Alfalaval HPM M-15 User manual

IM-TE91A920
First published: 2013-11
ESE02460-EN5 2017-01
Original manual
Instruction Manual
Alfa Laval Hybrid Powder Mixer HPM M-15 & HPM S-15
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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
1. EC Declaration of Conformity ....................................................................... 5
2. Product programme .................................................................................. 6
2.1. Standard ........................................................................................... 6
3. Safety .................................................................................................... 7
3.1. General hazards .................................................................................. 7
3.2. Intended use of the machine .................................................................... 7
3.3. Protective measures .............................................................................. 7
4. Specific safety instructions and the symbols used ............................................. 8
4.1. Important information ............................................................................. 8
4.2. General safety instructions ....................................................................... 8
4.3. Basic safety measures during normal operation ............................................... 9
4.4. Basic safety measures during maintenance, repair and cleaning ............................ 10
4.5. Working on the electrical equipment ............................................................ 11
4.6. Working on the flush tank ........................................................................ 11
4.7. Observe the environmental protection instructions ............................................ 11
4.8. Residual risks ..................................................................................... 12
5. Functioning ............................................................................................. 13
5.1. Function description .............................................................................. 13
5.2. Construction of the AL HPM ..................................................................... 14
6. Setting up and installation ........................................................................... 17
6.1. Unpacking and setting up ........................................................................ 17
6.2. Connecting the product pipes ................................................................... 17
6.3. Flush tank and axial face seal ................................................................... 18
6.4. Power supply ...................................................................................... 18
7. Commissioning ........................................................................................ 19
7.1. Connecting the AL HPM to a mixing tank ...................................................... 19
7.2. Brief test ........................................................................................... 20
7.3. Information on working with products .......................................................... 21
7.4. Powering up the machine ........................................................................ 21
8. Cleaning and maintenance .......................................................................... 22
8.1. Cleaning (CIP) ..................................................................................... 22
8.2. The axial face seal ................................................................................ 22
8.3. C-Ball Valve ........................................................................................ 22
8.4. Rotor/Stator ....................................................................................... 22
8.5. Barrier fluid installation ........................................................................... 22
8.6. Drive ................................................................................................ 22
9. Installation and removal .............................................................................. 23
9.1. Rotor/Stator ....................................................................................... 23
9.2. Installing the drive ................................................................................. 23
10. Technical data ......................................................................................... 24
11. Operational data ....................................................................................... 26
11.1.Technical data ..................................................................................... 26
11.2.Dimensions/weight ............................................................................... 27
12. HPM-M15 - parts drawings and lists .............................................................. 28
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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
12.1.Powder Mixer complete, HPM-M15 ............................................................ 28
12.2.Base frame ........................................................................................ 30
12.3.Butterfly valve ..................................................................................... 32
13. HPM-S15 - parts drawings and lists ............................................................... 34
13.1.Powder Mixer complete, HPM-S15 ............................................................. 34
14. HPM-M15 & HPM-S15 - common parts, part drawings and lists ............................. 36
14.1.Flush container .................................................................................... 36
14.2.C-ball valve ........................................................................................ 38
14.3.Inlet tube ........................................................................................... 40
14.4.High shear and pump unit ....................................................................... 42
15. Additional documents ................................................................................ 44
16. General information ................................................................................... 45
16.1.Service and repair ................................................................................ 45
16.2.Warranty ........................................................................................... 45
16.3.How to contact Alfa Laval Kolding A/S ......................................................... 45
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1 EC Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Hybrid Powder Mixer
Designation
Alfa Laval HPM-M15 & HPM-S15
Type
From serial number 50001 to 60000
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) 1935/2004 and Regulation (EC) No. 10/2011
- Low Voltage Directive (LVD) 2006/96/EF Directive 2006/95/EC on low voltage
- EMS Directive 2004/108/EF
- ROHS Directive 2002/95/EEC
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 Signature
Kolding 2016-09-01
Place Date
(This Declaration of Conformity replaces Declaration of Conformity dated April 7, 2014)
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2 Product programme
This manual covers the product program for Alfa Laval Hybrid Powder Mixer HPM-M15 and HPM-S15.
