Alfa Laval Toftejorg SaniJet 20 Instruction Manual
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Alfa Laval Toftejorg SaniJet 20 Instruction Manual

Alfa Laval Toftejorg SaniJet 20 Instruction Manual

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Instruction Manual
Alfa Laval Toftejorg™ SaniJet 20 Media Driven
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/IECEx Certification in accordance with Directive 2014/34/EU
First published: 07-2000
ESE01819-EN13
Original manual
2019-07

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Summary of Contents for Alfa Laval Toftejorg SaniJet 20

  • Page 1 Instruction Manual Alfa Laval Toftejorg™ SaniJet 20 Media Driven 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/IECEx Certification in accordance with Directive 2014/34/EU...

  • Page 3: Table Of Contents

    ................... 6.1. Preventive maintenance ................6.2. Reserved rights for design changes of Alfa Laval equipment used in validated processes 6.3. Service and repair of ATEX/IECEx certified machines ......... 6.4. Service and repair of machines ordered with Q-doc and with Q-doc + FAT-SAT ..
  • Page 4 The information herein is correct at the time of issue but may be subject to change without prior notice 11. General information ................... 11.1. Service and repair ................11.2. How to order spare parts ................ 11.3. How to contact Alfa Laval Kolding A/S ............

  • Page 5: Ec/Eu Declaration Of Conformity

    Phone No. hereby declare that Tank Cleaning Machine Designation Alfa Laval Toftejorg SaniJet 20 Media Driven Type From serial number 2019-0001 to 2030-99999 is in conformity with Machinery Directive 2006/42/EC and the following harmonized standard is used: DS/EN ISO 12100:2011 Safety of Machinery - Risk Assessment is in conformity with (Ex / ATEX) Directive 2014/34/EU and the following harmonized standards are used: EN ISO 80079-36:2016, EN ISO 80079-37:2016, DS/EN ISO/IEC 80079-34:2011, Annex A, paragraph A.5.3 Rotating machines...

  • Page 6: Safety

    2 Safety SaniJet 20 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...

  • Page 7: Introduction

    SaniJet 20 3.1 Introduction This manual has been prepared as a guide for installing, operating and maintaining your Alfa Laval Toftejorg tank cleaning machine. Should you require further assistance, our Technical Sales Support department and worldwide net of sales offices are pleased to help you.

  • Page 8: Patents And Trademarks

    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.

  • Page 9: Atex/Iecex Marking

    SaniJet 20 3.6 ATEX/IECEx marking The Alfa Laval Toftejorg SaniJet 20 is certified as category I component. The ATEX certification is carried out by the Notified Body SGS Fimko Oy, who has issued the certificate no. Baseefa05ATEX0117X. The IECEx certification is carried out by the Certification Body SGS Baseefa Ltd., who has issued the certificate no. IECEx BAS 19.0063X.

  • Page 10: Atex/Iecex Temperature Class And Code

    3 Introduction SaniJet 20 3.7 ATEX/IECEx temperature class and code The maximum surface temperature depends mainly on operating conditions which are the temperature of the cleaning fluid and the ambient temperature. Group II EPL Ga The gas temperature class is corrected with a safety margin of 80% due to a requirement for Group ll EPL Ga equipment. The gas temperature class depends on the cleaning fluid temperature or the ambient temperature, whichever of the two is the highest.

  • Page 11: Installation

    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.

  • Page 12: Functionality

    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.
  • Page 13 4 Installation SaniJet 20 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.

  • Page 14: General Safety And Installation Instructions

    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.

  • Page 15: Specific Conditions For Safe Use In Accordance With Atex/Iecex Certification

    4 Installation SaniJet 20 4.5 Specific conditions for safe use in accordance with ATEX/IECEx Certification Directive 2014/34/EU NOTE Explosion protection type is constructional safety “c”. Warning: Operated in a hazardous area The unit my be operated in a hazardous area only when completely filled with cleaning fluid/steam. If a medium other than the cleaning fluid/steam is passed through the equipment, the flow must not be high enough to cause the equipment to operate.
  • Page 16 4 Installation SaniJet 20 4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification Warning: Max. permitted steaming temperature The maximum permitted steam temperature trough the machine and ambient temperature is 140°C. Warning: Steaming tanks larger than 100 m³ Tanks with capacities larger than 100 m³...
  • Page 17 4 Installation SaniJet 20 Warning: Process generated electrostatic The user must address the electrostatic hazards generated from the process of the equipment in accordance with guidance document IEC/TS 60079-32-1:2013. Warning: Electrostatically charged liquid Liquids can become electrostatically charged when they move relative to contacting solids or the spraying of liquids can also create a highly charged mist or spray.

