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Alfa Laval GJ PF-FT, Instruction Manual, Page: 15 / 43

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Alfa Laval GJ PF-FT Instruction Manual Download Page 15

4  Operation 

15 

 

The Tank Cleaning  machine  is designed  for cleaning  in place (CIP). CIP  = Cleaning  In Place.  Study the instructions  carefully and 
pay special attention to the warnings! NaOH = Caustic  Soda.

 

HNO3 = Nitric acid.

 

 
 

4.5  Recommended Cleaning 

 
Step 1 

 

 

Always handle lye and acid with great care. 

 

Caustic  danger! 

 

 
 
 
 

Always use rubber gloves!  

Always use protective goggles! 

 

Step 2 

 

Never touch the pump or the pipelines when sterilizing. 

Step 3

 

 

Danger of burns! 

 

 

Always rinse well with clean water after using a cleaning agent. 

 
 
 

 

NOTE 
Cleaning agents must be stored/disposed of in accordance with 
current regulations/directives. 

 

Always rinse! 

 

 

Clean Water 

Cleaning  agent 

Summary of Contents for GJ PF-FT

Page 1: ...Instruction Manual Alfa Laval GJ PF FT Covering Standard Machines First published 2015 07 ESE032025 EN1 2015 07 Original manual ...

Page 2: ......

Page 3: ...akage 13 4 4 Poor Cleaning Performance 14 4 5 Recommended Cleaning 15 5 Maintenance 16 5 1 General Maintenance 16 5 2 Preventative Maintenance 17 5 3 General Dismantling 18 5 4 Inspection and Service of Components 19 5 5 Reassembly 21 6 Technical Data 23 6 1 Technical Data 23 6 2 Performance Data 24 6 3 Dimensions 26 6 4 Trax Simulation Tool 27 7 Parts List and Service Kits 28 7 1 AL GJ 10 View 28...

Page 4: ...cleaning machine 1 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 Indicates important information to simplify or clarify procedures 1 2 Warning Signs General warning Dangerous electrical voltage Caustic agents ...

Page 5: ...n an Alfa Laval Gamajet is operating there should be covers over every tank opening These covers should be sealed well enough to withstand the full force of the jet striking the cover plate If the cleaning solution were hot corrosive or toxic a leak would present a serious hazard to any personnel in the immediate vicinity or to any exposed electrical equipment Warning Any tank cleaning machine can...

Page 6: ... time can be adjusted for special applications by changing the stator and or nozzle size Interchangeable stators and nozzle sizes are available for either low or high pressures and or flow rates The performance capabilities of these options are detailed in Section 7 Technical Data 2 2 Intended Use It is to be verified by the end user That the tank cleaning machine is in conformity with respect to ...

Page 7: ...UTION Alfa Laval cannot be held responsible for incorrect unpacking Check the delivery for 1 Complete Cleaning Machine 2 Delivery note Step 2 Remove any packing materials Step 3 Inspect the tank cleaning machine for visible transport damage Inspection ...

Page 8: ...ill be mounted with the inlet connection pointing up however the Alfa Laval GJ PF FT will function at any orientation The Alfa Laval GJ PF FT can be suspended from the top of the tank via a flexible hose The dual nozzle machine is designed to have balanced forces in order to keep it centered even while hanging We do not however recommend attaching the machine to a flexible hose while in the invert...

Page 9: ...arry abrasive solids in suspension adequate filtration is a must These particles can be extremely destructive to the Alfa Laval GJ PF FT pumps valves and other system components Filters properly installed and maintained will more than pay for themselves with lower overall operating costs in these applications Furthermore to ensure that clogged filters or strainers are cleaned we recommend using au...

Page 10: ...energy recovery Plastics should be recycled or burnt at a licensed waste incineration plant Metal straps should be sent for material recycling Maintenance All metal parts should be sent for material recycling Scrapping At end of use the equipment must be recycled according to relevant local regulations Beside the equipment itself any hazardous residues from the process liquid must be considered an...

Page 11: ...rmed in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval Gamajet To ensure the longest possible life of the machine please verify the operating conditions and most importantly the machine s cycle time The cycle time can be measured by first picking a fixed point inside of a vessel as a reference and second timing how long it takes the same nozzle to pass ...

