Alfa Laval Gunclean Toftejorg 270FT Mark 1 Instruction Manual
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Alfa Laval Gunclean Toftejorg 270FT Mark 1 Instruction Manual

Alfa Laval Gunclean Toftejorg 270FT Mark 1 Instruction Manual

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Instruction Manual
Gunclean Toftejorg 270FT Mark 1
IM-TE102766-3-EN10
Date of issue: March 16, 2010

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Summary of Contents for Alfa Laval Gunclean Toftejorg 270FT Mark 1

  • Page 1 Instruction Manual Gunclean Toftejorg 270FT Mark 1 IM-TE102766-3-EN10 Date of issue: March 16, 2010...

  • Page 3: Table Of Contents

      Tools ........................51   How to order spare parts ..................52   How to contact Alfa Laval Tank Equipment A/S ............52   Service Card ......................53   Claim Report - Working Conditions ................. 54 Instruction Manual, Gunclean Toftejorg 270FT Mark I...

  • Page 4: Handling Of Loads

    Handling of loads Back position of the centre of gravity: L/2 H/2 D/2 Warning: Do not walk under hanging loads!

  • Page 5: Introduction

    This Instruction Manual is published by Alfa Laval Tank Equipment A/S without any warranty. Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Tank Equipment A/S without prior notice. Such changes will, however, be incorporated in new editions of this Instruction Manual.

  • Page 6: General Description

    General Description Gunclean Toftejorg 270 FT (fixed turbine driven) tank cleaning unit consists of two main parts: the Gun Unit (GU) and the Power Unit (PU). The GU is mounted in the deck, protrudes into the tank and directs the liquid jet. The PU is the drive and operation unit and is permanently mounted on the GU inlet housing.
  • Page 7 General Description (continued) PROGRAMMABLE POWER UNIT GUN UNIT D102275 Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 5 IM-TE102766-3-EN10...

  • Page 8: The Cleaning Liquid Flow

    General Description (continued) The Cleaning Liquid Flow The liquid of the jet comes from the tank cleaning supply line. Passes through the shut-off valve, proceeds into the inlet housing, past the turbine, turns downwards into the main pipe through the deck, then through the main pipe down to the vertical housing which rotates around a vertical axis.
  • Page 9 General Description (continued) Cleaning Liquid Flow Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 7 IM-TE102766-3-EN10...

  • Page 10: Technical Description

    Technical Description Power Unit Power Unit Working Principle By using the fluid in the lines, a turbine fitted in the inlet housing drives the lower one way clutch and rocker which is transmitting power to the turning worm gear, connected to the lifting rod. The lifting rod is fitted with a long key and can slide up and down inside the turning worm gear hub.

  • Page 11: Principal Drawing

    Technical Description (continued) Principal Drawing Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 9 IM-TE102766-3-EN10...

  • Page 12: Manual Override

    Technical Description (continued) Manual Override An extension of the lifting gear screw is accessible from the outside of the Power Unit. By turning this shaft with a handle the nozzle can be manually rised to the starting point or during cleaning moved forward in its programme.
  • Page 13 Technical Description (continued) Gun Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 11 IM-TE102766-3-EN10...
  • Page 14 - Blank - Page 12 Instruction Manual, Gunclean Toftejorg 270FT Mark I IM-TE102766-3-EN10...

  • Page 15: Technical Data

    Technical Data General Data The Gunclean Toftejorg 270FT equipment is generally operated in a range of 7-12 kg/sqcm media supply. Depending on the pressure and nozzle diameter the media flow and jet will be according to the diagrams on page 14 and 15. Normal leakage approximately 2%.

  • Page 16: Flow Rate

    Technical Data (continued) Flow rate Flow rate Performance diagram Alfa laval Type: Gunclean Toftejorg 270FT [m³/h] Single Nozzle Nozzle size 32 mm 31 mm 30 mm 29 mm 28 mm 27 mm 26 mm 25 mm 24 mm 23 mm...

