Alfalaval Toftejorg SaniJet 20 User manual

4107-0142
Covering: Standard, Hastelloy
Q-doc: Equipment Documentation (3.1 Inspection Certificate - EN 10204)
Q-doc + FAT-SAT: Qualification Documentation
Improved surface finish (0.5 µm Ra internal/external media contact parts)
Machines delivered with ATEX Certification in accordance with Directive 2014/34/EU
TE91A792-EN12. First published: 07-2000
ESE01819-EN12 2016-07
Original manual
Instruction Manual
Alfa Laval Toftejorg™ SaniJet 20 Media Driven
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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/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. Reserved rights for design changes ............................................................ 8
3.5. ATEX marking ..................................................................................... 9
4. Installation .............................................................................................. 10
4.1. General description ............................................................................... 10
4.2. Quality system .................................................................................... 10
4.3. Functionality ....................................................................................... 11
4.4. General safety and installation instructions ..................................................... 13
4.5. Specific conditions for safe use in accordance with ATEX Certification ..................... 14
5. Operation ............................................................................................... 15
5.1. Normal operation ................................................................................. 15
5.2. Safety precautions ................................................................................ 16
6. Maintenance ........................................................................................... 17
6.1. Preventive maintenance .......................................................................... 17
6.2. Reserved rights for design changes of Alfa Laval equipment used in validated processes 17
6.3. Service and repair of ATEX certified machines ................................................. 18
6.4. Service and repair of machines ordered with Q-doc and with Q-doc + FAT-SAT .......... 19
6.5. Every 150/300 working hours ................................................................... 20
6.6. Turbine Unit - dismantling and reassembling ................................................... 21
6.7. Cleaner Head Unit - dismantling and reassembling ........................................... 22
6.8. Base Unit - dismantling and reassembling ..................................................... 23
6.9. Rotacheck system ................................................................................ 25
7. Trouble Shooting Guide .............................................................................. 26
8. Technical Data ......................................................................................... 28
9. Product Programme .................................................................................. 31
9.1. Standard configurations .......................................................................... 31
9.2. Available add-ons ................................................................................. 33
9.3. Available add-ons for spare parts ............................................................... 34
9.4. Accessories ....................................................................................... 34
10. Parts Drawing and Lists, Service Kits and Tools ................................................ 35
10.1.Part list drawing ................................................................................... 35
10.2.Part list - Toftejorg SaniJet 20 Media Driven ................................................... 36
10.3.Part list - Toftejorg SaniJet 20 Media Driven with improved surface finish .................. 37
10.4.Part list - Toftejorg SaniJet 20 Media Driven, Hastelloy version .............................. 38
10.5.Service kits ........................................................................................ 39
10.6.Tools ............................................................................................... 40
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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. General information ................................................................................... 41
11.1.Service and repair ................................................................................ 41
11.2.How to order spare parts ........................................................................ 41
11.3.How to contact Alfa Laval Kolding A/S ......................................................... 41
12. Miscellaneous .......................................................................................... 42
12.1.Declarations of Conformity per EN 10204 2.2 ................................................. 42
12.2.ATEX - Specific conditions of use ............................................................... 44
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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
Tank Cleaning Machine
Designation
Alfa Laval Toftejorg SaniJet 20 Media Driven
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
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. Baseefa05ATEX0117X
Marking: II 1 GD c T140°C
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 installation and for the persons who will be operating and maintaining your tank
cleaning machine. The key to long life for your tank cleaning machine is a carefully planned system for preventive maintenance;
you must appreciate that a tank cleaning machine which has a rough and dirty job to do will need more frequent attention than
one working under 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.
Should you require further assistance, our Technical Sales Support 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 helps us to help you. The
type, article and serial numbers are laser engraved on the Base house of the tank cleaning machine.
4107-0046
Warning: Before installing the machine and setting it into operation carefully read the General Installation and Safety
Instructions (page 13) and the special conditions for safe use in accordance with ATEX Certification Directive
2014/34/EU (page 14) 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.
