Alfalaval Toftejorg TZ-74 User manual

Instruction Manual
Toftejorg TZ-74
IM-TE91A150-EN041
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Contents
Contents ....................................................................................................................1
Introduction................................................................................................................3
General Description...................................................................................................4
Functioning ......................................................................................................................... 4
Standard Configurations for Toftejorg TZ-74....................................................................... 5
Standard Configurations for Toftejorg TZ-74 with Self-cleaning Nozzle.............................. 5
Standard option................................................................................................................... 5
Technical Data...........................................................................................................6
For Toftejorg TZ-74.............................................................................................................6
For Toftejorg TZ-74 with self-cleaning nozzle ..................................................................... 8
Installation and Normal Operation...........................................................................10
General Installation Instructions........................................................................................ 10
Normal operation .............................................................................................................. 11
Maintenance and Repair .........................................................................................12
Preventive Maintenance.................................................................................................... 12
Top Assembly ................................................................................................................... 14
Bottom Assembly .............................................................................................................. 16
Hub Subassembly............................................................................................................. 18
Stem Subassembly ........................................................................................................... 20
Gear Subassembly ........................................................................................................... 22
Replacement of Collar Bushes.......................................................................................... 24
Replacement of Ball Races............................................................................................... 26
Replacement of Main Collars ............................................................................................ 28
Tools........................................................................................................................30
Standard Tool kit for Toftejorg TZ-74 ................................................................................ 30
Sketch of tools for replacement of Main collars................................................................. 31
Trouble Shooting Guide ..........................................................................................32
Symptom: Slow rotation or failure of machine to rotate..................................................... 32
Reference List of Parts for Toftejorg TZ-74.............................................................34
Cross Sectional Drawing for Toftejorg TZ-74..........................................................35
Reference List of Parts for Toftejorg TZ-74 with Self-cleaning Nozzle ...................36
Cross Sectional Drawing for Toftejorg TZ-74 with Self-cleaning Nozzle ................37
Standard Spare Part and Service Kits ....................................................................38
Standard Spare Part Kit for Toftejorg TZ-74, Article No. TE21D299................................. 38
Service Kit for Toftejorg TZ-74, Article No. TE21D285 ..................................................... 38
Service Kit for Toftejorg TZ-74, Article No. TE21D286 ..................................................... 38
How to order Spare Parts and Claim Procedure.....................................................39
How to contact Alfa Laval Tank Equipment A/S......................................................39
Service Card............................................................................................................40
Claim Report Working Conditions ...........................................................................41
Instruction Manual, Toftejorg TZ-74 Page 1
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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.
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 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 improvements are our policy, we reserve the right to alter or modify any unit
specification on any product without prior notice or any obligation.
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General Description
The Toftejorg TZ-74 is a media driven and media lubricated tank cleaning machine. As it is self-
lubricating, there are no lubricating substances such as oil grease etc. in the machine which need to be
regularly changed.
The Toftejorg TZ-74 is available in a version with a self-cleaning nozzle on the body for better cleaning of
the down pipe and the body.
Functioning
The flow of the cleaning fluid passes through a guide and a turbine, which accordingly 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 5 5/8 revolutions of the Hub with nozzles (5 3/8 revolutions 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 1/8 of the mesh in the pattern. After a total of 45 revolutions of 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 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 leakage 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 the 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 for Toftejorg TZ-74
Connection
Turbine/
Inlet Guide
Nozzles (mm)
(½" thread conn.) Article No.
100%
4 x ø6
4 x ø7
4 x ø8
TE21D108
TE21D110
TE21D112
Top Cone:
1½"NPT, Female
0%
4 x ø7
4 x ø8
2 x ø10
TE21D128
TE21D130
TE21D132
100%
4 x ø6
4 x ø7
4 x ø8
TE21D208
TE21D210
TE21D212
Top Cone:
1½" BSP,
Female
0%
4 x ø7
4 x ø8
2 x ø10
TE21D228
TE21D230
TE21D232
Standard Configurations for Toftejorg TZ-74 with Self-cleaning Nozzle
Connection
Turbine/
Inlet Guide
Nozzles (mm)
(½" thread conn.) Article No.
100%
4 x ø6
4 x ø7
TE21D008
TE21D010
Top Cone:
1½"NPT, Female
0%
4 x ø7
4 x ø8
2 x ø10
TE21D028
TE21D030
TE21D032
100%
4 x ø6
4 x ø7
TE21D058
TE21D060
Top Cone:
1½" BSP,
Female
0%
4 x ø7
4 x ø8
2 x ø10
TE21D078
TE21D080
TE21D082
The machine is equipped with a clutch in the hub, which gives the possibility of rotation by hand the
nozzles, when the machine is to be lifted out through a tank opening.
Standard option
Toftejorg TZ-74 machines with Hub deflector: TE21Dxxx-03.
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Technical Data
For Toftejorg TZ-74
Weight of machine : 6,1 kgs (13,6 lb)
Working pressure : 3-12 bar (45-175 psi)
Recommended inlet pressure : 3-8 bar (45-120 psi)
Working temperature max. : 950C (200 F)
Materials : Stainless steel AISI 316L, PTFE, Tefzel 200, PEEK, Teflon
TFM
Principal dimensions in mm
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Technical Data (continued)
For Toftejorg TZ-74
Flow rate Throw length
Note: Throw lengths are measured as max.
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.
Cleaning Time, f. complete Pattern (= 8 cycles)
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Technical Data (continued)
For Toftejorg TZ-74 with self-cleaning nozzle
Weight of machine : 6,1 kgs (13,6 lb)
Working pressure : 3-12 bar (45-175 psi)
Recommended inlet pressure : 3-8 bar (45-120 psi)
Working temperature max. : 950C (200 F)
Materials : Stainless steel AISI 316L, PTFE, Tefzel 200, PEEK, Teflon
TFM
Principal dimensions in mm
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Technical Data (continued)
For Toftejorg TZ-74 with self-cleaning nozzle
Flow rate Throw length
Note: Throw lengths are measured as max.
