HIPERBARIC 420 User manual

HIPERBARIC S.A.
C/ Condado de Treviño 6, 09001 BURGOS –SPAIN
Tel.: [phone] [e-mail]
www.Hiperbaric.com
INSTRUCTION MANUAL
HIGH PRESSURE PROCESSING
- Hiperbaric 420 integrated –
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HIPERBARIC S.A.
C/ Condado de Treviño 6, 09001 BURGOS –SPAIN
Tel.: [phone] [e-mail]
www.Hiperbaric.com
Hiperbaric Equipment General Safety Instructions
1. Introduction
Safety must be the first and most important design consideration in any piece of industrial equipment. We are
issuing this document to ensure, from our leadership position in this technology, that our current and future
customers fully understand some relevant aspects to the safety assurance of HPP equipment. These points are
critically important and should never involve compromise.
Hiperbaric solution is based on a design to firstly prevent failure probability and then furthermore include a
secondary safety system capable of detecting and eliminating hazardous conditions.
The Hiperbaric machines are built in accordance with the accepted safety and technical regulations, European
Directives and ASME Code Rules that may apply. However, when in operation, there may be risks to the life and
health of the operators or third parties, in addition to damage to the machine or other objects. Fluids under high
pressure involve potential risks. The energy in pressurized fluids is considerable and can cause damage to
personnel and/or equipment if released without control. Even though the Hiperbaric machines have been
designed to minimize risks, it is mandatory that the user handles the equipment and maintain it according to the
instructions included in the instructions manual. At all times the equipment must be operated within specified
operating parameters. Any tampering or bypassing of standard safety features and provisions can create unsafe
conditions which may result in equipment damage and possible personal injury.
2. Responsibilities
HIPERBARIC, S.A. shall be under no liability in respect of any defect, consequences and damage arising from fair
wear and tear, wilful damage, negligence, abnormal working conditions, failure to follow the HIPERBARIC’s
instructions (whether oral or in writing), failure to follow the Operations Manual, or alteration or repair of the
Goods without the HIPERBARIC’s approval or if the machine securities are manipulated;
3. High pressure equipment safety instructions
Use the Hiperbaric machine only when there are no technical faults that may endanger safety, and use the
servicing instructions! Remove immediately all types of error which could affect safety. To remove or to
manipulate the safety devices of the equipment could affect safety and put peoples life at risk.
In case of sudden failure of high pressure components, the contained energy is released as shock waved or
projected parts. There are many pressure components like pipes, fittings, high pressure intensifiers, pressure
transducers that are protected by shields and protection covers that must be in place when the equipment is
operated to ensure safety in case any of the high pressure components should fail. All the mounting instructions
of these components have to be followed.
People must not stay inside the covering when the machine is in operation
Normal use
The Hiperbaric H.P. machines must not be used for other types of work not specified by HIPERBARIC, S.A.
Normal use of the Hiperbaric H.P. machine; this means that:
-the machine is only used for the operations it was designed for (high pressure processing of
food using water),
-the machine is only used within the limits specified on the data sheets included in the
instructions manual, including water properties,
-the instructions for servicing must be adhered to, and the inspection and maintenance rules
followed.
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HIPERBARIC S.A.
C/ Condado de Treviño 6, 09001 BURGOS –SPAIN
Tel.: [phone] [e-mail]
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Staff must comply with the following
Staff working with the machine must be familiar with both the servicing instructions and the safety
instructions, and must have understood them. This refers specially to staff who only operate the machine
from time to time, e.g. for maintenance work. These instructions shall be made available by everybody
involved in the equipment and also all plant safety procedures must be observed.
Only Qualified personnel should work on or around the machine. Personnel not familiar with the
equipment use and the potential risks with high pressures must not work and/or operate the machine.
Qualified person: For the purpose of this manual, a qualified person is one who is familiar with the
installation, construction and operation of the equipment, and the hazards involved. In addition, he or
she has the following qualifications:
a) Is trained in the tasks that he is going to perform.
b) Is trained in the proper care and use of protective equipment, such as gloves, hard hat, safety
glasses, face shields, etc., in accordance with established safety practices.
c) Is trained in rendering first aid.
