Alfa Laval ALF-R Installation, Operating & Safety Manual
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Alfa Laval ALF-R Installation, Operating & Safety Manual

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Installation, Operating & Safety Manual
ALF Filter
Model
Standard (Steel)
Standard (Glass fiber)
Valid for
Original manual
ALF Instruction Manual UM_Filter_100B03
ALFA LAVAL COPENHAGEN A/S
:
ALF-R, ALF-S, ALF-P
:
ASME VIII or EN 13445
:
ASME X or EN13121
:
10S/15S/20S/30S
:
20P/30P/40P
:
20R/30R/40R/50R/60R/80R
English EN

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Summary of Contents for Alfa Laval ALF-R

  • Page 1 Installation, Operating & Safety Manual ALF Filter Model ALF-R, ALF-S, ALF-P Standard (Steel) ASME VIII or EN 13445 Standard (Glass fiber) ASME X or EN13121 Valid for 10S/15S/20S/30S 20P/30P/40P 20R/30R/40R/50R/60R/80R English EN Original manual ALF Instruction Manual UM_Filter_100B03 ALFA LAVAL COPENHAGEN A/S...
  • Page 2 The instructions given in this manual are intended as a general instruction to Alfa Laval Filter type ALF Alfa Laval reserves the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated.

  • Page 3: Table Of Contents

    Foundation ..................11 Mechanical Installation ..............11 Electrical Installation ................ 15 Parts position ................... 16 Main Components ................18 TYPE ALF-R ..................18 TYPE ALF-S ..................19 TYPE ALF-P ..................20 Operating instructions ..............21 Field of Application ................21 Operating Principle ................
  • Page 4 Maintenance ..................31 Introduction ..................31 Safety Instructions ................31 Removal and Insertion of the Filter Basket ........33 Alfa Laval “Combined Shaft Puller and Pusher” ....... 35 Trouble Shooting................36 Spare Parts ..................38 Ordering Spare Parts ............... 38 Alfa Laval Service ................

  • Page 5: Safety Instructions And Warnings

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Safety Instructions and Warnings The following symbols in this manual point out safety precautions. It means your attention is needed and your safety is involved. WARNING This symbol is used to indicate the presence of a hazard, which can or will cause severe personal injury, if the warning is ignored.

  • Page 6: General Safety Regulations

    • If the safety regulations are not followed, there is a risk of injuries as well as damage to the machinery and the surrounding environment. If these safety regulations have not been followed, Alfa Laval cannot be claimed responsible. If manuals are translated to local language the unit complies with the European Machinery Directive 2006/42/EC and EN ISO 12100-1/2:2003 standards.

  • Page 7: Modifications And Reconstruction

    Modifications and Reconstruction Please note that the machinery must not be altered or modified in any way if not directly approved by Alfa Laval. Use of original spare parts and accessories guarantee a safe operation. Use of parts from other manufacturers can lead to premature failure of the machinery, cause damage to the machine and surrounding area and jeopardize the warranty.

  • Page 8: Storage Guidelines

    Alfa Laval Copenhagen A/S Storage guidelines Storage Unless otherwise agreed, Alfa Laval delivers the equipment ready to be put in operation upon arrival and after installation. If it is necessary to store equipment for a longer period (1 month or more), certain precautions shall be made in order to protect and prevent unnecessary wear of the equipment.

  • Page 9: Installation

    When unpacking, take care not to damage the filter Make sure that the ALF filter has not been damaged during the transport. If transport damages are found, please contact local Alfa Laval agent. Page 9 of 67 ALF Instruction Manual UM_Filter_100B03...

  • Page 10: Lifting

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Lifting The ALF filter should only be lifted by using proper lifting slings fitted to the ALF filter as according to the following drawing. Lifting of filters mounted with lifting lugs.

