Alfalaval TJ40G User manual

Covering:StandardMachines,Heavyduty(HD),
Q-doc-EquipmentDoc(31InspectionCertificate-EN10204)
MachinesdeliveredwithATEX/IECExCertificationinaccordancewithDirective2014/34/EU
TE91A725Firstpublished:2017-01
ESE03480-EN82022-11
Originalmanual
InstructionManual
AlfaLavalTJ40GRotaryJetHead

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................5
2.Safety..........................................................................................7
21Importantinformation7
22Warningsigns7
3.Introduction..................................................................................8
31Introduction8
32Intendeduse8
33Patentsandtrademarks9
34Marking9
35ATEX/IECExmarking10
36ATEX/IECExtemperatureclassandcode11
37Qualitysystem11
4.Installation....................................................................................12
41Generaldescription12
42Functioning12
43Generalsafetyandinstallationinstructions14
44SpecificconditionsforsafeuseinaccordancewithATEX/IECExcertification15
5.Operation.....................................................................................18
51Normaloperation18
52Safetyprecautions19
6.Maintenance..................................................................................20
61Preventivemaintenance20
62ServiceandrepairofATEX/IECExcertifiedmachines20
63MaintenanceIntervalsandservicekits21
64Generalassembly/disassemblyrecommendations22
65Disassemblytools22
66Disassemblyinstructions23
67Assemblyinstructions25
7.Troubleshootingguide.....................................................................28
8.Technicaldata................................................................................29
81PerformancedataforTJ40G30
82PerformancedataforTJ40GBurst33
83PerformancedataforTJ40G-HD35
84PerformancedataforTJ40G-HDBurst38
9.Productprogramme.........................................................................40
91Standardconfigurations40
92Standardconfigurations,Burst41
93Availableadd-ons42
94Availableadd-onsforspareparts42
95Availableweldingandthreadadaptors43
96Overviewofguideandimpellercombinations-4nozzles44
97Overviewofguideandimpellercombinations-2nozzles45
10.Partslistsanddrawings,servicekitsandtools..........................................46
101AlfaLavalToftejorgTJ40G46
3

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
102AlfaLavalToftejorgTJ40G-HD48
103Tools50
11.Generalinformation.........................................................................51
111Serviceandrepair51
112Howtoorderspareparts51
113HowtocontactAlfaLavalKoldingA/S51
4

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
RotaryJetHead
Designation
TJ40G
Type
Serialnumberfrom2018-0001to2030-99999
isinconformitywiththefollowingdirectiveswithamendments:
-MachineryDirective2006/42/EC
-ATEXDirective2014/34/EUandthefollowingharmonizedstandardsareused:
ENISO80079-3:201,ENISO80079-37:201,DS/ENISO/IEC80079-34:2011,AnnexA,paragraphA.5.3Rotatingmachines
ECTypeExaminationCertificatenoBaseefa17ATEX0018XandIECExBAS170017X
II1GExhIIC85ºC175ºCGa
Marking:II1DExhIIICT85ºCT140ºCDa
TheQAN(QualityAssuranceNotification)iscarriedoutbySGSFimkoOy,Särkiniementie3,Helsinki00211,Finland.NotifiedBodyNo.0598.
EUTypeExaminationCertificationiscarriedoutbySGSFimkoOy,Särkiniementie3,Helsinki00211,Finland.NotifiedBodyno.0598.
IECExCertificateofConformityiscarriedoutbyBaseefaLtd.,RockheadBusinessPark,StadenLane,Buxton,DerbyshireSK179RZ,United
Kingdom.IECExAcceptedCertificationBody(ExCB).
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–11–08
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformityreplacesDeclarationofConformitydated2019-05-01
5

1DeclarationsofConformity
UK UK
UKDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
RotaryJetHead
Designation
TJ40G
Type
Serialnumberfrom2018-0001to2030-99999
isinconformitywiththefollowingdirectiveswithamendments:
-TheSupplyofMachinery(Safety)Regulations2008
-TheEquipmentandProtectiveSystemsIntendedforuseinPotentiallyExplosiveAtmospheresRegulations2016
andthefollowingharmonizedstandardsareused:ENISO80079-3:201,ENISO80079-37:201,DS/ENISO/IEC80079-34:2011,
AnnexA,paragraphA.5.3Rotatingmachines
ECTypeExaminationCertificatenoBaseefa17ATEX0018XandIECExBAS170017X
II1GExhIIC85ºC175ºCGa
Marking:II1DExhIIICT85ºCT140ºCDa
TheQAN(QualityAssuranceNotification)iscarriedoutbySGSFimkoOy,Särkiniementie3,Helsinki00211,Finland.NotifiedBodyNo.0598.
EUTypeExaminationCertificationiscarriedoutbySGSFimkoOy,Särkiniementie3,Helsinki00211,Finland.NotifiedBodyno.0598.
IECExCertificateofConformityiscarriedoutbyBaseefaLtd.,RockheadBusinessPark,StadenLane,Buxton,DerbyshireSK179RZ,United
Kingdom.IECExAcceptedCertificationBody(ExCB).
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–11–08
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_112022
6

