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Related Manuals for Alfa Laval CIP 200L
Summary of Contents for Alfa Laval CIP 200L
- Page 1 Operating & Maintenance Manual Cleaning In Place Unit Model CIP 200L & 400L Valid for CIP 200L & 400L Manufacturing numbers : 969951-00, 969951-01, 969951-10, 969951-11, 969952-00, 969952-01 Original Manual - English Document No: 130021 R08 Alfa Laval Support Services Pvt Ltd <...
- Page 2 The instructions given in this manual are intended as a general instruction to Alfa Laval CIP units 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.
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Page 3: Table Of Contents
8.2.0 Maintenance Interval ..........................32 8.3.0 TROUBLE SHOOTING ..........................34 9.0.0 10.0.0 SPARE PARTS ............................36 10.1.0 Ordering Spare Parts ..........................36 10.2.0 Alfa Laval Service ............................ 36 11.0.0 REVISION HISTORY ..........................37 ....................... 38 1: EC D PPENDIX ECLARATION OF CONFORMITY www.alfalaval.com... -
Page 4: Introduction
1.0.0 Introduction Alfa Laval Cleaning - In - Place unit has been designed as a portable cleaning unit specifically, for use in confined areas of service around a Plate Heat Exchanger. The unit is thus equipped with a tank for mixing and storage of liquids during the Cleaning in place of Plate Heat Exchangers. -
Page 5: Field Of Application
Subject Page FIELD OF APPLICATION 5 of 38 2.0.0 Field of Application The Cleaning-In-Place is designed for cleaning compact heat exchangers like Gasketed, Welded & Brazed plate heat exchangers. It can also be used for cleaning Spiral heat exchangers and Compact tubular heat exchanger but with alteration some details in the instructions in below sections. -
Page 6: Safety Instructions And Warning
Subject Page SAFETY INSTRUCTIONS AND WARNING 6 of 38 3.0.0 Safety Instructions and Warning 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 7: 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. WARNING Emergency stop must be installed on control panel as per local regulations. -
Page 8: Safety Regulations During Installation
Subject Page SAFETY INSTRUCTIONS AND WARNING 8 of 38 3.2.0 Safety Regulations during Installation Read and follow the Operator’s manual before attempting to install or operate the modules and supporting equipment. Do not operate the system before installation is complete. ... -
Page 9: Noise Emission
Modifications and Reconstruction Please note that the machinery must not be altered or modified in any way if not directly approved of 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 10: Installation And Commissioning Guidelines
Make sure that the CIP unit has not been damaged during the transport. If transport damages are found, please contact local Alfa Laval agent. Alfa Laval cannot be responsible for incorrect unpacking & handling of CIP unit. www.alfalaval.com... -
Page 11: Lifting Instructions
Follow local safety precautions/guidelines while lifting CIP units. The CIP unit should only be lifted by using lifting slings fitted according to the following illustrations. CIP 200L and 400L 1) Place lifting slings around tank as shown in the drawing carefully, see how the tank, Pump trolley balances. - Page 12 Subject Page INSTALLATION GUIDELINES 12 of 38 WARNING Always use lifting slings of appropriate strength and dimension to handle the weight of the CIP unit. Always lift the CIP unit by the lifting points, as shown above. Operators should avoid lifting of heavy components. www.alfalaval.com...
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Page 13: Electrical Installation
Subject Page INSTALLATION GUIDELINES 13 of 38 4.3.0 Electrical Installation All electrical installations must be done in accordance with local regulations. A professional electrician should carry out this job. Apart from the fact that the electrical installation must be effected in a safe, proper and approved way, the different methods of how to regulate the equipment should be considered. -
Page 14: Commissioning Preparation Work
Subject Page INSTALLATION GUIDELINES 14 of 38 4.4.1. Commissioning preparation work Before commissioning or start-up of the system can be initiated, the following conditions should be fulfilled: 1) Mechanical completion Mechanical Completion is the checking and testing of equipment and construction to confirm that the installation is in accordance with drawings and specifications and ready for commissioning in a safe manner and in compliance with project requirements. - Page 15 Subject Page INSTALLATION GUIDELINES 15 of 38 3) Pre-commissioning Pre-commissioning is the phase where a system or unit is prepared for the commissioning. The purpose of the pre-commissioning is to verify and check if all parameters necessary for the operation are in accordance with the specifications.
