Alfalaval Toftejorg TJ20G User manual

Instruction Manual
Alfa Laval Toftejorg
T
M
TJ20G
IM-TE91A600-EN6
ESE01794EN
Date of issue: May 8, 2014
First published: June 2000
With
Standard
Distillery
Secured
High temp
Hastelloy
3.1 Inspection Certificate – EN10204
ATEX Certification in accordance with Directive 94/9/EC
Original manual
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Contents
Toftejorg TJ20G, Product Program ...........................................................................3
Introduction................................................................................................................5
Marking......................................................................................................................6
Serial number explanation..................................................................................................6
ATEX Marking ...........................................................................................................6
Serial number explanation..................................................................................................7
Intended use..............................................................................................................8
Patents and trademarks ............................................................................................8
General Description...................................................................................................9
Quality system ...........................................................................................................9
Functionality...............................................................................................................9
Technical Data.........................................................................................................11
Dimensions.......................................................................................................................11
Performance Data.............................................................................................................12
Installation
Installation Manual – Contents ................................................................................13
General Installation Instructions ..............................................................................14
Special Conditions for Safe Use – ATEX ................................................................16
Operation
Operational Manual - Contents................................................................................19
Operation.................................................................................................................20
Cleaning Media.................................................................................................................20
Product .............................................................................................................................20
Pressure ...........................................................................................................................20
Temperature.....................................................................................................................20
After Use Cleaning............................................................................................................21
Safety Precautions............................................................................................................22
Maintenance
Maintenance Manual – Contents.............................................................................23
Preventive Maintenance Guidelines........................................................................24
Service and Repair of ATEX approved machines...................................................25
Maintenance intervals and Service Kits selection....................................................26
Minor Service Kit for Toftejorg™ TJ20G...........................................................................27
Major Service Kit for Toftejorg™ TJ20G...........................................................................28
Available add-on´s for Spare parts...................................................................................29
General recommendations ...............................................................................................29
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Assembly drawing....................................................................................................30
Reference list of parts..............................................................................................31
Toftejorg™ TJ20G, TE20G000_024 + TE20G050_054 (except TE20G010-TE20G018).31
Toftejorg™ TJ20G, TE20G010_014.................................................................................32
Toftejorg™ TJ20G, TE20G016_018.................................................................................33
Toftejorg™ TJ20G, TE20G030_044.................................................................................34
Toftejorg™ TJ20G, TE20HXXX........................................................................................35
Toolkit and tools for assembly and disassembly.....................................................36
Standard Tool Kit for Toftejorg™ TJ20G ..........................................................................36
Torque Wrench Tool Kit for Toftejorg™ TJ20G................................................................36
Disassembly ............................................................................................................37
Assembly.................................................................................................................39
Replacement of Ball Races ..............................................................................................41
Trouble Shooting Guide...........................................................................................42
Symptom: Loose Nozzle Hub ...........................................................................................42
Symptom: Slow rotation or failure of machine to rotate....................................................42
Symptom: Slow rotation or failure of machine to rotate (continued).................................43
How to Order Spare Parts .......................................................................................44
How to contact Alfa Laval Tank Equipment.............................................................44
Miscellaneous
Misc. - Contents.......................................................................................................45
EU Declaration of Conformity incl. ATEX ................................................................46
Declaration of Conformity, EN 10474, sub clause 2.2 Test Report.........................47
ATEX-Special Conditions for safe use ....................................................................49
Declaration of Complaince with 10/2011 – Food contact materials.........................50
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Toftejorg TJ20G, Product Program
This manual covers the product program for ToftejorgTM TJ20G tank cleaning machine
Toftejorg™ TJ20G options
Connection
Nozzles
(mm)
Standard
Article No.
Distillery
Article no.
Hastelloy
Article no.
Secured
Article no.
High temp.
Article no.
