Alfa Laval Contherm 6X11 Instruction Manual Download Page 112

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10 Appendix A: Additional Installation Drawings

5. Installing the Contherm to the vertical column.

Insert the lower media port into and through the cross-arm holes then insert the upper media port through the upper
crossarm hole and secure with the 3-inch mounting nuts.

112

Summary of Contents for Contherm 6X11

Page 1: ...100000820 EN01 2018 10 Original manual Instruction Manual Contherm Single Wall Scrape Surface Heat Exchangers...

Page 2: ......

Page 3: ...e Components of the Rotor Lifting Device 31 6 7 Mounting and Installing the Standard Contherm or a Contherm Core in a Horizontal Configuration 36 6 8 Installing Ancillary Equipment or Piping to Suppor...

Page 4: ...m 93 9 Troubleshooting 100 9 1 Introduction 100 9 2 Seal Leaks 101 9 3 Lower Bearing 102 9 4 Rotor Lift System 103 9 5 Product Heating 103 9 6 Product Cooling Water Glycol Brine 105 9 7 Product Coolin...

Page 5: ...Convap Alfa Laval Inc herewith declares that the following national technical standards and specifications have been used ASME Section VIII Division 1 Other Directives applied 2014 68 EU 1935 2004 202...

Page 6: ...en permission of Alfa Laval Corporation Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated Please forward this info...

Page 7: ...termined by the level of hazard seriousness the user is exposed to DANGER Indicates hazards which will result in severe personal injury or death WARNING Indicates hazards or unsafe practices which cou...

Page 8: ...inch Hazard Rotating Shaft Sharp Edges Potentially Corrosive Materials Burn Hazard Inspection Point Leaking Hazard Consult Manual Hoist Needed Checklist is Recommended Heavy Weight Positive Pressure M...

Page 9: ...afety and Potential Hazards Drawing Figures 2 1A and 2 1B list all safety warning signs and their meanings and highlights safety concerns Figure 2 1A Safety Warnings Refer to section 2 3 for safety an...

Page 10: ...2 Safety Summary Figure 2 1B Safety Warnings Refer to section 2 3 for safety and inspection symbols 10...

Page 11: ...ontherm SSHE WARRANTY Warranty excludes all on site unapproved equipment modifications equipment supplied by others or failure to properly integrate the Contherm into overall system related to externa...

Page 12: ...ork with our local representatives in your area If you cannot locate an Alfa Laval Inc representative in your area please contact us directly at the following location Alfa Laval Inc 111 Parker Street...

Page 13: ...es 6 attached to the Contherm rotor 8 continuously remove product from the cylinder wall 9 to ensure uniform transfer of heat from the media to the product An optional coil in the annulus 5 increases...

Page 14: ...orming maintenance and clear space required for rotor extraction as well as space for various product and media piping and insulation necessary for integrating into a system Time Limits Life limits of...

Page 15: ...lled in a safe manner Contherm equipment must not be subjected to detrimental external forces from other equipment or personnel climbing on equipment Table 4 1 Contherm Limits of Machinery Product Fea...

Page 16: ...o 1 inch 25 mm Particulate Size Up to 1 3 inch 33 mm Gentle Low Shear Slotted Blades High Shear Mix ing Aeration High rpm 600 rpm Aseptic Processing with Ammonia Freon Crystallization with Propylene G...

Page 17: ...ded Vertical installation S Stainless Steel C Coiled N No Coating Not Included horizontal installation D Duplex 2205 P Plain A Alfaloy H HIPEX Thin Wall Stainless Steel N Nickel C Chrome No HIPEX T Tr...

Page 18: ...terial Information 5 2 Contherm Name Plate The serial number is inscribed on the inspection plate mounted on the exterior of the Contherm and on the pressure vessel heat exchanger cylinder Figure 5 1...

Page 19: ...NING Only qualified Electricians should be allowed to connect power to Contherm drive motors and hydraulic lift pump WARNING Only qualified personnel should be allowed to move crates uncrate hoist ins...

Page 20: ...and ensure proper personnel promptly receives this information Alfa Laval is not responsible for lost items Table 6 1 Typical Contents of a Contherm Crate 1 Drive motor s See lifting instructions belo...