  • Page 17: Design Throw Length

    Technical Data (continued) Design throw length Performance diagram Design Throw Length* Alfa laval Type: Gunclean Toftejorg 270FT Single Nozzle Nozzle size 32 mm 31 mm 30 mm 29 mm 28 mm 27 mm 26 mm 25 mm 24 mm 23 mm...

  • Page 18: Installation Data, Standard

    Technical Data (continued) Installation Data, Standard GASKET Yard supply: M20 stud, washer and nut Nitrile gasket Doubling ring to classification societies requirements Page 16 Instruction Manual, Gunclean Toftejorg 270FT Mark I IM-TE102766-3-EN10...

  • Page 19: Installation Data, Jis Flange Standard

    Technical Data (continued) Installation Data, JIS Flange Standard GASKET Yard supply: M20 stud, washer and nut Nitrile gasket Doubling ring to classification societies requirements Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 17 IM-TE102766-3-EN10...

  • Page 20: Installation And Normal Operation

    Installation and Normal Operation Before Installation Make sure that the pipes have been properly flushed before installation of the machine. We know from experience that welding rods, plastic bags, rags and other debris will block the turbine. This may result in damage and poor performance. Before Use Fill oil in Power Unit.
  • Page 21 Installation and Normal Operation (continued) To pre-set pitch angles Turn programming knob to programme 1. With the handle turn first worm screw until the rocker assy rests on the highest point of the cam. Turn the adjusting screw to the point where the rocker starts to lift from the cam. This setting will give programme 1 a pitch angle of 0°.

  • Page 22: Programming Knob

    Installation and Normal Operation (continued) Programming Knob Turns of the adjusting screw from 0° pitch Turns Pitch 0° 0.375 0.5° 0.75 1° 1.5° Programmes with four different basic settings will give the pitch angle shown in the table below. Intermediate settings are of course also possible. Factory setting is shaded.

  • Page 23: Speed Adjustment

    Installation and Normal Operation (continued) Speed Adjustment Type 1 Before the speed can be adjusted, the Power Unit and turbine must be drained from oil. Loosen the nut on the turbine shaft and adjust the turbine to desired position. Reduce measure A to reduce speed. Increase measure A to increase speed.

  • Page 24: How To Calculate Pitch Angle

    Installation and Normal Operation (continued) How to Calculate Pitch Angle Calculating formula Number of revolutions on shaft A to make one revolution on shaft B Pitch/revolution of gun Pitch/revolution of gun = D = Example C: Number of revolutions of shaft A = 51 D: Pitch/revolution of gun C = D 51 = 3°...
  • Page 25 Installation and Normal Operation (continued) Calculating formula Pitch angle (elevation per rev) Rotation speed rpm Washing angle (angle to be washed) Washing time, minutes Washing time, minutes = D = Example Pitch angle = 3° Rotation speed = 1 rpm Washing angle 20°...

  • Page 26: To Remove Cover

    Installation and Normal Operation (continued) To Remove Cover For programming, spot cleaning and service the cover has to be removed. Loosen the two screws on top of Power Unit. Unscrew the hand crank screw on the side of the Power Unit and remove the programming knob, fitted with a grub screw.

  • Page 27: Cleaning

    Installation and Normal Operation (continued) Cleaning Turn the programming knob to desired programme. Crank the Power Unit to the starting angle Note: Open arrows for down, filled arrows for up, see fig. Slowly open the valve to start cleaning Note: After cleaning, the Power Unit must be handcranked to 0°, the resting position Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 25 IM-TE102766-3-EN10...
  • Page 28 Installation and Normal Operation (continued) Figure 1 shows the actual movement of the nozzle in a double wash. The Power Unit is hand cranked to 30° up. The valve is opened and the cleaning starts. The Power Unit rotates and lifts then nozzle to 150°...
  • Page 29 - Blank - Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 27 IM-TE102766-3-EN10...