  • Page 11: Foundation

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S 4.3.1 Lifting Lug Table The following sizes are always supplied with lifting lugs: ALF 15-S ALF 20-S ALF 20-R ALF 30-S ALF 30-R ALF 30-P ALF 40-R ALF 40-P...
  • Page 12 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Service distance for Shaft Basket Size (R, S, P) (mm above flange) (mm from end cover (minimum) flange) 1050 1300 1600 1150 2150 1600 2600 (from shell) 2. Proper Pipe Support shall be considered for the flushing pipe line. Otherwise due to the high velocity, flushing pipe will be damaged.
  • Page 13 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Page 13 of 67 ALF Instruction Manual UM_Filter_100B03...
  • Page 14 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Installation Example Page 14 of 67 ALF Instruction Manual UM_Filter_100B03...

  • Page 15: Electrical Installation

    14. A shut off valve mounted in the air supply in front of the control panel is mandatory (not part of Alfa Laval delivery) WARNING Failure to comply with electrical regulations can cause risk of death by touching electrified parts.

  • Page 16: Parts Position

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Parts position Positions: 1. Service Area 2. Pipe Supports 3. Flow Direction 4. Flushing Valve 5. Actuators 6. Shut-Off Valve 7. Bypass Pipe 11. Flushing Pipe 14. Outlet Pipe 17.
  • Page 17 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S 4.7.1 Piping Installation The piping should be arranged in as short and easily assembled parts as possible. Size of piping should be appropriate for the size on the ALF filter (see dimension drawing).

  • Page 18: Main Components

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Main Components TYPE ALF-R ALF-R: A pressure vessel of carbon steel Rubber lined inside for corrosion protection containing a strainer for filtration of water Filter Body Filter Basket Flow Diverter...

  • Page 19: Type Alf-S

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S TYPE ALF-S ALF-S: A pressure vessel of Stainless steel with a rubber lined end cover containing a strainer for filtration of water Filter Body Filter Body Filter Basket Flow Diverter...

  • Page 20: Type Alf-P

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S TYPE ALF-P ALF-P: A pressure vessel of Glass Fibre Reinforced Polyester containing a strainer for filtration of water Filter Body Filter Basket Flow Diverter Flushing Valve Flow Diverter Actuator...

  • Page 21: Operating Instructions

    Operating instructions Field of Application The Alfa Laval Filters, type ALF-R, ALF-S and ALF-P are designed to provide filtration of natural water sources, such as sea, river or lake water. The filters are designed to remove residuals contained in the water. Filtration rate depends on the selection of filter basket. Filters can be put into operation in both indoor and outdoor areas.
  • Page 22 ALF filter piping shall be designed with a by-pass system, if continuous plant operation is • needed. (See installation example). During piping design, ensure that it is possible to drain the Alfa Laval Filter, either by outlet • direction or by an optional drainage connection.

  • Page 23: Normal Operation

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Normal Operation At normal operation the flow diverter is open and the flushing valve is closed. The incoming liquid passes through the filter basket and out through the outlet connection. The liquid velocity in the inlet section is sufficient to keep the inlet section clean.
  • Page 24 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S 6.4.2 Primary Flushing The flushing valve is opened. The total flow through the filter increases, debris adhering to the filter body, pipe walls and filter basket is loosened and is flushed out via the flushing outlet.

  • Page 25: Alf Filter Start, Operation And Shut Down - 2Touch

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S ALF Filter Start, Operation and Shut down – 2Touch Type The following procedure should be carried out after initial installation and / or after each periodic service and maintenance.
  • Page 26 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Open the inlet and outlet vales in order to flood the filter. Ensure that air pockets are not present. J. Start the pump. K. Initiate several extra flushing sequences during the first hour of operation to remove any unexpected debris that is left over in the pipe system.
  • Page 27 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S An automatic procedure to measure the valve opening and closing time is performed during factory acceptance test. The function moves the valves to closed position. Then the valves are opened. A timer starts when the valves start to move and measure the time from closed to open position.

