Alfalaval IM 20 User manual

Covering:
Standard Machines
Machines Delivered with ATEX Certification in Accordance with Directive 2014/34/EU
First published: 2009-12
TE91I350
ESE02185-EN9 2018-02
Original manual
Instruction Manual
Alfa Laval Rotary Jet Mixer IM 20

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC/EU Declaration of Conformity .................................................................. 5
2. Safety .................................................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6
3. Introduction ............................................................................................ 7
3.1. Introduction ....................................................................................... 7
3.2. Intended use ...................................................................................... 8
3.3. Patents and trademarks ......................................................................... 8
3.4. ATEX marking ..................................................................................... 9
4. Installation .............................................................................................. 10
4.1. General description ............................................................................... 10
4.2. Functioning ........................................................................................ 11
4.3. General safety and installation instructions ..................................................... 14
4.4. Specific conditions for safe use in accordance with ATEX Certification ..................... 16
5. Operation ............................................................................................... 17
5.1. Normal operation ................................................................................. 17
6. Maintenance ........................................................................................... 18
6.1. Preventive maintenance .......................................................................... 18
6.2. Service and repair of ATEX certified machines ................................................. 19
6.3. Top assembly ..................................................................................... 20
6.4. Bottom assembly ................................................................................. 22
6.5. Hub subassembly ................................................................................ 24
6.6. Stem subassembly ............................................................................... 26
6.7. Gear subassembly ................................................................................ 28
6.8. Replacement of collar bushes ................................................................... 30
6.9. Replacement of ball races ....................................................................... 32
6.10.Replacement of main collars .................................................................... 34
7. Technical data ......................................................................................... 36
7.1. Rotary Jet Mixer IM 20 with 2 nozzles .......................................................... 36
7.2. Rotary Jet Mixer IM 20 with 4 nozzles .......................................................... 37
7.3. Performance data ................................................................................. 38
8. Product programme .................................................................................. 39
8.1. Standard configuration for Alfa Laval Rotary Jet Mixer IM 20 ................................ 39
8.2. Available add-ons ................................................................................. 39
9. Trouble shooting guide ............................................................................... 40
10. Part lists and drawings, service kits and tools ................................................... 42
10.1.Parts drawing and list - IM20 with 2 nozzles ................................................... 42
10.2. Parts drawing and list - IM20 with 4 nozzles .................................................. 44
10.3.Service intervals ................................................................................... 46
10.4.Tools ............................................................................................... 47
11. General information ................................................................................... 49
11.1.Service & repair ................................................................................... 49
11.2.How to order spare parts ........................................................................ 49
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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
11.3.How to contact Alfa Laval Kolding A/S ......................................................... 49
12. Miscellaneous .......................................................................................... 50
12.1.ATEX - Special conditions for safe use ......................................................... 50
4

1 EC/EU 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
Alfa Laval Rotary Jet Mixer
Designation
IM-20
Type
From serial number 2016-0001 to 2030-99999
is in conformity with the following directive with amendments:
Machinery Directive 2006/42/EC
DS/EN ISO 12100:2011
The Pressure Directive 97/23/EC
According to its own volume and the rated pressure range, the product is regarded an Article 3, paragraph 3 Equipment
FDA 21CFR§177
Regulation (EC) 1935/2004
Equipment Explosive Atmospheres (ATEX) Directive 2014/34/EU
(Applicable for machine certified as category 1 and 2 component, see machine engraving)
DS/EN 13463-1:2009, DS/EN 13463-5:2011, DS/EN ISO/IEC 80079-34:2011, Annex A, paragraph A.5.3 Rotating machines
EC Type Examination Certificate no. Baseefa10ATEX0188X
Marking: II 1 GD c T175ºCTamb0ºCto+140ºC
SGS Baseefa Ltd., Certification body number 1180, Rockhead Business Park, Staden Lane, Buxton, Derbyshire SK17 9RZ, United Kingdom
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
ATEX Responsible Engineer Denniz Høxbroe
Title Name Signature
Kolding 2016-05-01
Place Date
(This Declaration of Conformity replaces Declaration of Conformity dated 2016-01-01)
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2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
Always read the manual before using the tank cleaning machine!
2.1 Important information
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the tank cleaning machine
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
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3 Introduction
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3.1 Introduction
This manual has been prepared as a guide for the persons who will be operating and maintaining your Alfa Laval Rotary Jet
Mixer IM 20. The key to long life for your mixer will always be a system of carefully planned maintenance procedures; you will
appreciate that a mixer which has a rough job to do will need more frequent attention than one working in ideal conditions.
