Alfalaval Contherm 6X3 User manual

100000820-EN01 2018-10
Original manual
Instruction Manual
Contherm™Single Wall Scrape Surface Heat Exchangers

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. CE Declaration of Incorporation for Machinery .................................................. 5
2. Safety Summary ....................................................................................... 7
2.1. Introduction ........................................................................................ 7
2.2. Safety Precautions ................................................................................ 7
2.3. Safety and Inspection Symbols ................................................................. 8
2.4. Safety and Potential Hazards Drawing ......................................................... 9
3. Warranty and Product Support ..................................................................... 11
3.1. Contherm™ Scraped Surface Heat Exchanger Warranty .................................... 11
3.2. Product Support Services ....................................................................... 11
4. Portfolio Description & Equipment Limitations .................................................. 13
4.1. General Description ............................................................................... 13
4.2. Limits of Machinery ............................................................................... 14
5. Serial Number and Material Information .......................................................... 17
5.1. Serial Number Information ....................................................................... 17
5.2. Contherm™ Name Plate ......................................................................... 18
6. Installation .............................................................................................. 19
6.1. Introduction ........................................................................................ 19
6.2. Uncrating and Unpacking the Equipment ...................................................... 20
6.3. Installing the Vertical Mount ...................................................................... 24
6.4. Mounting and Installing the Contherm™ In a Vertical Configuration ......................... 27
6.5. Installing the Coupling Guard .................................................................... 29
6.6. Installing the Components of the Rotor Lifting Device ........................................ 31
6.7. Mounting and Installing the Standard Contherm™ or a
Contherm™ Core in a Horizontal Configuration ............................................... 36
6.8. Installing Ancillary Equipment or Piping to Support Heating or Cooling in the Contherm™
...................................................................................................... 40
6.9. Installing a Steam Heating System .............................................................. 41
6.10.Installing an Ammonia for Freon: Full-Flooded Refrigeration System ........................ 43
6.11.Installing a Liquid Heating or Cooling Media System .......................................... 46
6.12.Uninstalling the Contherm™ ..................................................................... 47
7. Operations .............................................................................................. 48
7.1. Introduction ........................................................................................ 48
7.2. Operating the Hydraulic Rotor Lifting System .................................................. 48
7.3. Rotor Lift Helper Plate to Aid in Serving Lower Components ................................ 51
7.4. Contherm™ Pre-Test ............................................................................. 54
7.5. Start Up and Initial Testing of the Contherm™ ................................................. 54
7.6. Operating the Contherm™ in a Steam Heating Configuration ............................... 55
7.8. Operating the Contherm™ in an Ammonia or Freon Full-Flooded Refrigeration
Configuration ...................................................................................... 56
7.9. Operating a Water Heating or Cooling Contherm™ or Brine Cooling Contherm™ ........ 57
7.10.Shutting Down the Contherm™ ................................................................. 58
7.11.Cleaning the Contherm™ ........................................................................ 58
8. Inspection & Maintenance ........................................................................... 60
8.1. Introduction ........................................................................................ 60
8.2. Recommended Inspection ....................................................................... 62
8.3. Scheduled Maintenance ......................................................................... 64
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Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
8.4. Seals ............................................................................................... 64
8.5. Scraping Blades .................................................................................. 73
8.6. Bearings ........................................................................................... 82
8.7. Heat Exchanger Cylinder ......................................................................... 89
8.8. Hydraulic Pump and Stack Valve Assembly ................................................... 90
8.9. Disassembly and Reassembly of the Contherm™ ............................................ 93
9. Troubleshooting ....................................................................................... 100
9.1. Introduction ........................................................................................ 100
9.2. Seal Leaks ......................................................................................... 101
9.3. Lower Bearing ..................................................................................... 102
9.4. Rotor Lift System ................................................................................. 103
9.5. Product Heating .................................................................................. 103
9.6. Product Cooling (Water/Glycol/Brine) ........................................................... 105
9.7. Product Cooling (Ammonia/Freon) .............................................................. 106
10. Appendix A: Additional Installation Drawings .................................................... 108
11. Appendix B: Other Equipment Supplier Documentation ....................................... 121
12. Appendix C: Available Tools to Assist in Inspection and Maintenance ...................... 121
13. Appendix D: Contherm Cylinder Capacity ........................................................ 122
14. Appendix 1: Project-Specific Documentation ................................................... 124
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1 CE Declaration of Incorporation for Machinery
CE Declaration of Incorporation for Machinery
Directive 98/37/EC, Annex 11 sub B
The Responsible Person
Name Mr. Giovanni Treglia
Business Name Alfa Laval Parma
Address Via Botteri 13/A
43122 PARMA
ITALY
Manufacturer Alfa Laval Inc.
Address 111 Parker Street
Newburyport, MA 01950 USA
Description of Machinery:
Model: Contherm, Contherm Core, Contherm HP, Contherm Max, Convap
Alfa Laval Inc. herewith declares that the following national technical standards and specifications have been used: ASME
Section VIII, Division 1.
Other Directives applied: 2014/68/EU, 1935/2004 & 2023/2006.
The Machinery to which this Declaration of Incorporation relates must not be put into service until the relevant Machinery into
which it is to be incorporated has been declared in conformity with the provisions of the Machine Directive.
Kevin Davey
Quality Assurance Signature
26 November 2018
Date
Alfa Laval Inc.
111 Parker Street
Newburyport, MA 01950 USA
Telephone: [phone]. Telefax: [phone]
5