  • Page 28: Alf Filter Start, Operation And Shut Down - S7 Panel

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S ALF Filter Start, Operation and Shut down – Siemens S7 Type The following procedure should be carried out after initial installation and / or after each periodic service and maintenance.
  • Page 29 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S H. Open the inlet and outlet vales in order to flood the filter. Ensure that air pockets are not present. Start the pump. J. Initiate several extra flushing sequences during the first hour of operation to remove any unexpected debris that is left over in the pipe system.
  • Page 30 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S 6.6.2 Extra Flushing Procedure If the differential pressure across the filter increases, the filter might be clogged. If the filter is equipped with the differential pressure control system (optional) a flushing sequence will be initiated automatically.

  • Page 31: Maintenance

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Maintenance Introduction The ALF filter only requires very little maintenance. However following the maintenance instructions will ensure performance and availability. The ALF filter basket can be replaced without removing the filter from the piping system. The actuators, flushing valve and diverter shaft/disc can also be replaced.
  • Page 32 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S 7.2.3 Maintenance Interval The ALF-Filter should be opened minimum once a year for inspection checking its condition by a: Check of the operation of and the condition for the flow diverter (open/close position •...

  • Page 33: Removal And Insertion Of The Filter Basket

    See actuator manufacturers operation manual. Removal and Insertion of the Filter Basket 7.3.1 Dismantling Before disassembly of the filter ensure that the Alfa Laval service kit is available. It contains O-rings, sleeve bearings, sealing ring / hose clamp, lifting lug and gasket.
  • Page 34 There is a special tool available to perform this operation which can be supplied by Alfa Laval. See the chapter “Alfa Laval “Combined Shaft Puller and Pusher”” Loosen the hose clamp/rubber profile or sealing ring that is located at the end of the filter basket.

  • Page 35: Alfa Laval "Combined Shaft Puller And Pusher

    A hydraulic special tool can be used to pull out and insert the flow diverter shaft. The special tool is available in three sizes. The correct size to use depends on the ALF filter type/size. Please contact Alfa Laval Copenhagen A/S for further information or make a request to your local Alfa Laval representative.

  • Page 36: Trouble Shooting

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Trouble Shooting. Problem Indication Possible Cause Remedy Leakage In main flanges. Insufficiently Tighten. tightened. (inlet and outlet) Damaged lining or Open and check, damaged gaskets. change and repair if necessary.
  • Page 37 ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S No flushing. Flushing valve alarm. Flushing valve Dismantle actuator incorrectly mounted on and turn valve disc to the filter body. correct position. Power supply failed. Ensure fuses are (Electrical).

  • Page 38: Spare Parts

    3. Article number / part number (from filter specification) Also please refer to the specific manuals for the components to identify spare parts. Alfa Laval Service Please contact your local Alfa Laval agent for Parts and service questions. Page 38 of 67 ALF Instruction Manual UM_Filter_100B03...

  • Page 39: Index

    ALF – Installation, Operating and Safety Manual Alfa Laval Copenhagen A/S Index Actuator Alarm ......................................27 ALF-P ........................................20 ALF-R ........................................18 ALF-S ........................................19 Assembling ......................................34 Back Flushing ......................................24 back pressure ......................................21 Basket ........................................33 butterfly .........................................12 control panel ......................................15 Control Panel ......................................43 control system .......................................25 Differential Pressure ....................................23...

  • Page 40: Appendix A: Tables

    Alfa Laval Copenhagen A/S Appendix A 11. APPENDIX A: Tables Pressure Drop Data Min. Flow Max. Flow Min. Flushing Min. Max. Normal Normal Flow Differential Differential Measurement Operation Operation Rate Pressure Pressure ∆p~3 kPa ∆p~30 kPa Approximately P1-P3 P1-P3 US gpm...
  • Page 41 Alfa Laval Copenhagen A/S Appendix A Pressure Drop Diagram Page 41 of 67 ALF Instruction Manual UM_Filter_100B03...
  • Page 42 Alfa Laval Copenhagen A/S Appendix A Nozzle Load Table: FILTER TYPE Fx Fy Fz Fx Fy Fz Fx Fy Fz ALF 20-R 15 15 15 1,0 25 25 25 2,5 15 15 15 1,0 ALF 30-R 15 15 15 1,5...

