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Alfa Laval FLEXITHERM-FB Operation Manual
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Alfa Laval FLEXITHERM-FB Operation Manual

Alfa Laval FLEXITHERM-FB Operation Manual

Pasteurization
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Operation Manual
FLEXITHERM™ - Pasteurization

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Summary of Contents for Alfa Laval FLEXITHERM-FB

  • Page 1 Operation Manual FLEXITHERM™ - Pasteurization...
  • Page 2 Maskinvej 5 DK-2860 Søborg/Copenhagen DENMARK Further copies Can be ordered from nearest Alfa Laval company. When ordering, always state the module type and Serial No. as stated on the name plate. Copyright © All rights reserved. No part of this documentation may be reproduced or copied in any form or by any means without the written consent of Alfa Laval Copenhagen A/S.
  • Page 3 OPERATION MANUAL TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY INSTRUCTIONS .
  • Page 4 OPERATION MANUAL www.alfalaval.com...
  • Page 5 OPERATION MANUAL Production ......... . 40 Circulation .
  • Page 6 OPERATION MANUAL www.alfalaval.com...
  • Page 7 Manufacturer Alfa Laval Copenhagen A/S Maskinvej 5 DK-2860 Søborg/Copenhagen DENMARK Name plate The plate below is an example of the attached plate. The plate con- tains the data needed when contacting Alfa Laval Copenhagen A/S concerning this particular module. www.alfalaval.com...
  • Page 8 Plate Heat Exchanger Programmable Logic Controller Pasteurizing Unit Design modifications The directives in this documentation are in accordance with the de- sign and construction of the module at the time it was released by the Alfa Laval production facility. www.alfalaval.com...
  • Page 9 Safety instructions OPERATION MANUAL Safety instructions To ensure maximum safety always read this section carefully before carrying out any work or inspection on the equipment . If the safety instructions are not followed, there is a risk of per- sonal injury . Use of hazard informations Hazard informations in this documentation have the following sig- nificance:...
  • Page 10 Safety instructions OPERATION MANUAL Use of signs Warning signs are used as below. Substances that may be harmful to body tissues. Do not touch without proper pro- Corrosive tection. Temperatures exceeding 60°C may occur. Hot surface Do not touch without proper protection. An electric shock can injure or kill.
  • Page 11 Safety instructions OPERATION MANUAL Cleaning solution Handling of cleaning solution Cleaning solution normally contains caustic soda (NaOH) or nitric acid (HNO ). These chemicals may cause burning of body tissues. Follow the instructions given by the supplier. Whenever there is a risk of exposure to these chemicals, always wear: •...
  • Page 12 Safety instructions OPERATION MANUAL www.alfalaval.com...
  • Page 13 General description OPERATION MANUAL General description Application FLEXITHERM™ is a pre assembled skid mounted module for pas- teurization of beer and carbonated products. It offers accurate control of the pasteurization parameters to ensure uniform treatment of the product. The FLEXITHERM™ capacity is automatically adjusted as a result of variations in the filling machine demand, which can be due to breaks in the filling operation or changeover to other size of packages etc.
  • Page 14 General description OPERATION MANUAL Principle layouts 1. Plate heat exchanger for product 2. Holding cell 3. Control panel 4. Pumps 5. Control/regulating valve(s) 6. Flow meter 7. Frequency converter (optional) www.alfalaval.com...
  • Page 15 General description OPERATION MANUAL Denominations (example of design) Control panel The control panel contains all equipment necessary for indication of process status, supervision of process performance, and control of automatic functions. The FLEXITHERM™ automation is based on a PLC. The controller features: Process sequence control Timers Control loops...
  • Page 16 General description OPERATION MANUAL Controlling/regulating valve Sanitary electro-pneumatic modulating valve(s) controls/regulates the flow(s). Flow meter The flow is measured with electromagnetic flow meter. These instru- ments measure accurately, are wear free and corrosion resistant, cause no additional pressure drop, and have no moving parts or parts which intrude into the meter tube.