2Safety
TJ40G
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
Always Always
Alwaysread read readthe the themanual manual manualbefore before beforeusing using usingthe the thetank tank tankcleaning cleaning cleaningmachine! machine! machine!
2.1Importantinformation
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjury
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothetankcleaningmachine
NOTE NOTE
NOTE
Indicatesimportantinformationtosimplifyorclarifyprocedures
2.2Warningsigns
Generalwarning:
ATEX/IECExwarning:
7

3Introduction
TJ40G
3.1Introduction
TheAlfaLavalToftejorgTJ40GRotaryJetHeadhasbeendevelopedtomeetthehighestdemandsforefficiency,reliabilityand
hygienewithinfoodandbeverage,pharmaceuticalandbiochemicalindustry
Thismanualhasbeenpreparedasaguideforinstalling,operatingandmaintainingyourAlfaLavalToftejorgtankcleaning
machineShouldyourequirefurtherassistance,ourTechnicalSalesSupportdepartmentandworldwidenetofsalesoffices
arepleasedtohelpyouPleasequotethetype,articleandserialnumberswithallofyourenquiries;thishelpsustohelpyou
Thetypeandserialnumberareplacedonthebodyofthetankcleaningmachine
GetthebestandmosteconomicalperformancefromyourtankcleaningmachineInsufficientpreventivemaintenancemeans
poorperformance,unscheduledstops,shorterlifetimeandextracostsOnthecontrary,goodpreventivemaintenancemeans
goodperformance,nounscheduledstopsandsuperiortotaleconomy
IftheAlfaLavalToftejorgTJ40Gstopsrotatingunintentionallywithinthewarrantyperiod,pleasereturnthemachinetoAlfaLaval
Pleasedonottrytofixanymechanicalproblemsbeforeshipping
W W
War ar arning: ning: ning:Beforeinstallingthemachineandsettingitintooperation,carefullyreadtheGeneralsafetyandinstallation
instructions(page14)andtheSpecificconditionsforsafeuseinaccordancewithATEX/IECExdirective
2014/34/EU(page15)andtakeallnecessaryprecautionsaccordingtoyourapplicationandlocalregulations
NOTE NOTE
NOTE
TheillustrationsandspecificationscontainedinthismanualwereeffectiveatthedateofprintingHowever,ascontinuous
improvementsareourpolicy,wereservetherighttoalterormodifyanyunitspecificationonanyproductwithoutpriornoticeor
anyobligation
TheEnglishversionoftheinstructionmanualistheoriginalmanualWemakereservationsinregardtopossiblemistranslationsin
languageversionsoftheinstructionmanualIncaseofdoubt,theEnglishversionoftheinstructionmanualapplies
3.2Intendeduse
Theend-usershouldverify:
-thatthetankcleaningmachineisinconformitywithrespecttotank,vesselorcontainersizeinwhichitisused
-thattheconstructionmaterials(bothmetallicandnonmetallic)arecompatibilitywithproduct,flushingmedia,cleaning
media,temperaturesandpressureundertheintendeduse
Thetankcleaningmachine/rotaryjetmixerisintendedforuseinclosedtank,vesselorcontainerIfusedinopenenvironment
see43Generalsafetyandinstallationinstructions(page14)
8

3Introduction
TJ40G
3.3Patentsandtrademarks
ThisinstructionmanualispublishedbyAlfaLavalwithoutanywarrantyImprovementsandchangestothisinstructionmanual
mayatanytimebemadebyAlfaLavalwithoutpriornoticeSuchchangesareincorporatedinneweditionsofthisinstruction
manual
AlfaLavalKoldingA/SAllrightsreserved
TheAlfaLavallogotypeisatrademarkoraregisteredtrademarkofAlfaLavalCorporateAB"Toftejorg"isatrademarkorreg-
isteredtrademarkofAlfaLavalTheAlfaLavalToftejorg™TJ40GproducthasapendingpatentintheEPOmemberstates(EP
141997320),intheUSandinothercountriesOtherproductsorcompanynamesmentionedhereinmaybethetrademarksof
theirrespectiveownersAnyrightsnotexpresslygrantedhereinarereserved
3.4Marking
AlfaLavaltankcleaningmachinesaremarkedtoallowforrecognitionoftypeofmachine,machinename,serialnumberand
manufacturingaddress
Themarkingisplacedonthebodyofthetankcleaningmachine
Serial Serial
Serialnumber number numberexplanation explanation explanation
Machinessuppliedwithorwithoutstandarddocumentation:
yyyy-xxxxx:serialnumber
yyyy:year
xxxxx:5digitsequentialnumber
Markingarea
9

