Alfalaval ALT-SB-15 User manual

100000242-EN3 2020-05
Original manual
Instruction Manual
ALT-SB-15

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Intended use ...................................................................................... 5
2.4. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 7
3.1. Unpacking/delivery ............................................................................... 7
3.2. Requirement for installation, personnel ......................................................... 8
3.3. Installation, welding and mechanically .......................................................... 9
3.4. Installation, electrically ............................................................................ 15
3.5. Recycling information ............................................................................. 15
4. Operation ............................................................................................... 16
4.1. General information ............................................................................... 16
4.2. Aeration ............................................................................................ 16
4.3. Inspection ......................................................................................... 17
4.4. Troubleshooting ................................................................................... 17
4.5. Cleaning ........................................................................................... 18
5. Maintenance ........................................................................................... 20
5.1. General maintenance ............................................................................. 20
5.2. Disassembling of Agitator ........................................................................ 21
5.3. Assembling of Agitator ........................................................................... 28
5.4. Replacement of gear motor ..................................................................... 29
5.5. Replacement of seals ............................................................................ 29
6. Technical Data ......................................................................................... 30
6.1. ALT-SB-15, With Aeration (item number 9614322301) ....................................... 30
6.2. ALT-SB-15, Without Aeration (item number 9614328901) ................................... 31
7. Parts list/Service kits ................................................................................. 32
7.1. ALT-SB-15, with aeration ........................................................................ 32
7.2. ALT-SB-15, without aeration .................................................................... 34
7.3. ALT-SB-15, with and without aeration .......................................................... 36
7.4. Accessories ....................................................................................... 40
7.5. Installation drawing ............................................................................... 42
8. Appendix ............................................................................................... 43
8.1. Declaration of Compliance ....................................................................... 43
8.2. Order specific “Tank With Agitator” drawing, example ........................................ 44
8.3. Drive Unit lubrication .............................................................................. 45
8.4. Drive Unit instructions ............................................................................ 50
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity: 2018-01-01
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
ALT-SB
Designation
15
Type
Serial number from AAC000000001 to AAC999999999
is in conformity with the following directive with amendments:
Machinery Directive 2006/42/EC
FDA 21CFR§177
Regulation (EC) 1935/2004
The person authorised to compile the technical file is the signer of this document.
Global Product Quality Manager, Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2020-01-01
Place Date (YYYY-MM-DD) Signature
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 Important information
Always read the manual before using the Agitator!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the Agitator.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning: !
Caustic agents:
Dangerous electrical voltage:
2.3 Intended use
- The Agitator in only for mixing/conditioning/stirring of liquids in a tank.
- The Agitator is only made for top mounting position on the top plate/welding flange on the tank.
5

2 Safety
All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that serious personal injury and/or damage to the Agitator are avoided.
2.4 Safety precautions
2.4.1 Installation:
Always read the technical data thoroughly (see chapter 6 Technical Data).
Always follow installation instructions thoroughly (see chapter 3 Installation).
Never expose the Agitator to undue vibrations or shocks.
Never start the Agitator in the wrong direction of rotation.
Ensure that the tank media is not corrosive to the Agitator.
Only install the Agitator in environments within temperature limit: -20°C and +40°C.
Only install the Agitator in altitudes less than 1000 m above sea level.
Only use authorized personnel when electrically equipment is connected.
!
2.4.2 Operation:
Always read the technical data thoroughly (see chapter 6 Technical Data).
Never start Agitator in the wrong direction of rotation.
Beware of Agitator in operation can produce sound levels in excess of 85dB(A). !
Always handle lye and acid with great care.
Always rinse well with clean water after cleaning.
Never run the Agitator for a longer time (seconds) without product, water or cleaning liquid in the tank.
2.4.3 Maintenance:
Always follow the maintenance instruction thoroughly (see chapter 5 Maintenance.)
Always follow the maintenance instruction for gear motor thoroughly (see section 8.4 Drive Unit instructions). !
Always study the parts list and assembly drawing carefully (see chapter 7 Parts list/Service kits).
Never touch the moving parts while the Agitator is connected to the power supply.
Always disconnect the power supply while servicing the Agitator.
Ensure correct rotation direction of propeller before startup and after any maintains there might
have impact on the direction.
Never service the Agitator or tank with product or cleaning liquid in the tank.
2.4.4 Transportation:
Always transport the Agitator in original packaging.
Always support the shaft adequately, to protect shaft and bearings.
Never expose the Agitator to undue vibrations or shocks.
Control for oil leakage on gears with vent screw.
Ensure correct rotation direction of impeller before startup and after any maintenance which might have impact on the direction.
6