1 CE Declaration of Incorporation for Machinery
Information contained in this manual is subject to change without notice and does not represent a commitment on the part of
Alfa Laval Corporation. No part of this manual may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying and recording, for any purpose, without the express written permission of Alfa Laval
Corporation. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would
be gratefully appreciated. Please forward this information to the address below. If further clarification regarding this manual is
required, please contact your local Alfa Laval representative.
Copyright © 2018 Alfa Laval Corporation. All Rights Reserved.
Revision: 1 Date: 11/2018
Alfa Laval 111 Parker Street Newburyport, MA 01950 USA
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Website: www.alfalaval.com
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2 Safety Summary
2.1 Introduction
Always read the manual before working with or using the Contherm™.
It is the responsibility of the end user to ensure that personnel working with our equipment are trained and comply to the
latest industrial safety standards that apply to your country and location. Unsafe and hazardous conditions may occur if the
equipment is used by untrained personnel or without regard or knowledge of applicable safety precautions. These unsafe and
hazardous conditions or lack of proper use of personal protective equipment (PPE) may cause serious personal injury and/or
damage to the equipment.
Inherent hazardous situations are commonly present in Contherm™installations including slipping and tripping hazards, caustic
or acidic fluids, high pressure, high or low temperature fluids or substances, elevated working and service points, low ceilings,
electrical hazards and spaces that are not ergonomically ideal.
Equipment users must wear proper PPE suitable for the intended interaction when working on or around Contherm™
equipment. This includes but is not limited to safety glasses, gloves for both hot and cold temperatures, noise protection,
chemical resistant outerwear, and slip resistant safety shoes.
2.2 Safety Precautions
Three types of safety precautions are used in this manual, with each type determined by the level of hazard seriousness the
user is exposed to.
DANGER
Indicates hazards which will result in severe personal injury or death.
WARNING
Indicates hazards or unsafe practices which could result in severe personal injury or death.
CAUTION
Indicates hazards or unsafe practices which could result in minor personal injury or product or property
damage.
If you have any safety concerns that are not addressed within this manual, please notify your supervisor and/or your local Alfa
Laval Inc. representative.
INSTALLATION AND DISASSEMBLY
Refer to INSTALLATION for additional safety information.
Have the Contherm™electrically connected by authorized personnel.
OPERATION
System Pressure Relief: To ensure safe operation, it is the end users responsibility to install pressure relief equipment to ensure
over pressurization of the Contherm™will not occur within the product and media pipework.
MAINTENANCE
Always use OEM Parts: OEM parts are to be used to maintain safe function of the equipment. Alfa Laval is not responsible for any
adverse effects to operator, equipment or product (being processed) safety that is created from the use of non-OEM components.
Always de-energize and lockout-tagout electrical circuits before working on the equipment.
TRANSPORTATION
Never lift the Contherm™equipment in a way other than described in this manual.
Always drain fluids from all chambers and ensure no leakage of fluids or lubricants.
Use original packing or similar and ensure the unit is securely fixed in its container.
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2 Safety Summary
2.3 Safety and Inspection Symbols
Below table 2-1 is a listing of all safety warning symbols and their meanings.
Danger Cold Surface
High Pressure Slip Hazard
Hand Crush / Pinch Hazard Rotating Shaft
Sharp Edges Potentially Corrosive Materials
Burn Hazard Inspection Point
Leaking Hazard Consult Manual
Hoist Needed Checklist is Recommended
Heavy Weight Positive Pressure May Be Present
Electric Hazard Extreme Temperatures May Exist
Automatic Start Lock Out Equipment for Safety
Crush Foot Maintenance / Service Required
Watch Head Inspect / Check Measurements
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2 Safety Summary
2.4 Safety and Potential Hazards Drawing
Figures 2-1A and 2-1B list all safety warning signs and their meanings and highlights safety concerns.
Figure 2-1A Safety Warnings
(Refer to section 2.3 for safety and inspection symbols)
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2 Safety Summary
Figure 2-1B Safety Warnings
(Refer to section 2.3 for safety and inspection symbols)
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