

6.2 Lifting and assembly of the equipment ........................................................................... 4

6.3 Hydrostatic test of the integrated unit............................................................................ 4

7 Inspection after installation ....................................................................................................5

7.1 Inspection after installation of mechanical parts ............................................................ 5

7.2 Inspection after installation of electrical parts ............................................................... 5

7.3 Inspection after installation of pipelines ......................................................................... 5

8 Use and management .............................................................................................................5

9 Safe operation .........................................................................................................................6

9.1 Preparations before treatment ....................................................................................... 6

9.1.1 Inspection of the integrated autoclave with shredder............................................. 6

9.1.2 Vacuum pump inspection ......................................................................................... 7

9.1.3 Compressed air source inspection ........................................................................... 7

9.1.4 Steam generator inspection ..................................................................................... 7

9.1.5 Process pipeline inspection ...................................................................................... 8

9.2 Inspection before operation............................................................................................ 8

9.3 Operating program .......................................................................................................... 8

9.3.1 Treatment procedures.............................................................................................. 8

9.3.2 Operating procedures .............................................................................................. 9

9.4 Emergency measures ...................................................................................................... 9

9.4.1 Common faults and countermeasures ..................................................................... 9

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 9.4.2 Measures against abnormal power outage during operation ............................... 12

9.5 Safety precautions ......................................................................................................... 12

10 Inspection, maintenance and service ................................................................................. 13

10.1 Integrated Autoclave with Shredder Inspection ......................................................... 13

10.2 Maintenance and service ............................................................................................ 13

10.3 Vacuum pump ............................................................................................................. 17

10.4 Reducer........................................................................................................................ 17

10.5 Control cabinet ............................................................................................................ 17

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1. Applicable 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 the safe and correct operation, please read
these Instructions carefully before installation and operation, and assign special personnel to
be responsible for maintenance and service of the equipment.

2. Brief introduction to the system (working principle)

Integrated Autoclave with Shredder has the following characteristics:
1) The whole medical waste treatment process (shredding → autoclaving) is completed in
an enclosed space.
2) It is designed with integrated shredder and autoclave.
3) The main body consists of a loading chamber, a shredding chamber and a sterilization
chamber, which are assembled to form a closed pressure vessel.
4) The shredder is of a special dismountable structure; replacement and maintenance of the
shredding blade can be absolutely done outside of the equipment.
Working procedures of the equipment: the dumper lifts and pours medical wastes into the
loading chamber; the top door closes; the medical wastes enter the shredding chamber for
shredding; shredded medical wastes then fall into the sterilization chamber where they are
sterilized with high-temperature steam; after sterilization, the wastes are cooled, dried and
deodorized. When all the procedures are completed, the discharging (bottom) door will open
to discharge the wastes. After treatment, the medical wastes will have bacteria effectively
killed and become general wastes of smaller volume and lighter weight, so that they may be
discharged into the municipal waste collection and treatment system for disposal.

3. Composition of the system

The integrated autoclave with shredder system mainly consists of an integrated
shredder-autoclave unit, soft water tank, a vacuum pump, air compressor, pipe valves,
instruments and meters, a steam generator, an operation platform and an electric control
system. The integrated shredder-autoclave unit further consists of a loading chamber, a
shredding chamber and a sterilization chamber.
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4. Working environment and external conditions

4.1 Basic conditions

 Water supply: 0.35MPa~0.5MPa

 Compressed air supply: 0.5~0.7MPa
 Power supply: 3N~380V/220V/50Hz (or according to the local power supply condition)
 Steam pressure: 0.5~0.7MPa
 Safety valve set-pressure: 0.28MPa
 Waste water and exhaust treatment facilities conforming to local laws and regulations.