3 Installation
The instruction manual is part of delivery. Study the instructions carefully.
The Agitator is for permanent fastening.
Make sure the motor corresponds to the environment.
Check the direction of rotation before operation.
3.1 Unpacking/delivery
!
Always use lifting equipment when handling the Agitator.
Alfa Laval cannot be responsible for incorrect unpacking.
Step 1
Inspect the delivery for visible transportation damage (crates and packaging) - all issues should be reported to carrier.
Step 2
Check that deliveries are according to delivery notes.
Complete Agitators can be delivered in more than one shipment.
Step 3
Inspect Agitator parts for visible transport damage.
Step 4
Do NOT use eye bolts on gear motor to lift the Agitator. They are only for gear motor removal.
Step 5
During lifting:
- Always support the shaft adequately to protect shaft and bearings.
- Be carefully not to damage shaft-end with treads.
- Never expose the Agitator to undue vibrations or shocks.
- Control for oil leakage on gears – leave vent plug in gear until gear is installed and in correct position (see Figure 1).
Figure 1, un-activated vent plug
7

3 Installation
The instruction manual is part of delivery. Study the instructions carefully.
The Agitator is for permanent fastening.
Make sure the motor corresponds to the environment.
Check the direction of rotation before operation.
3.2 Requirement for installation, personnel
Erectors:
- Experience from similar types of installation.
- Proven skills in reading installation guidelines and drawings ensuring that the installation is carried out safe for
personnel and property. !
Electrician:
- Certified according to local regulations and experience from similar types of installation.
- Proven skills in reading installation guidelines and drawings ensuring that the installation is carried out safe for
personnel and property. !
Welder:
- Experience from similar types of installation, covering TIG, MIG and MAG welding procedures in stainless steel
thin walled material.
- Proven skills in reading installation guidelines and drawings ensuring that the installation is carried out safe for
personnel and property.
!
8

3 Installation
All position numbers and item numbers refer to the drawings show and specified in chapter 7 Parts list/Service kits.
3.3 Installation, welding and mechanically
3.3.1 Requirement for installation
This work should be carried out by at least two persons and for safety reasons a platform or a scaffold should be
established around the tank top.
During installation ensure to use sufficient lightning.
The tank top must be horizontally during installation.
!
Ensure that the tank does not contain neither dangerous liquid nor gasses and that good ventilation is established.
Always have safety elements removed by authorized personnel.
Never cover or remove nameplates.
Always use lifting equipment when handling heavy parts of the Agitator.
!
Never connect to power during installation.
Always have the Agitator connected to power supply by authorized personnel.
NOTE
Alfa Laval highly recommend installing motor protection guard and a soft starter, or a frequency converter, with a start
ramp up time of 2-7 sec. to the Agitator.
All position numbers and item numbers refer to the drawings show and specified in chapter 7 Parts list/Service kits.
9

3 Installation
All position numbers and item numbers refer to the drawings show and specified in chapter 7 Parts list/Service kits.
All position numbers and item numbers refer to the drawings show and specified in chapter 7 Parts list/Service kits.
Step 1
3.3.2
1. The complete assembled drive unit comes with loose connections for Aeration (28) and connections for CIP (27) depending
on actual delivery (see section 4.2 Aeration and section 4.5 Cleaning). The tubes for both types of the connections are
delivered with protection plugs ensuring that no debris or the likes are left in the sealing system of the Agitator during freight
and installation. It must be decided if the delivered connections are the right types to the actual installation – if not other
connections have to be acquired before they can be welded onto the tubes.
2. Fasten the complete drive unit in a work bench enable good welding work conditions to be carried out.
3. Remove the protection plugs and insert another temporary type of protection inside the tube (textile or the like) ensuring that
no debris are left inside the sealing system during the welding process.
4. Weld on the required connections to the tubing using as less introduced heat as possible.
5. Grind and clean the weldings before removing the temporary protection inside the tubes.
Step 2
3.3.3
1. Clean shaft and propeller threads for grease.
2. The propellers and shafts can be assembled outside the tank if the size of the top flange (99) and the head room above
the tank is sufficiently – otherwise the shaft and propeller unit must be assembled inside the tank. The shaft and propeller
unit can consist of two shafts and two propellers or of one shaft and one propeller – see actual order specific drawing –
example shown in section 8.2 Order specific “Tank With Agitator” drawing, example.
3. Assemble the shafts, propellers, gaskets, O-rings and Loctite: Position 2, 3, 4, 32, 34, 29.
4. Apply Loctite to the threads and tighten to 100-300 Nm.
5. Screw on the lifting eye tool (51) onto the upper shaft part (3) and lift the shaft and propeller unit using a hoist with a sling.
10