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Page 16: Storage Guidelines
Often the best solution is to leave the equipment in the packing until installation will occur. In this case Alfa Laval should be informed and proper type of packing should be ordered. -
Page 17: General Technical Data
Subject Page GENERAL TECHNICAL DATA 17 of 38 6.0.0 General Technical Data 6.1.0 Technical specification: Refer the General technical data in Technical documentation. 6.2.0 Equipment list: Refer the General technical data in Technical documentation. 6.3.0 Valve list: Refer the General technical data in Technical documentation. www.alfalaval.com... -
Page 18: Operating Instructions
The heat exchanger should be isolated from the normal system. 7.2.0 Operating Principle Alfa Laval CIP units includes following operations mainly - Shut off and drain the heat exchange to be cleaned. Connect the CIP unit to the heat exchanger. - Page 19 Subject Page OPERATING INSTRUCTIONS 19 of 38 Mix the cleaning agent with water in the tank and heat it up to specified temperature. Circulates the cleaning solution for specified time. Drain the cleaning solution as per any of the options 7.3.5 – 7.3.8 and rinse the system with clean water.
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Page 20: Start-Up Preparation
Subject Page OPERATING INSTRUCTIONS 20 of 38 7.2.1 Start-up preparation: Heater Make sure the heater is in Off-position before connecting the power. Check that the thermostat is in the correct position. The most effective cleaning interval is between 50 to 70 C. - Page 21 Subject Page OPERATING INSTRUCTIONS 21 of 38 Pump Check rotation of the pump by watching an arrow on the fan cover. The pump should rotate counter clock wise when seen from the motor fan. If it is incorrect: switch 2 phases.
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Page 22: General Operating Procedure
Subject Page OPERATING INSTRUCTIONS 22 of 38 7.2.2 General Operating procedure: 7.2.2.1 Operation of valves: Pull the handles outwards while rotating them. When valve V05 is in a position between “Open valve” and “Closed valve”, the flow is reduced. To operate this valve, turn the handle and then rotate it. This unit is supplied with a valves arrangement. - Page 23 PHE is approx. 52 liters. This figure is the same for both CIP 200L and CIP 400L since only tank B01 has a heater in the latter case and circulation should not engage both tanks, see section 7.2.0.
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Page 24: Operating Procedures
Subject Page OPERATING INSTRUCTIONS 24 of 38 7.3.0 Operating procedures 7.3.1 Start-up, mixing and pre-heating of cleaning liquids Assemble the hoses according to P&I diagram. S03 must be connected to HE lower port and S02 must be connected to HE upper port ... -
Page 25: Cip-Cleaning Of The Heat Exchanger
Subject Page OPERATING INSTRUCTIONS 25 of 38 To heat up 200 litres from 20°C to 70°C will take approximately 2 hours with 6 kW and 1 hour with 12 kW. Heating times are not including the effect of the material in the heat exchanger, this differs per content and temperature of “other”... -
Page 26: Reverse Flow
Subject Page OPERATING INSTRUCTIONS 26 of 38 7.3.3 Reverse flow If your heat exchanger is fitted with only one grouping, (see the heat exchanger drawing) go to “Neutralization” If your heat exchanger is fitted with multi pass grouping it is necessary to change the flow direction after half of the recommended operation time specified in the CIP- cleaning. -
Page 27: Neutralization
Subject Page OPERATING INSTRUCTIONS 27 of 38 7.3.4 Neutralization Some Cleaning liquids require neutralization prior to disposal. (Refer Cleaning liquids procedures) If the cleaning liquid is to be re-used do not neutralize it. The neutralization process is done by adding the neutralization liquid to the cleaning liquid in accordance with the separate instruction for neutralization liquids. -