4.2 Environmental requirements

The autoclave system shall be placed in a special workshop where the floor shall be hard
concrete. Within the workshop, there shall be access to power source, steam source, water
source as well as to drainage and ventilation facilities; meanwhile, there shall also be special
and reliable grounding devices.
The autoclave system shall be placed where there is sound ventilation; proper surrounding
space shall be reserved for installation and maintenance; within the loading area of the
dumper and the unloading area of the integrated unit, there shall also be enough space
reserved for convenient access of materials.
The unit is provided with a safety valve; the discharge port of the safety valve shall be
connected to the exhaust pipe of the vacuum pump.
For connection to power source, a special switchboard shall be provided. A wire trench shall
be reserved between the integrated unit and the electric control cabinet.
Water and steam sources shall be provided with piezometers and corresponding manual
valves to ensure convenient and safe use.

5. Main parameters
SN Name and model Para. Name and unit Value
Working press. MPa 0.25(-0.06)
Design press. MPa 0.3(-0.1)

1 MWI-150 Working temp. ℃ 138

Design temp. ℃ 143

Capacity L/cycle 150

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Cycle time min/cycle 60
Power of shredder kW 5.5
Rated evaporation kg/h 40

Rated pressure MPa 0.7

Steam generator
2 Rated steam temp. ℃ 170
WDR0.04-0.7
Power input kW 30
η % 97
Feeding pump kW 1.1
3 Auxiliary machine Air compressor kW 0.55

Vacuum pump kW 0.81

6. Instructions for installation and operation of the system

The equipment is transported in skid-mounted, the pipelines that connect with the machine
should be installed on site. Before assembly and installation of the equipment, please read the
following text carefully.

6.1 Preparations before installation

Read the drawings and relevant data provided along with the equipment.
Construct the foundation based on the Equipment Foundation Drawing; when the equipment
is set in place, use expansion bolts to fix it onto the ground.
Determine the position for installation of the equipment based on the Equipment Layout Plan,
with consideration given to reservation of space for operation and maintenance.
Prepare an equipment assembly plan based on the site conditions; before assembling, read the
equipment drawings carefully and check item numbers to avoid operation failure of the
equipment due to mistaken assembly.
Disassemble the safety valves of the autoclave and steam generator and send them to
calibrate by local safety valve calibration organization. The active pressure of the autoclave
safety valve is 0.3MPa and 0.7MPa for steam generator.
Note:
Since the autoclave for medical waste treatment is a pressure vessel, it shall be installed, in
observance of applicable local laws and regulations at the place where the user is located, by
professional installation personnel or an enterprise/company of corresponding installation
qualification, installation skills, experience and accomplishments.
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6.2 Lifting and assembly of the equipment

For lifting the equipment, proper lifting gears shall be selected based on the equipment
weight. The lifting gears or slings shall be reliably fixed at the position where the equipment
is to be installed, and be lifted only when no surrender of the equipment safety to such lifting
is assured.
As the system is skid mounted, no need assembly again but connect with water power
source and then it can be operated.
Note:

(1) Before lifting, lifting gears shall be checked for firmness and solidity. Lifting shall be
conducted under the instruction of a specialist.
(2) To avoid operation failure of the equipment due to mistaken assembly, it is required to
assemble the equipment in observance of corresponding drawings and item numbers
with good understanding of the relationship between different parts.

6.3 Hydrostatic test of the integrated unit

After the main units are assembled, temporarily remove the thermometer and safety valve,
block the ports for connection of the thermometer and safety valve and close all valves for
hydrostatic testing. Water for hydrostatic testing shall have the content of chloride ions
controlled under 25mg/L. After conformity is verified, it is required to immediately drain
water and blow the inside for drying. Procedures of hydrostatic testing:
a. Fill water into the container by using the spray water pipe on the top of the equipment;
b. When the container wall temperature gets close to the water temperature, 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 slowly to 75% of the working pressure (i.e.
0.19MPa), and maintain the pressure for 10 minutes under observation;
d. When it is confirmed normal, continue boosting to the rated pressure (i.e. 0.3MPa); if no
leakage occurs, continue boosting to the test pressure (i.e. 0.375MPa), and maintain the
pressure for 30 minutes;
e. Then depressurize to the rated pressure (i.e. 0.3MPa), and maintain the pressure for 30
minutes and check whether the pressure remains constant. If no leakage, seepage, visible
deformation or abnormal noise of the container occurs, it shall be deemed that conformity

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is verified through the pressure test. Finally, slowly depressurize to the normal pressure;
drain and dry the container;
The hydraulic test for steam generator is 1.05MPa, and holding time no less than 20 minutes.
Note: Hydraulic test can be performed as per local regulation.

