Alfalaval Toftejorg User manual

IM-TE91A100-EN1
March 2005
Toftejorg TZ-67
Instruction Manual
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Contents
Contents ....................................................................................................................1
Introduction................................................................................................................3
General Description...................................................................................................4
Functioning ......................................................................................................................... 4
Standard configurations ...................................................................................................... 5
Standard options................................................................................................................. 5
Technical data ...........................................................................................................6
Installation and Normal Operation.............................................................................8
General Installation Instructions.......................................................................................... 8
Normal Operation................................................................................................................9
Maintenance and Repair .........................................................................................10
Preventive Maintenance.................................................................................................... 10
Top Assembly ................................................................................................................... 12
Bottom Assembly .............................................................................................................. 14
Hub Subassembly............................................................................................................. 16
Stem Subassembly ........................................................................................................... 18
Gear Subassembly ........................................................................................................... 20
Replacement of Collar Bushes.......................................................................................... 22
Replacement of Ball races ................................................................................................ 24
Replacement of Main Collars ............................................................................................ 26
Tools........................................................................................................................28
Standard Tool kit for Toftejorg TZ-67, Article no. TE81B050 ............................................ 28
Sketch of tools for replacement of Main collars................................................................. 29
Trouble Shooting Guide ..........................................................................................30
Reference List of Parts............................................................................................32
Cross Sectional Drawing .........................................................................................33
Standard Service Kits and Upgrade Kits.................................................................34
Standard Service Kit for Toftejorg TZ-67, Article No. TE55H000...................................... 34
Standard Service kit for Toftejorg TZ-67, Article No. TE21B299....................................... 34
Upgrade Kit for Toftejorg TZ-67, Article No. TE21C285.................................................... 34
Upgrade Kit for Toftejorg TZ-67, Article No. TE21C286.................................................... 35
How to order spare parts and claim procedure.......................................................36
How to contact Alfa Laval Tank Equipment A/S......................................................36
Service Card............................................................................................................37
Claim Report Working Conditions ...........................................................................38
Instruction Manual, Toftejorg TZ-67 Page 1
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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.
It is in your own interest to get the best and most economical performance from your tank cleaning
machine. Neglect of maintenance means poor performance, unscheduled stoppages, shorter life and
expense. Good maintenance means good performance; no unscheduled stoppages and better 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.
Note: The illustrations and specifications contained in this manual were effective at the date of printing.
However, as continuous improvement is the policy of Alfa Laval Tank Equipment, we reserve the right
to alter or modify any unit specification on any product without notice or any obligation.
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General Description
The Toftejorg TZ-67 is a media driven and media lubricated tank cleaning machine. As it is self
lubricating, there is no lubricating substances such as oil, grease etc. in the machine which needs to be
regularly changed.
Functioning
The flow of the cleaning fluid into the machine passes through a guide and a turbine, which is set into
rotation. The turbine rotation is through a gearbox transformed into a combined horizontal rotation of
the machine body and a vertical rotation of the nozzles.
The combined motion of the machine body and the nozzles ensures a fully indexed tank cleaning
coverage. After 55/8revolutions of Hub with nozzles (55/8revolutions of the machine body), one coarse
cleaning pattern is laid out on the tank surface. During the following rounds, this pattern is repeated 7
times, each of which is displaced 1/8of the mesh in the pattern. After a total of 45 revolutions of the Hub
with nozzles (43 revolutions of the machine body), a complete cleaning pattern has been laid out, and
the first pattern is repeated.
First cycle Full pattern
The speed of rotation of the turbine depends on the flow rate through the machine. The higher the flow
rate is, the higher the speed of rotation will be. In order to control the RPM of the machine for a wide
range of flow rates, the efficiency of the turbine can be changed (100% and 0% Turbine/Inlet guide).
Apart from the jet flow through the nozzles, fluid is leaking through the top of the machine, at the hub
and through the bottom cover. The leakages between the moving parts at the top and at the hub are
cleaning the gabs and thus preventing build-up of material that might cause extra friction. The flow
through the bottom cover is due to the fact that the machine is media lubricated, and that accordingly a
flow through the gearbox is needed.
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General description (continued)
Standard configurations
Connection
Turbine/
Inlet Guide
Nozzles (mm)
(1/2” thread connection) Article No.