3 Installation
All position numbers and item numbers refer to the drawings show and specified in chapter 7 Parts list/Service kits.
4304-0010
11

3 Installation
All position numbers and item numbers refer to the drawings show and specified in chapter 7 Parts list/Service kits.
Step 3
3.3.4
1. Having the shaft and propeller assembly positioned in the tank a second sling is attached to the lifting eye (51) and that
second sling is pulled through the top plate (100) (which has the welding flange for the Agitator (60) welded into it).
2. Using the second sling the shaft and propeller assembly can be positioned and secured at the top of the welding flange
(60) using the fastener tool (50) (see section 7.4 Accessories, Mounting tools). Remember to have the gasket (101)
positioned correctly.
3. Unscrew the lifting tool (51) from the shaft and propeller unit and store it.
4304-0011
12

3 Installation
All position numbers and item numbers refer to the drawings show and specified in chapter 7 Parts list/Service kits.
Step 4
3.3.5
1. Clean the threads (3 and 5) and lift the complete drive unit using a hoist (do not use the lifting eye on the gear motor) and
screw on the shaft (5), (incl. the complete drive unit) applying Loctite to the threads and tighten to 100-300 Nm.
2. The complete unit is lifted a little higher enabling the fastener tool (50) to be removed.
3. The complete unit is positioned on top of the welding flange (60) (ensure that the O-ring (35) is installed correctly).
4. The washers (17) and nuts (16) are positioned and sequentially tightened to about 200 Nm.
4304-0012
13

3 Installation
All position numbers and item numbers refer to the drawings show and specified in chapter 7 Parts list/Service kits.
Step 5
3.3.6
1. The oil vent plug is activated on the gear motor (see Figure 2 and optionally section 8.4 Drive Unit instructions).
Figure 2, Activation of gear vent plug
14

3 Installation
The instruction manual is part of delivery. Study the instructions carefully.
The Agitator is for permanent fastening.
Make sure the motor corresponds to the environment.
Check the direction of rotation before operation.
3.4 Installation, electrically
!
- Operation by unauthorized personnel may endanger personnel and property.
- Treat all electrical equipment as powered.
- Switch off the power before maintenance and repair.
- The electrician must be certified according to local regulations and with at least 3 years’ experience from similar types of
installations.
- The electrician must have proven skills in reading and working from drawings and cable lists.
- The electrician must have knowledge of local safety regulations for power and automation and making sure that any work
carried out is safe for personnel and property before the equipment is put back into operation.
If you need assistance or have questions – please contact Alfa Laval.
- The motor requires the power supply as indicated on the name plate.
- It is recommended to secure the motor with a motor protection.
- We recommend starting the motor by use of a soft starter, or a frequency converter, with a start ramp up time of 2-7 sec.
- We recommend installation of a service switch at the Agitator to secure the personnel during service work.
- Perform a visual inspection of the direction of rotation. The direction required is indicated on the name plate.
!
- Rotation of Agitator must be clockwise looking from the tank top and down. Otherwise the Agitator will be damaged.
3.5 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
- Wood and cardboard boxes can be re-used, 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.
- All metal parts should be sent for material recycling.
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non-metal wear parts must be disposed of in accordance with local regulations.
• Scrapping
- At the end of use, the equipment must be recycled according to 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.
15

4Operation
Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation. Alfa Laval
recommends a soft starter for the Agitator to reduce the load on tank and Agitator.
All position numbers and item numbers refer to the drawings shown and specified in chapter 7 Parts list/Service kits.
4.1 General information
!
Rotation of Agitator must always be clockwise.
Use of gear motor covers is not permitted due to risk of reduced cooling on motor.
If batch rotation is observed during operation, the optimum effect of the Agitator is achieved by interval agitation instead. If
interval agitation is used, the gear motor must be installed with a soft-starter or a frequency converter to increase gear motor life
time and reduce forces on the tank top system.
If a sensitive product is processed, agitation speed and time should be reduced as much as possible.
If the Agitator is equipped with an aeration valve, it is possible to aerate the product through the shaft during the agitation.
4.2 Aeration
If Agitator is equipped with Aeration feature the upper connection (28) can be used letting in sterile air into the batch through the
inside of the shafts and out at the lower propeller. The flow versus pressure can be calculated from the formula described in
chapter 6 Technical Data.
A: Sterile air
B :Mechanical seal
C: Mechanical seal
D: Hollow shaft for aeration
E: CIP pipe
AB
C
D
E
4304-0013
a: Nozzles for aeration and CIP
4304-0014
a
16