Reconstruction / Modifications
No modifications, extras and rebuilding relating to the safety of the machine should be carried out
without consent from HIPERBARIC, S.A. Also no change of placement of the machine shall be done
without the explicit consent of HIPERBARIC, S.A.
Machine components have been carefully designed because stresses in high pressure components are
very high. Welding, machining, drilling and other kinds of modifications are totally forbidden because it
can reduce the fatigue life or strength of the components affecting the safety.
Spare and wear parts
Only original HIPERBARIC, S.A. spare and wear parts may be used. The machine components have been
designed and materials have been selected carefully to increase life and safety of the Hiperbaric machine.
The user shall keep a stock of spares according to HIPERBARIC, S.A. recommendation. The use of not
original Hiperbaric S.A. wear and spare parts or not previously approved by Hiperbaric S.A. will result on
the cancellation of the warranty and can create unsafe conditions.
Safety features
There are many safety devices located in the machine. Manipulation of these safety devices, sensors,
spot plates and PLC’s control software could affect the safety of the machine. The setting of these have
been carefully chosen by HIPERBARIC, S.A. so it is totally forbidden to move, bend or manipulate them
because it could affect the safety of the machine. The main safety features are:
1. Yoke and vessel alignment control, if vessel and yoke are not properly aligned the system
may become unstable and the misalignment would increase up to a critical point. Hiperbaric
alignment control will not allow the machine to operate over a previously set misalignment. If
Hiperbaric’s alignment control is altered and a misalignment occurs the yoke may not able to
maintain operational integrity and the consequence is an abrupt release of the pressure ejecting
some parts such as plugs or wedges.
The Vessel position relative to the Yoke is continuously monitored by the safety PLC to be sure that
system works within a safe margin and sensors are fitted at each vessel end to control the relative
displacement between vessel and Yoke.
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HIPERBARIC S.A.
C/ Condado de Treviño 6, 09001 BURGOS –SPAIN
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2. Overpressure system, an overpressure system device has been installed composed by two
pressure transmitters and some sensors. Altering or bypassing the overpressure system is totally
forbidden and can also create unsafe conditions
3. Safety System, All Hiperbaric systems are fitted as standard with a PLC for safety integrity
level (SIL) 3, as defined in ANSI/ISA 84.00.01-2004 part 1. This safety PLC monitors pressure and
alignment, and whenever the machine surpasses a predefined set values it quickly release the
pressure eliminating hazardous conditions.
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HIPERBARIC S.A.
C/ Condado de Treviño 6, 09001 BURGOS –SPAIN
Tel.: [phone] [e-mail]
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Hiperbaric HPP machine LOTO sequence
LOTO operation for HPP machine maintenance:
Intensifier/ high pressure failure detection
The high pressure leaks can be detected by the machine operator, observing abnormal pressurization times,
alarms, or steam clouds through the plastic windows.
On the intensifiers, however, are the maintenance personnel who usually detect steam leaks on intensifiers while
checking performance (because these leaks usually don't affect gravely the cycle time), looking through the lexan
windows and seeing leaking points. So, these leaks mean that the seals or other parts need to be replaced or
fixed.
The high pressure leaks are the most common problem; however this LOTO protocol can be followed in case of all
kind of failure situation
How to proceed. General
As the leaks detection must be done while the machine is performing a cycle, the maintenance operator must
weigh the better option to stop the machine on each situation:
-Slight leak. This is the normal scenario. The M.O. (Maintenance operator) must go to the main command
panel (HMI) and wait till the current cycle is finished (to avoid the product spoilt, in case that reprocessing is
forbidden)
-Strong leak. This is a rare scenario, because the machine operator should have had problems previously
and probably alarms of times exceeded. In this situation the M.O. can push any e-stop for an immediate pressure
releasing or go to the main command panel (HMI) and turn down the cycle there.