Nipple:
1½” BSP,
Male
di: ø38
100%
4xø6
4xø7
TE21C208
TE21C210
0 %
4xø7
4xø8
2xø10
TE21C228
TE21C230
TE21C232
Nipple:
1½” NPT,
Male
di: ø38
100%
4xø6
4xø7
TE21C108
TE21C110
0%
4xø7
4xø8
2xø10
TE21C128
TE21C130
TE21C132
The machine is equipped with a clutch in the hub, which gives the possibility of rotating by hand the
nozzles, when the machine is to be lifted out through a tank opening.
Standard options
Special options are available with hub deflector for direction of cleaning 180°upwards or downwards:
Article No.:
180°upwards: Standard article No. -04
180°downwards: Standard article No. -03
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Technical data
Weight of machine : 6,5 kgs (14,3 lb)
Working pressure : 2-12 bar (30-175 psi)
Recommended inlet pressure : 3-8 bar (45-120 psi)
Working temperature max. : 95°(200°F)
Materials : Stainless steel AISI 316/316L, Tefzel 200, PEEK, A4, bronze,
ACO212CF
Principal dimensions in mm
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Technical data (continued)
Flow rate Throw length
Note: Throw lengths are measured as horizontal
throw length at static condition. Vertical throw
length upwards is approx. 1/3 less.
Effective throw length is defined as impact centre
of jet 250 mm water column (50 lbs/sq.ft).
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
Cleaning Time f. complete Pattern (= 8 cycles)
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Installation and Normal Operation
General Installation Instructions
The tank cleaning machine should be installed in vertical position (upright or upside down). It is
recommended to install a filter in the supply line in order to avoid large particles to clog inside the
machine. Before connecting the machine into the system, all supply lines and valves should be flushed
to remove foreign matter.
Note:The machine shall be installed in accordance with national regulations for safety and other
relevant regulations and standards.
Precautions shall be made to prevent starting of the cleaning operation, while personnel are inside the
tank or otherwise can be hit by jets from the nozzles.
In EU-countries the complete system must fulfil the EU-machine directive and shall be CE-marked.
Warning:
If the machine is used in potential explosive atmospheres, tapes or joint sealing
compounds which are electrical insulators must not be used on threads or joints, unless
an electrical connection is otherwise established to ensure an effective earthing. In
addition, connecting pipe work, must be electrically conductive and earthed to the tank
structure. The resistance between the nozzles and the tank structure should not exceed
20,000 Ohm. This is essential to avoid the build-up of static electricity on the machine.
For further information see CENELEC R044-001 Safety of Machinery, guidance and
recommendations for the avoidance of hazards due to static electricity.
To protect your tank coating it is recommended to mount bumpers on the tank cleaning machine.
The machine as delivered has been tested at the factory before shipping. For transportation reasons,
the nozzles have been screwed off after the test. In order to secure the nozzles against falling off due
to vibrations and other external strains it is important that the nozzles are tightened properly after
mounting. If not, the nozzles may be blown off during tank cleaning and cause severe damage on tank,
valves and pump. This is especially important if machines are fixed installed in tanks and vessels within
the transportation sector in trucks, railcars and onboard ships.
Normally, it is sufficient to tighten the nozzles with the specified torque. However, depending on the
application and local policies an extra securing may be preferred.
Subject to the intended use, environment and any inhouse user requirements or policies, a liquid
threadlocker such as Loctite No. 243 or equivalent could be used. Other methods could be acceptable
and subject to customer preference. For detailed instruction on pre-cleaning and application of the
product carefully follow the instruction on the used locking system.
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Installation and Normal Operation (continued)
1. Clamp machine firmly in a vice. Protect machine with rubber pad under the machine and use
rubber jaws on the vice. Mount jaws upside down to ensure firm grip on the machine. Set torque
wrench at the specified tightening torque.
2. Hold one nozzle with flat spanner to counteract while tightening the opposite nozzle with the
torque wrench.
Rubber jaw mounted
upside down
Protect with rubber
pad
Recommended tightening torque: 40 Nm
3. Check that the machine is in operating condition by inserting hex Screwdriver (tool No. TE134A) in
screw in top of Turbine shaft and easily turn Turbine shaft clockwise. If any resistance is
recognised, the machine should be disassembled to localise the cause.
Normal Operation
Cleaning Media
Use only media compatible with stainless steel AISI 316/316L, Tefzel 200, A4, bronze, ACO212CF and
PEEK. Please note that PEEK is not resistant to concentrated sulfuric acid. Normal detergents,
moderate solutions of acids and alkalics will be acceptable. Aggressive chemicals, excessive
concentrations of chemicals at elevated temperatures, as well as certain hypochlorids should be
avoided. If you are in doubt, contact your local Alfa Laval Tank Equipment sales office.