2.1 Standard
HPM-M15
Version Item no. Motor Funnel Inlet Outlet
Frequency converter, for
voltage
US TE35A001
NEMA TEFC Wash
Down (IP66) 40 l TriClamp TriClamp 3 Phase 380-480 Vac (±10%)
50-60 Hz
CANADA TE35A002
NEMA TEFC Wash
Down (IP66) 40 l TriClamp TriClamp
3 Phase 525-690 Vac (±10%)
(Canada) 50-60 Hz
ROW TE35A000 IEC IP55 + Shroud 40 l DIN DIN
3 Phase 380-480 Vac (±10%)
50-60 Hz
HPM-S15
Version Item no. Motor Funnel Inlet Outlet Motor voltage
US/CAN 9614302801 NEMA TEFC Wash
Down (IP66)
40 l TriClamp TriClamp 3 Phase 230/460 Vac (±10%)
60 Hz
ROW 9614302701 IEC IP55 + Shroud 40 l DIN DIN 3 Phase 380-420D/660- 690Y
50 Hz
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3 Safety
This manual covers the product program for Alfa Laval Hybrid Powder Mixer HPM-M15 and HPM-S15.
3.1 General hazards
The machine is not dangerous in itself, provided that it is used as intended. To prevent injury to people and damage to the
machine, it must only be operated as intended. However, the manufacturer is unable to foresee dangers that may result from
installing or combining the machine with other machines. The machine operator must observe the safety instructions when
operating the machine. The machine may only be operated by authorised, trained operators. The machine may only be
commissioned when fully installed.
3.2 Intended use of the machine
The machine is used for wetting and dispersing powder in fluids and also for blending fluids in fluids. The machine is suitable
for producing products with viscosities up to 500 mPas, based on the viscosity at the powder mixer impeller in the case of
Newtonian products.
To protect the mixing tools against damage by foreign objects, e.g. screws, stones, pieces of wood, etc., we recommend the
use of suitable measures to prevent such objects from entering the machine. The safety mesh provided is one such measure
and should be used at all times. Place the safety mesh in the funnel before introducing the powder.
3.3 Protective measures
Operator’s duty of care
The machine (including the sub-assemblies) has been designed and built taking into account a risk analysis and after careful
selection of harmonised standards and other technical specifications to be observed. It therefore conforms to the state of the
art and provides maximum safety in operation.
However, the safety of the machine in practice can only be achieved if all the necessary measures are adopted for this purpose.
It is part of the machine operator’s duty of care to plan these measures and monitor their implementation.
In particular, the operator must make sure that:
- the machine is only used as intended
- the machine is only operated if it is in perfect working order and, in particular, the functioning of the safety devices is
checked regularly
- the necessary personal protection for operating, maintenance and repair personnel is both available and worn
- the operating instructions are always legible and complete versions are available at the place where the machine is installed
- only duly qualified and authorised personnel operates, maintains and repairs and the machine
- this personnel is instructed regularly in all relevant issues relating to health and safety in the workplace and protection of the
environment and is also familiar with the operating instructions and the safety information contained in those instructions
- safety and warning information on the machine is not removed and it is legible
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4 Specific safety instructions and the symbols used
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the Mixer!
4.1 Important information
The following operating instructions include specific safety information that refers to unavoidable residual risks when operating
and maintaining the machine. The residual risks include risks for:
-people
- product and machine
- the environment
The symbols used in the operating instructions must draw attention to the safety instructions in particular.
WARNING
Indicates that personal danger in particular is to be expected. (danger to life, risk of injury).
CAUTION
This symbol means that danger is to be expected in particular for machine, material and the environment.
NOTE
This symbol is not a safety instruction, but provides information to allow a better understanding of the machine operations.
The English version of the instruction manual is the original manual. We make reservations in regard to possible mistranslations in
language versions of the instruction manual. In case of doubt, the English version of the instruction manual applies.
4.2 General safety instructions
Changes may only be made to the installation or parts of it subject to the written consent of ALFA LAVAL, otherwise, the
warranty and declaration of conformity will lapse.
The machine is live when the power supply is connected. This voltage can have life-endangering effects on contact.
We reserve the right to make technical changes.
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4 Specific safety instructions and the symbols used
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the Mixer!
4.3 Basic safety measures during normal operation
Before switching on the machine, make sure you know what to do in the event of an incident.
The machine may only be operated by qualified, authorised personnel, who are familiar with the operating instructions (including
those for the sub-assemblies) and are able to work accordingly!
Replace all hoses regularly as a preventive maintenance measure, even if not obviously damaged). (Observe the manufacturers’
information)
If components of the installation are temperature-controlled, there is a risk that parts not insulated and supply lines may catch
fire above a temperature of 65°C. In this case, the operator must protect the hot parts against contact.
If water is used as a barrier medium, it must be cooled at temperatures above 85°C, otherwise, the seal may be damaged.
NOTE!