Page 21: ...mark the items when unpacking them Identify all small boxes of parts and put into a safe location so items do not get lost 2 Locate the product documentation manual and pressure vessel certifications...

Page 22: ...the outer jacket as shown to the below right Proper lifting of a Contherm from its Crate Figure 6 2 Proper Lifting of a Contherm from its Crate For vertical mounting columns strap column at center of...

Page 23: ...Horizontal Contherm Mount Note Motor and other important items such as spare parts blades and documentation will likely be in the crate with the horizontal frame as shown Figure 6 4 Typical Contents...

Page 24: ...able 6 5 for installation instructions Both mounting methods are shown in Figure 6 5 The A Frame for bolting the mount to the wall and the ceiling plate for bolting the mount to the ceiling are not su...

Page 25: ...Mounting column 2 Contherm cross arm 3 Motor cross arm 4 Motor mounting plate 5 Mount floor plate and tie down bolt 6 Ceiling plate bolted to ceiling by installer 7 A Frame bolted to wall by installe...

Page 26: ...nut P N 7401248 01 3 When securing cross arms to the column ensure the cross arm components sit on top of the support brackets and not below the support brackets 1 Cross arm installed on top of mount...

Page 27: ...t with 3 inch 76 mm threaded connection 2 Mount cross arm 3 3 inch 76 mm Locknut 7401266 01 4 3 inch 76 mm Hex wrench tool 7403126 01 Figure 6 6 Side View of Contherm Trim Sheet and Mounting Arm 3 Fig...

Page 28: ...401248 02 on each of the four threaded rods P N 7401836 that secure the motor plate assembly to the vertical mount Refer to Figure 8 Use the vertical adjustment bolt P N 7401241 16 to lower the motor...

Page 29: ...r must be off before attempting this step Place the coupling guard ring over the bearing housing before installing the coupling hub Verify the couplings are installed correctly and properly aligned be...

Page 30: ...6 Installation Figure 6 11A Installing the coupling guard Figure 6 11B Installing the coupling guard continued 30...

Page 31: ...raulic lift cylinders at the same time DANGER 1 More than one operator of the hydraulics and equipment alignment increases the risk of creating a pinch point and injury between the lower product head...

Page 32: ...on fittings for both supply and return lines along with fittings for connections to the Contherms hydraulic lift cylinder assembly are located on the stack valve assembly Each Stack Valve Assembly can...

Page 33: ...lifting device 1 Supply from the hydraulic pump 2 Supply from right top stack valve to bottom of hydraulic lift pistons 3 Return from top of lift pistons to bottom right stack valve 4 Return from stac...

Page 34: ...Contherm mounting assembly has been provided by Alfa Laval Inc the location of the stack valve assembly on the mount is predetermined at the factory Otherwise you must locate the assembly near the lo...

Page 35: ...rge the air from the Contherms hydraulic rotor lifting cylinder If your configuration uses more than one Contherm then you must purge the air from every unit s rotor lifting cylinder This is accomplis...

Page 36: ...hen how to install the Contherm on the mount 6 6 1 Mounting and Installing the Contherm On a Horizontal Mount Refer to table 6 6 above as affixing the Contherm to a preassembled mounting structure is...

Page 37: ...ic general arrangement drawing otherwise pooling of product CIP solution or moisture can occur causing premature bearing failure Figure 6 11 Head Port Location 1 Drive end see below image of head orie...

Page 38: ...l Trough As shown in Figure 6 15 the horizontal mount provided by Alfa Laval Inc includes a rotor removal trough P N 7402714 This device will help you manually remove the rotor from the Contherm To re...

Page 39: ...driven side head assembly from the Contherm 3 Lift the rotor slightly to permit the rotor removal trough P N 7402714 to be slid into the bottom of the heat exchanger cylinder below the rotor and scrap...

Page 40: ...dia side without pressure relief protection Thermal expansion or contraction can seriously damage the equipment or create an extreme pressure situation causing injury or death 2 Safety relief valves s...

Page 41: ...or self actuating control valve 2 Solenoid valve 3 Pressure gauge 4 Bypass and shut off valves 5 Return Steam trap piping and bypass valves 6 Purge valve 7 Flanged connections to the Contherm NOTE Saf...