- that the construction materials (both metallic and non-metallic) are compatibility with product, flushing media, cleaning
media, temperatures and pressure under the intended use.
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. All rights reserved.
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. "Toftejorg" and “SaniJet” are
trademarks or registered trademarks of Alfa Laval Kolding A/S. The Toftejorg™ SaniJet 20 product has patents in the EPO
member states, in the US and in other countries. Other products or company names mentioned herein may be the trademarks
of their respective owners. Any rights not expressly granted herein are reserved.
3.4 Reserved rights for design changes
Alfa Laval is continuously working on improving our equipment and services. In this improvement work Alfa Laval may for
example change the design and material in our equipment. A change in the design will not necessarily entail a change of the
specification and item no. for the equipment.
Alfa Laval reserves the right to change the design of Alfa Laval equipment without any notifications for improvements of our
design.
If Equipment from Alfa Laval is used in connection with, for example, a validated plant, and an order for replacements is
made, the design of the replacement may have been changed even if the specifications /item no. is the same as the existing
installed and validated ones.
When ordering a replacement please contact Alfa Laval sales support in this matter before placing the order.
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3 Introduction
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3.5 ATEX marking
The Alfa Laval Toftejorg SaniJet 20 is certified as category 1 component. The certification is carried out by the Certification
body SGS Baseefa, who has issued the certificate no. 05ATEX0117X. The marking on the ATEX certified Alfa Laval Toftejorg
SaniJet 20 is as follows:
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 Kolding A/S. If changes are made – or spare parts other
than Alfa Laval original spare parts are used - the EC Type
Examination certification (the ATEX Directive) is no longer valid.
Important information: Also see “Maintenance” page 18
regarding special conditions for repair of ATEX certified
machines.
*Note
4107-0050
*Note: For FAT-SAT machines with index no. -6x, the s/n must be yyyy-FAT-SAT-xxx
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4 Installation
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4.1 General description
The Alfa Laval Toftejorg SaniJet 20 is a tank cleaning machine intended for industrial use in closed tanks for processing storage
and transportation. There is a broad range of application areas within pharmaceutical, food and chemical industries.
The Alfa Laval Toftejorg SaniJet 20 is a sanitary cleaning device of the rotary jet head type for permanent installation that
provides a 360° indexed cleaning pattern. Provided it is installed in an upright position, the Alfa Laval Toftejorg SaniJet 20 is
completely self-cleaning and self-draining, and it has an integrated self-cleaning down pipe (patent pending). The drive
mechanism is located outside the tank or process equipment, leaving a minimum of parts to be submerged into the product.
All product contact surfaces are AISI 316/316L, duplex SAF 2205, Ti, Hastelloy C22/C276 stainless steel and USP Class VI
and/or FDA approved polymer materials such as PEEK, EPDM, Viton and FFKM.
No threads or screws have been used in the product contact areas.
The cleaning device is lubricated by the cleaning media. No oil, grease or other lubricants are used.
The Alfa Laval Toftejorg SaniJet 20 is available in media driven or motor driven (air) version. The motor driven version is
equipped with a magnetic clutch providing a leakage-proof transmission and provide an effective drive for low flow machines
in rough environments. The air motor has variable speed in order to adjust cleaning intensity. The air version is covered by
Instruction Manual IM-TE91A793.
The Alfa Laval Toftejorg SaniJet 20 is designed for use in pharmaceutical, biotechnological, food and dairy processing
applications. Tanks and vessels between 0.5-30 m3 (130-8,000 US gallons). The design makes the Alfa Laval Toftejorg
SaniJet 20 especially well suited when processing high viscous, foaming or thixotropic products and in chemical processing
applications, where product cross contamination is unacceptable and must be avoided.
For use in explosive hazard zones the media version can be used, provided it is installed according to safety instructions
in local regulations.