  • Page 43: Appendix B: Control Panel 2Touch

    Alfa Laval Copenhagen A/S APPENDIX B 12. APPENDIX B: Control Panel 2Touch 12.1 Control Panel - 1 Filter 12.1.1 Basic control panel, operators instructions Front view, basic panel: Push buttons explanations are displayed in the following table. -Push button (PB)
  • Page 44 Alfa Laval Copenhagen A/S APPENDIX B PB 5: Diverter PB: Manual open diverter While closed or closing in valve While opening in both While open in both Valve Open both manual and auto LED: Show open diverter manual and auto mode...
  • Page 45 Alfa Laval Copenhagen A/S APPENDIX B The operator can set an own password. This password can be removed by changing back to 0000 if logged in. The service password overrides the user password and cannot be changed or removed. Page 45 of 67...
  • Page 46 Alfa Laval Copenhagen A/S APPENDIX B Mounting Plate Mounting Plate Electrical actuator Internal Pneumatic valves 24VDC (Solenoid valve block installed inside of the control panel). Mounting Plate Mounting Plate External Pneumatic Valves 110-240VAC External Pneumatic Valves 24VAC (Solenoid valves are installed on the actuators).
  • Page 47 APPENDIX B ALF Filter Operator Interface 12.1.2 Operator Interface 2Touch Document Information Document Department: CAT-028031108-EN Project: AL Filter First created: 2011-01-29 Rev nr: 1.6 Revision History Version Description Rev by Date Document Created 2011-01-29 1.2.3.2 updated BHND 2012-03-12 Page 47 of 67 ALF Instruction Manual UM_Filter_100B03...
  • Page 48 APPENDIX B 12.1.3 Operator interface for ALF filter Operator interface is shown on picture below FLUSH MANUAL DIVERTER VALVE VALVE FLUSH FLUSH DIVERTER VALVE VALVE Figure 1- Preliminary 12.1.4 Pages on the operator panel Scroll between three different pages using the <escape> Main page Settings page Alarm page...
  • Page 49 APPENDIX B Figure 2 – Pages on the operator panel 12.1.4.1 Main page The main page, together with the function buttons and LED indicators, is used for process control. This page is automatically reached after power on. Scroll between operation info and analogue process values using the arrow keys. Press the escape key to return to the main page from any submenu.
  • Page 50 APPENDIX B Following figures shows the user interface on start and first run Start P a n e l F i r m w a r e V 1 . 4 0 S y s t e m s t a r t i n g . P l e a s e w a i t …...
  • Page 51 APPENDIX B 12.1.5.2 Settings menus Parameters (see 12.1.6) Time settings (see 12.1.7) Operation info (see 12.1.8) I/O test (see 12.1.9) Alarm History (see 12.1.10) Flush History (see 12.1.11) System info (see 12.1.12) IP Settings (see 12.1.13) Password/Login (see 12.1.14) Set contrast (see 12.1.15) _ _ _ S E T T I N G S _ _ _ _ _ _ _ _ _ 1 P a r a m e t e r s...
  • Page 52 APPENDIX B Remark: If there are more than two options to select (only two are visible), it is possible to cycle between those options by pressing on up or down arrows (showed by red circle in the Figure below) Current setting P 1 0 1 L o c a l c t r l N e w...
  • Page 53 APPENDIX B 12.1.6.5 Settings -> 1 Parameters -> P110 Prim. FlushInt P 1 1 0 6 0 m i n M a x : 1 2 0 M i n : N e w = 6 0 m i n Figure 14 12.1.6.6 Settings ->...
  • Page 54 APPENDIX B (Start flushing if Differential pressure is higher than this setpoint) 12.1.6.12 Settings -> 1 Parameters -> P117 Diffpres high P 1 1 7 5 0 0 . 0 0 m B a r M a x : 1 0 0 0 0 . 0 0 M i n : 0 .
  • Page 55 APPENDIX B 12.1.6.18 Settings -> 1 Parameters -> P123 Press.LPfilte P 1 2 3 5 . 0 0 s M a x : 9 9 9 . 0 0 M i n : 0 . 0 0 N e w = 5 .
  • Page 56 APPENDIX B 12.1.6.24 Settings -> 1 Parameters -> P129 FBack CloseFlowValve P 1 2 9 N e w S e t t i n g Y e s Figure 32 12.1.6.25 Settings -> 1 Parameters -> P130 FBack OpenFlowValve P 1 3 0 N e w S e t t i n g Y e s...
  • Page 57 APPENDIX B 12.1.6.31 Settings -> 1 Parameters -> P142 Alarm delay valves P 1 4 2 5 . 0 0 s M a x : 6 0 0 . 0 0 M i n : 0 . 0 0 N e w = 5 .
  • Page 58 APPENDIX B 12.1.8.2 Settings -> 3 Operation info -> 1 Timers, counters -> 1 Power time 1 P o w e r o n t i m e s i n c i n s t a l l a t i o n 6 h o u r s , 3 5 m i n Figure 44 12.1.8.3 Settings ->...
  • Page 59 APPENDIX B _ _ S e t _ T e s t _ m o d e _ _ _ _ _ A c t i v a t e t e s t m o d e ? _ _ P a r a m e t e r r e s e t _ _ _ _ _ Figure 51 R e s e t p a r a m e t e r s...
  • Page 60 APPENDIX B Step through the list using the arrow keys. Additional information is available pressing the <info> key for the selected alarm. A 0 0 7 1 1 5 V / 2 3 0 V p o w e r s u p p l y t o v a l v e s 1 0 .
  • Page 61 APPENDIX B 12.1.13.3 Settings -> 8 IP Settings -> 3 Change subnet mask C u r r e n t s u b n e t m a s k : 2 5 5 . 2 5 5 . 0 . 0 N e w s u b n e t m a s k - - - - - - - - - - - - - - - - - - - Figure 62...
  • Page 62 APPENDIX B 12.1.14.3 Settings -> 9 Password/LogIn -> 3 Change user pw (if there is no user password e.g. First start) _ _ _ P A S S W O R D _ _ _ _ _ _ _ _ E n t e r n e w p a s s w o r d * - - - Figure 66...