Check the level (sight glass) of the flush tank every day. If the axial face seal is flushed with fresh water, make sure the flow
volume is sufficient (0.25-0.5 l/min.).
NOTE!
The machine may not be commissioned (even briefly) if the barrier medium circuit is not intact, otherwise the axial face seal
may be destroyed.
NOTE!
The machine is not suitable for processing pure dry substances without the use of fluids. This can cause serious damage to
the machine.
NOTE!
When changing the dry substance, check whether the materials of the axial face seal and of the O-rings are still compatible. In
some cases, it is necessary to change the parts for different materials. If there is any doubt, consult the supplier.
NOTE!
After all the installation work has been completed, the movement of the drive shaft must be checked on the machine by rotating
it manually before the drive is switched on. Make sure the drive cannot be switched on accidentally.
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4 Specific safety instructions and the symbols used
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the Mixer!
4.4 Basic safety measures during maintenance, repair and cleaning
The machine may only be maintained according to the safety instructions by qualified, authorised persons, who are familiar with
the operating instructions (and those for the sub-assemblies) and can work accordingly.
Before maintenance and repair work, switch off the main power supply switch and secure with a padlock. The person carrying
out the maintenance or repair work must keep the key to this lock.
When changing heavy machine parts, only use suitable and safe load handling devices and sling gear.
Before any maintenance and repair work, make sure that any parts of the machine which may be touched have cooled
down to room temperature.
Before any maintenance or repair work, make sure that unauthorised persons cannot access the work area. Attach or set up a
sign drawing attention to the maintenance or repair work in progress.
Observe the inspection and maintenance intervals specified in the operating instructions.
Observe the maintenance and repair instructions for sub-assemblies included in these operating instructions.
Dispose of environmentally hazardous lubricants, coolants or cleansing agents in a responsible manner.
NOTE!
After all the installation work has been completed, the movement of the drive shaft must be checked on the machine by rotating
it manually before the drive is switched on. Make sure the drive cannot be switched on accidentally.
NOTE!
The rotor shaft nut must be tightened by hand and then with a torque wrench (tightening torque approximately 30 Nm). It is also
advisable to lock the thread with a liquid thread lock, such as Loctite, for example.
NOTE!
Any work on the axial face seal must be done very carefully. The seals consist of a brittle material and are therefore sensitive
to shocks. Avoid impact.
The cleaning (CIP) of the powder mixer is carried out in combination with the cleaning of the tank or when cleaning the pipe
system of the entire installation. The funnel and the ball valve must be removed and replaced by the blind flange supplied. This
guarantees that no CIP fluid, such as soda lye or acid, for example, will leak out if the ball valve is opened accidentally.
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4 Specific safety instructions and the symbols used
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the Mixer!
4.5 Working on the electrical equipment
NOTE!
Switch on briefly to check whether the motor is rotating in the direction indicated (arrow on the pump housing).
NOTE!
The machine connection must comply with VDE standards.
When the motor is connected to the power supply, check that the motor voltage, frequency converter and mains voltage
correspond.
The voltages are indicated on the motor rating plate or the frequency converter data sheet.
Only qualified electricians may repair the machine’s electrical equipment.
Check the electrical equipment regularly.
Re-tighten any loose connections.
Replace damaged lines/cables immediately.
Keep the frequency converter locked and clean at all times!
Only authorised persons with key/tool are allowed access.
Never hose down a frequency converter to clean it.
4.6 Working on the flush tank
The machine must not be commissioned (even briefly) if the barrier medium circuit is not intact, otherwise the axial face seal
may be destroyed.
Check that screw connections are firmly tightened after any maintenance or repair work.
After completion of the maintenance or repair work, and before resuming production, make sure that all the materials, tools and
other equipment required for carrying out the maintenance or repair work are removed from the work area of the installation and
that all the installation’s safety devices are functioning properly.
4.7 Observe the environmental protection instructions
The legal obligations relating to the prevention of waste and recycling/disposal must be observed whenever work is done on
and with the machine. Particularly when installation, repair and maintenance work is performed, water-hazardous substances,
such as:
- Lubricating grease and oil
-Hydraulicfluids
- coolants
- solvent-containing cleaning fluids
do not contaminate the soil or enter the drains.
These substances must be stored, transported, collected and disposed of in suitable tanks.
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4 Specific safety instructions and the symbols used
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the Mixer!
4.8 Residual risks
The machine has been designed so that the machine itself and its accessories cannot cause any risks for people, products
and the environment. The operating instructions have been written so that no risks arise when observing warning signs and
maintenance specifications.