4.2 Quality system
The Alfa Laval Toftejorg SaniJet 20 is produced according to Alfa Laval Kolding’s ISO 9001 International Standard certified
quality system. All parts are made from certified material and all non-metal parts are made from FDA and USP Class VI
approved materials. (Viton is, however, not USP Class VI approved).
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4 Installation
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4.3 Functionality
Alfa Laval Toftejorg SaniJet 20 consists of 3 main parts: The Drive unit with flow inlet and the Base housing placed outside
the tank, and inside the tank: the Down pipe with the rotating Outer tube and the Cleaner unit.
The flow of the cleaning fluid passes from the inlet through the Base housing,
through the Down pipe, into the Cleaner head and out through the Nozzles.
The Outer tube of the Down pipe is rotably suspended on a Stationary shaft
with a Ball bearing inside the Outer tube. The Drive mechanism rotates the
Outer tube with the Cleaner unit around the vertical axis. Via a set of Bevel
gears on the Stationary shaft and the Cleaner head, the Cleaner head with the
Nozzles is simultaneously rotated around the horizontal axis in a fixed relation
thus moving the nozzles and the jets 360°around in the tank making a pre-set
indexed cleaning pattern.
The Alfa Laval Toftejorg SaniJet 20 utilises the patented “Golden Section” cleaning pattern. The distance between the tracks
of the jets ensures an efficient removal of remaining product from the tank surface right from the beginning of the cleaning
sequence, allowing for short cleaning time.
Example - 2 nozzle machine:
TD523451
TD523452 TD523453
0.8min. 2.3min. 6min.
The time needed to perform a proper cleaning depends on type of soilage, distance, cleaning procedure and agent. For
substances that are easily mobilised, i.e. are easy to remove, less than 1 min. could be sufficient while in cases of more heavy
soilage (high viscous, sticky substances, etc.) a more dense pattern/longer time will be needed.
The machine is driven by the cleaning media, which is supplied under pressure via the inlet connection. The flow enters the Inlet
cap tangentially and rotates the Impeller. The velocity of the liquid determines the rotation speed of the Impeller. This depends
on the actual flow rate and the size of the inlet opening. The Inlet cap is made with two different size openings.
The Impeller shaft is in mesh with a Planet gear, of which the
Output shaft rotates the Down pipe with the Cleaner unit.
The Planet gear is placed in the middle of the flow and thus
flushed through axially while in operation, securing that all the
Gear parts are thoroughly lubricated and cleaned. Bearings
are designed to allow flow through the bearings for lubrication
and cleaning.
*
4107-0047 *Main flow, rotation of impeller
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4 Installation
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Self-cleaning
Apart from the main flow flushing the inside of the Base housing and the Down pipe, and thereafter forming the jets through the
Nozzles, fluid is flushed through all internal cavities, through Bevel gear, Ball bearings and gabs between moving parts and is
finally also used for cleaning of the outside surfaces of the machine. From the gab between the Base housing and the rotating
Down pipe, a cleaning jet is directed against the Down pipe, thus loosening and removing product remains on the outside. A
liquid film flushing all around the tube further assists by continuously transporting away loosened product remains. The front of
the Cleaner head is flushed by a liquid flow from the gab between the Cleaner head and the Retaining ring.
In order to ensure a proper self-cleaning, the machine must be installed in an approx. upright position and the inlet pressure
must be min. 3 bar. In the bottom of the Cleaner head, in the Retaining ring, the machine is equipped with a hole to ensure
self-draining. This self-draining is only ensured, if the machine is installed in an upright position.
Cleaning Pattern, The Golden Section
The patented Golden Section cleaning pattern (EP-Patent No.: 0495883. US-Patent No.: 5,279.675) is unique in building up
the pattern in an ultimate uniform way. The pattern starts very coarse and refines itself in a step-less way by laying out the
tracks approximately in the middle between the two most distant tracks already made. This means that the jets always clean
the areas containing most remaining product, and thereby remove as much deposit as possible in the shortest possible way.