After Use Cleaning
After use flush the machine with fresh water. Cleaning solutions should never be allowed to dry or set-
up in the system due to possible "salting out" or "scaling" of the cleaning ingredient. If cleaning media
contains volatile chloride solvents, it is recommended not to flush with water after use, in case this can
create hydrochloric acid.
Pressure
Avoid Hydraulic shocks. Put on pressure gradually. Do not exceed 12 bar inlet pressure.
Recommended inlet pressure appears from Technical Data (page 6-7). High pressure in combination
with high flow rate will increase consumption of wear parts.
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Maintenance and Repair
Preventive Maintenance
In order to keep your tank cleaning machine servicing you as an efficient tool in your tank cleaning
operations, it is essential to maintain its high performance by following a simple preventive
maintenance programme, which will always keep your tank cleaning machine in good condition.
Good maintenance is careful and regular attention!
The following recommended preventive maintenance is based on tank cleaning machines working in
average conditions. However, 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. We trust that you
will adjust your maintenance programme to suit.
Always use only proper tools. Use Toftejorg TZ-67 standard tool kit. Never force, hammer or pry
components together or apart. Always perform all assembly/disassembly steps in the order described
in this manual.
Never assemble components without previous cleaning. This is especially important at all mating
surfaces. Work in a clear well lighted work area.
Every 300 working hours
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with Scotch-brite, S-Ultrafine, eventually
chemical cleaner and fine abrasive cloth.
3. Check Slide bearings (pos. 28) for wear. If hole is worn oval to max. diameter more than 10.4 mm,
Slide bearing should be replaced. If endface of Slide bearing is worn more than x mm into Slide
bearing, it should be replaced.
Under Turbine shaft: x = 1.5 mm
At Horizontal shaft: x = 0.5 mm
4. Check Collar bushes (pos. 10) in Gear frame. If holes are worn oval to max. diameter more than
13.4 mm, Collar bush should be replaced. How to replace Collar bushes, see page 22.
Note: Timely replacement of slide bearings and collar bushes will prevent costly damage to the
gearbox.
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Maintenance and Repair (continued)
Preventive Maintenance
5. Check Worm wheels (pos. 11 and pos. 33). If extremely worn, they should be replaced.
6. Check Main bush (pos. 5). If worn it should be replaced.
7. Assemble machines as described in the following pages.
8. Check that the machine is in operating condition by inserting hex Screwdriver (tool No. TE134A) in
screw in top of Turbine shaft and easily turn Turbine shaft clockwise. If any resistance is
recognized, the machine should be disassembled to localize the cause.
Apart from the parts specifically mentioned above, all the remaining wear parts should regularly be
inspected for wear. Which parts that are wear parts appear from Reference List of Parts, page 32.
Service Card
For your registration of maintenance carried out, fill in service card which you will find at the back of this
manual (see page 37).
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Maintenance and Repair (continued)
Top Assembly
Disassembly
1. Remove Screws (pos. 15). Loosen with Key (tool No. TE134) and unscrew with Screwdriver (tool
No. TE134A).
2. Lift off Nipple (pos. 1).
3. Remove Guide/Guide ring (pos. 2). The Guide has a groove in the outer diameter. The Guide is
easily lifted out of the Stem by means of two ordinary Screwdrivers inserted into the groove.
4. Remove Screw (pos. 15), Spring washer (pos. 16) and Washer (pos. 13). To secure Impeller
against rotation, insert carefully Screwdriver (tool no. TE134A), through Impeller (pos. 4) into a
hole in the Stem.
5. Pull off Impeller (pos. 4).
Reassembly
1. Reinstall Impeller (pos. 4). Make sure that Impeller is correctly rotated to be pushed onto Turbine
shaft. Do not try to hammer Impeller in position, as this will damage Slide bearing under Turbine
shaft.
2. Mount Washer (pos. 13), Spring washer (pos. 16) and Screw (pos. 15) and tighten. To secure
Impeller against rotation insert carefully Screwdriver (tool No. TE134A) through Impeller (pos. 4)
into a hole in the Stem.
3. Reinstall Guide/Guide ring (pos. 2)
4. Mount Nipple (pos. 1). Make sure that it is in correct position over Guide/Guide ring (pos. 2).
Rotate Nipple to align holes in Nipple and Stem.