Page 42: ...Product inlet 2 Contherm Product outlet 3 Steam supply Inlet 4 Steam return Outlet 5 Steam control valve 6 Temperature or pressure gauge 7 Process control 8 Temperature signal to controller 9 Steam t...

Page 43: ...he freezing point of the product Once the system has returned to within its normal operating range the pressure is reduced to continue the cooling of product If freeze up does occur emergency hot gas...

Page 44: ...eatest cooling capacity at the Contherm Sniffer Line A sniffer line is used with Freon refrigeration systems to purge oil from the accumulator The following paragraphs identify several precautionary s...

Page 45: ...Accumulator vessel 6 Dual back pressure regulator 7 Pressure relief valve 8 Hand expansion valve 9 Level sensing float switch 10 Sniffer line Freon only 11 Hot gas line 12 Down leg purge valve drain 1...

Page 46: ...ow must be sufficient to maintain the above stated media flow rates in each Contherm Temperature sensors are important tools that should be incorporated within your Contherm cooling system to monitor...

Page 47: ...nsure the internal equipment such as rotor blades and seal components are clean and free of any material that will make disassembly unsafe or result in contamination or handling issues Utilize the abo...

Page 48: ...wed to come in contact with the product Ensure rotating equipment is spinning concentrically with little to no vibration that all equipment is properly and tightly fastened and guarded If any of these...

Page 49: ...Install the blade funnel before raising the rotor into the Contherm Refer to section 8 5 2 Inspecting the Scraping Blades and figure 8 8 for a detailed description on use of the blade funnel 10 Before...

Page 50: ...7 1 Hydraulic Rotor Lift System Component List 1 Stack valve handle 2 Hydraulic tubing 3 Blades 4 Rotor hold down feature 5 Helper plate 6 Helper plate Contherm cylinder clamp Figure 7 1 Hydraulic Ro...

Page 51: ...t of blade pins contacts bottom of Rotor Lift Helper Plate and secures it into place 5 Securely clamp the Rotor Lift Helper Plate in place as shown in Figure 7 2A NOTE Before proceeding to the next st...

Page 52: ...7 Operations Figure 7 2A Installing the Rotor Helper Plate Figure 7 2A Installing the Rotor Helper Plate 52...

Page 53: ...7 Operations Figure 7 2B Using Helper Plate to Access Lower Head Seal Components Figure 7 2B Using Helper Plate to Access Lower Head Seal Components 53...

Page 54: ...therm you are ready to start the Contherm and perform initial testing with your company s product Sections 7 6 through 7 9 of this manual describe the start up and initial testing procedures for Conth...

Page 55: ...itial start up and operating procedure that is provided below Table 7 8 Start Up and Operation of Steam Heating Contherm Step Action 1 Using water as the test product start flowing the water through t...

Page 56: ...or must manually restart the entire system If your Contherm is not equipped with the Maintain Status feature then the drive sensor is not provided as part of the system and the procedures described in...

Page 57: ...ed Contherm Step Action 1 Using water as the test product start flowing it through the Contherm via the product inlet When water begins exiting the unit s product chamber via the product outlet start...

Page 58: ...Specific product soils can cause variations in the cleaning chemicals and procedure selections For additional recommendations on cleaning and sanitizing your Contherm contact your local chemical supp...

Page 59: ...Sanitize 68 F 20 C 0 5 2 minutes Depends on sanitizer used Depends on sanitizer used Sanitize surface Notes 1 The recommended CIP flow rate range is 120 150 gpm 27 34 m3 hr Optimal CIP flow rate will...

Page 60: ...intenance schedule detailed procedures for performing all maintenance actions required to support the equipment and components of your Contherm are provided WARNING Refer to chapter 2 Safety before pr...

Page 61: ...head clamp or the lower bearing clamp until you have verified that the hydraulic Rotor Lifting System is turned on and is operating correctly WARNING Only Alfa Laval OEM parts are to be used to mainta...

Page 62: ...ction of lower seal assembly 2A 2B Check cylinder end for damage Check inside cylinder for wear or failing chrome 6 Check upper hydraulic connections for leaks Check integrity of retaining rings for s...