In case a complete cleaning pattern is not required, it will be possible to reach the same cleaning level within half the time and
by using half the amount of cleaning fluid compared to a traditional step-wise cleaning pattern. Furthermore, due to the uniform
cleaning pattern, the cleaning can be stopped at any time, whereas with traditional non-uniform cleaning pattern this would not
be advantageous. However, after the complete cleaning pattern has been established, the difference between the Golden
Section and the traditional stepwise cleaning pattern is negligible.
Golden Section - Cleaning pattern Traditional - Cleaning pattern
TD523454 TD523455
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4 Installation
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4.4 General safety and installation instructions
The Alfa Laval Toftejorg SaniJet 20 is designed to be installed in a vertical upright position.
It is recommended to install a filter with mesh size 250 µm (0,0001") in the supply line in order to avoid particles, scale etc.
from clogging inside the machine. It is essential to avoid fine solid particles, such as fine sand, in the cleaning fluid as they
will increase wear considerably. This is particular important in case of recirculation.
In order to prevent accidental leakage of cleaning fluid into the tank it is recommended to install a shut-off valve close to
the machine inlet. This will also prevent back-flow of liquid from the tank through the machine in case the cleaner head is
submerged and there is an over-pressure inside the tank. The installation and operation shall be made in such a way
that the draining of the machine is ensured.
It is recommended that the fluid valve fitted is of a type that prevents hydraulic shocks, which may cause severe damage to
the entire installation.
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 finish of the machine.
The Alfa Laval Toftejorg SaniJet 20 machine has been tested in a test tank, according to Alfa Laval test procedures at the
factory before shipping. For the media driven version it is advised to check if the shipping has made any damaged to the
machine which may cause performance disturbance. This is done by blowing compressed air into the inlet and verify that the
machine rotates evenly. If resistance is recognised, the machine should be disassembled in order to localise the cause.
Note: Do not try to turn Nozzle head by hand, since this may damage the Gear. Nozzle head can be turned by blowing air
from an air pistol through the inlet connection of the media driven machine or the intake port of the air motor.
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 and shall be CE-marked before it is
set into operation.
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 nozzles.
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 joints, if this may violate the grounding ofthemachinetothetank.
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 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.
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4 Installation
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4.5 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 completely filled with the process fluid.
ATEX warning: The maximum permitted process fluid temperature is +90°C, with an ambient temperature range of 0°C to
140°C.
ATEX warning: The maximum permitted process fluid pressure is 13 bar.
ATEX warning: Theunitmustnotb
e operated in a vessel having an enclosed volume of greater than 100m³.
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 13 must be observed.
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5Operation
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5.1 Normal operation
Pressure
In order to protect the machine, your pipe and valve installation etc. against damage:
Avoid hydraulic shocks! Put on pressure gradually!
Recommended working pressure: 5 - 8 bar (73 - 116 psi). Too high pressure will increase consumption of wear parts.
The machine is designed to stand up to 13 bar working pressure. This is normally not recommended but may be used for
special purposes, where high pressure at close distance is preferred.
ATEX warning: Steam cleaning pressure
If stream cleaning is done through the machine, the steam pressure must not cause the machine to rotate.
ATEX warning: Draining
If the machine is drained using compressed air, then the compressed air pressure must not cause the
machine to rotate.
Cleaning Media
Use only cleaning fluids, which are compatible with Stainless Steel AISI 316/316L, SAF2205, Titanium, Hastelloy C22/C276,
PEEK, EPDM, Viton and FFKM. Please note that PEEK is not resistant to concentrated sulfuric acid. Normal detergents,
moderate solutions of acids and alkalics are acceptable as well as a number of solvents at ambient temperature during
cleaning. Aggressive chemicals, excessive concentrations of chemicals at elevated temperatures as well as certain solvents
and hydrochlorides should be avoided. If you are in doubt, contact your local Alfa Laval sales office.
Temperature
The machine is designed to operate with cleaning media at temperatures up to 90°C (194 °F). However, it stands temperatures
up to 140°C (284°F) inside the tank when it is not operating, and it is possible to steam the tank through the machines.