3Introduction
TJ40G
3.5ATEX/IECExmarking
TheAlfaLavalToftejorgTJ40GiscertifiedascategoryIcomponentTheATEXcertificationiscarriedoutbytheNotifiedBody
SGSFimkoOy,whohasissuedthecertificatenoBaseefa17ATEX0018X
TheIECExcertificationiscarriedoutbytheCertificationBodySGSBaseefaLtd,whohasissuedthecertificatenoIECExBAS
170017X
Note Note
Note
Explosionprotectiontypeisconstructionalsafety“c”
ThemarkingontheATEX/IECExcertifiedAlfaLavalToftejorgTJ40Gisasfollows(forinformationonmarkingpositionseesection
34Marking):
Serial Serial
Serialnumber number numberexplanation: explanation: explanation:
Machinessuppliedwithorwithoutstandarddocumentation:
yyyy-xxxxx:serialnumber
yyyy:year
xxxxx:5digitsequentialnumber
10

3Introduction
TJ40G
3.6ATEX/IECExtemperatureclassandcode
Themaximumsurfacetemperaturedependsmainlyonoperatingconditionswhicharethetemperatureofthecleaningfluidand
theambienttemperature
Gr Gr
Group oup oupII II IIEPL EPL EPLGa Ga Ga
Thegastemperatureclassiscorrectedwithasafetymarginof80%duetoarequirementforGroupllEPLGaequipment
Thegastemperatureclassdependsonthecleaningfluidtemperatureortheambienttemperature,whicheverofthetwois
thehighest
Tablefordeterminingtemperatureclass(gasatmospheres)
TemperatureClassCleaningfluidTemperature,
Tp(°C)
Ambienttemperature,
Tamb(°C)
85°C(T6)≤+68°C≤+68°C
100°C(T5)≤+80°C≤+80°C
135°C(T4)≤+108°C≤+108°C
175°C≤+140°C≤+140°C
Gr Gr
Group oup oupIII III IIIEPL EPL EPLDa Da Da
Thedusttemperatureclassdependsonthecleaningfluidtemperatureortheambienttemperature,whicheverofthetwois
thehighest
Nodustlayerisconsidered
Tablefordeterminingtemperatureclass(dustatmospheres)
TemperaturecodeCleaningfluidtemperature,
Tp(°C)
Ambienttemperature,
Tamb(°C)
T85°C≤+85°C≤+85°C
T100°C≤+100°C≤+100°C
T135°C≤+135°C≤+135°C
T140°C≤+140°C≤+140°C
Exampleofgasclassdetermination
Cleaningfluidtemperatureis67°Candambienttemperatureis75°C
Gasclass=T5
ATEX/IECExmarkingontheequipment:
II1GExhIIC85°C…175°CGa
II1DExhIIICT85°C…T140°CDa
3.7Qualitysystem
TheAlfaLavalToftejorgTJ40Gisdesignedtobebest-in-classonhygienicdesignusingrecognisedprinciplesofhygienicdesign
whereverfeasibleItisproducedaccordingtoAlfaLavalKolding’sISO-9001internationalStandardcertifiedqualitysystemAll
partsaremadefromcertifiedmaterialandallnon-metalpartsaremadefromFDAandEU10/2011compliantmaterials
11