Page 12: ...ing Bearing pos 23 Section 5 4 Inspection and Service of Components Worn Tee Housing Cup pos 24 Section 5 4 Inspection and Service of Components Worn Nozzle Housing Bearings pos 25 pos 26 Section 5 4 Inspection and Service of Components Worn Nozzle Housing Cup pos 27 Section 5 4 Inspection and Service of Components Does only Tee Housing pos 8 index Worn Tee Housing Bevel Gear pos 15 or Nozzle Hous...

Page 13: ...round the Input Shaft 39 In addition check for any debris caught in the outlet holes of the Stem 7 the nose of the Tee Housing 8 the Nozzle Housing 9 and the Nozzles 47 4 3 Cleaning Solution Leakage Note The Alfa Laval GJ PF FT is a self flushing machine and thus has up to 15 leakage designed into the machine Excessive leakage may indicate a larger issue Worn Bearings and Seals Leakage from the Te...

Page 14: ...ting is necessary also check that the solution is at the proper temperature Plugged Nozzles Unscrew the Nozzles 47 and inspect for any debris Slow or no Rotation of the Housings This will result in partial or erratic washing coverage Refer to previous sections for more information Alfa Laval GJ PF FT Configuration Determine if the deposit being cleaned requires greater jet impact or longer jet dwe...

Page 15: ...mended Cleaning Step 1 Always handle lye and acid with great care Caustic danger Always use rubber gloves Always use protective goggles Step 2 Never touch the pump or the pipelines when sterilizing Step 3 Danger of burns Always rinse well with clean water after using a cleaning agent NOTE Cleaning agents must be stored disposed of in accordance with current regulations directives Always rinse Clea...

Page 16: ... Always keep Minor spare parts kit in stock 5 1 General Maintenance Step 1 Always read the technical data thoroughly see chapter 6 Technical Data Step 2 Recommended spare parts Order service kits from the service kits list See 7 10 Minor Service Kit 7 11 Major Service Kit Ordering spare parts Contact your local Alfa Laval Sales company ...

Page 17: ...t the O rings during prolonged contact in storage The best position to store the machine is to stand it up with the inlet connection facing down Step 3 External Inspection Intervals Before every shift the Stator 12 and the Nozzles 47 should be inspected for debris Examine the 12 by loosening the Set Screw 34 while holding on the flats of the Cap 6 remove the main section of the machine from the Sa...

Page 18: ...f the Cap 6 unthread it from the body drawing 11 Warning Hold or turn on Stem 7 DO NOT hold or turn on Tee Housing 8 or Tee Housing Cap 14 Doing so will damage the Geartrain drawing 6 Pull the Geartrain drawing 6 from the remainder of the body drawing 11 Two slotted screwdrivers can be placed on either side of the Rotor 48 and used to lift the Geartrain out This is only for leverage and should not...

Page 19: ... side of the assembly facing up Using a brass pick or a small screw driver remove the Internal Retaining Ring 41 and remove the Top Planetary Large Washer 45 Remove the internal components of the gearhead Use caution to ensure that no components get lost during this operation If the internal components are not easily removed they can be pushed up from the bottom of the gearhead Also the other 41 a...

Page 20: ...rior of the 23 and check their fit in the Tee Housing Cups 24 While they should turn freely a 23 should be replaced if the thickness of the flange is 2 41mm 0 095 or less to avoid shortening the life of the Bevel Gears 15 and 16 Inspect the Tee Housing Cap O ring 3 for compression set or deterioration Replace if needed Inspect the Tee Housing Bevel Gear 15 for worn damaged or sharp pointed teeth E...

Page 21: ...ides of the 48 and the 20 facing each other Fasten the Rotor Lock Washer 4 and the Rotor Nut 5 onto the top of the 39 and tighten with a 5 16 socket wrench The 48 can be held with smooth jaw pliers to keep it from rotating Do not grip the Input Pinion 38 while tightening the 5 because this will cause damage to the gear Press the top of the geartrain assembly firmly onto the top of the gearhead ens...

