Alfalaval Toftejorg SaniMicro User manual

Instruction Manual
Toftejorg SaniMicro with ATEX Certification in accordance with Directive
94/9/EC
IM-TE91A746-EN1
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Instruction Manual, Toftejorg SaniMicro with ATEX Certification Page 1
in accordance with Directive 94/9/EC
IM-TE91A746-EN1
Contents
Contents ....................................................................................................................1
Introduction................................................................................................................3
ATEX marking ...........................................................................................................3
General Description...................................................................................................4
Quality system .................................................................................................................... 4
Functioning ......................................................................................................................... 5
Spray Pattern ......................................................................................................................5
Technical Data...........................................................................................................6
Standard Configurations for Toftejorg SaniMicro ................................................................ 6
Performance Data for Toftejorg SaniMicro.......................................................................... 7
Installation and Normal Operation.............................................................................9
General Installation Instructions.......................................................................................... 9
Special Conditions for Safe Use in accordance with the ATEX Certification,
Directive 94/9/EC .............................................................................................................10
General Safety Precautions..............................................................................................11
Normal Operation.............................................................................................................. 12
Cleaning Media.................................................................................................................12
Temperature .....................................................................................................................12
Pressure............................................................................................................................12
After-Use Cleaning ...........................................................................................................12
Claim Procedure......................................................................................................13
How to contact Alfa Laval Tank Equipment A/S......................................................13
Claim Report Working Conditions ...........................................................................14
EU Declaration of Conformity..................................................................................16
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Introduction
This manual has been prepared as a guide for installation and for the persons who will be operating
and maintaining your tank cleaning machine.
The information in this manual is simple to follow, but should you require further assistance, our
Customer Service department and worldwide net of sales offices will be pleased to help you. Please
quote the type, article and serial numbers with all of your enquiries; this will help us to help you.
Warning:
Before installing the machine and setting it into operation carefully read the General
Installation Instructions (page 9) and the Safety Precautions (page 10 - 11) 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.
ATEX marking
The Toftejorg SaniMicro is certified as category I component. The certification is carried out by the
notified body Baseefa, who has issued the certificate no. 04ATEX0357X. The marking on the ATEX
certified Toftejorg SaniMicro is as follows:
xxxx is equal to the serial number.
Instruction Manual, Toftejorg SaniMicro with ATEX Certification Page 3
in accordance with Directive 94/9/EC
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Page 4 Instruction Manual, Toftejorg SaniMicro with ATEX certification
in accordance with Directive 94/9/EC
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General Description
The Toftejorg SaniMicro is a tank cleaning machine intended for industrial use in closed tanks for
processing storage. There is a broad range of application area within pharmaceutical, food and
chemical industries.
The Toftejorg SaniMicro is a sanitary cleaning device of the rotating fan jets type for permanent
installation that provides a cleaning pattern from 180° - 360°C. The machine is designed in such a way
that it is completely self-cleaning. If Installed according to drawing on page 9, the Toftejorg SaniMicro is
completely self-draining in the shown positions. All products contacts surfaces are AISI 316L stainless
steel or FDA approved polymer materials.
No open thread or screws in the product areas.
The cleaning device is lubricated by the cleaning media. No oil, grease or other lubricants are used.
The Toftejorg SaniMicro is designed for use in pharmaceutical, biotechnological, food and dairy
processing applications. It may be used in storage tanks, reactors, mixing tanks, spray dryers and other
process equipment with a volume ranging from 0.1-10m³ (27-2,700 US gallons). For larger volumes,
multiple Toftejorg SaniMicros may be applied.
Application assistance and optimal position recommendation is available.
For use in explosive hazard zones all types can be used, provided they are installed according to the
safety instructions in local regulations.
