Alfalaval PlusClean User manual

Alfa Laval PlusClean® - Alfa Laval PlusClean®
UltraPure
Wall mounted cleaning nozzle
BRITISH ENGLISH
4129-0060
Lit. Code 200009288-1-EN-GB
Manual No. 100001847 Instruction Manual

Published by
Alfa Laval Kolding A/S
Albuen 31
DK-6000 Kolding, Denmark
[phone]
The original instructions are in English
© Alfa Laval 2023-03
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval AB (publ) or any of its affiliates (jointly “Alfa Laval”). No part of this
document may be copied, re-produced or transmitted in any form or by any means, or for any purpose, without Alfa Laval’s prior express written permission. Information and services
provided in this document are made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these
services for any purpose. All rights are reserved.

Contents
1 Declarations of Conformity.................................................................................5
1.1 EU Declaration of Conformity....................................................................................5
1.2 UK Declaration of Conformity....................................................................................6
2 Safety............................................................................................................................... 7
2.1 Safety Instructions and Warnings..............................................................................7
2.2 Warning Signs in Text..............................................................................................10
2.3 Requirements of Personnel.....................................................................................10
2.4 Recycling Information.............................................................................................. 11
2.5 Unpacking/Delivery..................................................................................................12
2.6 Intended Use........................................................................................................... 12
3 Introduction.................................................................................................................13
3.1 Functioning..............................................................................................................14
3.2 Marking....................................................................................................................16
3.3 Patents and Trademarks......................................................................................... 16
3.4 Quality System........................................................................................................ 16
4 Installation................................................................................................................... 17
4.1 General Installation Instructions.............................................................................. 17
4.2 Weld Plate............................................................................................................... 18
4.3 Installation............................................................................................................... 19
4.3.1 Inlet Connections....................................................................................... 19
4.3.2 Mounting.................................................................................................... 20
4.4 Mounting Blind Cap................................................................................................. 24
5 Operation..................................................................................................................... 25
5.1 Actuator................................................................................................................... 26
6 Maintenance.............................................................................................................. 27
6.1 Preventive Maintenance..........................................................................................27
6.2 Troubleshooting.......................................................................................................28
6.3 Recommended Cleaning.........................................................................................29
6.4 Recommended Service Intervals and Service Kits................................................. 30
6.5 Dismantling..............................................................................................................31
6.5.1 Dismounting the Pneumatic Actuator.........................................................32
6.5.2 Disassembly of Alfa Laval PlusClean®...................................................... 34
6.5.3 Inspection of Parts..................................................................................... 39
6.5.4 Reassembly of Alfa Laval PlusClean®....................................................... 39
6.5.5 Mounting the Pneumatic Actuator..............................................................40

7 Technical Data and Performance Data....................................................43
7.1 Technical Data.........................................................................................................43
7.2 Dimensions..............................................................................................................44
7.3 Performance Data................................................................................................... 45
8 Pressure Rating for Weld Plates..................................................................47
8.1 Specification of Pressure Weld Plates According to PED 2014/68/EU................... 47
8.2 Specification of Pressure Weld Plates According to ASME VIII div. 1 and div. 2.... 48
9 Parts Lists and Exploded Views................................................................... 49
9.1 Media Driven........................................................................................................... 49
9.2 Pneumatic Driven.................................................................................................... 50
9.3 Accessories and Tools.............................................................................................51
10 Spare Parts.................................................................................................................53
10.1 Ordering Spare Parts...............................................................................................53
10.2 Alfa Laval Service....................................................................................................53
11 Appendix...................................................................................................................... 55
11.1 Appendix A - Weld Plate Installation....................................................................... 55