Page 22: ...sure the 37 aligns with the hole in the 26 This will hold the 26 during installation and will keep the hole in the 26 to be properly aligned with the 37 Using a slotted screwdriver screw the 10 26 assembly completely snug Drawing 18 Completed Assembly Rotate the Rotor 48 using a Hex Key screwdriver or thin rod It should spin easily and its veins must not strike the walls of the Cap 6 Continue turn...

Page 23: ...rn First Cycle Full Pattern The above drawings show the cleaning pattern achieved on a cylindrical horizontal vessel The difference between the first cycle and the full pattern represents the number of additional cycles available to increase the density of the cleaning Certificate 2 1 Material Certificate PHYSICAL DATA Materials 1 4404 316L PPS FKM EPDM and FKM available Temperature Max working te...

Page 24: ...nical Data 24 It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data 6 2 Performance Data Standard and Low Profile PF FT 2 nozzle ...

Page 25: ...6 Technical Data 25 It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data Standard and Low Profile PF FT 4 nozzle ...

Page 26: ... OR 1 1 2 BSP 2 CAMLOCK Low Profile A B C D E F G H I mm 272 204 76 42 94 97 129 97 129 in 10 70 8 01 2 98 1 64 3 69 3 82 5 05 3 82 5 05 NOTE 1 1 2 FNPT 2 CAMLOCK OR 1 1 2 BSP 2 CAMLOCK PF FT 4 nozzle Standard Low Profile Standard A B C D E F G H I mm 272 204 175 44 94 176 202 165 202 in 10 7 8 01 6 88 1 73 3 69 6 90 7 95 6 48 7 95 NOTE 1 1 2 FNPT 2 CAMLOCK OR 1 1 2 BSP 2 CAMLOCK Low Profile A B C...

Page 27: ...ations TRAX Simulation Tool TRAX is a unique software that simulates how the Alfa Laval GJ PF FT performs in a specific tank or vessel The simulation gives information on wetting intensity pattern mesh width and cleaning jet velocity This information is used to determine the best location of the tank cleaning device and the correct combination of flow time and pressure to implement A TRAX demo con...

Page 28: ...7 Parts List and Service Kits 28 The Drawing shows Alfa Laval GJ PF FT Tank Cleaning Machine 7 1 AL GJ PF FT View GJPFFT00 ...

Page 29: ...2 3 Drawing 1 Input Shaft Upper Bearing Housing Drawing 2 Input Shaft Lower Bearing Housing A Press Fit A Press Fit Drawing 3 Input Shaft A Press Fit Note The 38 must be completely perpendicular to the 39 or it will not press on correctly and damage the 38 or 39 GJPFFT01 GJPFFT02 GJPFFT03 ...

Page 30: ...7 Parts List and Service Kits 30 The Drawing shows Alfa Laval GJ PF FT Tank Cleaning Machine 7 3 Assembly Drawing 4 Drawing 4 Gearhead A Press Fit GJPFFT04 ...

Page 31: ...Drawing shows Alfa Laval Gamajet 10 Tank Cleaning Machine 7 4 Assembly Drawings 5 6 Drawing 5 Rotor A Press Fit Drawing 6 Geartrain A Drawing 5 B Drawing 1 C Drawing 3 D Drawing 4 E Drawing 2 GJPFFT05 GJPFFT06 ...

Page 32: ... FT Tank Cleaning Machine 7 5 Assembly Drawings 7 8 9 10 11 Drawing 7 Stem Drawing 8 Tee Housing A Press Fit A Press Fit B Used for Pin Drive Machines Only Drawing 9 Stem Base Drawing 10 Tee Housing Bevel Gear A Press Fit A Press Fit GJPFFT07 GJPFFT08 GJPFFT10 GJPFFT09 ...

Page 33: ...33 The Drawing shows Alfa Laval GJ PF FT Tank Cleaning Machine Drawing 11 Body Assembly A Left Handed Thread B Drawing 9 C Drawing 8 D Drawing 10 E Drawing 7 GJPFFT11 ...

Page 34: ...7 Parts List and Service Kits 34 The Drawing shows Alfa Laval GJ PF FT Tank Cleaning Machine 7 6 Assembly Drawing 12 Drawing 12 Install Geartrain and Cap A Drawing 6 B Drawing 11 GJPFFT12 ...