  • Page 30: Maintenance And Repair

    Maintenance Intervals and Service Kits Selection Alfa Laval Service Kits for Tank Cleaning Machine type, 270FT Mark I are available at two main levels: Minor Service and Major Service for both Drive unit and Cleaner unit.
  • Page 31 Maintenance and Repair (continued) Major Service kit for Drive unit (above deck) is recommended to be replaced every 500 working hours or 5 years, whichever comes first. Major Service Kit for Cleaner (below deck) is recommended to be replaced every 1000 working hours or 10 years, whichever comes first.
  • Page 32 Maintenance and Repair (continued) Additional maintenance recommendations Internal parts in the drive unit are preserved for storage up to six months from delivery. Before use: • The drive unit must be filled with oil • Grease gears • Preserve internals, parts which is not covered by oil due to condensation See recommended oils, greases and preservers below.

  • Page 33: How To Fill Oil

    Maintenance and Repair (continued) How to Fill Oil To fill oil in Power Unit or to clean glass, the cover has to be removed, see instructions on page 24. Caution: Oil leak can cause slippery floor! Caution: Before operation the cover must be put back! Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 31 IM-TE102766-3-EN10...
  • Page 34 Maintenance and Repair (continued) For guns tilted more than 15° Oil shall be filled to a level above the pipe to the turbine housing to secure the lubrication of the turbine. Gears above oil level shall be greased and all other parts rust protected, see page 30. Page 32 Instruction Manual, Gunclean Toftejorg 270FT Mark I IM-TE102766-3-EN10...
  • Page 35 - Blank - Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 33 IM-TE102766-3-EN10...

  • Page 36: Reference List Of Parts

    Reference List of Parts Power Unit Article no. SWM0-TE104180C4 Pos. Ref. No. Unit Description Material Notes TE900545 Drain plug Bronze TE914310 O-ring Rubber TE900513 O-ring Rubber TE104129 Cover Stainless TE900516 Rubber seal Rubber TE104330-12 Glass Plastic TE900518 Bronze TE101174 Programming knob Bronze TE910857 Grub screw...
  • Page 37 Reference List of Parts (continued) Power Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 35 IM-TE102766-3-EN10...
  • Page 38 Reference List of Parts (continued) Power Unit Article no. SWM0-TE104180C4 Pos. Ref. No. Unit Description Material Notes TE104154 Worm gear Bronze TE104140 Bracket Steel TE910412 Screw Steel TE913054 Retaining ring TE900480 Washer TE104036 Lifting yoke Bronze TE104198 Lock washer Steel TE104197 Lock washer Steel...
  • Page 39 Reference List of Parts (continued) Power Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 37 IM-TE102766-3-EN10...
  • Page 40 Reference List of Parts (continued) Power Unit Article no. SWM0-TE104180C4 Pos. Ref. No. Unit Description Dim. Material Notes TE104128 Gable ASSY Steel Left side TE104135 Gable ASSY Steel Right side TE910412 Screw Steel TE104095 Worm bracket, rear Steel TE104131 Worm bracket Steel TE104132 Worm gear, lifting...
  • Page 41 Reference List of Parts (continued) Power Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 39 IM-TE102766-3-EN10...
  • Page 42 Reference List of Parts (continued) Power Unit Article no. SWM0-TE104180C4 Pos. Ref. No. Unit Description Material Notes TE104134 Worm screw, upper Steel TE104166 Washer Steel TE900511 One way clutch TE104066 Rocker ASSY TE51L035 Roller clutch TE104192 Spring Steel TE914033 Lock nut Steel TE51L152 Flange bearing...
  • Page 43 Reference List of Parts (continued) Power Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 41 IM-TE102766-3-EN10...
  • Page 44 Reference List of Parts (continued) Power Unit Article no. SWM0-TE104180C4 Pos. Ref. No. No/Unit Description Material TE201014-20 Inlet housing TE916319 O-ring Rubber TE914325 O-ring Rubber TE910394 Screw Steel TE910746 Screw Stainless TE208269 Stainless TE201045 Lifting rod ASSY TE208243 Location sleeve Bronze TE201073-20 Turbine ASSY...
  • Page 45 Reference List of Parts (continued) Power Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 43 IM-TE102766-3-EN10...