  • Page 18: Operation

    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. Product...

  • Page 19: Safety Precautions

    SaniJet 20 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.

  • Page 20: Maintenance

    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.

  • Page 21: Service And Repair Of Atex/Iecex Certified Machines

    Changes to the machine are not allowed without approval by the person responsible for the ATEX/IECEx certification at Alfa Laval. If changes are made – or spare parts other than Alfa Laval original spare parts are used - the EC Type Examination certification (the ATEX/IECEx Directive) is no longer valid.

  • Page 22: Service And Repair Of Machines Ordered With Q-Doc And With Q-Doc + Fat-Sat

    - 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.

  • Page 23: Every 150/300 Working Hours

    6 Maintenance SaniJet 20 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 44). 1.

  • Page 24: Turbine Unit - Dismantling And Reassembling

    6 Maintenance SaniJet 20 6.6 Turbine Unit - dismantling and reassembling Dismantling 1. Remove M5 Screws (40). Loosen and unscrew with a Socket wrench (tool no. TE462A). 2. Lift off Inlet cap (39). If it is necessary to replace Bearing bush (38), remove Bearing bush from Inlet cap. Do not remove Bearing bush unless it must be replaced, as the bush is easily damaged when removed.

  • Page 25: Cleaner Head Unit - Dismantling And Reassembling

    1. Loosen Cleaner unit (14) with Hook spanner (tool no. TE20B701). Insert carefully into holes in Retaining ring (3). Turn counter-clockwise and draw out Cleaner unit. Never use Pipe wrench or any other tool than the Alfa Laval Toftejorg SaniJet 20 special Hook spanner, which is developed especially to protect the surface from being damaged.

  • Page 26: Base Unit - Dismantling And Reassembling

    6 Maintenance SaniJet 20 6.8 Base Unit - dismantling and reassembling Dismantling of Outer tube In order to dismantle the parts in the Outer tube, it is necessary first to release the Inner shaft (14). 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.
  • Page 27 SaniJet 20 Alfa Laval Toftejorg SaniJet 20 is as a standard prepared for monitoring by a Rotacheck Sensor (see Rotacheck System page 28). A Plug (22) is fitted in the Base housing in the opening designed for the Rotacheck sensor.

  • Page 28: Rotacheck System

    6 Maintenance SaniJet 20 6.9 Rotacheck system The Rotacheck System is an ex-proof system, designed for monitoring the operation of the tank cleaning machine. The Sensor is supplied from a special Relay. The Sensor will send a signal to the Relay each time it is hit by a jet from the rotating tank cleaning machine, thus providing verification that the machine is rotating, of the rotation speed, and that the nozzles are not blocked.

  • Page 29: Trouble Shooting Guide

    7 Trouble shooting guide SaniJet 20 Slow rotation or failure of machine to rotate Fault finding Possible Causes No or insufficient liquid flow a) Check if supply valve is fully open. b). Check if inlet pressure to machine is correct. c).
  • Page 30 7 Trouble shooting guide SaniJet 20 Fault finding Possible Causes Wear a) Slide bearings See page 20 to 23. b) Bearings for Turbine shaft See page 20 to 23. c) Planet wheels See page 20 to 23. d) Shafts for Planet wheels Check clearance of Planet wheels on Shafts.

  • Page 31: Technical Data

    8 Technical data SaniJet 20 Perfomance Data for Alfa Laval Toftejorg SaniJet 20 Media Driven Weight of machine: 9.5 kg (21 lbs) Working pressure: 3-13 bar (45-185 psi) Recommended media pressure: 5-8 bar (73-116 psi) Max. working temperature: +90°C (194°F) Max.
  • Page 32 8 Technical data SaniJet 20 Principal dimensions in mm Inlet connection: 1” Clamp ISO2852 For permanent installation machine can pass through 3” Tank connection: 3” Clamp ISO2852 clamp of max. length 50 mm: A: 1” Clamp ISO2852 B: 3” Clamp ISO2852 C: Max.
  • Page 33 8 Technical data SaniJet 20 Performance data for Alfa Laval Toftejorg SaniJet 20 Media Driven Throw length Flow rate Inlet pressure Inlet pressure A: m /h. B: USgpm. C: Nozzles mm. D: psi. E: bar A: m. B: ft. C: Nozzles mm. D: psi. E: bar...