Page 35: ...3 14 15 16 17 Drawing 19 Nozzle Housing Assembly A Drawing 18 Drawing 14 Nozzles Top Standard Bottom Low Profile Drawing 15 Nozzle Housing A Press flush with bottom edge A Drawing 14 B Part will protrude when installed Press until part bottoms out B Drawing 13 GJPFFT13 GJPFFT15 GJPFFT14 ...

Page 36: ...List and Service Kits 36 The Drawing shows Alfa Laval GJ PF FT Tank Cleaning Machine Drawing 17 Install Nozzle Housing A Drawing 12 B Drawing 15 C Drawing 16 Drawing 16 Nose Plate A Press Fit GJPFFT16 GJPFFT17 ...

Page 37: ...37 The Drawing shows Alfa Laval GJ PF FT Tank Cleaning Machine 7 8 Assembly Drawing 18 Drawing 18 Completed Assembly A Drawing 17 ...

Page 38: ...ar Retaining Ring 1 18 9614643901 10 125 Planetary Ring Gear 1 19 9614644001 10 126 Planetary Large Washer 3 20 9614644201 10 128 F Input Shaft Upper Bearing Housing 1 21 9614644401 10 129 F Input Shaft Lower Bearing Housing 1 22 9614644501 10 130 Stem Base 1 23 9614644701 10 131 FT Tee Housing Bearing 2 24 9614644801 10 132 Tee Housing Cup 2 25 9614644901 10 133 Nozzle Housing Lower Bearing 1 26 ...

Page 39: ...put Shaft Upper Carbide Bushing 1 51 9614609301 E 841 Input Shaft Carbide Thrust Washer 1 52 9614609401 E 842 Output Shaft Lower Carbide Bearing 1 53 9614609801 E 847 Stem Taper Cap Screw Lockwasher 4 54 1 9614610801 E 862 Large Collar O ring Viton 1 54 2 9614610802 E 862 E Large Collar O ring EPDM 1 54 3 9614610803 E 862 K Large Collar O ring Kalrez 1 54 4 9614610804 E 862 T Large Collar O ring T...

Page 40: ...LE HOUSING BEARING 2 pcs 33 3 9614646501 10147K GJ PF CLUTCH O RING 1 pcs 54 3 9614610803 E862K GJ VIII COLLAR STEM SM O RING 1 pcs 55 3 9614610903 E863K GJ VIII COLLAR STEM LG O RING 1 pcs 3 2 9614636802 7458K HOUSING O RING COLLAR O RING 2 pcs 19 9614644001 10126 GJ PF FT PLANETARY WASHER 3 pcs 40 9614647901 10896 GJ PF FT PLANET GEAR WASHER 16 pcs 42 9614601601 E127 PLANET GEAR BUSHING 16 pcs 4...

Page 41: ... 39 9614647801 10822FT GJ PF FT ROTOR SHAFT 1 pcs 51 9614609301 E841 GJ VIII RS CARBIDE THRST WASH 1 pcs Article no 9614651001 10PFFTKALMAJ ALFA LAVAL GAMAJET FT PF MAJOR KIT KALREZ Pos no Part No Gamajet Part No Description No 23 9614644701 10131FT GJ PF FT TEE HOUSING BEARING 2 pcs 26 9614645001 10133PF GJ PF NOZZLE HOUSING BEARING 2 pcs 33 3 9614646501 10147K GJ PF CLUTCH O RING 1 pcs 54 3 9614...

Page 42: ...O RING 1 pcs 3 3 9614636803 7458V HOUSING O RING COLLAR O RING 2 pcs 19 9614644001 10126 GJ PF FT PLANETARY WASHER 3 pcs 40 9614647901 10896 GJ PF FT PLANET GEAR WASHER 16 pcs 42 9614601601 E127 PLANET GEAR BUSHING 16 pcs 46 3 9614602703 E175V GEARHEAD O RING VITON 2 pcs 13 9614643001 10112F GJ PF FT OUTPUT SHAFT 1 pcs 9614643201 10113FT GJ FT POWERFLEX GEARHEAD 1 pcs 24 9614644801 10132 GJ 10 TEE...

Page 43: ...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 Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law including the seeking of criminal prosecution How to contact Alfa L...

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