  • Page 46: Turbine Unit

    Reference List of Parts (continued) Turbine Unit Article no. SWM2-TE201073-20 Pos. Ref. No. Description Material Unit TE201062 Turbine Stainless TE201075 Turbine shaft Stainless TE201071 Turbine bearing Bronze TE201072-6 Turbine housing Cast iron TE201076 Shaft Steel TE201052 Bearing housing Steel TE201058 Eccentric Steel TE914396...
  • Page 47 Reference List of Parts (continued) Turbine Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 45 IM-TE102766-3-EN10...

  • Page 48: Gun Unit

    Reference List of Parts (continued) Gun Unit Article no. SWM1-TE208270, Rev. B Part No. TE102231 List dated 1994-03-15 Pos. Ref. No. Unit Description Material Notes TE208257 Nozzle Bronze TE910850 Screw Stainless Alt. “Loctite” TE208034 Flow guide Stainless TE208256 Nozzle tube Stainless TE208248 Horizontal housing...
  • Page 49 Reference List of Parts (continued) Gun Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 47 IM-TE102766-3-EN10...
  • Page 50 Reference List of Parts (continued) Gun Unit Article no. SWM1-TE208270, Rev. B Part No. TE102231 List dated 1994-03-15 Pos. Ref. No. Unit Description Material TE208057 Link Bronze TE910536 Screw Stainless TE208022 Shaft Stainless TE900515 O-ring Rubber TE208252 Vertical cover Bronze TE914128 Washer Stainless...
  • Page 51 Reference List of Parts (continued) Gun Unit Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 49 IM-TE102766-3-EN10...

  • Page 52: Service Kits

    Service Kits TE55A601 Minor Service Kit 270FT MK I Drive Unit Part number No./kit Description TE201047-6 Gasket TE900513 O-ring TE900542-M8 Washer TE914310 O-ring TE914319 O-ring TE914325 O-ring TE914396 O-ring TE916306 O-ring TE916319 O-ring TE51L035 Roller clutch TE55A630 Minor Service Kit 270FT MK I Cleaner Unit Part number No./kit Description...

  • Page 53: Te55A640 Major Service Kit 270Ft Mk I Cleaner Unit

    Service Kits (continued) TE55A640 Major Service Kit 270FT MK I Cleaner Unit Part number No./kit Description TE208252 Cover, vertical TE208254 TE900330 Bonding wire TE910536 Screw TE910544 Screw TE910850 Screw TE910863 Screw TE914043 Locking Nut TE914045 Locking Nut TE915744 Split Pin TE910536 Screw TE55A630...

  • Page 54: How To Order Spare Parts

    Example: Pos. Part no. Q’ty Description TE650135 Bearing How to contact Alfa Laval Tank Equipment A/S For further information please feel free to contact: Alfa Laval Tank Equipment A/S Baldershoej 19 P.O. Box 1149 2635 Ishoej Denmark Phone no.: +45 43 55 86 00 Fax no.:...

  • Page 55: Service Card

    Service Card Type of Machine Serial No. Configuration Nozzle diameter Impeller Guide No. of Working Maintenance Actions/ Remarks Sign. Date Hours Exchanged Parts Machine put into operation V. 94.2 Instruction Manual, Gunclean Toftejorg 270FT Mark I Page 53 IM-TE102766-3-EN10...

  • Page 56: Claim Report - Working Conditions

    Claim Report - Working Conditions Page 1/2 Ref. Claim Case Serial No.: Machine/Cleaner Type Configuration - Nozzles x ø - Turbine/Inlet Guide Working Conditions Inlet pressure at machine/cleaner Type of Valve in inlet line Can hydraulic shock be disregarded: Inlet line flushed before installation of tank cleaner? Working hours before failure hours Cleaning Programme...
  • Page 57 Claim Report - Working Conditions (continued) Page 2/2 Condition of Cleaning Media Clean Contaminated with (nature and description) Chemicals/Solvents ___________________________ High viscous Soluble Sticky/tenacious Low viscous Solidifying Hard particles/size _____________________________ Crystallizing Soft particles/size ______________________________ Has filter been installed in inlet line? Mesh size: Is tank cleaner flushed with clean water after tank cleaning? Type of Soilage/Tank Contents to be removed...

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