Note: Get the best and most economical performance from your tank cleaning machine. Insufficient preventive maintenance
means poor performance, unscheduled stops, shorter lifetime and extra costs. Good preventive maintenance on the contrary
means good performance, no unscheduled stops and superior total economy.
You will find the information contained in this manual simple to follow, but should you require further assistance, our Technical
Sales Support department and worldwide net of sales offices are 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 body of the mixer.
Warning: Before installing the mixer and setting it into operation carefully read the general ssafety and installation
instructions (page 14) and the special conditions for safe use in accordance with ATEX Certification Directive
2014/34/EU (page 16) and take all necessary precautions according to your application and local regulations.
NOTE
The illustrations and specifications contained in this manual were effective at the date of printing. However, as continuous
improvements are our policy, we reserve the right to alter or modify any unit specification on any product without prior notice or
any obligation.
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.
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3 Introduction
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3.2 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.
- the constructions materials (both metallic and non-metallic) are compatible with product, flushing media, cleaning media,
temperatures and pressure under the intended use.
The rotary jet mixer is intended for use in closed tank, vessel or container. If used in open environment see 4.3 General safety
and installation instructions (page 14).
3.3 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, 2011. All rights reserved.
Alfa Laval Rotary Jet Mixer IM 20 product has patents in the EPO member states and in other countries. The Alfa Laval logotype
is a trademark or a registered trademark of Alfa Laval Corporate AB. 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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3.4 ATEX marking
If ordered with ATEX certificate:
ATEX Marking
The Alfa Laval Rotary Jet Mixer IM-20 is certified as category I component. The certification is carried out by the certification
body SGS Baseefa, who has issued the certificate no. 10ATEX0188X. The marking on the ATEX certified Alfa Laval Rotary Jet
Mixer IM-20 is as follows:
IM20_ATEX
Serial number explanation
Machines supplied with or without standard 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. 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.
Also see page 19 regarding special conditions for repair of ATEX certified machines.
Important ATEX
information:
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4 Installation
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4.1 General description
The Alfa Laval Rotary Jet Mixer IM 20 is a media driven and media lubricated tank/reactor mixer.
The Rotary Jet
Mixing technology
Traditional
Mixing technology
Round pumping Propeller mixing
A
B
C
D
4301-0002
B
A
4301-0003
B
A
4301-0004
A = Rotary Jet Mixer A = Liquid feed
B=Gas B=Product
C=Product
D=Liquidfeed
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4.2 Functioning
The Alfa Laval Rotary Jet Mixer IM 20 is placed inside the tank/reactor under the liquid surface of the liquid volume to be mixed.
The mixer is combined with an external recirculation loop. The fluid of the tank/reactor is recirculated through this loop and
reintroduced in the tank/reactor through the Alfa Laval Rotary Jet Mixer IM 20. The more fluid being recirculated, the
more effective mixing is obtained.
The mixer should be placed in the centre of the fluid to be mixed. Minimum ½ meter under the liquid surface.
4301-0027
A
B
C
Min. 500 mm
A: normal liquid level B: Possible liquid or powder supply C: Possible gas supply
The flow of fluid to be mixed passes from the tank into the mixer through a turbine, which is set into rotation. The turbine rotation
is through a gearbox transformed into a combined horizontal rotation of the mixer body and a vertical rotation of the nozzles.
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Machines with 2 nozzles
The combined motion of the mixer body and the nozzles ensures a fully indexed tank mixing. After 11¼ revolutions of the Hub
with nozzles (103/4 revolutions of the mixer body), one coarse movement pattern has been established which when projected
on the tank surface looks as Figure 1. During the following cycles, this pattern is repeated 3 times, each of which is displaced
¼ of the mesh in the pattern. After a total of 45 revolutions of the Hub with nozzles (43 revolutions of the machine body), a
complete “mixing pattern” has been laid out, and the first pattern is repeated. This feature eliminates "dead volumes" in the
tank, and makes the Rotary Jet Mixer Isos-Mix very efficient automatic tank cleaning machine, when the tank is empty.
First cycle Second cycle Third cycle Forth cycle
Machines with 4 nozzles
The combined motion of the mixer body and the nozzles ensures a fully indexed tank mixing. After 55/8 revolutions of hub
with nozzles (55/8 revolutions of the mixer body), one coarse movement pattern has been established which when projected
on the tank surface looks as figure 1. During the following cycles, this pattern is repeated 7 times, each of which is displaced
1/8 of the mesh in the pattern. After a total of 45 revolutions of the hub with nozzles (43 revolutions of the mixer body), a
complete mixing pattern has been established, and the first pattern is repeated. This feature eliminates "dead volumes" in the
tank, and makes the Rotary Jet Mixer IM 20 a very efficient automatic tank cleaning machine, when the tank is empty.