7 Inspection after installation

7.1 Inspection after installation of mechanical parts

Check all connecting bolts for tightness and tighten any loose bolt.
Check the equipment for firmness; if it is unfirm, track down the causes and eliminate the
problem.
Check if the safety interlock is reliable;
Apply lubricant to parts with relative movement. Refill lubricant for the reduction gear.

7.2 Inspection after installation of electrical parts

Check electric devices for sound grounding.

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

7.3 Inspection after installation of pipelines

Check valves for correct flow direction.

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

8 Use and management

 The equipment must be operated and maintained as required by the local supervisory
authority; it shall be operated in strict observance of the technical parameters. No
over-temperature or overpressure operation is allowed.
 Personnel responsible for management, operation and maintenance of the equipment
must be trained and examined to be qualified before taking corresponding posts.
 The user shall formulate Procedures for Safe Operation of the Medical Waste Autoclave
System, and operate the equipment in strict compliance with the Procedures.

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9 Safe operation

9.1 Preparations before treatment

9.1.1 Inspection of the integrated autoclave with shredder

 Check whether the top and bottom autoclave doors are properly installed and flexible,
and whether they are abnormal, such as subject to automatic closing or opening.
 Check whether the seal ring of autoclave door is well installed and if any foreign matters
on the seal surface.
 Manually turn the shredder to check whether it can rotate normally forwards and
backwards, or whether there is any abnormal noise, scratch or clamp.
 Check whether bolts for connecting the shredder with the cylinders are tight and properly
fastened.
 Check whether safety accessories are complete of safety valves, piezometers,
thermometers, pressure sensors, temperature sensors and safety interlocking bolts etc.,
and whether the accessories are reliably installed.
 Check whether the steam inlet, vacuum port, drainage and condensate drainage pipelines,
valve system are properly installed.
 Check whether all instruments and valves in the automatic control system are under
normal working conditions. Check the cylinder and its pipeline system for properness
and reliability of the valves and connections and check connections of pneumatic valves
and pipelines of the cylinder against leakage.
 Calibrate instruments and set safety valve pressure.
 Adjust the pressure of steam and compressed air.
 Adjust the stretching and retracting speed of the cylinders to the operation requirements
of the equipment.
 The operator shall prepare a “book for operation records of the autoclave system”.
 Prior to initial operation, the equipment shall be subject to a load-free trial operation,
during which safety pressure of the safety valves shall be adjusted properly. Adjust the
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steam pressure to the working pressure and maintain the condition for 30 minutes;
conduct an overall inspection of the autoclave, particularly check leakage, as well as
operation of piezometers, safety valves and the shredder. If any abnormality is
discovered, the equipment shall be immediately stopped and inspected until it can
normally operate.
 Safety interlock inspection
a. This facility is applicable for the working environment of dry and temperature ranges
between-10℃~60℃.
b. Periodically inspect the reliability of this facility, Inspect the performance of this
facility daily and electrical control system weekly.

9.1.2 Vacuum pump inspection

 Check whether the manual valve of the vacuum pump inlet pipeline is open.
 Check whether the level of cooling water is normal.
 Manually inch to check whether the vacuum pump motor rotates in the correct direction
and whether there is any abnormal noise, scratch or clamp.

9.1.3 Compressed air source inspection

 Open the water outlet of the air compressor to drain condensate water inside of the air
compressor.
 Open the water outlet of the filter in the air handling device of the integrated unit to drain
water from the separation device.
 Check whether the output pressure of the air compressor satisfies corresponding
 requirement; boost or reduce the pressure as needed.