4Operation
Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation. Alfa Laval
recommends a soft starter for the Agitator to reduce the load on tank and Agitator.
All position numbers and item numbers refer to the drawings shown and specified in chapter 7 Parts list/Service kits.
4.3 Inspection
Part Inspection Interval
Gear motor
- Clean surfaces to avoid overheating
- Check for oil leakages Monthly
Monthly
Sealing
- Verify that the seals are not leaking Monthly
4.4 Troubleshooting
Problem Cause/result Remedy
Not starting - Defect - Dismantle gear motor, check for
correct rotation
- Replace gear motor
Gear motor - Fault at power supply - Check power supply connection
- Check voltage and frequency
correspond with motor name plate
- Check frequency converter adjustment
correspond with motor name plate
Agitator - Obstructed - Check that Agitator can rotate freely
without striking anything
Vibrations
Propeller - Damaged
- Unbalanced - Contact Alfa Laval
- Clean propeller
Shaft - Damaged - Contact Alfa Laval
Unusual sounds - Find root cause of sound - Change and/or repair parts
Leakage
Gear motor - Oil leakage
- CIP fluid or other from drain - Renovate or change gear motor
- Replace sealing
Performance - Deviation from normal operation - Operation must be according to
specification
17

4Operation
Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation. Alfa Laval
recommends a soft starter for the Agitator to reduce the load on tank and Agitator.
All position numbers and item numbers refer to the drawings shown and specified in chapter 7 Parts list/Service kits.
4.5 Cleaning
4.5.1 General Information
!
The Agitator is fitted with a rotating spray ball designed to clean Agitator and tank as part of the same cleaning process
(Cleaning In Place - CIP).
The lower propeller is equipped with nozzles cleaning all down facing propeller blades (both lower and upper - if included) –
up facing propeller blades are cleaned by the spray ball.
Cleaning requires CIP fluids to be connected to (27 and 28) if with Aeration and (27) only if without Aeration.
A: CIP
B: Mechanical seal
C: Mechanical seal
D: Hollow shaft for aeration
E: CIP pipe
F: CIP-annulus - flushing upwards
G: Hydraulic balanced CIP seal
H: Spray ball
I: O-ring seal
J: PTFE seal
4304-0015
A
F
B
C
D
E
F
G
I
J
H
Figure 3, CIP in propeller
The Agitator does not require a special cleaning procedure but the process can be integrated in the usual tank cleaning
concept. However, hot caustic cleaning is always recommended.
18

4Operation
Study the instructions carefully and pay special attention to warnings! Always check the Agitator before operation. Alfa Laval
recommends a soft starter for the Agitator to reduce the load on tank and Agitator.
All position numbers and item numbers refer to the drawings shown and specified in chapter 7 Parts list/Service kits.
NOTE
The Agitator must not be run at temperatures above 90°C.
Ensure that all surfaces in contact with product are totally clean so product is not contaminated and that the Agitator itself is
notexposedpitcorrosion.
Pay special attention to:
- Impeller device surfaces.
- Surfaces between propellers and shaft.
- Surfaces around sealing and bushings.
- Surfaces around weldings.
4.5.2 Cleaning examples
- CIP fluids to be connected to CIP connection (27 and 28) if with Aeration and (27) only if without Aeration.
- Pre-rinse with cold water for approximately 3-5 minutes.
- Thecausticcleaningstepshouldbemadewithhotcaustic60-70°C30-45minutes.
- The yeast mixer should be running continuously during CIP.
- The recommended CIP flows versus pressures can be calculated from the formula in section 6.1 ALT-SB-15, With Aeration
(item number 9614322301) and 6.2 ALT-SB-15, Without Aeration (item number 9614328901).
- The cleaning should be made as soon as possible after emptying the tank, while the inside surfaces are still wet.
- Final-rinse with hot water for approximately 3 minutes followed by cold water for 3-5 minutes or until last rinsing water is
free from chemicals.
19

5 Maintenance
Ensure totally clean surfaces during mounting. Always use original Alfa Laval parts.
If product wetted parts are soiled during de-commissioning or installation, these must be manually cleaned prior commissioning
of the equipment.
5.1 General maintenance
!
- Maintenance of the Agitator should only be performed by authorized personnel.
- For maintenance instructions of gear motor please see section 8.3 Drive Unit lubrication.
- Ensure totally clean surfaces during maintenance.
- For lifting instruction, please see chapter 3 Installation.
- Always disconnect the power supply when servicing the Agitator.
- Always use proper tools.
- Always replace worn sealing elements before reassembling.
- Follow the dismantling and assembly instructions to the letter.
- All scrap must be stored/disposed of in accordance with current rules and directives.
- Always use original Alfa Laval spare parts.
Part Replace every
Sealing (Mechanical, PTFE and O-rings) 3000 hours or 2nd year
20