  • Page 17 General description OPERATION MANUAL Holding cell The holding cell is used to hold the product at the pasteurizing tem- perature for the time specified. Heat exchanger for hot water Hot water is generated with low pressure steam in a heat exchanger. The generated hot water is circulated through the main HE for prod- uct thus gently bringing the product to the required pasteurization temperature.
  • Page 18 Process description OPERATION MANUAL Process description FLEXITHERM™-FB working principle The purpose of FLEXITHERM™ is to pasteurize beer by heating it for a short time. The pasteurizing effect is measured as PU (pasteurizing units), and is calculated from the formula below. The PLC controls the module operation, and ensures constant pas- teurizing effect.
  • Page 19 Process description OPERATION MANUAL FLEXITHERM™-FB description Beer is pasteurized in the module by heating it up to pasteurizing temperature and holding it for a given time. The incoming product is pumped to the regenerative section of the plate heat exchanger (PHE) before final heating by hot water in the heating section.
  • Page 20 Process description OPERATION MANUAL Emptying The product supply is stopped and water is taken into the module. The product is purged to the tank or filler until the system is filled with water. The outlet is then diverted to drain or recovery to rinse out the module.
  • Page 21 Process description OPERATION MANUAL FLEXITHERM™-VB/VM working principle By utilizing a pasteurized beer buffer tank, circulation of the beer is avoided and over-pasteurization does not occur. This is achieved by monitoring the level in the pasteurized beer tank. If the filler capacity decreases, the level in the tank will increase and the FLEXITHERM™...
  • Page 22 Process description OPERATION MANUAL Example 2 The same FLEXITHERM™ (100 liters holding cell), but the flow is reduced to 60 hl/h. Flow 60 hl/h = 1,667 l/second This gives a holding cell time = 100/1.667 = 60 seconds PU = 60/60 x 1.39 = 53.4 (72-60) That is, if the holding temperature is constant and the flow rate re-...
  • Page 23 Process description OPERATION MANUAL FLEXITHERM™-VB/VM control philosophy If not “fixed temperature” has been selected, the basic function is to maintain a constant PU dose in the product. The current level in the pasteurized beer tank (PBT) is used to deter- mine the required capacity.
  • Page 24 Process description OPERATION MANUAL www.alfalaval.com...
  • Page 25 Process description OPERATION MANUAL FLEXITHERM™-VB/VM description Beer is pasteurized in the module by heating it up to pasteurizing temperature and holding it for a given time. The incoming product is pumped to the regenerative section of the plate heat exchanger (PHE) before final heating by hot water in the heating section.
  • Page 26 Process description OPERATION MANUAL Production The product enters the module and is pasteurized and stored in the buffer tank. From here it is fed through to the filling machine. The level in the tank is controlling the throughput of the pasteurizer. If the level tends to rise, the capacity will decrease.
  • Page 27 Control panel OPERATION MANUAL Control panel Denominations The front of the control panel is equipped with the following equip- ment: 1. Mains switch 2. Emergency stop button 3. Emergency reset button 4. Operator panel (HMI) 5. Indication lamps Red lamp for indication of alarm - Flashing light indicate unacknowledged alarm - Steady light indicate acknowledged alarm Yellow lamp for indication of warning...
  • Page 28 Control panel OPERATION MANUAL Operator panel The main parts of the pictures are as below. Note! The following pictures are examples and may vary depending on type and options. Display Indication of the Flexitherm™ steps Time and/or volume in Flexitherm™ step (if applicable) Indication of the tank steps (if applicable) Indication of time in tank step (if applicable) Indication of present process value.
  • Page 29 Control panel OPERATION MANUAL Push-buttons When a function is selectable, it appears as a push-button. If the function has been selected the background is green. Selectable Selected Step symbols Different color codes on the symbols indicate different status. When a sequence is selected but not yet started the symbol back- ground is white.
  • Page 30 Flexitherm™ Tank (if applicable) Sterilization Sterilization Production Production Emptying Emptying Stabilize Drain Circulation Password/user name There are three password/user name levels. Preset Preset password user name Level 1 Maintenance 1234 Level 2 Supervisor/Management 9999 Level 3 Alfa Laval Service www.alfalaval.com...