Page 63: ...ll connections are tight and secure 11 Inspect for product or leaking material that may cause a slip hazard 16 If applicable ensure mounting flange bolts are tight as this is a weight bearing componen...

Page 64: ...otor Bearings Inspection Monthly Inside Surface of Cylinder Clean in place CIP Weekly and when lowering the rotor Hydraulic Lines Clean by flushing Before initial operation Then on an as required basi...

Page 65: ...Carbide or Tungsten Carbide material Because the rotary seal is maintained by the continuous moving contact between the two surfaces the integrity of this sealing action will degrade over time To ensu...

Page 66: ...8 Inspection Maintenance Figure 8 2 Component List Figure 8 2 66...

Page 67: ...nce testing and replacement procedures for the Flushed Standard and Flushed Hard Face Seal Assemblies are identical to those performed for the Standard Rotary and Hard Face Seals Figure 8 3 identify t...

Page 68: ...detailed Seal Inspection and Replacement procedure is provided in Table 8 6 Equipment Needed You will need the following items to properly maintain and replace a seal Lapping Film 30 micron P N 74020...

Page 69: ...ft to mate the lower head assembly to the cylinder and the hub Then reattach the lower product head clamp Note Do not over tighten the product head clamp Minimal force applied with a hand wrench is su...

Page 70: ...first apply a food grade lubricant to the O ring Install the seal assembly onto the rotor 9 Test for leaks by operating the Contherm with water as the product for several minutes If a small leak occur...

Page 71: ...off the top of the damaged pin Be sure that the pin is flush with the shaft surface and is of a sanitary finish 32 in 1 6 m 2 Mark the location of the new drill hole to the dimensions specified below...

Page 72: ...dimensions provided in Table 8 11 are for the A dimension shown in Figure 8 4 Figure 8 5 Seal Pin Locations for Rotors with Internal Bearings Table 8 12 Seal Pin Locations for Rotors with Internal Be...

Page 73: ...or A slot at each end of the blade pin will accept the blade For Contherms with plastic blades each blade s insert rod is inserted into the slot on the blade pin If stainless steel blades are used the...

Page 74: ...e Contherms lower head clamp P N 7403038 01 and lower the rotor using the hydraulic rotor lifting device Note Refer to Table 7 4 Operating the Hydraulic Rotor Lift System and Table 7 5 Operating the R...

Page 75: ...o not come into contact with the cylinder edge causing damage to both the blade and cylinder edge 7 Remove blade funnel when tips of the last set of blades are within the cylinder Raise rotor to engag...

Page 76: ...pose of the Blade Funnel When raising the rotor using the hydraulic lift blade pins can contact the cylinder end and damage this area which can cause the Contherm to leak due to an un flat surface Fig...

Page 77: ...8 Inspection Maintenance Figure 8 8B Inst the Blade Funnel Follow the below sequence of installing the funnel and raising of the rotor Figure 8 8B Inst the Blade Funnel 77...

Page 78: ...8 Inspection Maintenance Figure 8 8C Removing the Blade Funnel Remove the funnel once the last set of blades is within the Contherm cylinder Figure 8 8C Removing the Blade Funnel 78...

Page 79: ...020 inches 0 5 mm Refer to Figure 8 9 The blade may be dressed until its width is 1 25 31 8 mm Figure 8 9 Dressing the Contherms Scraping Blades 1 Flat mill file 2 Vise jaws 3 Scraping blade 4 Soft m...

Page 80: ...nuous starting the rotation of the rotor when the product viscosity is extremely high 4 Damage caused by the blade pin hitting the cylinder end as in Figure 8 8A If the slot has been worn or damaged t...

Page 81: ...and strike the pad with a hammer 3 Check the 0 125 inch 3 2 mm thick feeler gauge until the proper opening is obtained Check the width of the blade pin s slot frequently 4 Maintain a perpendicular ori...

Page 82: ...ng cycles and equipment wash downs that the Contherms are often subjected to The most common cause of bearing failure is breach of the seal and contamination of the internal grease Ensure proper use o...

Page 83: ...1 from underneath the Lift Beam Assembly part number 7401283 01 to detach the bearing cap part number 7401618 01 5 Use a bearing puller tool to remove the lower bearing part number 7401391 01 from the...