Page 28: Use Of Pump For Emptying He Back To Cip Tank
Subject Page OPERATING INSTRUCTIONS 28 of 38 7.3.5 Use of pump for emptying HE back to CIP tank To let air into the system, a spool piece with two valves are provided along with module. Install the spool piece on nozzle or pipe of heat exchanger above the highest point of fluid level in the HE to avoid it getting filled with fluid and allow air to get in. -
Page 29: Draining Of Phe Externally Through Pump
Subject Page OPERATING INSTRUCTIONS 29 of 38 7.3.6 Draining of PHE externally through Pump Add an extra hose at valve V11 and put other end of hose at draining point or as per customer requirement. (Note that this hose is not scope of supply along with module due to variety of different draining possibilities at different customers) ... -
Page 30: Self Draining
Subject Page OPERATING INSTRUCTIONS 30 of 38 7.3.7 Self draining If for some reason, active draining with pump is not applicable, it is possible to self-drain the system with gravity only. Open V01-V05 valves on the CIP unit. Connect the drain of the CIP tank/tanks to a suitable barrel. ... -
Page 31: Disconnecting The Cip-Unit
Subject Page OPERATING INSTRUCTIONS 31 of 38 7.4.0 Disconnecting the CIP-unit STEP 1 – Disconnecting HE form CIP unit When disconnecting the hoses from the CIP-unit, inspect them for visible damages. Avoid damaging the electrical cables, or the inlets and outlets of the unit. STEP 2 –... -
Page 32: Maintenance
Subject Page MAINTENANCE 32 of 38 8.0.0 Maintenance 8.1.0 Introduction The CIP unit only requires very little maintenance. However, following the maintenance instructions will ensure performance and availability. CAUTION Always follow recommendations on maintenance and service specified in the specific manuals for each component. After disconnecting the CIP-unit - ... - Page 33 Subject Page MAINTENANCE 33 of 38 The CIP unit should be opened once a year for inspection, ease of operation, and checking its condition by a skilled / certified technician under the supervision of maintenance manager. Check operation and condition of the all valve. ...
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Page 34: Trouble Shooting
Subject Page TROUBLE SHOOTING 34 of 38 9.0.0 Trouble Shooting Problem Indication Possible Cause Remedy In main flanges. Tighten. Leakage Insufficiently tightened. (inlet and outlet) Open and check, change and repair if Damaged gaskets. necessary. Remove valve and check the rubber seat or foreign Incorrect assembly or particle or... - Page 35 Subject Page TROUBLE SHOOTING 35 of 38 Problem Indication Possible Cause Remedy Shut down the CIP unit, open end cover and clean the CIP High pressure drop CIP unit CIP unit blocked with unit manually. clogged. too much debris. Decreased water flow. See “Maintenance interval”...
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Page 36: 10.0.0 Spare Parts
- DC Lund: Place a ticket in Service Now BTHD - Pars Detectives Lund. - DC Thane: Suryakant Shelar with copy to Anant Pathak. 10.2.0 Alfa Laval Service Please contact your local Alfa Laval agent for Parts and service questions. www.alfalaval.com... -
Page 37: 11.0.0 Revision History
Subject Page REVISION HISTORY 37 of 38 11.0.0 Revision History Rev. Date Details Made by Checked by Approved by Comments 12/05/2017 SELUPEW INPADBE INPAYSA updated Updated as 13/04/2017 INPADBE SELUPEW INPAYSA per new design Comments 24/03/2017 SELUPEW INPAYSA INPAYSA updated Comments 10/03/2017 SELUPEW... -
Page 38: Appendix 1: Ec Declaration Of Conformity
Subject Page CIP - Operating & Maintenance Manual 38 of 38 Appendix 1: EC Declaration of conformity www.alfalaval.com...
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