4Installation
TJ40G
4.1Generaldescription
TheAlfaLavalToftejorgtankcleaningmachineisamediadrivenandmedialubricatedtankcleaningmachineNolubricating
substancessuchasoil,greaseetcareusedAllmaterialscomplywithFDA21CFR§177andforpolymersalsoEU10/2011
Themachineisself-cleaningieallinternalandexternalsurfacesarecleanedduringnormaloperation
ForuseinexplosivehazardzonestheATEX/IECExversioncanbeused,provideditisinstalledaccordingtosafetyinstructions
inlocalregulations
4.2Functioning
Theflowofcleaningfluidintothemachinepassesthroughaturbine,whichaccordinglyissetintorotationThroughagearset,
theturbinerotationistransmittedtothecleanerhead
ThecombinedmotionofthemachinebodyandthenozzlesensuresafullyindexedtankcleaningcoverageAfter55/8rev-
olutionsofthehubcoverwithnozzles(53/8revolutionsofthemachinebody),onecoarsecleaningpatternislaidoutonthe
tanksurfaceandthefirstcyclehasbeenmadeDuringthefollowingcycles,thispatternisrepeated7times,eachofwhichis
displaced,andthepatterngraduallybecomesmoredenseFinally,after8cycles-atotalof45revolutionsofthehubcoverwith
nozzles(43revolutionsofthemachinebody),acompletecleaningpatternhasbeenlaidout,andthefirstpatternisrepeated
(figure1)
FirstcycleSecondcycleThirdcycleForthcycle
Figure1:Buildupofpatternforcylindricaltankwiththemachineplacedinthecentre
Thenumberofcyclesneededtoperformapropercleaningdependsontypeofsoilage,positionofthetankcleaningmachine,
cleaningprocedure,cleaningtemperatureandcleaningagent
Forsubstancesthatareeasilymobilised,ieareeasytoremove,onecyclecouldbesufficientwhileincasesofmoreheavy
soilage(highviscous,stickysubstances,etc)amoredensepattern(morecycles)areneeded
TherotationspeedoftheturbinedependsontheflowratethroughthemachineThehighertheflowrate,thehigherthe
speedofrotationInordertocontroltheRPMofthemachineforawiderangeofflowrates,themachinehasdifferentturbines
accordingtothenozzlesize
12

4Installation
TJ40G
Apartfromthemainflowflushingthegearandthehub,andthereafter
formingthejetsthroughthenozzles,fluidisflushedthroughallinter-
nalareas,throughbevelgear,ballbearingsandgapsbetweenmoving
partsandfinallyalsousedforcleaningoftheoutsidesurfacesofthe
machineInthebottomofthebody,adrainholeispresenttoensure
self-drainingThisself-drainingisonlyensured,ifthemachineisin-
stalledinuprightposition
Theconeiscleanedfromthepatentpendingdesignofthehub;this
isbyimpactandsheetingaction
Thethreadedconnectionbetweendownpipeandmachineisnota
productcontactsurfaceasitisenclosedusingtwosealsandthe
weldingadaptorIfneeded,aweldingadaptor,dependingondownpipe
dimensions,mustbeorderedseparately(seepage43ff)
Forallversions:
Fordeviceswithtaperedthreadconnectionstothedownpipe,itis
recommendedthatyousecuretheconnectioninamannerappropriate
fortheapplicationSubjecttotheintendeduseenvironmentandany
inhouseuserrequirementsorpolicies,anadhesivesuchasLoctiteNo
2046orequivalentcouldbeusedOthermethodscouldbeacceptable
andsubjecttocustomerpreference
A:Downpipe
B:Weldingadapter
C:SealPTFE
D:SealEPDM
13

