Alfalaval Gunclean Toftejorg 270FT Mark 1 User manual

Instruction Manual
Gunclean Toftejorg 270FT Mark 1
IM-TE102766-3-EN10
Date of issue: March 16, 2010

Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 1
IM-TE102766-3-EN10
Contents
Contents ....................................................................................................................1
Handling of loads .......................................................................................................2
Introduction ................................................................................................................3
Trademarks................................................................................................................3
General Description ...................................................................................................4
The Cleaning Liquid Flow ................................................................................................... 6
Technical Description ................................................................................................8
Power Unit .......................................................................................................................... 8
Principal Drawing................................................................................................................ 9
Manual Override ............................................................................................................... 10
Gun Unit Working Principle............................................................................................... 10
Technical Data.........................................................................................................13
General Data .................................................................................................................... 13
Flow rate ........................................................................................................................... 14
Design throw length .......................................................................................................... 15
Installation Data, Standard................................................................................................ 16
Installation Data, JIS Flange Standard ............................................................................. 17
Installation and Normal Operation ...........................................................................18
Before Installation ............................................................................................................. 18
Before Use........................................................................................................................ 18
Programming .................................................................................................................... 18
Programming Knob........................................................................................................... 20
Speed Adjustment ............................................................................................................ 21
How to Calculate Pitch Angle............................................................................................ 22
To Remove Cover............................................................................................................. 24
Cleaning............................................................................................................................ 25
Maintenance and Repair .........................................................................................28
Preventive Maintenance Guidelines and Service Kits....................................................... 28
Maintenance Intervals and Service Kits Selection ............................................................ 28
How to Fill Oil.................................................................................................................... 31
Reference List of Parts ............................................................................................34
Power Unit ........................................................................................................................ 34
Turbine Unit ...................................................................................................................... 44
Gun Unit............................................................................................................................ 46
Service Kits..............................................................................................................50
TE55A601 Minor Service Kit 270FT MK I Drive Unit ........................................................ 50
TE55A630 Minor Service Kit 270FT MK I Cleaner Unit .................................................... 50
TE55A611 Major Service Kit 270FT MK I Drive Unit ........................................................ 50
TE55A640 Major Service Kit 270FT MK I Cleaner Unit .................................................... 51
Tools ........................................................................................................................51
How to order spare parts .........................................................................................52
How to contact Alfa Laval Tank Equipment A/S......................................................52
Service Card ............................................................................................................53
Claim Report - Working Conditions .........................................................................54

Handling of loads
Back position of the centre of gravity: L/2 H/2 D/2
Warning: Do not walk under hanging loads!

Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 3
IM-TE102766-3-EN10
Introduction
This manual has been prepared as a guide for the persons who will be operating and maintaining your tank
cleaning machine. The key to long life for your tank cleaning machine will always be a system of carefully
planned maintenance; you will appreciate that a tank cleaning machine which has a rough and dirty job to do
will need more frequent attention than one working in ideal conditions.
Note: Get the best and most economical performance from your tank cleaning machine. Insufficient preventive
maintenance means poor performance, unscheduled stops, shorter lifetime and extra costs. Good preventive
maintenance on the contrary means good performance, no unscheduled stops and superior total economy.
You will find the information contained in this manual simple to follow, but should you require further
assistance, our Customer Service Department and world-wide net of Distributors will be pleased to help you.
Please quote the type and serial number with all your enquiries; this will help us to help you. The type and
serial number are placed on the gear house of the tank cleaning machine.
This Instruction Manual is published by Alfa Laval Tank Equipment A/S without any warranty. Improvements
and changes to this Instruction Manual may at any time be made by Alfa Laval Tank Equipment A/S without
prior notice. Such changes will, however, be incorporated in new editions of this Instruction Manual.
© Alfa Laval Tank Equipment A/S, 2010. All rights reserved.
Trademarks
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Gunclean
Toftejorg™ is a trademark or registered trademark of Alfa Laval Tank Equipment A/S. Other products or
company names mentioned herein may be the trademarks of their respective owners. Any rights not expressly
granted herein are reserved