However, it cannot be ruled out that risks may occur as the result of human error.
No further risks are to be expected if the equipment is used correctly and the recommendations and instructions according to
the accident prevention regulations (UVV) and the occupational insurance associations are observed.
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5 Functioning
AL HPM
5.1 Function description
The Alfa Laval Hybrid Powder Mixer (AL HPM) is a combination of two technologies (powder mixer and pump) and is mainly
used to disperse solids (power or crystals) in fluids. Because of the high pressure that the HPM can generate, even during
powder intake (up to 4 bar), it can also be used as a mobile feed or discharge pump or as a CIP pump.
The powder to be mixed is delivered to the HPM via the funnel (item 1 in Figure 1) and homogenised or dispersed in the
fluid flow with the aid of a rotor-stator system in the first stage (item 2 in Figure 1). In the second stage, the mixture is then
discharged from the equipment with the aid of the impeller (item 3 in Figure 1). During this process, a product sub-flow is
recirculated via a second (smaller) connection (item 4 in Figure 1). This sub-flow is introduced into the injector (item 5 in Figure
1). This generates a negative pressure at the funnel outlet, which in turn allows the powder to be drawn in. NOTE: The function
is the same on the stationary HPM-S15 version shown on figure 2.
(A)
(B)
(C)
4302-0008
Pos. 1: Funnel
Pos. 2: Rotator/stator system
-1
st stage
Pos. 3: Impeller
Pos. 4: Circulation
Pos. 5: Injector
A: Inlet
B: Outlet
C: Flow
Figure 1
4302-0009
Figure 2
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5 Functioning
AL HPM
5.2 Construction of the AL HPM
The equipment consists of the following units:
- frequency converter (Only HPM-M15)
-drive
- axial face seal
- injector
- rotor/stator, stage 1
- pump impeller, stage 2
- sight glass (Only HPM-M15)
- funnel and top plate (Top plate only HPM-M15)
- frame with wheels (Only HPM-M15)
4302-0010
Figure 3, HPM-M15
4302-0011
Figure 4, HPM-S15
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5 Functioning
AL HPM
Frequency converter (Only on HPM-M15)
The frequency converter used is the Danfoss FC 300. Details of the frequency converter are given in the separate operating
instructions from Danfoss.
Drive
The power is transmitted from the electric motor to the drive shaft via a three-phase motor. Details of the drive are included in
the separate operating instructions for the multi-stage centrifugal pump LKH-112.
Axial face seal
Details of the axial face seal are included in the separate operating instructions for the multi-stage centrifugal pump LKH-112.
Injector
The injector allows the powder to be drawn into the fluid and generates the preliminary mixing of the two components.
It consists of a removable housing with a central suction pipe through which the component from the funnel is blended.
The sub-flow from the second stage of the pump serves as the propellant medium for the injector, which is made possible
via the small recirculation pipe (see Figure 5).
NOTE: HPM-S15 is supplied WITHOUT inlet valve.
A: Powder
B: Injector
C: Liquid
A
B
C
4302-0012 4302-0013
Figure 5
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5 Functioning
AL HPM
Rotor/stator, stage 1
The rotor/stator system is located on the drive shaft, upline of the pump impeller and downline of the injector. The main job
of the rotor/stator is to disperse the powder in the fluid.
A
B
C
D
EF G
H
4302-0014
A: Circulation
B: Stator
C: Flow
D: Rotor
E: Stage 1
F: Stage 2
G: Outlet
H: Impeller
Pump impeller, stage 2
The impeller is located on the drive shaft downline of the rotor/stator. The main job of the impeller is to deliver the powder/fluid
mixturebacktothetankathighpressureanddeliverasub-flowback to the injector via the circulation pipe (see Figure 6).
Sight glass (Only HPM-M15)
The sight glass is located in the HMP supply and is used to observe the fluid flow visually.
Funnel and cover plate (Cover plate only HPM-M15)
The funnel consists of two parts: the funnel itself, into which the powder is delivered, and the funnel cover plate, which is mainly
used as a support surface for the product. After cleaning, the cover plate is placed on the funnel and therefore protects it
from pollution in the funnel room outside operating hours.
Frame (Only HPM-M15)
The modular frame is made from easy to clean tubing and allows safe and easy handling of the HPM.
The frame stands on rollers, the complete system is mobile.
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6 Setting up and installation
AL HPM
6.1 Unpacking and setting up
When unpacking, check all parts for damage in transit. Damaged parts must not be used. In the event of any damage, notify
the transport company and relevant transport insurance company immediately.