1" BSP
Female 4 x ø3.9 4 x ø4.6
4 x ø5.5
TE20G000-xx
TE20G002-xx
TE20G004-xx
TE20G030-xx
TE20G032-xx
TE20G034-xx
TE20H000(-x0)
TE20H002(-x0)
TE20H004(-x0)
TE20G010-xx
TE20G012-xx
TE20G014-xx
TE20G016-x2
TE20G017-x2
TE20G018-x2
1" NPT
Female 4 x ø3.9 4 x ø4.6
4 x ø5.5
TE20G020-xx
TE20G022-xx
TE20G024-xx
TE20G040-xx
TE20G042-xx
TE20G044-xx
TE20H020(-x0)
TE20H022(-x0)
TE20H024(-x0)
1" BSP
Female
Sanitary*
4 x ø3.9
4 x ø4.6
4 x ø5.5
TE20G050-xx
TE20G052-xx
TE20G054-xx
TE20H050(-x0)
TE20H052(-x0)
TE20H054(-x0)
*see below for choices of sanitary welding connectors
Index no.:
TE20GXXX (no postfix): version w. PVDF impeller
TE20GXXX-X2: version w. PEEK impeller
TE20HXXX (no postfix): Hastelloy version w. PEEK impeller
Available documentation add-on’s
TE20XXXX-7X: ATEX
TE20XXXX-8X: 3.1 cert. + ATEX
TE20XXXX-9X: 3.1 cert
Explanation to Add-on’s:
3.1 certificate: Declaration of Compliance according to EN 10204 type 3.1 inspection Certificate
ATEX includes:
For TE20X000_054 except TE20G016_018:
ATEX approved machine for use in explosive atmospheres. Category 1 for installation in zone 0/20
in accordance to Directive 94/9/EC. Ex II 1 GD c T140°C.
For TE20G016_018:
ATEX approved machine for use in explosive atmospheres. Category 1 for installation in zone 0/20
in accordance to Directive 94/9/EC. Ex II 1 GD c T250°C Tamb 0°C to +200°C.
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Toftejorg TJ20G, Product Program
Page 4 Instruction Manual, Alfa Laval Toftejorg TJ20G
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A600_EN6
Available welding connection
Welding adapter (see right) with sealing assembly between Down pipe,
Welding adapter and machine.
Welding connections are ordered separately.
For use with sanitary connection cones use cone with seal (seals are
included for machines with sanitary cone).
Standard cone
Pipe Dimension in mm Connection Thread Article no.
1“ ISO thread pipe: ø33.7 x 3.25 1” BSP TE52D030
1“ ANSI Sch.40S: ø33.4 x 3.38 1” NPT TE52D031
1 ½” ISO Dairy pipe: ø38 x 1.2 1” BSP TE52D032
Sanitary connection cone
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Introduction
With a new revolutionary patented design, the Toftejorg™ TJ20G introduces a new generation of tank
cleaning machines.
Based on more than 30 years’ experience from practical tank cleaning and production, the Toftejorg™
TJ20G has been developed to meet the highest demands for efficiency, reliability and hygiene within
food and beverage, pharmaceutical and biochemical industry.
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 is always a system of
carefully planned maintenance; you will appreciate that a tank cleaning machine that has a rough and
dirty job to do, needs more frequent attention than one working in ideal conditions.
Warning:
It is in your own interest to get the best and most economical performance from your
tank cleaning machine. Neglect of maintenance means poor performance, unscheduled
stoppages, shorter life and expense. Good maintenance means good performance; no
unscheduled stoppages and better total economy.
If the TJ20G stops rotating unintentionally within the warranty period, please return the machine to Alfa
Laval Kolding A/S. Please do not try to fix any mechanical problems before shipping.
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Marking
Alfa Laval tank cleaning machines are all marked to allow recognition of machine type, machine name,
Serial number and manufacturing address. The marking are placed on the body of the tank cleaning
machine.
Serial number explanation
Machines supplied with or without normal
documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
Note: The illustrations and specifications contained in this manual were effective at the date of printing.
However, as continuous improvements are part of 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™ TJ20G is certified as category I component. The certification is carried out by the
certified body Baseefa, who has issued the certificate no. 04ATEX0358X. The marking on the ATEX
certified Toftejorg™ TJ20G is as follows:
Note:
TE20G016-72, TE20G017-72 and TE20G018-72
TE20G016-82, TE20G017-82 and TE20G018-82.
These machines has a special ATEX text for the “Ex” line.
Next to the “Ex” symbol this text shall be present:
II 1 GD c T250°C Tamb 0°C to +200°C
Marking
area
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Serial number explanation
Machines supplied with or without normal 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
ATEX
information:
Also see page 25
regarding special conditions for repair of ATEX certified
machines.
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Intended use
It is to be verified by the end-user that
•the TJ20G tank cleaning machine is in conformity with respect to tank -, vessel - or container
size in which it intended to be used.
•the construction materials (both metallic and non-metallic) are compatible with product,
flushing media, cleaning media, temperatures and pressure under the intended use.
To ensure the self cleanability and drainability the machine must be installed in vertical position
Warning: Before installation and operation of the tank cleaning machine carefully read the
General Installation Instructions (page 14), the special conditions for safe use in
accordance with ATEX Certification, Directive 94/9/EC (page 16) and the Safety
Precautions (page 22
) and take all necessary precautions according to your
application and local regulations.