Quality system
The Toftejorg SaniMicro is produced according to Alfa Laval Tank Equipment´s ISO 9001 international
Standard certified quality system. All parts are made from certified material and all non-metal parts are
made from FDA-approved materials, 21 CFR § 177
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General Description (continued)
Functioning
The flow of the cleaning media causes the head of the Toftejorg SaniMicro to rotate, with fan jets laying
out a swirling pattern throughout the vessel. This generates a vibrating impact and cascading flow that
covers all internal surfaces of the tank or reactor. The device’s self-cleaning feature is achieved by
directing the cleaning media through the rotating bearing track and onto the neck of the elongated
head.
Spray Pattern
360° 270° 180°
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Technical Data
Weight of machine : Thread and clip-on: 0.30 kg
On pipe: 0.55/0.90 kg
Working pressure : 1 – 3 bar
Recommended pressure : 2 bar
Max. working temperature : 95°C
Max. ambient temperature : 140°C
Wetting radius : Max. 3 m
Impact cleaning radius : Max. effective 1.4 m
Materials: inlet connections : 1.4404 (316L)
bearing race parts : SAF 2205 (UNS31803)
balls : 1.4401 (316)/PTFE (FDA approved 21 CFR § 177.1550)
head : 1.4404 (316L)
Lubricant : Self-lubricating with the cleaning fluid
Connections : 3/8” Rp or NPSH thread
Clip-on or weld-on for pipe:
ISO2037/DIN 11.850/BPE US tube
Standard Configurations for Toftejorg SaniMicro
Page 6 Instruction Manual, Toftejorg SaniMicro with ATEX certification
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Technical Data (continued)
Performance Data for Toftejorg SaniMicro
Flow rate Throw length
Note: 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 in consideration.
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Page 8 Instruction Manual, Toftejorg SaniMicro with ATEX certification
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Installation and Normal Operation
General Installation Instructions
Self draining position
It is recommended to install a filter with mesh size 250 µm (0.01”) in the supply line in order to avoid
particles, scale etc. from clogging the inside of the cleaner. It is essential to avoid fine solid particles,
such as fine sand, in the cleaning fluid as they will increase wear considerably, and may cause slower
rotation speed or stoppage. This is particular important in case of recirculation.
Before installation, all supply lines and valves must be thoroughly flushed to remove remains of welding
electrodes, grinding dust, scale and other foreign matter. During handling and installation handle the
machine with care in order not to damage the fine surface of the machine.
Note: The machine shall be installed in accordance with national regulations for safety and other
relevant regulations and standards. 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.
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in accordance with Directive 94/9/EC
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Installation and Normal Operation (continued)
General Installation Instructions (continued)
Special Conditions for Safe Use in accordance with the ATEX Certification, Directive 94/9/EC
Warning:
The unit may be operated, in a hazardous area, only when filled with the process fluid.
Warning:
The maximum permitted process fluid temperature in 95°C, with an ambient temperature
range of 0°C to 140°C.
Warning:
The maximum permitted process fluid pressure is 3 bar.
Warning:
The unit must not be operated in a vessel having an enclosed volume of greater than
100m3.
In addition to the above mentioned precautions relating to the ATEX guidelines Directive
94/9/EC of March 23 1994, the following safety precautions, page 11, must be observed.
Page 10 Instruction Manual, Toftejorg SaniMicro with ATEX certification
in accordance with Directive 94/9/EC
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Installation and Normal Operation (continued)
General Safety Precautions
The Toftejorg SaniMicro is intended for use inside a tank only, and must not be operated in open air or
when the tank is open.
Warning:
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 cleaner head
Warning:
If the machine is used in potential explosive atmospheres, tapes or joint sealing
compounds, which are electrical insulators, must not be used on joints, if this may
violate the grounding of the machine to the tank. Resistance between nozzles and tank
must not exceed 20.000 Ω. The intended installation with standard clamp connections
will ensure this. In addition, connecting pipe work, must be electrically conductive and
earthed to the tank structure.
This is essential to avoid the build-up of static electricity on the nozzles and the
machine. For further information see CENELEC R044-001 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. Magnetic cylinder
sensors shall be EX-approved.