4Installation
TJ40G
4.3Generalsafetyandinstallationinstructions
Duringhandlingandinstallationhandlethemachinewithcareinordernottodamagethesurfacefinishofthemachine
Uponarrivalcheckthatthemachineisinoperatingconditionusingan8mmsocketwrenchontheturbineshaftandeasilyturn
theturbineshaftanti-clockwiseIfresistanceisrecognized,disassembledthemachinetolocalizethecause
NOTE NOTE
NOTE
Donottrytoturnthehubwithhubnozzlesbyhand,sincethismaydamagethegearThehubwithnozzlescanbeturnedby
blowingcompressedairthroughtheinletconnectionorusingasocketwrenchontopoftheturbineshaft
Beforeconnectingthemachinetothesystem,allsupplylinesandvalvesshouldbeflushedforremovalofforeignparticles
Thetankcleaningmachineshouldbeinstalledinverticalposition(uprightorupsidedown)Theinstallationandoperationshallbe
madesothattheself-drainingofthemachineisensured
Themachineshouldbescrewedtightlyontothesupplylineusinga65mmflatjawedspanner(toolNoTE81B147)ontheflats,
machinedontheinletconeSubjecttotheenvironmentofintendeduseandanyin-houseuserrequirementsorpoliciesadhesives
suchasLoctiteno2046couldbeusedtopreventtheconnectionfromlooseningduetoexcessivevibrationinthesystem
InordertoseparatetheCIPsystemfromtheprocessitisrecommendedtoinstallashutoffvalveclosetothemachineinlet
Thisalsopreventsback-flowofliquidfromthetankthroughthemachineincasethemachineissubmergedandthereis
anover-pressureinsidethetank
ItisrecommendedthatthefluidvalvefittedisofatypethatpreventshydraulicshocksHydraulicshocksmaycausesevere
damagetothemachineand/ortheentireinstallationIdeally,useafrequencycontrolledpumpwitharampfunctionforstart-up
tosupplythecleaningliquid
Largerparticlesmaygettrappedinthenozzles,whilesmallerparticlesmaybegettrappedinthesmallerclearancesofthe
machineandincreasewearMagnitudeoftheissuesreliesontheparticleshapeandproperties(egsoftvshard)Experience
showsthatAlfaLavaltankcleaningmachinesmayoperatewithstrainersizeslargerthanrecommendedbelowContactyour
localAlfaLavalofficeforsupport
ForlowamountsofparticlesintherecirculatingCIPliquidlargerparticlesshouldbeavoidedandinthiscasea3mmstrainer
maybesufficientforareliableoperation
ForhighamountsofparticlesintherecirculatingCIPliquiditisrecommendedtoinstallastraineraccordingtothesmallest
clearanceinthemachinesFortheTJ40Gastrainerof01mmisrecommendedandfortheTJ40G-HDastrainerof1mmis
recommended
NOTE NOTE
NOTE
ThemachineshallbeinstalledinaccordancewithnationalregulationsforsafetyandotherrelevantregulationsandstandardsIn
EU-countriesthecompletesystemmustfulfiltheEU-machineDirectiveanddependingofapplication,theEU-PressureEquipment
Directive,theEU-ATEX/IECExDirectiveandotherrelevantDirectivesandshallbeCE-markedbeforeitissetintooperation
W W
War ar arning: ning: ning:Precautionsshallbemadetopreventstartingofthecleaning/mixingoperation,whilepersonnelareinside
thetankorotherwisecanbehitbyjetsfromthenozzles
Forinformationonuseinpotentialexplosiveatmospheresseeparagraph44Specificconditionsforsafeuseinaccordancewith
ATEX/IECExcertificationpage15
14

4Installation
TJ40G
4.4SpecicconditionsforsafeuseinaccordancewithATEX/IECExcertication
Dir Dir
Directive ective ective2014/34/EU 2014/34/EU 2014/34/EU
NOTE NOTE
NOTE
Explosionprotectiontypeisconstructionalsafety“c”
W W
War ar arning: ning: ning:Operated Operated
Operatedin in ina a ahazar hazar hazardous dous dousar ar area ea ea
Theunitmybeoperatedinahazardousareaonlywhencompletelyfilledwithcleaningfluid/steam
Ifamediumotherthanthecleaningfluid/steamispassedthroughtheequipment,theflowmustnotbehigh
enoughtocausetheequipmenttooperate
W W
War ar arning: ning: ning:Operating Operating
Operatingguidance guidance guidance
TheunitshallbeoperatedinlinewithguidanceprovidedbyIEC/TS60079-32-1fortankcleaning
W W
War ar arning: ning: ning:T T Temperatur emperatur emperature e eclass class classand and andambient ambient ambienttemperatur temperatur temperature e erange range range
Themaximumsurfacetemperaturedependsmainlyonoperationsconditionswhichisthetemperatureofthe
cleaningfluidandambienttemperature
Thetemperatureclassandambienttemperaturerangeareshowninparagraph36ATEX/IECExtemperature
classandcode,page11
W W
War ar arning: ning: ning:Max Max Maxpermitted permitted permittedtemperatur temperatur temperature e e
Whenworking:
Themaximumpermittedcleaningfluidtemperatureandambienttemperatureis95°C
Whennotworking:
Themaximumpermittedambienttemperatureis140°C
W W
War ar arning: ning: ning:Draining Draining Drainingusing using usingcompr compr compressed essed essedair air air
Drainingusingcompressedairmustnotbedoneinexclassifiedzone
Drainingusingcompressedairispossibleinnonexclassifiedzones(seepage18)
W W
War ar arning: ning: ning:Earthing Earthing Earthing
Allmetalandotherconductiveordissipativematerialshouldbeconnectedtoearthwiththeexceptionofvery
smallitems
ForfurtherinformationseeIEC/TS60079-32-1:2013Explosiveatmospheres–Part32-1:Electrostatichazards,
guidanceWithfocusonclause623,721,73,792,13
W W
War ar arning: ning: ning:Earthed Earthed Earthedwhen when whenin in inuse use use
Theunitmustbeeffectivelyearthedatalltimeswheninuse
15