Figure 1: First cycle Figure 2: Full pattern
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General for both 2 and 4 nozzle machines
The speed of rotation of the turbine depends on the flow rate through the mixer. The higher the flow rate is, the higher the
speed of rotation will be. In order to control the RPM of the mixer for a wide range of flow rates, the efficiency of the turbine
can be changed by using 100% or 0% turbine/inlet guide.
Apart from the jet flow through the nozzles, fluid is leaking through the top of the mixer, 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 required to ensure proper lubrication of the gearbox.
The number of rotations required for a satisfactory mixing of a given tank volume depends on the energy input (kw/m3tank
volume), the viscosity of the liquid, required mixing time, and number of mixers per tank.
It is possible to add fluid, gas or solids in the recirculation loop. These ingredients will very effectively be mixed into the
entire tank/reactor volume.
When the tank/reactor is empty the Alfa Laval Rotary Jet Mixer IM 20 can be used as a tank cleaning machine.
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4.3 General safety and installation instructions
The Alfa Laval Rotary Jet Mixer IM 20 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 mixer. Before connecting the mixer 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 inhouse user requirements or
policies, a liquid thread locking adhesive such as Loctite No. 243 or equivalent could be used. Other methods could be
acceptable and subject to customer preference.
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 fulfill 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.
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 IEC/TS 60079-32-1:2013, 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.
ATEX
Warning:
In case potentially explosive liquids are used, precautions should be taken against incidental creation of an
explosive mixture with oxygen in the tank atmosphere.
The Rotary Jet Mixer IM 20 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 during normal cause of service
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 mixing and cause damage on tank, valves and pump. This is especially important if mixers
are 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 extra securing may be preferred.
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Method for tightening the nozzles
With 2 nozzles
1. Clamp machine firmly in a vice: Place machine on top of vice with Hub w. nozzles down wards as illustrated on the figure.
Clamp on the Hub. To protect machine use rubber jaws on the vice
2. Set torque wrench at the specified tightening torque.
3. Tighten nozzle with the torque.
TD523569
TD523570
Recommended tightening torque: 50 Nm.
With 4 nozzles
1. Clamp machine firmly in a vice: Place machine on top of vice with Hub w. nozzles down wards as illustrated on the figure.
Clamp on the Hub. To protect machine use rubber jaws on the vice.
2. Set torque wrench at the specified tightening torque.
3. Hold one nozzle with flat spanner to counteract while tightening the opposite nozzle with the torque wrench.
Rubber jaw mounted upside
down
Protect with rubber pad
TD523567
TD523568
Recommended tightening torque: 50 Nm.
Check that the machine is in operating condition by inserting 3/16" 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.
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4.4 Specific conditions for safe use in accordance with ATEX Certification
Directive 2014/34/EU
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 is 95°C, with an ambient temperature range of 0°C to
140°C.
ATEX Warning: The maximum permitted process fluid pressure 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 "IEC/TS 60079-32-1:2013“.
Following a guidance document such as "IEC/TS 60079-32-1:2013“ 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 IEC/TS 60079-32-1.
In addition to the above mentioned precautions relating to the ATEX guidelines Directive 2014/34/EU, the Safety Precautions on
page 14 must be observed.
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5Operation
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5.1 Normal operation
Media to be mixed
The Rotary Jet Mixer IM 20 should be used only in fluids compatible with stainless steel AISI 316/316L, PEEK 450G, SAF
2205, Teflon, TFM, Tefzel, ceramics (AL203). Please note that PEEK is not resistant to concentrated sulfuric acid. Furthermore,
the fluids to be mixed should not contain abrasive materials and fibrous material and the viscosity should not be above 450
cP. Aggressive chemicals, excessive concentrations of chemicals at elevated temperatures, as well as certain hydrochlorides
should be avoided. If you are in doubt please contact your local Alfa Laval sales office.
Pressure shock
Avoid hydraulic shocks. Increase pressure gradually. Do not exceed 12 bar inlet pressure. Recommended inlet pressure
appears from Technical Data page 36. High pressure in combination with high flow rate will increase consumption of some of
wear parts. It is recommended to install a hydrofor in the system, if a positive pump is used for recirculation.