Instruction Manual, Toftejorg SaniMicro with ATEX certification Page 11
in accordance with Directive 94/9/EC
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Installation and Normal Operation (continued)
Normal Operation
Cleaning Media
Use only media compatible with Stainless Steel AISI 316L, SAF 2205 and PTFE. Normal detergents,
moderate solutions of acids and alkalics are acceptable. Aggressive chemicals, excessive
concentrations of chemicals at elevated temperatures, as well as certain solvents hydrochlorides
should be avoided. If you are in doubt, contact your local Alfa Laval Tank Equipment sales office.
Temperature
In accordance with the ATEX specifications regarding special conditions for safe use, see page
10.
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.
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.
Pressure
Please make sure that the connections are correctly mounted before opening of the washing valve. Put
on pressure gradually in order to avoid hydraulic shocks, which might stress mechanical parts in the
Toftejorg SaniMicro cleaner. Max. pressure is 5.0 bar.
After-Use Cleaning
After use flush the machine with fresh water. Cleaning media should never be allowed to dry or set-up
in the system due to possible "salting out" or "scaling" of the cleaning media If cleaning media contains
volatile chloride solvents, it is recommended not to flush with water after use, as this might create
hydrochloric acid
Warning:
Hot chemicals and steam under pressure may be used for cleaning and sterilising.
Protect against scalding and burning. Never tamper with or try to open clamps or other
connections while system is in operation. Make sure that system is de-pressurised and
drained before disassembly.
Page 12 Instruction Manual, Toftejorg SaniMicro with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A746-EN1
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Claim Procedure
In case of failure that needs assistance from Alfa Laval Tank Equipment A/S, it is essential for our
evaluation that the problem, as well as the working conditions of the machine, is described as detailed
as possible.
For description of the working conditions, fill in the form “Claim Report - Working Conditions”, which
you will find at the back of this manual.
How to contact Alfa Laval Tank Equipment A/S
For further information please feel free to contact:
Alfa Laval Tank Equipment A/S
Baldershoej 19
P.O. Box 1149
2635 Ishoej
Denmark
Phone no.: [phone]
Fax no.: [phone]
www.alfalaval.com
www.toftejorg.com
Contact details for all countries are continually updated on our websites.
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Claim Report Working Conditions
Page 1/2
Ref. Claim Case :
Machine/Cleaner Type : Serial No.:
Configuration
- Nozzles : x ø mm
- Turbine/Inlet Guide : %
Working Conditions
Inlet pressure at machine/cleaner :
Type of Valve in inlet line :
Can hydraulic shock be disregarded: : Yes No
Inlet line flushed before installation of tank cleaner? : Yes No
Working hours before failure : hours
Cleaning Programme
Cleaning media and conc. Temperature Time Recirculation?
Is sterilising being used? : Yes No
Procedure (media/temp.)? :
Is steam injection being used for heating? : Yes No
Time: __________
Temperature: ___________________
V. 98.1
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in accordance with Directive 94/9/EC
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Instruction Manual, Toftejorg SaniMicro with ATEX certification Page 15
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Claim Report Working Conditions (continued)
Page 2/2
Condition of Cleaning Media
Clean
Contaminated with (nature and description)
Chemicals/Solvents ___________________________ High viscous
Soluble Sticky/tenacious
Low viscous Solidifying
Hard particles/size _____________________________ Crystallising
Soft particles/size ______________________________
Has filter been installed in inlet line? Yes
Mesh size: mm
No
Is tank cleaner flushed with clean water after tank cleaning? Yes No
Type of Soilage/Tank Contents to be removed
Name, formula/concentration of material to be removed from tank :
What is material soluble in :
Nature of material:
Volatile/explosive Sticky/tenacious Contains soft particles
Low viscous Solidifying Contains hard particles/fibres
High viscous Crystallising
Is tank cleaner submerged in material? Yes No
Other information/Remarks
Date: Sign.:
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EU Declaration of Conformity
Page 16 Instruction Manual, Toftejorg SaniMicro with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A746-EN1
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