4Installation
TJ40G
44SpecificconditionsforsafeuseinaccordancewithATEX/IECExcertification
W W
War ar arning: ning: ning:Max Max Maxpermitted permitted permittedsteaming steaming steamingtemperatur temperatur temperature e e
Themaximumpermittedsteamtemperaturetroughthemachineandambienttemperatureis140°C
W W
War ar arning: ning: ning:Steaming Steaming
Steamingtanks tanks tankslarger larger largerthan than than100 100 100m³ m³ m³
Tankswithcapacitieslargerthan100m³thatcouldcontainaflammableatmosphereshouldnotbesteam
cleaned,assteamcleaningtanksproducesanelectrostaticallychargedmistTankssmallerthan100m³may
besteamcleaned
ForfurtherinformationseeIEC/TS60079-32-1:2013Explosiveatmospheres–Part32-1:Electrostatichazards,
guidanceWithfocusonclause710and85
T T
Tank ank anksize size sizeinformation information information
NOTE:Thetankcleaningmachinehasbeencertifiedbyaccreditednotifiedbodyandcanoperateintankshavinganenclosed
volumeupto100m³aslongasallATEX/IECExwarningsintheinstructionmanualarecompliedwith
General General
Generalguidelines guidelines guidelinesfor for fortanks tanks tankslarger larger largerthan than than100 100 100m m m3 3
3: :
:
Tankslargerthan100m³mustnotbesteamcleaned–SeeguideIEC/TS60079-32-1:2013clause7105and85
Tousetheunitintankslargerthan100m³ispossibleundercertainconditions
Itisnecessarytoknowthecurrentfactorssuchastanksize,cleaningsolventandproduct
Additivescanbeusedinthecleaningsolvent,or,forexample,thetankcanbefilledwithnitrogenThebasicguidelinesare
describedintheguideIEC/TS60079-32-1:2013
Itmustbeensuredthattheequipollentlybondingofallconductivemetalobjectsisinaccordancewithnationalregulations
foruse
Thecleaningfluidconductivitymustcorrespondtotheproductsinthegroup“Highconductivity”,cfIEC/TS60079-32-1:2013
clause71and72
Highconductivity>10000pS/m
Mediumconductivitybetween25×εrpS/mand10000pS/m
Lowconductivity<25×εrpS/m
Forliquidswithadielectricconstantofaround2,(eghydrocarbons),theseclassificationsreduceto:
Highconductivity>10000pS/m
Mediumconductivitybetween50pS/mand10000pS/m
Lowconductivity<50pS/m
FollowingaguidancedocumentsuchasIEC/TS60079-32-1:2013toestablishsafeuseofmachineryandprocessistheusers
ownresponsibilityandisnotcoveredbytheATEX/IECExcertificationforthisunitexceptfortanksupto100m3Forfurther
informationseeIEC/TS60079-32-1:2013Explosiveatmospheres–Part32-1:Electrostatichazards,guidancewithfocuson
clause713,714,721,724
16

4Installation
TJ40G
44SpecificconditionsforsafeuseinaccordancewithATEX/IECExcertification
W W
War ar arning: ning: ning:Pr Pr Process ocess ocessgenerated generated generatedelectr electr electrostatic ostatic ostatic
Theusermustaddresstheelectrostatichazardsgeneratedfromtheprocessoftheequipmentinaccordance
withguidancedocumentIEC/TS60079-32-1:2013
W W
War ar arning: ning: ning:Electr Electr Electrostatically ostatically ostaticallycharged charged chargedliquid liquid liquid
Liquidscanbecomeelectrostaticallychargedwhentheymoverelativetocontactingsolidsorthesprayingof
liquidscanalsocreateahighlychargedmistorsprayTheliquidmustbemadeelectricallyconductiveby
additivesorotherwise
ForfurtherinformationseeIEC/TS60079-32-1:2013Explosiveatmospheres–Part32-1:Electrostatichazards,
guidanceWithfocusonclause713,714,721,724
W W
War ar arning: ning: ning:Appr Appr Appropriate opriate opriatecleaning cleaning cleaningfluid fluid fluid
Thecleaningfluidshouldbeappropriatefortheapplication(egsonochemicalreactioncantakeplacebetween
thecleaningfluidandtheresidueofprocessfluid/powder/compoundwhichcangenerateheatorahybridmixture)
ChemicalreactionsinZone20-Hybridmixtures:
End-usermustensurethatthecleaningfluiduseddoesnotcreateahybridmixtureaccordingtoIEC
60079-10-1:2015AnnexI1inconnectionwithpowder/dustresiduesinthetankinzone20
Thisshouldensurethattheatmospheredoesnotchangetoaclassificationthatliesoutsidethemachine's
certifiedscopeWhenthemachineisusedforcleaningtankscontainingpotentiallyflammabledustatmospheres,
andapotentiallyflammablefluidisusedasthecleaningfluidthenanassessmentofthehybridmixtureshallbe
undertakenbytheuser,priortooperation
ForfurtherinformationseeIEC60079-10-1:2015Explosiveatmospheres–Part10-1:Classificationofareas–
ExplosivegasatmospheresWithfocusonclause366andAnnexI–Hybridmixtures
W W
War ar arning: ning: ning:Fluid Fluid Fluidpr pr pressur essur essure e e
Themaximumpermittedcleaningfluidpressureis12bar
In In
Inaddition addition additionto to tothe the theabove above abovementioned mentioned mentionedpr pr precautions ecautions ecautionsr r relating elating elatingto to toDir Dir Directive ective ective2014/34/EU, 2014/34/EU, 2014/34/EU,the the theSafety Safety SafetyPr Pr Precautions ecautions ecautionson on onpage page page14 14 14must must must
be be
beobserved observed observed
17