Page 84: ...6 Bearing 7401391 01 7 Rotor End 7402982 02 8 Bearing Cap Cover 7402993 01 9 Socket Head Cap Screw 7401242 10 10 Lock Washer 7401244 06 11 Hex Head Cap Screw 7401241 21 12 Socket Head Cap Screw 740124...

Page 85: ...Remove the three 3 socket head cap screws Part Number 7401242 10 from the bearing cap cover Note There is a press fit between the bearing and both the rotor end Part Number 7402982 02 and the bearing...

Page 86: ...seal 7401621 01 4 Bearing 7401391 01 5 Bearing Clamp 7401579 01 6 Bearing Cap 7401618 01 7 Bolt Sleeve 7401289 01 8 Hex Head Cap Screw 7401286 01 9 Retaining Ring 7401243 08 10 Lift Beam Assembly 740...

Page 87: ...7401361 01 press out the drive coupling Part Number 7401203 02 for hydraulic drives and Part Number 7403769 01 for direct drives and the bearings from the bearing housing Discard the bearings 7 Use a...

Page 88: ...8 Inspection Maintenance Figure 8 13 Upper Bearings Direct Coupled Electric Drive Motor 88...

Page 89: ...ing and scalloping 5 If any of the above conditions exist please contact your local Alfa Laval Inc representative for additional assistance 8 7 2 Replacing the Cylinder If your inspection shows the ne...

Page 90: ...ly is a hydraulic directional control valve used to lower or raise the Contherms rotor assembly Compression fittings for both supply and return lines along with fittings for connections to the Conther...

Page 91: ...th O rings Shims 7402083 03 4 Handle Kit with Linkage Pins Retaining Rings 7402083 01 5 Mounting Bracket 7401781 01 6 Tube Fitting Elbow 7402076 22 7 Tube Fitting Straight 7402076 21 8 Tie Rod One Sec...

Page 92: ...ly remove all five O rings P N 7401137 24 from the center section Clean the area on the center section of any debris or O ring remains Install five new O rings 5 Reattach the Inlet Body to the center...

Page 93: ...bly of the Contherm is provided in Table 8 26 Table 8 26 Disassembly of The Contherm Steps Action 1 Disconnect the Contherms power supply to the drive motor and disengage any related drive couplings 2...

Page 94: ...ed in the product head 12 On the lower end of the unit remove the shoulder bolts from the hydraulic lift beam to release the lift beam from the bearing cap 13 Repeat Step 11 for the lower product head...

Page 95: ...7 Tighten all clamps 8 Lift the Contherm back onto the mount replacing the locknuts Part Number 7401266 01 Refer to Chapter 6 section 6 4 Figure 6 3 Do not touch seal faces Clean seal faces with alcoh...

Page 96: ...by releasing the retaining ring Part Number 7401243 07 located at the top of the lift cylinder and removing the cylinder cap 3 If the piston rod has not been operating smoothly the U cups P N 7401109...

Page 97: ...ng Size 116 BUNA 14 1 7401243 01 Lift Beam Assembly Hydraulic Inboard Bearing 5 1 7401162 01 Cap Hydraulic Lift Cylinder 15 1 7401283 01 Lift Beam Assembly Hydraulic Rotor Hold Down 6 1 7401164 01 Hea...

Page 98: ...243 06 Retaining Ring Ext Hydraulic Lift Cylinder 12 2 7401243 07 Retaining Ring Internal 1 7 8 Bore 13 3 7401243 08 Retaining Ring Hydraulic Lift Cylinder 14 1 7401283 01 Lift Beam Assembly Hydraulic...

Page 99: ...8 Inspection Maintenance Figure 8 18B CONTHERM Hydraulic Lift Assembly With Hold Down 99...

Page 100: ...ory Applicable Table s 9 2 Seal Leaks Product Seals Flush Seals Flushing media entering atmosphere Table 9 2 Product Seal Leaks Table 9 3 Flush Seal Leaks 9 3 Lower Bearing Lower bearing wearing out p...

Page 101: ...4 3 Seal Inspection and Replacement Lubricate before installing new O Rings Defective or twisted O Rings Replace O Rings Refer to Section 8 4 3 Seal Inspection and Replacement Foreign matter lodged i...