1. Switch off the machine (Once the cycle has totally finished or an e-stop pressed) On the machine manual
the following steps are explained in detailed.
-Change the selector on HMI from "AUT" to "0" or "MAN".
If the cycle has finished normally, then the machine will be in "initial positions" (vessel
aligned with feeding conveyors)
In case an e-stop has being pressed, then a red screen will appear on the HMI. There is a
button that when pushing sends the machine to "initial positions".
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2. -On main control cabinet, change the circuit breaker to "0FF".
3. -Padlock the main control panel circuit breaker
4. -All the mains that feeds the machine should be closed (tap water (there are lockable valves), compressed
air, coolant fluid, electrical power…)
At this stage the machine will be completely stopped, isolated and without any kind of energy
accumulation. So the machine is safe to be fixed by the M.O.
NOTE: there are two hydraulic oil accumulator relieve valves, one manual and another automatic.
The manual one is manually opened and it is necessary to access inside the enclosure to do this
operation. In this way you will be able to relief the hydraulic pressure and perform any
maintenance work on the hydraulics circuit or on the high pressure relief valves. However in
order to not access inside the enclosure to do this operation, there is one valve electrically
controlled. If the circuit breaker is switch off, this valve will be automatically open.
Up to this point the LOTO process is common for any kind of maintenance operation (relief valves,
hydraulics, plug seals, high pressure pipes and elements...). To do these operations the whole machine
will remain disabled along the fixing.
Hand valve
Electrically controlled valve
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Once the problem has been solved, the machine can be restarted normally (see instruction manual)
However when the problem occurs on the intensifiers, the problematic one can be isolated, and the
machine can continue running with the remaining ones.
NOTE: One special maintenance operation that does not meet this LOTO procedure is the adjustment of
the LVDT’s that control the vessel alignment. In this case, some hydraulic power is needed because the
vessel has to continue pushing in the closing position. To perform this operation it is necessary to set the
alignment mode.
How to proceed. Vessel alignment mode
As this is a mode that involves certain risks because there is hydraulic pressure while people are inside the
machine, it requires a fairly strict safety protocol. “if you are not in special alignment mode you cannot
energize any part of the machine with the doors open”. To enter the mode the first thing to do is to
place the vessel in pressure position (inside), to ensure that the vessel is in the correct position the
machine has four safety sensors which are connected to the safety PLC. If any of them are not detected
by the machine at any moment, the safeties break down.
The second step to set the alignment mode is to select the alignment mode in the HMI. To do this, it is
needed to log in as a user with maintenance permissions. When you select in the HMI the special mode,
the safeties in the machine break down, that means that you cannot move any part of the machine. To
set this mode is needed to have the “Manual-0-Automatic selector”in 0 position.
At this moment you can open the doors of the machine, note that the safeties in the machine keep down,
therefore no movements in the machine will occur.
Next step to ensure safety is to take the “safety joystick”used to protect the operator.
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The operator must be pressing the ”safety enabling switch”while he is inside the machine. If the safeties
are rearmed and he drop or over press the “safety enabling switch”, the safeties break down.
Once the operator has taken the “safety enabling switch”, he is pressing it, the mode is configured in the
HMI and the vessel is in the correct position, the machine has the conditions to be rearmed in the
alignment mode. To do this, there is a “alignment rearm button”lighting in green. “The machine cannot
be rearmed pushing the “safety rearm buttons”outside the machine. The situation must be controlled
by the operator who is inside the machine”.
When the operator push the “alignment rearm button”, the machine starts to rearm, you notice that the
machine is rearming because there is a yellow beacon inside the machine flashing and a sound beacon is
making sound intermittently too. Ten seconds after the operator has pressed the “rearm button”, the
machine is rearmed. Once it is rearmed you can activate the “vessel pressing button” on the top of the
“safety enabling switch”to activate the hydraulic unit in order to press the vessel against the top.