5. Mount Screws (pos. 15) with Screwdriver (tool No. TE134A). Tighten with Key (tool No. TE134).
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Maintenance and Repair (continued)
Top Assembly
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Maintenance and Repair (continued)
Bottom Assembly
Disassembly
1. Turn machine upside down.
2. Remove Screws (pos. 15) and Spring washer (pos. 16) from Bottom cover (pos. 30).
3. Remove Bottom cover (pos. 30)
4. Remove Screws (pos.15) in Bearing cover (pos. 14). Carefully push out Turbine shaft (pos. 6)
from opposite end. Do not try to hammer out Turbine shaft, since this can damage Slide bearing.
5. Remove Screw (pos. 15) and Spring Washers (pos. 16) along the circumference of Gear frame
(pos. 29). Turn Gear frame clockwise about 1 cm (½"). Draw out Gear Subassembly (holes in
Gear frame are excellent for holding Gear Subassembly).
Reassembly
1. Reinsert Gear subassembly in bottom of machine body. Turn Gear Frame (pos. 29) to align holes
in Gear frame and 3/16" threads in body. Mount Spring washers (pos. 16) and Screws (pos. 15)
along circumference of Gear frame (pos. 29). Tighten screws crosswise.
Note: To secure meshing between Gear wheel (pos. 7) and Pinion (pos. 9), it might be necessary
to rotate slightly either the whole Gear Subassembly or the Gear wheel.
2. Reinsert Turbine shaft (pos. 6) with Slide bearing carefully through Gear wheel (pos. 7). Push
carefully Slide bearing (pos. 28) into position. Mount Bearing cover (pos. 14) with Screws (pos.
15). Tighten crosswise.
3. Place Bottom cover (pos. 30).
4. Mount Spring washers (pos. 16) and Screws (pos. 15) and tighten crosswise.
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Maintenance and Repair (continued)
Bottom Assembly
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Maintenance and Repair (continued)
Hub Subassembly
Disassembly
1. Remove Nozzles (pos. 20). Nozzles are untightened with a wrench on the faces of the nozzles.
2. Remove Screws (pos. 16) and Spring washers (pos. 16) and Hub cover (pos. 19).
3. Draw out Hub (pos. 21) together with Ball retainer with balls (pos. 24) and Bevel gear (pos. 18).
If Ball races in Hub cover (pos. 19.1) and in Bevel gear (pos. 18.1) are extremely worn, they should
be replaced as well as the Ball retainer with balls (pos. 24). How to replace Ball races see page 24.
4. Remove Lipseal (pos. 22) and check for wear. If the Lipseal is worn, it has to be replaced.
Reassembly
1. Mount the Lipseals (pos. 22).
2. Slide on Hub (pos. 21). Reinsert Bevel gear with race (pos. 18) and Ball retainer with balls (pos.
24).
3. Mount Hub cover with race (pos. 19), and set with Spring washers (pos. 16) and Screw (pos. 15).
4. Screw on Nozzles (pos. 20) and tighten with wrench. If desired, secure with liquid threadlocker
Loctite no. 243 or equivalent, see page 8-9.
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Maintenance and Repair (continued)
Hub Assembly
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Maintenance and Repair (continued)
Stem Subassembly
Disassembly
1. Place machine in upside-down position.
2. Remove Screws (pos. 15) in Gear wheel (pos. 7). To prevent rotation of Stem (pos. 3) mount two
screws in two holes opposite one another in BIG end of Stem. Place Stem in a vice held by the
heads of the two screws.
3. Draw out Gear wheel with ball race (pos. 7) and Ball retainer with balls (pos. 24).
4. Push out Stem (pos. 3).
5. If worn, press out Main bush (pos. 5).
If Ball races in Body (pos. 26.3) and on Gearwheel (pos. 7.1) are extremely worn they should be
replaced together with Ball retainer with balls (pos. 24). How to replace Ball races see page 24.
Reassembly
1. If replaced, press Main bush (pos. 5) into Stem (pos. 3).
2. Push Stem into Body. Turn machine upside-down.
3. Place Ball retainer with balls (pos. 24) and Gearwheel (pos. 7) into Body on Ball race. Rotate
gearwheel to check free rotation. Mount Gearwheel with Screws (pos. 15) and tighten crosswise.
To prevent rotation of Stem (pos. 3) mount two screws in two holes opposite one another in BIG
end of Stem. Place Stem in a vice held by the heads of the two screws.
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Maintenance and Repair (continued)
Stem Subassembly
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