ATEX Warning: Steam cleaning pressure:
If stream cleaning is done through the mixer, the steam pressure must not cause the machine to rotate.
ATEX Warning: Draining:
If the mixer is drained using compressed air, then the compressed air pressure must not cause the machine
to rotate.
After-use cleaning
After use flush the mixer with fresh water. Fluids should never be allowed to dry or set-up in the Alfa Laval Rotary Jet Mixer IM
20 system due to possible "salting out" or "scaling" of the ingredient.
Temperature
In accordance with the ATEX specifications regarding special conditions for safe use, see page 16.
ATEX Warning: Steam cleaning:
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: Atmosphere/surface temperature:
In potentially explosive atmospheres, the temperature must not exceed the maximum surface temperature
according to the temperature class for the combustible gas or liquid.
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6 Maintenance
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6.1 Preventive maintenance
In order to keep your Alfa Laval Rotary Jet Mixer IM 20 servicing you as an efficient tool in your mixing operations, it is
essential to maintain its high performance by following a simple preventive maintenance programme, which will always
keep your mixer in good condition.
Good maintenance is careful and regular attention!
The following recommended preventive maintenance is based on a Alfa Laval Rotary Jet Mixer IM 20 working in average
conditions. However, you will appreciate that a mixer, 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 standard tool kit for Alfa Laval Rotary Jet Mixer IM 20 (page 47). If not stated otherwise
never use unnecessary force (i.e. 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.
Every 4000 working hours (depending on working conditions)
1. Disassemble mixer 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. 28) 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
5. Check worm wheels (pos. 11 and 33). If extremely worn, they should be replaced.
6. Check main bush (pos. 5). Check main bush (pos. 5). If worn oval to max diameter more than 15.4 mm, it should be replaced.
7. Assemble mixer as described in the following pages.
8. Check that the mixer is in operating condition by inserting 3/16” Hex screwdriver (tool no. 134A) in screw in top of turbine
shaft, and easily turn turbine shaft anti-clockwise. If any resistance is recognised, the mixer should be disassembled in
order to localise the cause.
Note: Timely replacement of ball bearings and collar bushes will prevent costly damage to the gearbox.
Apart from the parts specifically mentioned above, all the remaining wear parts should regularly be inspected for wear. Which
parts that are wear parts appear from the Spare part Mmnual, available from the on-line Alfa Laval product catalogue Anytime or
the Close at hand spare part catalogue.
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6 Maintenance
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6.2 Service and repair of ATEX certified machines
All service and repair of ATEX certified machines can be performed by Alfa Laval Kolding A/S, Denmark or by an Alfa Laval
service center approved by Alfa Laval Kolding A/S.
In order to ensure compliance with the ATEX regulations and keep the machine ATEX certification valid the service
or repair must be performed by an authorized person with knowledge of the ATEX requirements and regulations.
All spare parts must be original Alfa Laval spare parts and the repair or service must be done according to the
instructions in the related manual.
ATEX
Warning:
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 traceability of all relevant documents in order to ensuring the retention of the ATEX certification
of the machine.
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6 Maintenance
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6.3 Top assembly
Disassembly
1. Remove 1/4" screws (pos. 17). Loosen and unscrew with a socket wrench (tool no. 962A).
2. Lift off top cone (pos. 1).
3. Remove guide/guide ring (pos. 2). The guide has a groove in the outer diameter. The guide is easily lifted out of the stem by
means of two ordinary screwdrivers inserted into the groove.
4. Remove 3/16" screw (pos. 15), spring washer (pos. 16) and washer (pos. 34). To secure impeller against rotation, insert
carefully screwdriver (tool no. 135A), through impeller (pos. 4) into a hole in the stem.
5. Pull off impeller (pos. 4).
Reassembly
1. Reinstall impeller (pos. 4). Make sure that impeller is correctly rotated to be pushed onto turbine shaft. Do not try to hammer
impeller in position, as this will damage slide bearing under turbine shaft.
2. Mount washer (pos. 34), spring washer (pos. 16) and 3/16" screw (pos. 15) and tighten. To secure impeller against rotation
insert carefully screwdriver (tool No. 135A) through impeller (pos. 4) into a hole in the stem.
3. Reinstall guide/guide ring (pos. 2).
4. Mount top cone (pos. 1). Make sure that it is in correct position over guide/guide ring (pos. 2). Rotate top cone to align
holes in top cone and stem.
5. Mount 1/4" screws (pos. 17) with a socket wrench (tool no. 962A).
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