  • Page 31 Control panel OPERATION MANUAL Main picture When a valve or pump is activated the sym- bol changes to green. 1. Indication of accumulated volume in production, press to reset 2. Displays the cooling temperature con- troller 3. Displays the pasteurizer flow controller 4.
  • Page 32 Control panel OPERATION MANUAL Operation picture The functions inside the frame have to be confirmed, with either “1” to start or “0” to stop, within 10 seconds from pushing. Tank (if applicable) 1. Sterilization 2. CIP 3. Production hold 4. Production 5.
  • Page 33 Control panel OPERATION MANUAL Service picture 1. Selection of register number 2. Indication of present register value 3. Register number, counting up or down 4. Saving of changes 5. Displays the CONTROL PANEL picture 6. Displays the PASSWORD picture 7. Displays the DATE & TIME picture 8.
  • Page 34 Control panel OPERATION MANUAL Beer type service picture 1. Beer type for service 2. Beer type number, counting up or down 3. Saving of changes 4. Return to SERVICE picture Setpoint selections A. PU value B. Pasteurization temperature C. Cooling temperature D.
  • Page 35 Control panel OPERATION MANUAL Supervision of fault When a fault occurs, the signal lamp FAULT starts to flash and a fault window appears in the display. When button ACKNOWLEDGE is pressed the FAULT lamp goes steady or is extinguished when the fault has disappeared. By pressing the ALARM button the alarm list is displayed showing the last occurred faults.
  • Page 36 Control panel OPERATION MANUAL Fault list Supervised faults can be found in the Basic Process Description . A list with preset values for timers etc., used to supervise the process is found in the Parameter List. Note! Some of the listed faults belong to optional equipment and might not be applicable.
  • Page 37 Operation OPERATION MANUAL Operation Preparations 1) Check that required utilities are avail- able. - Water pressure, open manual shut-off valve (if applicable) - Steam pressure, open manual shut- off valve (if applicable) - Coolant pressure, open manual shut- off valve (if applicable) - Air pressure, open manual shut-off valve (if applicable) - Electricity, switch on main supply...
  • Page 38 Operation OPERATION MANUAL Start-up/sterilization Caution! Do not proceed if personnel are present in the risk area Before starting check that: - The FLEXITHERM™ is in OFF - The upstream/downstream equip- ment are connected for sterilization If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture.
  • Page 39 Operation OPERATION MANUAL 3) Start the sterilization by pressing the STERILIZATION button followed by the START button. 4) The FLEXITHERM™ is now being filled with water and starts heating the water. See Basic Process Description for explanation of the STERILIZATION op- eration.
  • Page 40 Operation OPERATION MANUAL Production Before starting check that: - The FLEXITHERM™ is in READY FOR PRODUCTION (step 107) - Check that the set points are correct for the product in question - Delivering tank(s) is/are ready - Receiving tank/filler is/are ready - No fault is displayed on the panel If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the...
  • Page 41 Operation OPERATION MANUAL Circulation Before starting, check that the FLEXITH- ERM™ is in PRODUCTION. If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture. 2) Select circulation by pressing the CIR- CULATION button. 3 ) The FLEXITHERM™ is now in circula- tion on product.
  • Page 42 Operation OPERATION MANUAL Emptying Before starting, check that the FLEXITH- ERM™ is in PRODUCTION. If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture. 2) Select emptying by pressing the EMP- TYING button followed by the START button.
  • Page 43 Operation OPERATION MANUAL Stabilize/Shut down Before starting, check that the FLEXITH- ERM™ is in READY FOR PRODUCTION. If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture. 2) Select the stabilize/shut down by press- ing the STABILIZE button followed by the START button.
  • Page 44 Operation OPERATION MANUAL Tank sterilization (if applica- ble) Before starting check that: - The FLEXITHERM™ is in OFF - The upstream/downstream equip- ment are connected for sterilization If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture.
  • Page 45 Operation OPERATION MANUAL Tank production (if applica- ble) Before starting check that: - The FLEXITHERM™ is in PRODUC- TION (step 205) - Receiving filler is ready If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture. 2) Start the production by pressing the TANK PRODUCTION button followed by the START button.