Safety enabling switch
Vessel pressing button
Alignment rearm button
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It is very important to notice that in the “alignment mode”there are other redundant safety measures.
The machine has a “low speed movements valve”that ensures that hypothetical movements in this
special mode (this mode has no movements, it is only a redundant safety measure) are extremely slow.
Another safety measure is that the only valve which will remain with power is the “vessel in valve”(the
rest of the electrovalves which allow any movement in the machine have no power supply), and this
does not produce any movement because the vessel is already in the end position. “All these safety
measures avoid any movement in the machine”.
All the special operation modes are controlled by the safety PLC.
How to proceed. Intensifiers LOTO
1. The M.O. goes upstairs and turns off the circuit breaker that controls the intensifier which is needed to
be repaired; then he can padlock only this switch.
Now the intensifier is in safe condition in terms of power supply.
Then it is necessary to isolate the intensifier maintenance working area from the pressurized pipes of the
opposite side.
Figure 1 - General view of electrical cabinet
HP2
SWITCH
HP1
SWITCH
MAIN
SWITCH
ELECTRIC
CABINET
TS PANEL
EMERGENCY
STOP
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2. The 4 intensifiers in the mezzanine center supply alternatively the hydraulic energy to the press, so that
the machine can perform its main movements (plugs, vessel, wedges and relief valves). These four
intensifiers oil pressure circuits are connected (isolated from each other by check valves and no leak
electro valves currently) Manual valves will be installed allowing to divert the possible check valve leaks to
the oil reservoir, so each intensifier can be hydraulically isolated. (see the scheme below) Once the
intensifier is disabled on the command panel, another intensifier will supply the hydraulic power
automatically, more information on stage 4)
3. The M.O. opens the upper hatch and proceeds to remove the red high pressure pipe that connects the
intensifier to the high pressure net
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Figure 2 –View of the high pressure circuit.
To do that the stainless steel guard must be removed first to have access
Figure 3 –Located covering.
To isolate the intensifier it is only necessary to remove the pipe from the ‘T’ to the covering.
Fitting
covering
High
pressure
pipe
High
pressure
Tee
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Figure 4 –Removing the cover of the fitting.
Figure 5 –High pressure pipe removed.
Now the pipe is removed and a high pressure plug is installed instead
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Figure 6 - High pressure plug. Figure 7 -High pressure plug
fitted from 3/8’’ to 9/16’’
Figure 8 –Stainless steel protection upside down.
Then the high pressure circuit from the other side is completely isolated and the repairing tasks can be
held over the intensifier.
Safety
switch
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Figure 9 –Intensifier ready to be repaired.
Now he needs to fasten the plate again but now the plate is rotated 180 degrees and the hole for the
pressure pipe is in the bottom part of the plate, in this position the holes for the padlock are in the right position
and the plate is padlocked, also the plate has security switch key and the electrical security lane is again closed
(the upper hatch can stay opened when the hole machine will be restarted).
4. Now the M.O. can go downstairs and remove the padlock from the main control panel circuit breaker,
switch on the machine again. On the command panel (HMI) the intensifier to be maintained must be
disabled (to avoid alarms and malfunctioning messages), then the automatic production can be restarted
without the intensifier that has been stopped. (see instruction manual for more detailed information).
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5. Once the production is restored, the M.O. can go upstairs and change the wear parts or fix the problem.
6. Once the problem on the intensifier has been solved, the M.O. can go downstairs to stop again the
machine and repeat the same safety process to connect the intensifier again to the high pressure circuit.
Repeat the general process steps (1, 2, 3 & 4) Switch off the machine circuit breaker to off, padlock, close
the mains.
7. After the pipe is correctly assembled and the pipe guard on its original position, the upper hatch has to be
closed, and the padlock removed from the intensifier circuit breaker and the machine turned on again.
8. Downstairs the main control panel circuit breaker padlock can be removed and turned on.
On the command panel (HMI) the repaired intensifier should be enabled again.
The machine can start to work normally with all the intensifiers working.