The machine is not designed to rotate during steaming. A slow rotation of the media driven machine might occur and is
not harmful
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.
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.
In accordance with ATEX specifications regarding conditions for safe use, see page 14.
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.
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5Operation
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5.2 Safety precautions
The machine is intended for use inside a tank only. As peak velocity of main jets reaches 40 m/s, Alfa Laval Toftejorg SaniJet 20
must not be operated in open air or when tank is open.
ATEX 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.
The cleaning jets impinging the tank surface are a source of noise. Depending on pressure and distance to the tank walls,
noise level may reach up to 85 dB.
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.
ATEX warning: Tanks with capacities greater than 100 m3that could contain a flammable atmosphere should not be steam
cleaned, as steam issuing from a nozzle could contain charged droplets.
Tanks smaller than this may be steam cleaned providing that the steam nozzles and other metal parts of
the system are reliably earthed and grounded to the tank structure.
ATEX warning: Tanks may contain poisonous/hazardous products or products which represent an environmental or safety
risk. Never open tank and dismount the machine without checking previous tank contents and necessary
precautions.
ATEX warning: Retaining screw on side of Base housing (16) must never be loosened, when machine is mounted in tank
unless down pipe is supported and Pressure line is disconnected, as otherwise the complete Down pipe
assembly will fall down.
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6 Maintenance
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6.1 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.
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.
Handle machine with care. Take proper action to protect fine surfaces from being damaged.
Always use only proper tools. Use Toftejorg™ SaniJet 20 standard tool kit (page 40). 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.
6.2 Reserved rights for design changes of Alfa Laval equipment used in validated processes
Alfa Laval is continuously working on improving our equipment and services. In this improvement work Alfa Laval may for
example change the design and material in our equipment. A change in the design will not necessarily entail a change of the
specification and item no. for the equipment.
Alfa Laval reserves the right to change the design of Alfa Laval equipment without any notifications for improvements of our
design.
If Equipment from Alfa Laval is used in connection with, for example, a validated plant, and an order for replacements is
made, the design of the replacement may have been changed even if the specifications /item no. is the same as the existing
installed and validated ones.
When ordering a replacement please contact Alfa Laval sales support in this matter before placing the order.
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6 Maintenance
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6.3 Service and repair of ATEX certified machines
In order to ensure compliance with the ATEX regulations for service and repair in accordance with EN 60079-19, all service
and repair of ATEX certified machines should be performed by Alfa Laval, Kolding, 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.
AllsparepartsmustbeoriginalAlfaLavalsparepartsandtherepairorservicemustbedoneaccordingtothe
instructions in the related manual.
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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6.4 Service and repair of machines ordered with Q-doc and with Q-doc + FAT-SAT
In order to ensure full traceability and to obtain full qualification and validation documentation, all service and repair of machines
ordered with Q-doc (Equipment Documentation) and Q-doc + FAT-SAT (Qualification Documentation) should be handled
and ordered in one of the 3 different ways described below:
1. Q-doc + FAT-SAT Service/Repair Order (Item no. TEREP-Q-doc):
(This maintenance order should be selected if the customer wishes to have Alfa Laval Kolding A/S to obtain full file log
of all FAT (Factory Acceptance Test) documents for the Tank Cleaning Machine).
-Maintenance/Repair is carried out at Alfa Laval Kolding A/S and Q-doc + FAT-SAT Maintenance Log, FAT-SURFACE
(if necessary), FAT-WELD (if necessary) and FAT-PERFORMANCE is performed. The FAT documents are stored in
the Q-doc + FAT-SAT Maintenance Log as PDF-files.
-Q-doc (Equipment Documentation) for all steel spare parts are stored in the Q-doc + FAT-SAT Maintenance Log
as PDF-files.
-The machine is returned to the customer incl. the Q-doc + FAT-SAT Log CD and hardcopy of all FAT documents, for
further qualification (SAT: Site Acceptance Test) and validation (PV: Process Validation).