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.
Cleaning Time, f. complete Pattern (= 8 cycles)
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Installation and Normal Operation
General Installation Instructions
The tank cleaning machine should be installed in a 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 inhouse 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.
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 shall be CE-marked.
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 CENELEC R044-001 Safety of Machinery, guidance and
recommendations for the avoidance of hazards due to static electricity.
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.
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.
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Installation and Normal Operation (continued)
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.
Rubber jaw mounted
upside down
Protect with rubber
pad
Recommended tightening torque: 40 Nm
3. 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.
Normal operation
Cleaning Media
Use only cleaning media compatible with stainless steel AISI 316L, Tefzel 200, PTFE, Teflon TFM and
PEEK. 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 hydrochlorides should be avoided. If
you are in doubt, contact your distributor.
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 6-9). High pressure in combination
with high flow rate will increase consumption of wear parts.
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Maintenance and Repair
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-74 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.
Every 300 working hours
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with Scotch-brite, S-Ultrafine, eventually
chemical cleaner and fine abrasive cloth.
3. Check Slide bearings (pos. 28 on the cross sectional drawings, page 35 and 37) for wear. If hole is
worn oval to max. diameter more than 10.4 mm, Slide bearings 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. 10) in Gear frame. If holes are worn oval to max. diameter more than
13.4 mm, Collar bush should be replaced. How to replace Collar bushes, see page 24.
Note: Timely replacement of Slide bearings and Collar bushes will prevent costly damage to the
gear box.
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Maintenance and Repair (continued)
Preventive Maintenance
5. Check Worm wheels (pos. 11 and pos. 33). If extremely worn, they should be replaced.
6. Check Main bush (pos. 5). If worn it should be replaced.
7. Assemble machines as described in the following pages.
8. Check that the machine is in operating condition by inserting 3/16” hex Screw-driver (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.
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 Reference Lists of Parts, page 34 and
36.
Service Card
For your registration of maintenance carried out, fill in service card which you will find at the back of this
manual.
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Maintenance and Repair (continued)
Top Assembly
Disassembly
1. Remove 3/16” Screws (pos. 17). Loosen and unscrew with a socket wrench (tool No. TE462A).
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. 13). To secure Impeller
against rotation, insert carefully Screwdriver (tool No. TE134A), 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. 13), Spring washer (pos. 16) and 3/16” Screw (pos. 15) and tighten. To
secure Impeller against rotation insert carefully Screwdriver (tool No. TE134A) 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 and tighten 3/16” Screws (pos. 17) with a socket wrench (tool No. TE462A).
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Maintenance and Repair (continued)
Top Assembly
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Maintenance and Repair (continued)
Bottom Assembly
Disassembly
1. Turn machine upside down.
2. Remove 3/16” Screws (pos. 31) from Bottom cover (pos. 30).
3. Remove Bottom cover (pos. 30) and Gasket (pos. 32).
4. Remove 3/16” Screws (pos. 15) in Bearing cover (pos. 14). Carefully push out Turbine shaft (pos.
6) from opposite end. Do not try to hammer out Turbine shaft, since this can damage Slide
bearing.
5. Remove 3/16” Screws (pos. 15) and Spring Washers (pos. 16) along the circumference of Gear
frame (pos. 29). Turn Gear frame about 1 cm (½”). Draw out Gear Subassembly (holes in Gear
frame are excellent for holding Gear Subassembly).
Reassembly
1. Reinsert Gear subassembly in bottom of machine body. Turn Gear Frame (pos. 29) to align holes
in Gear frame and 3/16” threads in body. Mount Spring washers (pos. 16) and 3/16” Screws (pos.
15) along circumference of Gear frame (pos. 29). Tighten screw crosswise.
Note: To secure meshing between Gear wheel (pos. 7) and Pinion (pos. 9). It might be
necessary to rotate slightly either the whole Gear Subassembly or the Gear wheel.
2. Reinsert Turbine shaft (pos. 6) with Slide bearing carefully through Gear wheel (pos. 7). Push
carefully Slide bearing (pos. 28) into position. Mount Bearing cover (pos. 14) with 3/16” Screws
(pos. 15). Tighten crosswise.
3. Place Bottom gasket (pos. 32) and Bottom cover (pos. 30).
4. Mount 3/16” Screws (pos. 31) and tighten crosswise.
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Maintenance and Repair (continued)
Bottom Assembly
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Maintenance and Repair (continued)
Hub Subassembly
Disassembly
1. Remove Nozzles (pos. 20). Nozzles are untightened with a wrench on the faces of the Nozzles.
2. Remove 3/16” Screws (pos. 31), Hub cover (pos. 19), and Gasket (pos. 25).
3. Draw out Hub (pos. 21) together with Ball retainer with balls (pos. 24) and Bevel gear (pos. 18).
If Ball races (pos. 18.1 and 19.1) in Hub cover and in Bevel gear are extremely worn, they should be
replaced as well as the Ball retainer with balls (pos. 24). How to replace Ball races see page 26).
Reasassembly
1. Slide on Hub (pos. 21). Reinsert Bevel gear with race (pos. 18) and Ball retainer with balls (pos.
24).
2. Mount Gasket (pos. 25) and Hub cover with race (pos. 19), and set with 3/16” Screws (pos. 31).
Tighten clockwise.
3. Screw on Nozzles (pos. 20) and tighten with wrench.
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Maintenance and Repair (continued)
Hub Subassembly
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