1 Declarations of Conformity
1.1 EU Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, [phone]
Company name, address and phone number
Hereby declare that
Wall Mounted Spray Nozzle
Designation
PlusClean, PlusClean UP
Type
Serial number from 2021-0001 to 2030-99999
is in conformity with the following directives with amendments:
- Machinery Directive 2006/42/EC
The person authorised to compile the technical file is the signer of this document.
Global Product Quality Manager Lars Kruse Andersen
Title Name
Kolding, Denmark 2022–11–14
Place Date (YYYY-MM-DD) Signature
This Declaration of Conformity replaces Declaration of Conformity dated 2021-10-01
200009288-1-EN-GB 5
EN

1.2 UK Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, [phone]
Company name, address and phone number
Hereby declare that
Wall Mounted Spray Nozzle
Designation
PlusClean, PlusClean UP
Type
Serial number from 2021-0001 to 2030-99999
is in conformity with the following directives with amendments:
- The Supply of Machinery (Safety) Regulations 2008
Signed on behalf of: Alfa Laval Kolding A/S
Global Product Quality Manager Lars Kruse Andersen
Title Name
Kolding, Denmark 2022–11–14
Place Date (YYYY-MM-DD) Signature
DoC Revison_01_112022
200009288-1-EN-GB6
1 Declarations of ConformityEN

2 Safety
Read this first
This manual is designed for operators and service engineers working with the supplied Alfa Laval
product.
Operators must read and understand the “Safety, Installation and Operating Instructions” of
the respective product before carrying out any work or before you put the supplied product into
service!
Before installing the machine and setting it into operation, carefully read the General Installation
Instructions on page 17 and take all necessary precautions according to your application and
local regulations.
Not following the instructions can result in serious accidents.
This documentation describes the authorized way to use the supplied product.
Alfa Laval will take no responsibility for injury or damage if the equipment is used in any other
way.
This Instruction manual is designed to provide the user with the information to perform tasks
safely for all phases in the lifetime of the supplied product.
The user shall always read the safety section first. Hereafter the user can skip to the relevant
section for the task to be carried out or for the information needed.
Always read the technical data thoroughly (see Technical Data and Performance Data on page
43).
This is the complete manual for the supplied product.
NOTE The illustrations and specifications contained in this manual were effective at the date
of printing. However, as continuous improvements are our policy, we reserve the right to alter or
modify any unit specification on any product without prior notice or any obligation.
The English version of the instruction manual is the original manual. We make reservations regarding
mistranslations in language versions of the instruction manual. In case of doubt, the English version of the
instruction manual applies.
2.1 Safety Instructions and Warnings
Safety Signs
Corrosive substance.
DO NOT DISASSEMBLE
kg
!
Do not disassemble.
Dangerous electrical voltage.
Transportation with forklift truck or other industrial vehicles if heavy.
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EN

General Safety Precautions
General
Always ensure that personnel must have experience with lifting operations.
Always ensure the lifting point to be in line with center of gravity. Adjust lifting point if nec-
essary.
Always keep an eye on the load and stay clear during the lifting operation.
Always ensure that the lifting equipment is suitable for the specific supplied product.
Always use appropriate lifting equipment for heavy parts when relevant. Use lifting logs
when available.
Installation
Always follow this manual thoroughly.
Ensure that the product and CIP media is not corrosive to the cleaning device.
Any tank cleaning machine can develop a static electricity charge while in operation.
If the tank being cleaned contains a combustible liquid or vapor having a risk of ignition or
explosion, it is imperative to have the Alfa Laval tank cleaning product properly grounded.
Operation
Always read this manual thoroughly.
Necessary precautions must be taken if leakage occurs as this can lead to hazardous sit-
uations.
Always handle lye and acid with great care.
When an Alfa Laval PlusClean® is operating, there should be covers over every tank
opening. These covers should be sealed well enough to withstand the full force of the fan
striking the cover plate.
If the cleaning solution is hot, corrosive, or toxic, a leak would present a serious hazard to
any personnel in the immediate vicinity or to any exposed electrical equipment.
Maintenance
Always read this manual thoroughly.
Never service the tank cleaning machine when it is hot.
Always make sure the system is depressurised and drained before disassembly.
Always use Alfa Laval genuine spare parts.
Transportation and Lifting
Always drain the tank cleaning machine and accessories of any liquid.
Always ensure that the unit is securely fixed during transportation.
Always use original packaging or similar during transportation.
Incorrect installation, mounting and use, removal of security elements, lack of inspections,
lack of maintenance and improper connections may cause severe personal injury or prop-
erty damage. Therefore, it is important that the cleaning machine is transported, handled,
installed, started, controlled, serviced and repaired correctly exclusively by qualified per-
sonnel.
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2 SafetyEN

