Alfalaval Toftejorg TZ-79 User manual

Instruction Manual
Toftejorg™ TZ-79
IM-TE91A350-EN9
ESE01798EN
Date of issue: January 8, 2015
First published: 1988
Covering ▪Standard Machines
▪Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC
Original manual
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Contents
Contents...................................................................................................................................1
Introduction...............................................................................................................................3
Intended Use............................................................................................................................4
Patents and trademarks............................................................................................................4
ATEX Marking...........................................................................................................................5
General Description ..................................................................................................................6
Functioning................................................................................................................................................6
Standard configurations.............................................................................................................................7
Available add-ons......................................................................................................................................7
Standard options........................................................................................................................................7
Technical data ..........................................................................................................................8
Installation and Normal Operation ...........................................................................................12
General Installation and Safety Instructions.............................................................................................12
Normal Operation.....................................................................................................................................14
Special Conditions for Safe Use in accordance with the ATEX Certification, Directive 94/9/EC..............15
Maintenance and repair...........................................................................................................17
Service and Repair of ATEX Approved Machines....................................................................................17
Preventive Maintenance..........................................................................................................................18
Top Assembly..........................................................................................................................................20
Bottom Assembly.....................................................................................................................................22
Hub Subassembly....................................................................................................................................24
Stem Subassembly..................................................................................................................................26
Gear Subassembly ..................................................................................................................................28
Replacement of Collar Bushes ................................................................................................................30
Replacement of Ball races.......................................................................................................................32
Replacement of Main Collars...................................................................................................................34
Tools ......................................................................................................................................36
Standard Tool kit for Toftejorg TZ-79.......................................................................................................36
Sketch of tools for replacement of Main collars.......................................................................................37
Trouble Shooting Guide..........................................................................................................38
Reference List of Parts............................................................................................................40
Cross Sectional Drawing.........................................................................................................41
Service Kits.............................................................................................................................42
General Information ................................................................................................................44
How to Order Spare Parts........................................................................................................................44
Service and Repair..................................................................................................................................44
How to contact Alfa Laval Tank Equipment.............................................................................................44
EC Declaration of conformity...................................................................................................45
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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.
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing
intellectual property and thereto related rights. It is the responsibility of the user of this document to
comply with all applicable intellectual property laws. Without limiting any rights related to this
document, no part of this document may be copied, reproduced or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the
expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB will enforce its rights
related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
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Intended Use
It is to be verified by the end-user:
- that the tank cleaning machine is in conformity with respect to tank, vessel or container size in
which it will be used.
- that the construction materials (both metallic and non-metallic) are compatibility with product,
flushing media, cleaning media, temperatures and pressure under the intended use.
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.
ToftejorgTM is a trademark or registered trademark of Alfa Laval Kolding A/S. Other products or
company names mentioned herein may be the trademarks of their respective owners. Any rights not
expressly granted herein are reserved.
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If ordered with ATEX certificate:
ATEX Marking
The Toftejorg TZ-79 is certified as category I components. The certification is carried out by the
certified body Baseefa, who has issued the certificate no. 10ATEX0188X. The marking on the ATEX
certified Gunclean Toftejorg TZ-79 is as follows:
“TZ-xx”: TZ machine type
Serial number explanation
Machines supplied with or without normal documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
Changes to the machine are not allowed without approval by the person responsible for the ATEX
certification at Alfa Laval Tank Equipment. If changes are made – or spare parts other than Alfa Laval
original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no longer
valid.
Important
ATEX
information:
Also see page 17 regarding special conditions for repair of ATEX certified
machines.
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General Description
The Toftejorg TZ-79 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)
(3/4” thread connection)
Article No.
Top cone:
2” NPT,
Female 100% 4xø8
4xø9
2xø11
TE22D110
TE22D112
TE22D116
0% 4xø9
4xø10 TE22D130 TE22D132
Top cone:
2” BSP,
Female 100% 4xø8
4xø9
2xø11
TE22D210
TE22D212
TE22D216
0 % 4xø9
4xø10 TE22D230 TE22D232
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.
Available add-ons
ATEX, category 1 for installation in zone 0/20
TE22DXXX-70 ATEX
Explanation to Add-ons
ATEX, category 1 for installation in zone 0/20 in accordance with Directive 94/9/EC
Standard options
Machines with polymer wear parts: TE22Dxxx-06.
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Technical data
Weight of machine
:
13 kgs (28,6 lb)
Working pressure
:
2-12 bar (30-175 psi)
Recommended inlet pressure
:
3-8 bar (45-120 psi)
Working temperature max.
:
95°(200°F)
Ambient temperature 0 – 140°C (95°C – 140°C when
not
operated)
Materials
:
Stainless steel AISI 316/316L, PTFE, Tefzel, PVDF, Carbon,
Teflon TFM, PEEK
Principal dimensions in mm
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Technical data (continued)
Flow rate
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Technical data (continued)
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
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Technical data (continued)
Cleaning Time f. complete Pattern (= 8 cycles)
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Installation and Normal Operation
General Installation and Safety 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.