Page 102: ...ng If the lower bearing on your Contherm is wearing out prematurely this may result in excess vibration of the equipment The problem may be caused by one of the following conditions Worn bearing seal...

Page 103: ...tion due to water oil has creamy and foamy appearance Drain contaminated oil from system and replace with clean oil Refer to Table 6 8 for oil type recommendations Stack valve blocked Disconnect lines...

Page 104: ...atic effect on heat transfer Every application has an optimum scraping speed Problem Product Burning onto Cylinder Wall Table 9 7 Product Burning onto Cylinder Wall Possible Cause How To Resolve Produ...

Page 105: ...or adjust the flow rate down to compensate for the higher incoming product temperature Media temperature too high Reduce the temperature of the media Media flow rate too low Increase the media flow r...

Page 106: ...ng to Specified Temperature Ammonia Freon Possible Cause How To Resolve Product flow rate too high Reduce the product flow rate Product input temperature too high Reduce the temperature of the product...

Page 107: ...eature for more information Product supply has stopped empty feed tank Adjust controls to alert when product feed tank supply is low Do not let supply lines run dry Monitor current draw of motor with...

Page 108: ...ngs The below drawings follow a typical sequence of how to install your vertical Contherm scraped surface heat exchanger equipment 1 Assemble the mounting column Below demonstrates a split column Not...

Page 109: ...ndix A Additional Installation Drawings 2 Place the cross arms onto the column as shown The cross arms must sit on top of the column brackets and be bolted as shown for a safe installation Top of colu...

Page 110: ...nstall the drive motors onto the motor mounting plates Remove the motor plate from the mount Attach motor to the motor plate Attach the upper coupling hub to the motor shaft Install the upper coupling...

Page 111: ...the vertical column s Fix the column to a ceiling brace and to the floor The mount floor plate and the ceiling or wall bracing must be secured by others that are qualified and can ensure a safe insta...

Page 112: ...on Drawings 5 Installing the Contherm to the vertical column Insert the lower media port into and through the cross arm holes then insert the upper media port through the upper crossarm hole and secur...

Page 113: ...Install the coupling guard components Place the guard ring over the Contherm bearing housing as shown below Leave this ring loose at this step Install the lower coupling half to the Contherm drive sh...

Page 114: ...or onto the motor cross arm The motor and motor place should have already been preassembled Note orientation of motor couplings Install the couplings exactly as shown below Use adjustment hardware 1 2...

Page 115: ...pletely aligned via the use of a straight edge or laser shaft alignment device Use spacer provided 1 to ensure proper alignment Misalignment will cause premature wear to components Key stock or a smal...

Page 116: ...A Additional Installation Drawings 9 Install the coupling guard components Refer to section 6 5 for additional detail Secure the plastic ring to the bearing housing top plate with the 4 socket head ca...

Page 117: ...10 Appendix A Additional Installation Drawings 117...

Page 118: ...10 Appendix A Additional Installation Drawings 10 Install the hydraulic lift pump and stack valve components 118...

Page 119: ...section 6 7 for proper installation of hydraulic lifting system components 1 Oil return from piston 2 2 Oil return from piston 1 3 Oil return to pump from stack valve 4 Oil supply to piston 1 5 Oil su...

Page 120: ...aulic pump reservoir and test hydraulics Refer to table 6 10 for installation instructions and proper oil specification You are now ready to operate your Contherm equipment Make sure rotor raises and...

Page 121: ...ate is provided in Table 7 5 Seal Pin Jig 7404621 01 2 Spline 7404621 02 1 5 Spline CO6606 01 Special seal pin Heating CO6607 01 Special seal pin Cooling Used to allow customer to perform on site main...

Page 122: ...1 6 6X9 Liter 25 3 18 0 10 7 6 0 US Gallon 7 5 5 3 4 0 1 8 6X11 Liter 28 7 20 3 15 3 6 9 NCC 4 BLADED SST BLADES 2 INCH TANGENTIAL HEADS Model Capacity 3 in Rotor 76 mm 4 in Rotor 102 mm 4 5 in Rotor...

Page 123: ...123...

Page 124: ...s 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 r...

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