A suitably qualified member of staff must unpack, clean and assemble the machine in accordance with the installation
instructions.
Goods must be stored and transported in the original packing. Avoid any loading or mechanical stress, in particular of
housings, shafts, bearing points, through foreign objects or inadmissible vibration. Goods may only be transported on the load
handling equipment provided for this purpose.
The machine must be set up safely on the floor so that it is easily accessible.
The machine must not be exposed to any heat radiation or technical magnetic fields. No stands for people or other heavy
objects may be attached to the machine. The machine must not be set up in traffic areas. It must be accessible for
maintenance and operation at all times.
Install the machine as near to the production tank as possible.
Lock the rollers to prevent uncontrolled movement of the machine.
6.2 Connecting the product pipes
The product inlet and outlet must be firmly and tightly connected to the tank’s circulation pipe (see Figure 7). Keep the product
inlet pipe (intake pipe) as short as possible and do not use a diameter smaller than the connection of the unit. Use bigger
diameters for increased viscosity in order to reduce the pressure drop on the suction side.
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6 Setting up and installation
AL HPM
6.3 Flush tank and axial face seal
The flush tank and axial face seal can be operated in two ways:
1. Closed-circuit type with a defined volume of barrier fluid
2. Flushed type, where fresh water flows through the axial face seal and then into the gully (0.25-0.5 L/minute).
In order to guarantee the necessary circulation of the barrier medium through the axial face seal, the hoses have to be correctly
connected to the barrier medium tank.
The barrier medium used should have the following characteristics:
- low viscosity (similar to water, approximately 1 mPas)
- good lubrication capability
- good thermal conductivity
- product neutrality
Water with a 5% addition of glycerine or glycol is used as the barrier medium as standard.
The barrier fluid should reach the middle of the sight glass. At this level, the fill corresponds to approximately 0.7 litres.
It only usually has to be replaced if it becomes polluted.
After filling, the circuit and the axial face seal in particular should be vented. To do this, undo the return hose on the flush tank
and wait until fluid emerges. Then tighten again.
6.4 Power supply
Since no dangerous movements are accessible on the machine, no emergency stop has been provided.
The machine connection must comply with VDE standards. When the motor is connected to the power supply, check that the
motor voltage, frequency converter and mains voltage correspond.
The motor voltage is indicated on the motor rating plate or the frequency converter data sheet. Details of the frequency
converter are given in the attached operating instructions for the frequency converter.
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7 Commissioning
AL HPM
The operator must observe VDE standard 0530 when commissioning the machine.
The machine may only be operated by trained, authorised operating personnel. Never commission the machine if it is not
fully installed.
Before commissioning, remove all dirt and foreign objects from the machine and the connected pipes and tanks. Check that
machine rotor and stator are running freely and free from contact.
7.1 Connecting the AL HPM to a mixing tank
Before commissioning, the AL HPM must be permanently piped to a tank in which the powder solution is produced (see Figure
7, circulation pipe). Hoses approved for the operation may also be used.
Make sure that during operation, ideally, a back-pressure of approximately 2 bar is generated after the outlet of the HPM to
allow optimum powder intake (1 bar would also be possible). This can be achieved with the aid of an Isomix jet mixer (see
Figure 7) installed in the tank at the end of the circulation pipe. This has the advantage that optimum intermixing is achieved
inside the tank.
After mixing, the Isomix rotating jet mixer can also be used to clean the tank (CIP).
4302-0023
Figure 7
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7 Commissioning
AL HPM
If there is no Isomix to generate the back-pressure, a simple manual valve (see Figure 7, valve 1), which is connected after
the HPM and serves as a throttle, can be used. We recommend that a pressure gauge is always provided after the HPM in
order to check the back-pressure generated.
We also recommend positioning the HPM inlet at least 200 mm lower than the tank outlet so that the fluid can flow freely into
the mixer. The circulation pipe return should be piped so that no air pockets can form in the pipes. The highest point should be
the Isomix or the product inlet in the tank (see Figure 7).
When connecting permanent pipes, it is also advisable to include a compensator in the pipe in some circumstances.
The barrier medium circuit must be filled with a suitable medium before commissioning the machine for the first time (see page
1817, Flush tank and axial face seal).
The machine may not be commissioned (even briefly) if the barrier medium circuit is not intact, otherwise the axial face seal
may be destroyed.
7.2 Brief test
Check the following again with a short trial run:
1. contamination in the funnel
2. set the valve on the funnel outlet to the closed position
3. the direction of rotation of the motor
4. the fluid level in the flush tank
5. check for any unusual mechanical noises
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