-Word and PDF documents are stored in the Alfa Laval Q-doc + FAT-SAT Maintenance Log folder.
2. Q-doc Spare Part Order (Item no.: TE24XXXX-90, TE24XXXX-91 or TE24XXXX-94)
(This maintenance order should be selected if the customer wishes to carry out service or repair. The customer or
the repair shop thus carries the full responsibility for the full traceability of the material and FAT documentation
for the Tank Cleaning Machine).
-The spare part is sent to the customer incl. Q-doc (Equipment Documentation) as hardcopy.
3. Q-doc + FAT-SAT Spare Part Order (Item no.: TE24XXXX-5X for Inner shaft (14), Outer pipe (12) and Inlet cap (39))
(This maintenance order should be selected if the customer wishes to carry out service or repair. The customer or
the repair shop thus carries the full responsibility for the full traceability of the material and FAT documentation
for the Tank Cleaning Machine).
-The spare part is sent to the customer incl. Q-doc (Equipment Documentation) incl. Weld-Log documentation (Inner
shaft, Outer pipe) as hardcopy.
-This service information will not be recorded in the Alfa Laval Q-doc + FAT-SAT folder. The customer has to perform all
Qualification tests and documentation (FAT, SAT, IQ & OQ) himself.
Contact local Alfa Laval service and support (see. www.alfalaval.com). Important information to give to Alfa Laval:
-Serial No.
-Q-doc maintenance order type:
-Item no.: TEREP-Q-doc
or
-Item no.: TE24XXXX-90, -91 or -94
Item no.: TE24XXXX-5X (see page 34 for more information)
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6 Maintenance
ESE01819
6.5 Every 150/300 working hours
If the used cleaning media is tap water or commonly used CIP solvents, the recommended maintenance interval is 300 hours.
However, if special cleaning media is used such as e.g. WFI, the recommended maintenance interval is 150 hours (see page 39).
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with water or suitable chemical cleaner, possibly Scotch-brite,
S-Ultrafine.
3. Check Slide bearing (31) for wear. If endface of Bearing is worn more than 0.5 mm into Slide bearing, it should be replaced. If
hole is worn to more than ø6.2 mm, it must be replaced.
4. Check Bearing bush for Turbine shaft (38) in Inlet cap. If hole is worn oval to a max. diameter of more than 8.35 mm, Bearing
should be replaced. At the same time replace Bearing bushes in Base housing (20 + 19).
5. Check Carrier bearing (36). If worn to a max. diameter of more than ø12.2 mm, it should be replaced.
6. Check Bearing bushes (20 + 19) in Base housing by fitting Output shaft (30) and check sideways movement. Replace if
necessary. If bushes are worn they will allow Output shaft to tilt and eventually the planet gear will be blocked. Always replace
together with Bearing bush (38) in Inlet cap.
Note: Timely replacement of bearings for Turbine shaft and Output shaft will prevent costly damage to the gear. However, all
Bearing bushes, made from high performance plastic PEEK-material, are mounted with press-fit and should not be removed
unless they need to be replaced.
7. Check Planet wheel (35) while still mounted in Planet wheel carrier (33). It must rotate easily on Shaft. If restriction or much
clearance on Shaft is felt, Planet wheel should be dismounted for inspection of Bearing (hole in Planet wheel) and Shaft
for Planet wheel (34). Max diameter of holes: ø6.2 mm.
Check wear of the teeth.
8. Check unrestricted rotation of Ball bearings. Inspect for build-up of foreign material in Ball rings (10 + 4) and Ball races.
Balls must rotate freely in Ball rings.
9. Assemble machines as described in the following pages.
10. Check that the machine is in operating condition by blowing compressed air from an air pistol into the inlet. If any resistance
is recognised, the machine should be disassembled in order to localise the cause.
In order to ensure current good hygiene it is recommended to replace all rubber seals at each service inspection.
Apart from the parts specifically mentioned above, all the remaining wear parts should regularly be inspected for wear. Wear
parts are specified in the Reference Lists of Parts, pages 36 ff.
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