9.1.4 Steam generator inspection

Refer to the Instructions for Installation and Operation of Steam Generator.

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9.1.5 Process pipeline inspection

 Check whether the process pipeline is affected by any leakage or blocking.

 Check valves on the process pipeline for proper state (open/close) ready for operation of
the system.
 Check the drainage pipeline for smoothness

9.2 Inspection before operation

Test run the machine before normal operation, switch off the shredder and close the drainage
valve before test run.
B&D test.
a. Vacuum seal test should be performed without load and in dry environment, the
temperature difference between in and out of autoclave should 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 time and the decrease value of vacuum
degree 到 0.06MPa
b. Continuous test 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 any leakage, run the autoclave if with leakage is strictly forbidden.

9.3 Operating program

9.3.1 Treatment procedures

 Loading: Open the top autoclave door of the integrated unit, put the medical waste into
autoclave loading chamber, close the door after finish loading.
 Shredding: Start the shredding procedure. Medical wastes shredded in the shredding
chamber will enter the sterilization chamber.
 Sterilizing: Start the sterilization procedure, and high-temperature steam will be filled
into the integrated unit for sterilizing the shredded medical wastes.
 Cooling: Fill cooling water into the integrated unit to cool the sterilized medical wastes.
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 Drainage: Open the drainage valve to drain the cooling water from inside of the
equipment.
 Post-vacuum: Start the post-vacuum procedure to exhaust excessive gas from the
integrated unit.
 Vent: Open the blow valve to reduce the pressure inside of the integrated unit to zero.
 Discharge: Open the unloading door to unload the treated medical wastes.

9.3.2 Operating procedures

Refer to the Medical Waste Autoclave System Operation Manual.

Note: Before operation, please carefully read the Medical Waste Autoclave System
Operation Instructions and the Medical Waste Autoclave System Operation Manual; or
otherwise the system may fail or cannot run, or even cause damage to the equipment.

9.4 Emergency measures

9.4.1 Common faults and countermeasures

Abnormality of the integrated shredder-autoclave unit and countermeasures

SN Abnormality Countermeasures

Working pressure or temperature Press the “Auto Stop” button and directly pull the

1 inside of the equipment exceeds safety valve handle on the autoclave until the

the allowed value pressure or temperature drops

Cracking, bulging, deformation or

leakage occurs to the autoclave Immediately close the steam inlet valve of the
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door, cylinder and the steam autoclave

pipeline

The safety valve fails (conduct

manual discharge testing of the Immediately replace the safety valve with an
3
safety valve on a regular basis to acceptable and well-calibrated one

determine whether the

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component is effective)

The autoclave is not tightly closed

Immediately inform Gient or engage a specialist for
4 (according to tightness testing),
calibration and adjustment
resulting in poor seal

Connecting pipes or fasteners are

5 Make timely replacement
damaged

Immediately stop the equipment and check whether

The equipment and pipes vibrate
6 there is any residual condensate; if the problem still
violently
exists, notify Gient for treatment

1. Check whether transmission of the reduction gear

is normal;
The equipment vibrates violently
2. Check whether the connecting bolts of the
7 or even bounces during
reduction gear are loose;
shredding.
3.Check whether anchor bolts of the equipment are

fastened properly;

1. Check if the reduction gear works

normally.
2. Manually turn the shredder to make it rotate

forwards and backwards; check whether the

shredder is stuck; if it is still stuck after multiple

8 The shredder does not work
forward and backward rotations, skip the shredding

procedure and enter the next procedure; after the

following procedures are completed, open the

loading hatch to eliminate the problem.

1. Check whether the blade is broken, and

make timely replacement of the blade.
9 Obviously larger shredding size
2. The blade is seriously worn and needs to be timely

replaced.

1. Check if compressed air could meet the

10 Abnormal of safety latch Requirement;
2. Check if any loosen or leakage of
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compressed air pipeline;
c. Change the driven cylinder.