Storage
Ideally, as a guide Alfa Laval recommend:
• Store supplied product as supplied in original packaging
• Port opening should be protected against any ingress
• Bare steel (not stainless) should be lightly oiled/greased
• Store in a clean, dry place without direct sunlight or UV light
• Temperature range -5° C to +40° C (23° F - 104° F)
• Relative humidity less than 60%
• No exposure to corrosive substances (also air contained)
The Alfa Laval PlusClean® should be washed out with clean water after each use to re-
move any foreign material or soft substances left in the machine that may harden during
storage. A clean water rinse through the Alfa Laval PlusClean® also wash out any resi-
dues of chemical cleaners or recirculated wash water that could adversely affect the O-
rings during prolonged contact in storage.
Safety check
A visual inspection of any protective device (shield, guard, cover or other) on the supplied
product shall be carried out at least every 12 months. If the protective device is lost or
damaged, especially when this leads to deterioration of safety performance, it shall be re-
placed. The fixing of the protective device should only be replaced with fixings of the same
or an equivalent type.
Inspection acceptance criteria:
• It should not be possible to reach moving parts originally protected by a protective de-
vice
• The protective device must be securely mounted
• Ensure that screws for the protective device are securely tightened
Procedure in case of non-acceptance:
• Fix and/or replace the protective device
How to contact Alfa Laval
Contact details for all countries are continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
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Safety 2 EN

2.2 Warning Signs in Text
Pay attention to the safety instructions in this manual.
Below are definitions of the three grades of warning signs used in the text where there is a risk for
injury to personnel.
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTE
Indicates a potentially hazardous situation which, if not avoided, may result in property damage.
2.3 Requirements of Personnel
Operators
The operators shall read and understand the instruction manual for the supplied product.
Maintenance personnel
The maintenance personnel shall read and understand the instruction manual. The maintenance
personnel or technicians shall be skilled within the field required to carry out the maintenance work
safely.
Trainees
Trainees can perform tasks under the supervision of an experienced employee.
People in general
The public shall not have access to the supplied product.
In some cases special skilled personnel may need to be hired, like electricians and others. In some of
these cases the personnel has to be certified according to local regulations with experience of similar
types of work.
How to contact Alfa Laval
Contact details for all countries are continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
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2 SafetyEN

2.4 Recycling Information
Unpacking
Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
• Wood and cardboard boxes can be reused, recycled or used for energy recovery
• Plastics should be recycled or burnt at a licensed waste incineration plant
• Metal straps should be sent for material recycling
Maintenance
During maintenance oil and wear parts in the machine are replaced.
• Oil and all non-metal wearing parts must be disposed of in accordance with local regulations
• Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they
should be disposed in accordance with local regulations
• Bearings and other metal parts should be sent to a licensed handler for material recycling
• Seal rings and friction linings should be disposed to a licensed land fill site. Check your local
regulations
• All metal parts should be sent for material recycling
• Worn out or defected electronic parts should be sent to a licensed handler for material recycling
Scrapping
• At end of use, the equipment must be recycled in accordance with the relevant local regulations.
Besides the equipment itself, any hazardous residues from the process liquid must be considered
and dealt with in a proper manner. When in doubt, or in the absence of local regulations, please
contact your local Alfa Laval sales company.
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Safety 2 EN