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" is a trademark or registered trademark of Alfa Laval Kolding A/S. The Toftejorg™ TJ20G
product has patents in the EPO member states (EP 0 560 778), in the US (5333630) and in other
countries and has a new patent pending (PCT/DK/2007/000062). Other products or company names
mentioned herein may be the trademarks of their respective owners. Any rights not expressly granted
herein are reserved
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing
intellectual property and thereto related rights. It is the responsibility of the user of this document to
comply with all applicable intellectual property laws. Without limiting any rights related to this
document, no part of this document may be copied, reproduced or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the
expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB will enforce its rights
related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
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General Description
The Toftejorg™ TJ20G is a media driven and media lubricated tank cleaning machine. No lubricating
substances such as oil, grease etc. are used. All materials are selected for contact with food, and the
machine is self-cleaning i.e. all internal and external surfaces can be cleaned.
For use in explosive hazard zones the media version can be used, provided it is installed according to
safety instructions in local regulations.
Quality system
The TJ20G is designed in accordance with the EHEDG design guidelines for sanitary design of
processing equipment. It is produced according to Alfa Laval Kolding A/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 EU compliant materials.
Functionality
The flow of cleaning fluid into the machine passes through a turbine, which accordingly is set into
rotation. Through a gear set and a driver tube, the turbine rotation is transmitted to the Cleaner Head.
The combined motion of the machine Body and the Nozzles ensure a fully indexed tank cleaning
coverage. After 55/8 revolutions of the Hub cover with Nozzles (53/8 revolutions of the machine Body),
one coarse cleaning pattern is laid out on the tank surface and the first cycle has been made. During
the following cycles, this pattern is repeated 7 times, each of which is displaced, and the pattern
gradually becomes more dense. Finally, after 8 cycles - a total of 45 revolutions of the Hub Cover with
Nozzles (43 revolutions of the machine Body), a complete cleaning pattern has been laid out, and the
first pattern is repeated.
This is illustrated below for a spherical tank with the machine placed in the centre:
1st cycle
2nd cycle
3rd cycle
4th cycle
The number of cycles needed to perform a proper cleaning depends on type of soilage, distance,
cleaning procedure, cleaning temperature and cleaning agent.
For substances that are easily mobilised, i.e. are easy to remove, one cycle could be sufficient while in
cases of heavier soiling (high viscous, sticky substances, etc.) a more dense pattern/more cycles are
needed.
The rotation speed of the turbine depends on the flow rate through the machine. The higher the flow
rate, the higher the speed of rotation. In order to control the RPM of the machine for a wide range of
flow rates, the machine has different turbines according to the Nozzle size.
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Functionality
Page 10 Instruction Manual, Alfa Laval Toftejorg TJ20G
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A600_EN6
Apart from the main flow flushing the gear and
the Hub, and thereafter forming the jets through
the Nozzles, fluid is flushed through all internal
areas, through Bevel gear, Ball bearings and
gaps between moving parts and finally also used
for cleaning of the outside surfaces of the
machine. The areas behind the Screws on the
Cone are cleaned through small spray holes
behind the Screws. To ensure self-draining a hole
is located at the bottom of the Body. This self-
draining is only ensured, if the machine is
installed in upright position.
For Sanitary connection version:
The threaded connection between downpipe and
machine is not a product contact surface as it is
enclosed using two seals and the welding
adaptor.
For all versions:
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 in house user requirements
or policies, an adhesive such as Loctite No. 243
or equivalent could be used. Other methods could
be acceptable and subject to customer
preference.
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Technical Data
Weight of machine : 5.1 kgs (11.2 lb)
Working pressure : 3-8 bar (40-115 psi)
Recommended inlet pressure : 5-7 bar (70-100 psi)
Working temperature max. : 95°C (200°F)
Ambient temperature
No-EPDM machines
TE20G016-72/TE20G016-82
TE20G017-72/TE20G017-82
TE20G018-72/TE20G018-82
:
: 0 - 140°C (95°C/200°F - 140°C/284°F when not operated)
0 - 200°C (95°C/200°F - 200°C/392°F when not operated)
Materials
:
Stainless Steel AISI 316L, SAF 2205, PFA, PEEK, PVDF,
A4/EPDM
Materials - Hastelloy
:
Hastelloy C22, Hastelloy C276, PEEK, Viton, PFA
Dimensions
All dimensions are given in mm
Minimum required passage:
ø110 mm (4.33 inch) at flange thickness of maximum 25 mm (0.98 inch)
Otherwise ø150 mm (5.90 inch)
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Performance Data
Flow rate
Distillery version (20G030_044) – flow at 5 bar:
4 x Ø3.9 = 10 m3/h
4 x Ø4.6 = 12.4 m3/h
4 x Ø5.5 = 13.9 m3/h
Horizontal throw length at static condition
Cleaning time, complete pattern
Effective throw length is defined as 250 mm water
column (50 lbs/sq.ft.) impact force in centre of jet.