5Operation
TJ40G
5.1Normaloperation
Cleaning Cleaning
CleaningMedia Media Media
UseonlymediacompatiblewithStainlessSteelAISI316,SAF2205,PEEK,PFAHPandEPDMNormaldetergents,moderate
solutionsofacidsandalkalicsareacceptableAggressivechemicals,excessiveconcentrationsofchemicalsatelevated
temperatures,aswellascertainhypocritesshouldbeavoidedIfindoubt,contactyourlocalAlfaLavalsalesoffice
NOTE NOTE
NOTE
Donottrytoturnthehubwithnozzlesbyhand,sincethismaydamagethegearThehubwithnozzlescanbeturnedby
blowingcompressedairthroughtheinletconnectionorbyusingasocketwrenchontopoftheturbineshaft
PEEKisnotresistanttoconcentratedsulphuricacid
Pr Pr
Product oduct oduct
Incaseswherethemachineissubmergedin,orinotherwaysexposedto,productthecompatibilitybetweenstainlesssteel
AISI316,SAF2205,PEEK,PFAHPandEPDMandtheproductmustbeconsideredcarefully
NOTE NOTE
NOTE
EPDMswellssignificantlyexposedtofattymaterials
Pr Pr
Pressur essur essure e e
AvoidhydraulicshocksIncreasepressuregraduallyDonotexceed12barinletpressureRecommendedinletpressure:5-7
barHighpressureincombinationwithhighflowrateincreaseconsumptionofwearpartsHighpressurealsoreduces
thecleaningeffect
Draining Draining
Drainingusing using usingcompr compr compressed essed essedair air air
Ifthemachineisdrainedusingcompressedair,thenthecompressedairpressuremustnotcausethemachinebodyrotationto
exceed45rpm(correspondingtoapprox13secperrevofthebody)inordertoavoidriskofmachinebreakdown
Drainingshouldalwaysbedoneinsidethetank
Seeparagraph44SpecificconditionsforsafeuseinaccordancewithATEX/IECExcertification(page15)
Steam Steam
Steamcleaning cleaning cleaning
Ifstreamcleaningisdonethroughthemachine,thesteampressuremustnotcausethemachinebodyrotationtoexceed10
rpm(correspondingtoapprox6secperrevofthebody)inordertoavoidriskofmachinebreakdownSeeparagraph44
SpecificconditionsforsafeuseinaccordancewithATEX/IECExcertification(page15)
T T
Temperatur emperatur emperature e e
Themaximumrecommendedcleaningfluidtemperatureis95oCThemaximumrecommendedsteamtemperatureis140oC
Themaximumambienttemperatureis140oC
Seeparagraph44SpecificconditionsforsafeuseinaccordancewithATEX/IECExcertification(page15)
After After
Afteruse use usecleaning cleaning cleaning
AfteruseflushthemachinewithfreshwaterCleaningmediashouldneverallowtodryorsettleinthesystemduetopossible
"saltingout"or"scaling"ofthecleaningmediaIfcleaningmediacontainsvolatilechloridesolvents,itisrecommendednot not
notto to to
flush flush
flushwith with withwater water waterafteruse,asthismightcreatehydrochloricacid
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5Operation
TJ40G
5.2Safetyprecautions
ThemachineisintendedforuseinsideatankonlyAspeakvelocityofmainjetsreaches40m/sec,TheAlfaLavalToftejorg
TJ40Gmustnotbeoperatedinopenairorwhentankisopen
W W
War ar arning: ning: ning:HotchemicalsandsteamunderpressuremaybeusedforcleaningandsterilisingProtectagainstscalding
andburningNevertamperwithortrytoopenclampsorotherconnectionswhilesystemisinoperationMake
surethatsystemisdepressurisedanddrainedbeforedisassembly
ThecleaningjetsimpingingthetanksurfaceareasourceofnoiseDependingonpressureanddistancetothetankwalls,noise
levelmayreachupto85dB
W W
War ar arning: ning: ning:Tanksmaycontainpoisonous/hazardousproductsorproductswhichrepresentanenvironmentalorsafety