How to proceed. Control Cabinet Maintenance
The electrical cabinets shall be de-energized prior to perform any maintenance operation.
1. The enclosures are interlocked with the main switch so it shall be set to "0FF" prior to open it.
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HIPERBARIC S.A.
C/ Condado de Treviño 6, 09001 BURGOS –SPAIN
Tel.: [phone] [e-mail]
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INSTRUCTION MANUAL
HIGH PRESSURE PROCESSING
- HIPERBARIC 420 integrated
HIPERBARIC S.A.
Polígono Ind. Villalonquéjar
C/. Condado Treviño 6
09001 BURGOS - SPAIN
Tel. [phone]
Fax [phone]
www.hiperbaric.com
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HIGH PRESSURE EQUIPMENT INSTRUCTIONS MANUAL
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Table of Contents
Chapter 1 . Introduction.......................................................................................................................5
1.1. Description of the product ........................................................................................... 5
1.1.1. Introduction.......................................................................................................... 5
1.1.2. Operating Principles ............................................................................................ 5
1.1.3. Objective ............................................................................................................. 6
1.1.4. Presentation ........................................................................................................ 6
1.1.5. Description of the Elements ................................................................................. 8
1.1.5.1. Structural unit........................................................................................... 8
1.1.5.2. High Pressure Circuit ............................................................................... 9
1.1.5.3. Low Pressure Circuit...............................................................................11
1.1.5.4. Hydraulic Unit .........................................................................................13
1.1.5.5. System for Loading and Unloading the Product.......................................13
1.1.5.6. Guards and Safety devices on the Machine.............................................13
1.1.6. Description of Operation .....................................................................................14
1.1.7. Conclusion..........................................................................................................14
1.1.8. Work station .......................................................................................................14
1.2. Technical details of the equipment .............................................................................17
1.2.1. Dimensions.........................................................................................................17
1.2.2. Technical data....................................................................................................18
1.2.3. Foundation .........................................................................................................21
1.2.4. Intensifiers inlet water quality ..............................................................................22
1.2.5. Inlet water pressures...........................................................................................22
1.2.6. Sound Level .......................................................................................................22
Chapter 2 Commissioning.................................................................................................................24
2.1. Safety symbols ..........................................................................................................24
2.2. Transport, handling and housing................................................................................25
2.2.1. Handling instructions...........................................................................................26
2.3. Commissioning the unit..............................................................................................31
2.3.1. Mounting and installing the unit...........................................................................31
2.3.2. Starting up the system ........................................................................................33
Chapter 3 Operation..........................................................................................................................35
3.1. Introduction................................................................................................................35
3.2. Description of the control devices...............................................................................36
3.2.1. Elements in the cabinet.......................................................................................36
3.2.2. Elements on the button panel..............................................................................37
3.3. Operation modes .......................................................................................................38
3.4. Status bar..................................................................................................................41
3.5. Users.........................................................................................................................43
3.6. Screens.....................................................................................................................44
3.6.1. Main screen........................................................................................................44
3.6.2. Latest alarms and warnings currently activated...................................................45
3.6.2.1. Warnings & alarms log............................................................................46
3.6.2.2. List of warnings.......................................................................................46
3.6.2.3. List of alarms ..........................................................................................50
3.6.3. Beginning inputs.................................................................................................57
3.6.3.2. REMOTE DATA CYCLE .........................................................................60
3.6.3.3. Cycle options ..........................................................................................60
3.6.4. Operations..........................................................................................................64
3.6.4.1. Manual movements.................................................................................65
3.6.4.2. Low-pressure water circuit ......................................................................67
3.6.4.3. Feeder movements.................................................................................68
3.6.4.4. Output feeder movements.......................................................................69
3.6.4.5. High-pressure water circuit......................................................................75
3.6.4.6. Intensifiers ..............................................................................................78
3.6.4.7. Intensifiers: Manual movements..............................................................82
3.6.5. Cycles ................................................................................................................83
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