  • Page 34: Product Programme

    9 Product programme This manual covers the product programme for Alfa Laval Toftejorg SaniJet 20 Media Driven. For information on Alfa Laval Toftejorg SaniJet 20 Air Driven. please refer to Instruction Manual ESE01829 9.1 Standard configurations Media Driven: Alfa Laval Toftejorg SaniJet 20 (3” connection)
  • Page 35 9 Product programme This manual covers the product programme for Alfa Laval Toftejorg SaniJet 20 Media Driven. For information on Alfa Laval Toftejorg SaniJet 20 Air Driven. please refer to Instruction Manual ESE01829 Media Driven: Alfa Laval Toftejorg SaniJet 20 (4” connection)

  • Page 36: Available Add-Ons

    9 Product programme This manual covers the product programme for Alfa Laval Toftejorg SaniJet 20 Media Driven. For information on Alfa Laval Toftejorg SaniJet 20 Air Driven. please refer to Instruction Manual ESE01829 9.2 Available add-ons For: TE24GXXX, TE24FXXX, TE24BXXX, TE24EXXX...

  • Page 37: Available Add-Ons For Spare Parts

    9 Product programme This manual covers the product programme for Alfa Laval Toftejorg SaniJet 20 Media Driven. For information on Alfa Laval Toftejorg SaniJet 20 Air Driven. please refer to Instruction Manual ESE01829 9.3 Available add-ons for spare parts Item no.

  • Page 38: Parts Drawings And Lists, Service Kits And Tools

    10 Parts drawings and lists, service kits and tools Toftejorg SaniJet 20 Media Driven 10.1 Toftejorg SaniJet 20 Media Driven 4107-0031 Alfa Laval Toftejorg SaniJet 20, Media Driven - New Version - item numbers TE24Xxxx...
  • Page 39 Minor service kit Toftejorg SaniJet 20, all versions ... . . TE20B290  Service kit in EPDM for Toftejorg SaniJet 20 ....TE20B297 ...

  • Page 40: Toftejorg Sanijet 20 Media Driven With Improved Surface Finish

    10 Parts drawings and lists, service kits and tools Toftejorg SaniJet 20 Media Driven with improved surface finish 10.2 Toftejorg SaniJet 20 Media Driven with improved surface finish 4107-0031 Alfa Laval Toftejorg SaniJet 20, Media Driven - New Version - item numbers TE24Xxxx...
  • Page 41 Minor service kit Toftejorg SaniJet 20, all versions ... . . TE20B290  Service kit in EPDM for Toftejorg SaniJet 20 ....TE20B297 ...

  • Page 42: Toftejorg Sanijet 20 Media Driven, Hastelloy Version

    10 Parts drawings and lists, service kits and tools Toftejorg SaniJet 20 Media Driven, Hastelloy version 10.3 Toftejorg SaniJet 20 Media Driven, Hastelloy version 4107-0031 Alfa Laval Toftejorg SaniJet 20, Media Driven - New Version - item numbers TE24Xxxx...
  • Page 43 Service kits  Minor service kit Toftejorg SaniJet 20, all versions ... . . TE20B290 ♦ Service kit in FFKM (Perlast) for Toftejorg SaniJet 20 ..TE20C297 Please note that some of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric acid.

  • Page 44: Service Kits

    Article no. TE20B290 Parts list Pos. Denomination Bearing bushing Bearing bushing D1 Bearing bushing M Service Kit in EPDM for Alfa Laval Toftejorg SaniJet 20 media driven version Article no. TE20B297 Parts list Pos. Denomination Bearing bush Seal ring H...

  • Page 45: Tools

    10 Parts drawings and lists, service kits and tools Service kits Service Kit in FPM (Viton) for Alfa Laval Toftejorg SaniJet 20 media driven version Article no. TE20B298 Parts list Pos. Denomination Bearing bush Seal ring H Bearing ring, top...
  • Page 46 Service kits 11.1 Service and repair Upon every return of a product, no matter if for modifications or repair, it is necessary to contact your local Alfa Laval office to guarantee a quick execution of your request. You will receive instructions regarding the return procedure from your local Alfa Laval office. Be sure to follow the instructions closely.
  • Page 48 © 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.

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