 Countermeasures against faults of the vacuum pump

No. Faults Causes Countermeasures

Check connections and replace the
The suction pipeline leaks
seals where necessary

The cooling liquid temperature

Increase the flow rate of cooling
Insufficient rises, causing reduction of
liquid
1 suction flow of suction volume

the pump Check inside of the pump and

There are deposits in the against dirt and deposits, clean the

pumps pumps, and take measures to

prevent deposit when necessary.

The suction pressure is too low, Take protective measures against

The pump resulting in cavitation cavitation

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produces noise The cooling liquid temperature Increase the flow rate of cooling

is too high liquid to reduce its temperature

Leakage occurs

between the The mechanical seal

3 Replace the mechanical seal.
motor and the leaks

pump

The flow rate of cooling fluid is Reduce the flow rate of replenishing

There is liquid too high liquid

4 at the gas Check whether the effluent pipeline

outlet The effluent flow is too low is blocked and clean the pipeline

timely.

 Countermeasures against faults of the steam generator

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Refer to the Steam Generator Installation and Operation Instructions.

9.4.2 Measures against abnormal power outage during operation

Short-time power outage: disconnect the main power switch and resume operation when the
power is restored.
Long-time power outage (in case power outage lasts for over 24 hours):
a) Emergency power available: switch to the emergency power, and stop the equipment
when the treatment cycle is completed.
b) There is no emergency power, but sufficient pneumatic pressure available.
Disconnect the main power switch.
Leave the equipment alone until the pressure drops below 0.05MPa.
Manually pull the operating handle of the safety valve to evacuate residual gas from the
equipment.
Manually operate the solenoid valve to open the drainage valve and drain waste water
from the autoclave;
Manually operate the solenoid valve to retract the safety bottom safety latch.
Manually operate the solenoid valve to make the ring of the bottom autoclave door rotate
to the door-open position.
Manually operate the solenoid valve to open the bottom door.
Open the top door by the same way, remove the untreated medical waste and load by
collecting bins.
Push the bins into the cold storage.
Note: Protective measures shall be taken upon clearance of medical wastes to prevent direct

personal contact with medical wastes that have not been fully treated. It is suggested
that the user shall prepare an emergency power to prevent operational risks under
long-time power outage.

9.5 Safety precautions

Unless the equipment is scraped, it is not allowed to remove the safety bolt;

 The equipment can only be started for operation when the top and bottom autoclave

doors are closed and the safety latch is set in place;。

 Upon opening and closing the autoclave doors, it is required to simultaneously observe

the set-in-place signal and warning signal of the control cabinet.

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 It is not allowed to operate the equipment under over-temperature or overpressure！

 It is not allowed to enter the area covered by the opening and closing movement of the

autoclave doors;

10 Inspection, maintenance and service

10.1 Integrated Autoclave with Shredder Inspection

 The integrated unit shall be regularly inspected. External inspection shall be carried out

at least once a year; internal and external inspections shall be carried out in accordance

with relevant regulations on pressure vessels.

 Safety accessories (safety interlock device of the safety door, piezometer, safety valves,

thermometer etc.) shall be regularly checked; if any safety accessory is damaged, timely

repair or replacement shall be conducted.

 The integrated unit shall not be placed in the open air. If it has been left idle for over 3

months, it shall be carefully checked; in case of rusting, rust shall be removed and Gient

shall be notified for treatment.

 Repairs of the integrated unit shall be conducted in accordance with regulations relating

to pressure vessels.

 The shredding blade shall be regularly checked against wear and timely replaced when it

is seriously worn.

10.2 Maintenance and service

10.2.1 Daily maintenance and service

Daily maintenance and service shall be performed by the operator

 Remove residual slag and water in the integrated unit every day, without retaining any

condensed water. Meanwhile, dirt and scales at the drain outlet shall be timely removed,

so as to ensure free drainage.

 Check whether the seal rings are in sound conditions; if not, replace the rings with new
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ones;

 Test the vacuum tightness of the system before operation; check the integrated unit and

pipelines against leakage;

 Check pipelines for tightness;

 Discharge the condensate water from, autoclave bins;

 Check lubricating.