2.5 Unpacking/Delivery
The instruction manual is part of the delivery. Study the instructions carefully.
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
1Inspect the delivery for visible transportation
damages – Report all issues to carrier.
2Check the delivery for:
1. Complete cleaning machine
2. Delivery note
2.6 Intended Use
The Alfa Laval PlusClean® is a wall mounted cleaning nozzle for cleaning of shadow areas in the tank
and on tank installations; e.g. underneath agitator blades.
There is a broad range of application areas within pharmaceutical, food and chemical industries.
Some of the benefits of Alfa Laval PlusClean® are:
• It has minimal moving parts and relies on a simple spring mechanism for opening and closing
• The spring mechanism is outside the product contact area
• In the closed position, the piston and its O-ring seal against the inside of the body of the Alfa Laval
PlusClean®. This prevents liquid from the tank to enter the Alfa Laval PlusClean®
• No threads or screws are used in the product contact areas
• The cleaning device is lubricated by the cleaning media
• No oil, grease or other lubricants are used
A complete description of the technical specifications and construction of the Alfa Laval PlusClean® is
found in this manual. Application assistance and optimal position recommendation are available.
The end-user should verify:
• that the construction materials (both metallic and non-metallic) are compatible with product,
flushing media, cleaning media, temperatures and pressure under the intended use
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3 Introduction
Alfa Laval PlusClean® is a wall mounted cleaning nozzle designed for cleaning
of shadow areas in tanks; e.g. below agitator blades and other tank internals.
PlusClean is smoothly integrated into the tank wall. When activated during
Cleaning-in-Place (CIP), PlusClean covers cleaning shadow areas with a high
impact fan of cleaning media, giving the market’s first guarantee of 100%
impact cleaning coverage.
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EN

3.1 Functioning
The Alfa Laval PlusClean® is available in media driven or pneumatic driven versions.
Both versions have a spring mechanism located outside the product contact surface area.
Media driven:
• The piston retracts due to the pressure of the cleaning media and is extended back into closing
position by a spring
• The cleaning media enters the body through the 3/4” inlet connection
• The liquid pushes the piston, which retracts to open position by compressing the spring
mechanism
• At the same time the cleaning media passes through the body and out through the slot opening
• When cleaning is completed and the force from the cleaning media pressure drops below the
spring force, the piston position is restored by the integrated spring mechanism
4129-0002
4129-0003
Pneumatic driven:
• The piston is retracted by an external pneumatic Actuator and restored by the spring mechanism
• Air is applied to the pneumatic Actuator. This retracts the piston to open position by compressing
the spring mechanism
NOTE
IMPORTANT: Piston shall be retracted before cleaning media supply is started.
- The cleaning media passes through the body and out through the slot opening.
- When cleaning is completed, the supply of cleaning media is shut off.
- By shutting off the air supply to the pneumatic Actuator, the spring force restores the piston position by the
integrated spring mechanism.
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3 IntroductionEN

NOTE
For total drain the pneumatic Actuator can remain retracted during a draining phase to allow for e.g. air
purging.
4129-0004
Both versions of the Alfa Laval PlusClean® spray out a fan due to the flow of the cleaning fluid. The
pattern of this fan depends on the slot in the body as seen below. The three patterns provide fans with
different spread angles and flow rates. When the cleaning media pressure is shut off, the cleaning
media is drained through the 3/4" ferrule connection. The mounting position of the Alfa Laval
PlusClean® is important for draining.
Spray pattern
22º
4129-0005
14º
72º
4129-0006
4129-0007
27º
Offset slot Wide center slot Narrow center slot
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Introduction 3 EN