However, effective throw length varies depending
on jet transverse speed over surface, substance to
be removed, cleaning procedure and agent.
Note: Throw lengths are measured as horizontal
throw length at static condition.
Vertical throw lengths upwards are approx. 1/3
less.
The inlet
pressure has been measured
immediately at the machine inlet. In order to
achieve the performance indicated in the curves,
pressure drop in the supply lines between pump
and machine must be taken into consideration.
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Installation
Installation Manual – Contents
General Installation Instructions ..............................................................................14
Special Conditions for Safe Use – ATEX ................................................................16
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General Installation Instructions
The tank cleaning machine 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, scale etc. to clog
inside the machine. It is essential to avoid fine solid particles (e.g. fine sand) in cleaning fluid as they
will increase wear considerably.
In general a filter with 3 mm holes is recommended in the supply line. In case of fine solid particles
below 500 µm in the cleaning fluid, choose filter size accordingly.
In order to separate the CIP system from the process it is recommended to install a shutoff valve close
to the machine inlet. This will also prevents 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 gravity 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 TJ20G and/or the entire installation. Ideally, a frequency controlled pump
with a ramp function for start-up is used for supplying the cleaning liquid.
Before connecting the machine to the system, all supply lines and valves should be flushed in order to
remove foreign particles.
The machine should be screwed tightly onto its supporting supply line using a 36 mm flat jawed
spanner (tool No. TE81B040) on the flats machined on the inlet Cone.
During handling and installation handle the machine with care in order not to damage the surface
finishes of the machine.
The TJ20G machine has been tested at the factory before shipping. You can check that the machine is
in operating condition by blowing compressed air into the inlet, while holding the machine by the cone
and verify that the rest of the machine rotates evenly. If resistance is recognised, the machine should
be disassembled in order to localise the cause or returned to the nearest Alfa Laval Service Centre).
Upon arrival check that the machine is in operating condition by inserting a flathead Screwdriver in top
of Turbine shaft and easily turn Turbine shaft anti-clockwise. If any resistance is recognised, the
machine should be disassembled in order to localise the cause.
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 in-house user requirements or policies, an adhesive such as Loctite No. 243 or equivalent could be
used. Other methods could be acceptable and subject to customer preference.
Note: Do not try to turn the Nozzle head by hand, since this may damage the Gear. The Nozzle head
can be turned by blowing compressed air through the inlet connection.
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-Machinery
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.
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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 threads or joints, unless
an electrical connection is otherwise established to ensure that the machine is effective
grounded. In addition, connecting pipe work must be electrically conductive and
grounded 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 DS/CLC/TR 50404:2003 Safety
of Machinery, guidance and recommendations for the avoidance of hazards due to static
electricity.
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Special Conditions for Safe Use – ATEX
In accordance with the ATEX Certification, Directive 94/9/EC the following special conditions shall be
obeyed.
ATEX
Warning:
The unit may be operated, in a hazardous area, only when filled with the process fluid.
ATEX
Warning:
For standard machines:
Working temperature max:
The maximum permitted process fluid temperature and ambient temperature
when the machine is operating is 95°C.
Ambient temperature:
When the machine is not operating, the maximum permitted ambient
temperature is 140°C.
For high-temperature machines:
TE20G016-72 and TE20G016-82
TE20G017-72 and TE20G017-82
TE20G018-72 and TE20G018-82
Working temperature max:
The maximum permitted process fluid temperature and ambient temperature
when the machine is operating is 95°C.
Ambient temperature:
When the machine is not operating, the maximum permitted ambient
temperature is 200°C.
ATEX
Warning:
The maximum permitted process fluid pressure is 8 bar.
Continues on next page.
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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 "CLC / TR 50404:2003“.
Following a guidance document such as "CLC / TR 50404:2003“ to establish safe use of
machinery and process is the users own responsibility and is not covered by the ATEX
certification for this product.
In addition to the above mentioned precautions relating to the ATEX guidelines Directive
94/9/EC of March 23 1994, the general safety precautions, page 22, must be observed.
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