riskNeveropentankanddismountthemachinewithoutcheckingprevioustankcontentsandnecessary
precautions
Seealso36ATEX/IECExtemperatureclassandcode,page11
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6Maintenance
TJ40G
6.1Preventivemaintenance
FollowingtheAlfaLavalPreventiveMaintenanceGuidelinesandusingtheAlfaLavalServiceKitsensurestheavailabilityofyour
equipmentatalltimesandenablesyoutoplanyouroperatingbudgetandyourdowntimeTheriskofunscheduledbreakdowns
duetocomponentfailureisvirtuallyeliminatedandinthelongtermyouroperatingcostsarereduced
AlfaLavalTankCleaningEquipmentServiceKitscontainallyouneedTheycomprisegenuine,traceableAlfaLavalspareparts,
manufacturedtotheoriginalspecifications
TherecommendedpreventivemaintenanceprogramisbasedontankcleaningmachinesworkinginaverageconditionsHow-
ever,atankcleaningmachine,exposedtoheavysoilingandrecirculationCIPliquidcontainingabrasivesand/orparticulates(see
section43Generalsafetyandinstallationinstructionsforstrainerrecommendations),needsmorefrequentattentionthanone
exposedtolight/nosoilingandrecirculationwithordinaryCIPliquidAlfaLavalKoldingA/Srecommendsthatyouadjustthe
maintenanceprogramtosuitthecleaningtaskinhandContactyourlocalAlfaLavalsalesofficefordiscussion
ForfurtherinformationregardingAlfaLavalServiceKitsandserviceintervals,seeparagraph63MaintenanceIntervalsandservice
kitsonpage21ofthismanualortheSparePartsManual
NOTE NOTE
NOTE
HandletheAlfaLavalToftejorgmachinewithcareTakeproperactiontoprotectsurfacesfrombeingdamaged
AlwaysuseonlypropertoolsandtheAlfaLavalToftejorgTJ40Gstandardtoolkit(page22)Neveruseforce,hammerorpry
componentstogetherorapartAlwaysperformallassembly/disassemblystepsintheorderdescribedinthismanual
CleanallsurfacespriortoassemblingEspeciallytakecareofthematingsurfacesWorkinaclearwell-lightedworkarea
Accordingto“Regulation(EC)No1935/2004-Article17”effectivefrom27thofOctober2006,producersoffoodshallensure
traceabilityofthematerialsandarticlesintendedtocomeintocontactwithfoodstuffsItisrecommendedthatatraceability
systemissetupforreplacementofwearpartsandsparepartsThismakesitpossibletoidentifyintowhichmachineagiven
wearpartorspareparthasbeeninserted
6.2ServiceandrepairofATEX/IECExcertiedmachines
AllserviceandrepairofATEX/IECExcertifiedmachinescanbeperformedbyAlfaLavalKoldingA/S,Denmark,
orbyanAlfaLavalservicecenterapprovedbyAlfaLavalKoldingA/S
ChangestothemachinearenotallowedwithoutapprovalbythepersonresponsiblefortheATEX/IECEx
certificationatAlfaLavalIfchangesaremade–orsparepartsotherthanAlfaLavaloriginalsparepartsareused
-theECTypeExaminationcertification(theATEX/IECExDirective)isnolongervalid
InordertoensurecompliancewiththeATEX/IECExregulationsandkeepthemachineATEX/IECExcertification
valid,theserviceorrepairmustbeperformedbyanauthorizedpersonwithknowledgeoftheATEX/IECEx
requirementsandregulationsAllsparepartsmustbeoriginalAlfaLavalsparepartsandtherepairorservice
mustbedoneaccordingtotheinstructionsinthismanual
W W
War ar arning: ning: ning:
Ifacustomerwishestocarryoutserviceorrepairhimself,itistheresponsibilityoftherepairshoptoensurethat
theATEX/IECExrequirementsaremetinanywaypossibleAfterperformingserviceorrepair,therepairshop
thuscarriesthefullresponsibilityfortraceabilityofallrelevantdocumentsinordertoensuringtheretentionofthe
ATEX/IECExcertificationofthemachine
20