10.2.2 Monthly maintenance and service

Monthly maintenance and service shall be performed by maintenance personnel

 Test the safety valve by manually pulling the safety valve handle to confirm the safety

valve acts normally.

Note: Action test of the safety valve can only be conducted under the cold state！

 Check whether the cylinder and accessories are corroded or rusted;

 Check whether the open-close pneumatic system of the autoclave doors works normally;

 Check whether the autoclave doors can open and close freely; if not, engage a specialist

immediately to adjust them until they function normally;

 Check the lubricant level in the reduction gear of the shredder; if the level is too low,

timely replenish lubricant;

 Apply lubricating grease (resistant to a temperature high up to 150℃) to the bearings on

both ends of the shredder shaft;

 Check the shredding blade against wear, and timely replace it when it is seriously worn;

10.2.3 Quarterly maintenance and service

Quarterly maintenance and service shall be performed by a specialist

 Check whether auxiliary devices in the system work normally;
 Check whether the power system and control system are normal and whether circuits are loose or in
poorly contact;

 Apply lubricant to moving parts of the unit to facilitate their movement, particularly the bearings in

the ring adjusting mechanism; however, no lubricant shall be applied to the contact tooth surface

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between the autoclave door flange and the cylinder flange;

10.2.4 Yearly maintenance and service

Yearly maintenance and service shall be performed by a specialist

 Check the exterior of the integrated unit. Exterior inspection can be conducted by a

qualified pressure vessel inspector or a pressure vessel specialist designated by the user

and recognized by a competent supervision department;

 Seal rings of the integrated autoclave doors shall be replaced generally once every half

year;

 Safety accessories shall be checked out; when all are checked to be in conformity, the

checking organization shall issue a checkout report and seal the conforming safety

accessories;

 Check the interior and exterior surfaces of the integrated unit against corrosion and

 rusting; timely treat any corrosion or rusting; in serious cases, notify Gient or engage a

special unit for treatment, so as to prevent any potential safety accident.

 The shredding blade and wear-resistant lining plate shall be replaced generally once

every half year subject to the actual wear;

 Check the bearings at both ends of the shredding blade shaft; in case of any wear, it shall

be timely replaced;

 System inspection mainly includes inspection of major units, all technological pipelines,

auxiliary devices and electric elements etc., so as to eliminate various potential safety

hazards;
Warning: Do not arbitrarily reconstruct the equipment; or otherwise unpredictable consequences
may be resulted in!

10.2.5 Gear refill method for shredder

Refer to the following picture and steps as:

 Open the top door;
 Take out the hopper;

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 Fill grease on the gear tooth, remove the fan cover of the reducer motor and manually
rotate the fan blades to lubricate all the gear teeth.
 Fill grease into bearing seat through the lubricating nipple.

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10.3 Vacuum pump

 Rolling bearings are subject to life-long lubrication; it is only required to inject sufficient
lubricating grease based on experience.
 Mechanical seals of the pumps need no maintenance. After several thousand hours’
operation, the pumps may leak. If such leakage is caused by the mechanical seals, replace
the mechanical seal.
 If hard water is used as the working liquid, it is required to open the pump at least once
every 6 months to remove deposits in it.
 If the pump is left unused for a long time, it shall be drained; if necessary, it may be
protected against corrosion.
 Since dirt may accumulate in the pump, it is required to clean the pump every once in a
while.

10.4 Reducer

Check the gear box lubricating oil: GA320 periodically

10.5 Control cabinet

 Regularly check the lines, and particularly ensure reliable grounding.

 It is not allowed to use the power inside the electric control cabinet for welder or other
large power equipment.
 It is not allowed to touch the operation screen with hard objects.
 No water, steam or corrosive substance is allowed to enter the electric control cabinet.

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Chongqing Gient Heating Industry Co., Ltd.

Gaobaohu East Road 3, Yubei District, Chongqing
Zip: 401120
Tel.: 86-23-67383009
Fax: 86-23-67383279
Website: www.gient.net

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