For devices with tapered thread connections to the down pipe, it is recommended that you secure the
connection in a manner appropriate for the application. Subject to the intended use environment and
any in-house user requirements or policies, a liquid threadlocking adhesive such as Loctite No. 243 or
equivalent could be used. Other methods could be acceptable and subject to customer preference.
ATEX
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 DS/CLC/TR 50404:2003 Safety of Machinery, guidance and
recommendations for the avoidance of hazards due to static electricity.
Electrical equipment such as magnetic valves and electric actuators must not be installed in Ex-zones
without type approval and marking, corresponding to the EX-class in question.
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 depending of
application, the EU-Pressure Equipment Directive, the EU-ATEX Directive and other relevant
Directives and shall be CE-marked before it is set into operation.
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.
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Installation and Normal Operation (continued)
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.
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.
Recommended tightening torque: 50 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.
Rubber jaw mounted
upside down
Protect with rubber
pad
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Installation and Normal Operation (continued)
Normal Operation
Cleaning Media
Use only cleaning fluids compatible with Stainless Steel AISI 316/316L, PTFE, Tefzel, PVDF, Carbon,
PEEK and Teflon, TFM. 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 8-9). High pressure in combination
with high flow rate will increase consumption of wear parts.
ATEX
Warning: If stream cleaning is done through the machine, the steam pressure must not cause the machine to rotate.
ATEX
Warning: If the machine is drained using compressed air, then the compressed air pressure must not cause the machine to rotate.
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Installation and Normal Operation (continued)
Temperature
In accordance with the ATEX specifications regarding special conditions for safe use, see page16.
ATEX
Warning: Tanks with capacities greater than 100 m3that could contain a flammable atmosphere should not be steam cleaned, as steam issuing from a nozzle could contain charged
droplets.
Tanks smaller than this may be steam cleaned providing that: the steam nozzles and
other metal parts of the system are reliably earthed and grounded to the tank
structure.
ATEX
Warning: In potentially explosive atmospheres, the temperature must not exceed the maximum surface temperature according to the temperature class for the combustible gas or
liquid.
Special Conditions for Safe Use in accordance with the ATEX Certification,
Directive 94/9/EC
ATEX Warning: The unit may be operated, in a hazardous area, only when filled with the
process fluid.
ATEX Warning: The maximum permitted process fluid temperature and ambient temperature
when the machine is operating is 95°C.
When the machine is not operating, the maximum permitted ambient
temperature is 140°C.
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Installation and Normal Operation (continued)
Special Conditions for Safe Use in accordance with the ATEX Certification,
Directive 94/9/EC
ATEX Warning: The maximum permitted flush or cleaning fluid pressure difference across the
machine is 12 bar.
ATEX Warning: The unit must not be operated in a vessel having an enclosed volume of greater
than 100m3.
Tanks larger than 100 m³
To use Tank Cleaning Machines in tanks larger than 100m³ is possible under
certain conditions.
It is necessary to know the current factors such as tank size, cleaning solvent
and product.
Additives can be used in the cleaning solvent, or, for example, the tank can be
filled with nitrogen. The basic rules are described in the guide "CLC / TR
50404:2003“.
Following a guidance document such as "CLC / TR 50404:2003“ to establish
safe use of machinery and process is the users own responsibility and is not
covered by the ATEX certification for this product.
ATEX Warning: The unit must be effectively earthed at all times when In use.
ATEX Warning: The user must address the electrostatic hazards generated from the process of
the equipment in accordance with guidance document CLC/TR 50404:2003.
In addition to the above mentioned precautions relating to the ATEX guidelines Directive 94/9/EC of
March 23 1994, the Safety Precautions on page 12 must be observed.
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Maintenance and repair
Service and Repair of ATEX Approved Machines
In order to ensure compliance with the ATEX regulations for service and repair in accordance with EN
60079-19, all service and repair of ATEX approved machines should be performed by Alfa Laval Tank
Equipment, Kolding, Denmark.
ATEX
Warning: ATEX requirements regarding repair of ATEX approved machines according to EN 60079-19.
A tag with the following labelling information must be attached to the machine:
- Repair symbol R
- Alfa Laval logo and address
- Repair number
- Date of repair
- Machine serial number
The tag must be laminated and attached to the machine-downpipe outside the tank
using a cable tie.
If a customer wishes to carry out service or repair himself, it is the responsibility of the repair shop to
ensure that the ATEX requirements are met in any way possible. After performing service or repair, the
repair shop thus carries the full responsibility for the ATEX approval of the machine.
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Maintenance and Repair (continued)
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-79 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.
Note: Recommended tightening torque for all screws: 4-5 Nm.
Every 300 working hours
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with chemical cleaner and/or if desired
fine abrasive cloth.
3. Check Slide bearings (pos. 30) for wear. If hole is worn oval to max. diameter more than 12.4 mm,
Slide bearing should be replaced. If end face 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. 12) in Gear frame. If holes are worn oval to max. diameter more than
15.4 mm, Collar bush should be replaced. How to replace Collar bushes, see page 30.
Note:Timely replacement of Slide bearings and Collar bushes will prevent costly damage to the
gearbox.
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