  • Page 63: Appendix C: Alf Control Panel S7

    APPENDIX C Appendix C: ALF Control Panel S7 13.1 Control Panel - 1 Filter 71S3 Switch Program selector 6 time selector in use Filter groups Mounting Plate Mounting Plate Pneumatic Actuator Electric Actuator 13.1.1 ALF Filter Start, Operation and Service The following procedure should be carried out after initial installation and / or after service and maintenance.
  • Page 64 APPENDIX C 6 Check the operation of both the actuators during the flushing sequence to see whether cables and air hoses have been connected properly or not (see figure below): A. Flushing valve actuator opens counter clockwise (primary flushing) B. Flow diverter valve actuator closes clockwise (secondary flushing/ back flushing) C.
  • Page 65 APPENDIX C 10 If a differential pressure control system is available (optional), then check the setting of the differential pressure transmitter in the control panel. Open the panel and find the E+H RMA422 process transmitter(s) (76U2). Use only + or - key on the transmitter and read the individual values. The display is capable of showing three different values A.
  • Page 66 APPENDIX C Min. actuator travel time is set to avoid water hammer in the system. Max. actuator travel time is set to avoid actuator alarm (limit switches required). Suppose the travel time is not within the restrictions of the table please check "Trouble Shooting". Flow Diverter Flow Diverter Flushing Valve...
  • Page 67 APPENDIX C 13.1.3 Shut-Down and Service Procedure 1 Put the filter in question off stream. If isolation valves are available in the pipe system upstream and downstream of the filter do close these. 2 Select the filter(s) to be serviced and turn the corresponding filter on/off switch OFF Control panel S7 5001 / S7 6001: 1 pcs filter on/off switch Control panel S7 5002 / S7 6002: 2 pcs filter on/off switches Control panel S7 5004 / S7 6004: 4 pcs filter on/off switches...

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