  • Page 46 Operation OPERATION MANUAL 4) The tank production can be held tem- porarily by pressing the TANK HOLD button. 5) The tank will stay in HOLD until the TANK HOLD button is pressed again. www.alfalaval.com...
  • Page 47 Operation OPERATION MANUAL Tank emptying (if applica- ble) Before starting check that: - The tank is in PRODUCTION (step 202) - Receiving filler is ready If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture. 2) Start the emptying by pressing the TANK EMPTYING button followed by the START button.
  • Page 48 Operation OPERATION MANUAL Tank drain (if applicable) Before starting check that: - The FLEXITHERM™ isn’t in PRO- DUCTION - The tank is in OFF If the OPERATION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture. 2) Start the draining by pressing the TANK DRAIN button followed by the START button.
  • Page 49 Cleaning OPERATION MANUAL Cleaning Chemical hazard Cleaning solutions contain caustic soda (NaOH) or nitric acid (HNO ). These chemi- cals may cause severe burnings. Use pro- tective clothing as outlined in the SAFETY INSTRUCTIONS. Caution! Do not proceed if personnel are present in the risk area Before starting check that: - The FLEXITHERM™...
  • Page 50 Cleaning OPERATION MANUAL 3) Start the cleaning by pressing the CIP button followed by the START button. 4) The CIP operation is controlled from the external CIP STATION. 5) The FLEXITHERM™ goes to OFF when the external CIP system has finished, or after first pressing the button CIP and then the button STOP.
  • Page 51 Settings OPERATION MANUAL Settings Set points, volumes, timers etc. are stored in registers in the control system. Before changing these settings an access pass- word/user name has to be entered. For a complete listing of the registers, see Pa- rameter list. Caution! A change of setting(s) change(s) the way the FLEXITHERM™...
  • Page 52 Settings OPERATION MANUAL 5) If the register is to be changed, press the VALUE button, enter the desired value and then press ENTER. 6) To save the new value press the SAVE button. www.alfalaval.com...
  • Page 53 Settings OPERATION MANUAL Selection of beer type If the BEER TYPE PRODUCTION picture isn’t displayed: 1) Press the OPERATION button on the MAIN picture. 2) Press the BEER TYPE button. 3) Select the desired beer type by press- ing the up or down arrow and then the ENTER button.
  • Page 54 Settings OPERATION MANUAL 4) When a beer type is selected, set points as below are loaded to the controllers. - Pasteurizing units - Pasteurizing temperature - Cooling temperature - Fixed flow rate - Holding cell pressure - Tank pressure - Tank outlet pressure 5) These set points can be changed tem- porarily, by pressing the desired setpoint button.
  • Page 55 Settings OPERATION MANUAL Selection of PU/Fixed tem- perature If the TC01 CONTROLLER picture isn’t displayed: 1) Press the TC01 controller on the MAIN picture. 2) Select mode by pressing the desired symbol. The modes work as follows. A. PU, the system adjusts the pasteur- izing temperature in order to maintain a constant PU.
  • Page 56 Settings OPERATION MANUAL Selection of Auto/Min/Fixed flow (only if -VB/VM) If the FC01 CONTROLLER picture isn’t displayed: 1) Press the FC01 controller on the MAIN picture. 2) Select mode by pressing the desired symbol. The different modes work as follows. A.
  • Page 57 Settings OPERATION MANUAL Changing beer type set points If the BEER TYPE SERVICE picture isn’t displayed: 1) Press the SERVICE button on the MAIN picture. 2) Press the BEER TYPE button. 3) On the BEER TYPE SERVICE picture, select the desired beer type by pressing the up or down arrow.
  • Page 58 Settings OPERATION MANUAL 4) Press the setpoint to be changed. 5) If no valid password/user name has been entered, key in the correct password/ user name followed by ENTER. 6) Enter the new value followed by ENTER. 7) To save the new value press the SAVE button.
  • Page 59 Settings OPERATION MANUAL www.alfalaval.com...

This manual is also suitable for:

Flexitherm-vbFlexitherm-vm