Page 4 Instruction Manual, Gunclean Toftejorg 270FT Mark I
IM-TE102766-3-EN10
General Description
Gunclean Toftejorg 270 FT (fixed turbine driven) tank cleaning unit consists of two main parts: the Gun Unit
(GU) and the Power Unit (PU). The GU is mounted in the deck, protrudes into the tank and directs the liquid jet.
The PU is the drive and operation unit and is permanently mounted on the GU inlet housing. The PU gets its
driving power from the turbine fitted in the inlet housing. The turbine rotates by power generated by the
cleaning fluid.
The 270 FT Universal has an inlet housing where the turbine is mounted horizontally.
The rotation speed of the PU normally varies between 0.5 rpm and 3 rpm depending on the nozzle dia and line
pressure at the inlet housing but some adjustments can be carried out. The basic model of the Power Unit has
four programmes to choose from, all pre-programmed to give a tighter spray pattern in the bottom of the tank.
One further advantage with this Power Unit is the possibility to program the pitch angle of the nozzle to suit the
actual tank in which the machine is fitted.
The elevation of the nozzle in the vertical level is indicated by the nozzle angle scale, and the direction of the
nozzle in the horizontal plane is shown by the direction of the tab on top of the lifting rod.
The Gunclean Toftejorg 270 FT Power Unit is designed for easy operation and easy service. The cover is
easily removed to get access to the moving parts of the Power Unit for service and inspection.
Note: Service must be carried out by trained or authorised staff.
Caution: Before operation the cover must be put back.

Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 5
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General Description (continued)
PROGRAMMABLE
POWER UNIT
GUN UNIT
D102275

Page 6 Instruction Manual, Gunclean Toftejorg 270FT Mark I
IM-TE102766-3-EN10
General Description (continued)
The Cleaning Liquid Flow
The liquid of the jet comes from the tank cleaning supply line. Passes through the shut-off valve, proceeds into
the inlet housing, past the turbine, turns downwards into the main pipe through the deck, then through the main
pipe down to the vertical housing which rotates around a vertical axis.
From the vertical housing the liquid turns 90° into the horizontal housing which rotates around a horizontal axis,
turns 90° again, passes through the nozzle tube, the flow guide, out through the nozzle as a compact jet of
liquid in order, finally, with great power, to hit the surface to be cleaned.
Cleaning Pattern with Programmed Pitch
Danger: Tank cleaning must be made according to IMO and/or owners instructions.

Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 7
IM-TE102766-3-EN10
General Description (continued)
Cleaning Liquid Flow

Page 8 Instruction Manual, Gunclean Toftejorg 270FT Mark I
IM-TE102766-3-EN10
Technical Description
Power Unit
Power Unit Working Principle
By using the fluid in the lines, a turbine fitted in the inlet housing drives the lower one way clutch and rocker
which is transmitting power to the turning worm gear, connected to the lifting rod.
The lifting rod is fitted with a long key and can slide up and down inside the turning worm gear hub.
The lifting worm gear screw is connected to the turning gear worm screw by a programmable gearing. On the
lifting worm screw the upper one way clutch and rocker assy is fitted. The turning worm screw has a cam. This
cam lifts the upper rocker and turns the lifting worm screw an amount corresponding to the stroke the rocker is
allowed to do. The stroke is regulated by the programming knob and adjusting screw. Due to the one way
clutch the lifting worm screw only rotates one way. The lifting worm gear rotates a crank shaft where the crank-
pin is moving inside a lifting yoke fitted to the lifting rod. The lifting yoke is journalled on the lifting rod and only
transmits lifting and lowering movements to the lifting rod.
The programmable gearing is used to make it possible to choose a pitch angle suitable for most jet lengths
required.
A pitch giving a distance of max. 0.5 m height between two jets on the surface with the longest distance from
the gun can be used as a guide when choosing the pitch angle.
The programmable pitch and the pre-programmed lifting pattern giving a tighter pattern at the bottom of e.g. the
tanks make the Power Unit extremely easy to use.
No change of programme is required once the pitch angle is programmed. Hand-crank the nozzle to the
desired starting angle shown on the nozzle angle scale, open the valve and the Power Unit is running. One
cycle from top to bottom is usually all that is needed.
The rotation speed can vary between 0.5 rpm to 3 rpm depending on the nozzle dia and line pressure. Some
adjustments of the rotation speed can be carried out by adjusting the turbine mounted in the inlet housing.

Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 9
IM-TE102766-3-EN10
Technical Description (continued)
Principal Drawing

Page 10 Instruction Manual, Gunclean Toftejorg 270FT Mark I
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Technical Description (continued)
Manual Override
An extension of the lifting gear screw is accessible from the outside of the Power Unit. By turning this shaft with
a handle the nozzle can be manually rised to the starting point or during cleaning moved forward in its
programme.
Gun Unit Working Principle
Above deck the inlet housing is mounted onto the doubling flange welded on deck. In the inlet housing the
turbine is fitted. The turbine drives the Power Unit. The upper part of the lifting rod is radially connected to the
Power Unit, turning gear screw by a key, and axially fixed to the lifting yoke with the top screw. The Power Unit
rotates and lifts or lowers the lifting rod simultaneously.
The lower part of the lifting rod is fixed to the lower scissors link by a pin. The lower scissors link is connected
to the vertical housing by the upper scissors link and to the nozzle tube by the crescent link. The torsional
movement of the lifting rod is transmitted to the vertical housing – which can rotate round a vertical axis – by
the 2 scissors links.
The nozzle tube assy is carried in a couple of bearings in the vertical housing and can rotate around a
horizontal axis. The lifting movement of the lifting rod elevates the nozzle tube assys by means of the lower
scissors link and the crescent link.
Consequently, the lowering movement of the lifting rod lowers the nozzle.

Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 11
IM-TE102766-3-EN10
Technical Description (continued)
Gun Unit

Page 12 Instruction Manual, Gunclean Toftejorg 270FT Mark I
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Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 13
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Technical Data
General Data
The Gunclean Toftejorg 270FT equipment is generally operated in a range of 7-12 kg/sqcm media supply.
Depending on the pressure and nozzle diameter the media flow and jet will be according to the diagrams on
page 14 and 15.
Normal leakage approximately 2%.
Weight : Gun with 2.5 meters length of Main pipe : 110 kg
Per additional meter of Main pipe : 20 kg
Servicing space : Minimum 350 mm radius from centre of unit for handling and servicing.
Sound pressure : The sound pressure level at workstations will not exceed 70dB(A)

Page 14 Instruction Manual, Gunclean Toftejorg 270FT Mark I
IM-TE102766-3-EN10
Technical Data (continued)
Flow rate
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
6 7 8 9 10 11 12
Flow rate
[m³/h]
[bar]
Performance diagram
Alfa laval Type: Gunclean Toftejorg 270FT
Single Nozzle
Inlet pressure
Nozzle
size
32 mm
31 mm
19 mm
20 mm
30 mm
29 mm
27 mm
28 mm
25 mm
24 mm
21 mm
22 mm
26 mm
23 mm
18 mm

Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 15
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Technical Data (continued)
Design throw length
Note: Throw lengths are measured as max. horizontal throw length at static condition.The curve above
shows our design throw length. However, the maximum throw length is approximately 30-40% longer.
In general, effective throw length varies depending on jet transverse speed over surface, substance to be
removed, cleaning procedure and agent. The inlet pressure has been taken immediately before the
machine inlet. In order to achieve the performance indicated in the curves, the pressure drop in the supply
lines between pump and machine must be taken into consideration.
28
33
38
43
6 7 8 9 101112
[m]
[bar]
Performance diagram
Alfa laval Type: Gunclean Toftejorg 270FT
Single Nozzle
Design Throw Length*
Inlet
p
ressure
*Horizontal measured at static condition
Nozzle
size
18 mm
19
20 mm
21 mm
22 mm
23 mm
24 mm
25 mm
26 mm
27 mm
28 mm
30 mm
29 mm
31 mm
32 mm

Page 16 Instruction Manual, Gunclean Toftejorg 270FT Mark I
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Technical Data (continued)
Installation Data, Standard
GASKET
Yard supply:
M20 stud, washer and nut
Nitrile gasket
Doubling ring to classification
societies requirements

Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 17
IM-TE102766-3-EN10
Technical Data (continued)
Installation Data, JIS Flange Standard
Yard supply:
M20 stud, washer and nut
Nitrile gasket
Doubling ring to classification
societies requirements
GASKET

Page 18 Instruction Manual, Gunclean Toftejorg 270FT Mark I
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Installation and Normal Operation
Before Installation
Make sure that the pipes have been properly flushed before installation of the machine.
We know from experience that welding rods, plastic bags, rags and other debris will block the turbine.
This may result in damage and poor performance.
Before Use
Fill oil in Power Unit.
Programming
The 270 FT Power Unit has a four programme devise build in. Those programmes control the spacing of the
helical pattern, the pitch angle.
The pitch angle is the angle the nozzle rises or lowers for each revolution of the nozzle in the horizontal plane.
Because of the pre-programmed, varying helical pattern, the Power Unit automatically makes the helical
pattern closer at the lower angles (0° to 30°).
The steps between the programmes are fixed and not adjustable.
The step between programme 1 to 2 is 1° pitch
2 to 3 is 1° pitch
3 to full is 5.5° pitch
All values valid at 90° lift
The basic pitch angle, the pitch angle of programme 1, can be pre-set within certain limits by turning the
adjusting screw on the programming unit. Because of the fixed steps between the different programmes,
adjusting programme 1 also affects the other programmes.
The useful angle of programme 1 is 0° to 1.5°.