3.2 Marking
Alfa Laval tank cleaning machines are marked to allow for recognition of type of machine, machine
name, serial number, article number and manufacturing address.
The marking is placed on the side of the tank cleaning machine.
4129-0077
Serial number explanation
Machines supplied with or without standard documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
**********: article number
3.3 Patents and Trademarks
This Instruction Manual is published by Alfa Laval Kolding A/S without any warranty. Improvements
and changes to this Instruction Manual may at any time be made by Alfa Laval Kolding A/S without
prior notice. Such changes will, however, be incorporated in new editions of this Instruction Manual.
Alfa Laval Kolding A/S. All rights reserved.
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Other
products or company names mentioned herein may be the trademarks of their respective owners. Any
rights not expressly granted herein are reserved.
3.4 Quality System
The Alfa Laval PlusClean® cleaning nozzle is produced according to Alfa Laval Kolding´s ISO 9001
international Standard certified quality system.
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3 IntroductionEN

4 Installation
4.1 General Installation Instructions
During handling and installation, handle the machine with care in order not to damage the product
contact surface finish of the machine.
Before connecting the machine to the system, all supply lines and valves should be flushed to remove
foreign particles.
It is recommended to install a fluid valve upstream of the cleaning machine to prevent hydraulic
shocks. Hydraulic shocks may cause severe damage to the machine and the entire installation.
Ideally, the cleaning fluid supply pump should be frequency controlled with a ramp function for start-
up.
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EN

4.2 Weld Plate
NOTE
For installation of weld plate please refer to Appendix A at the end of the manual, see Appendix on page
55.
Alfa Laval PlusClean® has 2 types of weld plates: Adjustable weld plate and fixed weld plate.
4129-0062
Adjustable weld plate Fixed weld plate
The adjustable weld plate has a curved surface on the tank side of the weld plate and allows adjusting
the angle of the device ±5° from the center along all 3 axes. The adjustable weld plate with the Alfa
Laval PlusClean® is only drainable when installed at an angle of more than 30°.
The fixed weld plate only allows the device to rotate around Z-axis. It is drainable at all angles due to
the flat top surface.
Z
Y
X
4129-0063
5° 5°
The adjustable weld plate should be used in applications where the Alfa Laval PlusClean® is installed
on tank walls and tank bottoms with more than 30° inclination to horizontal.
The fixed weld plate should be used where the Alfa Laval PlusClean® is installed on the tank bottom
or surface with less than 30° inclination to horizontal.
Both types of weld plates have the same outer dimension and same welding process.
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4 InstallationEN

4.3 Installation
NOTE
For installation of weld plate please refer to Appendix A at the end of the manual, see Appendix on page
55.
Always read the technical data thoroughly.
Every Alfa Laval PlusClean® is operationally tested before shipment and is ready to run after unpacking. No
assembly is required prior to use.
Any change to the originally supplied operating conditions will affect the performance of the Alfa Laval tank
cleaning product accordingly.
4.3.1 Inlet Connections
• The Alfa Laval PlusClean® has a 3/4" ferrule connection on the inlet side. (ASME BPE –
L14AM-0.75 / DIN 32676 Reihe A DN 15)
• Centre of inlet should be aligned with center of piping system
• It is recommended to have a separate CIP supply line for each spray device used for the tank
If installed on a common CIP supply line make sure that either:
1. each spray device has the correct pressure at its inlet or
2. only one of the spray devices is running at a time with the correct pressure at its inlet
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Installation 4 EN

4.3.2 Mounting
• Before mounting the Alfa Laval PlusClean® make sure the supply line has been adequately flushed
• In all applications, the device should be mounted in the position where the inlet is directed
downwards, to allow draining at all times
• The Alfa Laval PlusClean® is designed for draining if installed according to the orientations shown
(for other orientations removal of residual liquid may be achieved using external force e.g. purging
for the device with pneumatic Actuator)
*
4129-0064
*) Important: Ensure flexibility in the supply line to accommodate the nozzle adjustment feature.
NOTE
The adjustable weld plate allows adjusting the angle of the PlusClean nozzle ±5° from the
center along all 3 axes. The fixed weld plate allows the PlusClean to rotate around the
centerline.
4129-0065
ü
Figure 1: Position of PlusClean nozzle
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4 InstallationEN