Instruction Manual
Alfa Laval GJ BB
Covering: Standard Machines First published: 2015-07
ESE032025-EN1
2015-07
Original manual
Страница 1: ...Instruction Manual Alfa Laval GJ BB Covering Standard Machines First published 2015 07 ESE032025 EN1 2015 07 Original manual ...
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Страница 3: ...Control 12 5 2 Trouble Shooting 13 5 3 Cleaning Solution Leakage 15 5 4 Poor Cleaning Performance 15 5 5 Recommended Cleaning 16 6 Maintenance 17 6 1 General Maintenance 17 6 2 General Dismantling Setup 18 6 3 General Dismantling 19 6 4 Inspection and Service of Components 20 6 5 Reassembly 22 7 Technical Data 24 7 1 Technical Data 24 7 2 Performance Data 25 7 3 Dimensions 26 7 4 Trax Simulation T...
Страница 4: ... 100 to H XXXX is in conformity with the following regulations and directives with amendments The Machinery Directive 2006 42 EC DS EN ISO 12100 2011 The Pressure Directive 97 23 EC According to its own volume and the rated pressure range the product is regarded an Article 3 paragraph 3 Equipment The person authorised to compile the technical file is the signer of this document Executive VP Operat...
Страница 5: ...cleaning machine 2 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 2 2 Warning Signs General warning Dangerous electrical voltage Caustic agents ...
Страница 6: ...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...
Страница 7: ... it will be used That the construction materials both metallic and non metallic are compatible with product flushing media cleaning media temperatures and pressure under the intended use 3 3 Patents and Trademarks This Instruction Manual is published by Alfa Laval Tank Equipment without any warranty Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Tank Equi...
Страница 8: ...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 ...
Страница 9: ...d23 to rotate Doing so may cause damage to the internal components Step 3 Inlet Connections The standard inlet connection for the Alfa Laval GJ BB is a 3 8 NPT female or 3 8 BSP female It is recommended that the mating male thread be wrapped with PTFE pipe joint tape prior to installation This will minimize any chance of leakage and will make subsequent removal much easier Step 4 Usage Before atta...
Страница 10: ...quate removal of particles and debris that can come from hard water dirty heating coils line sediment and well water A supply of clean wash fluid to the BB and more importantly the barrel is a must Step 7 Capacity of Supply Pump In the majority of cases a positive displacement PD style pump i e a pressure washer piston pump plunger pump and mechanical diaphragm pump will supply the wash fluid to t...
Страница 11: ...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...
Страница 12: ...his document indicates how the BB performed in our testing tank before it shipped based on the operating conditions supplied to The Alfa Laval Gamajet To ensure the longest possible life of the BB please verify the operating conditions and most importantly the machine s cycle time The cycle time can be measured by picking a fixed point inside of a vessel as a reference and timing how long it takes...
Страница 13: ... 22 both index when Rotor pos 46 is turned Cracked Loose Input Pinion pos 26 Section 6 4 Inspection and Service of Components Damaged Gearhead pos 27 Section 6 4 Inspection and Service of Components Worn Tee or Nozzle Housing Bearing pos 31 pos 32 or pos 33 Section 6 4 Inspection and Service of Components Does only Tee Housing pos 22 index Cracked Loose Input Pinion pos 26 Section 6 4 Inspection a...
Страница 14: ...ht in the outlet holes of the Stem 3 the nose of the Tee Housing 22 and the Nozzle Housing 23 Step 3 Insufficient Flow The Alfa Laval Gamajet was configured to meet certain operating conditions outlined at the time of the initial sale such as flow rate GPM pressure PSI temperature chemical content of the wash fluid cycle time etc If the Nozzle size is too small and or the opening at the bottom of ...
Страница 15: ...and hoses must be large enough to handle the flow rate required for the nozzle size being used to ensure adequate pressure Insufficient pressure may also result from line losses when the machine is far from the pump If this is the case the line size must be increased accordingly for long runs Although the Alfa Laval Gamajet will rotate at low flow rates effective cleaning may require considerably ...
Страница 16: ...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...
Страница 17: ...s Always keep Minor spare parts kit in stock 6 1 General Maintenance Step 1 Always read the technical data thoroughly see chapter 7 Technical Data Step 2 Recommended spare parts Order service kits from the service kits list See 8 7 Minor Service Kit 8 8 Major Service Kit Ordering spare parts Contact your local Alfa Laval Sales company ...
Страница 18: ...ners that could adversely affect the seals and O rings during prolonged contact in storage Step 3 External Inspection Intervals Before every shift examine the Stator 25 and the orifices of the Nozzle Housing 23 Inspect the 25 by loosening the Collar Set Screw 52 and removing the Collar 4 Step 4 Internal Inspection Intervals An interval of 100 hours is recommended initially If all of the components...
Страница 19: ...he Nozzle Housing 23 drawing 12 from the nose of the Tee Housing 22 Unthread and remove the Stem Cap 12 drawing 11 Tip The Stem Cap 12 is a Left Hand Thread Pull the 22 from the Stem 3 drawing 10 Remove the Tee Housing Bevel Gear 28 and the Upper Tee Housing Bearing 32 by pulling the 28 from the 3 Step 3 Output Shaft and Supply Tube Pull the Output Shaft 5 from the remainder of the Drive Body draw...
Страница 20: ...to arrange them is such a way that they are reinstalled in the same order as they were removed Examine the gears of the four different stages for any worn or broken teeth Also examine the main internal ring gear for bent or sharp teeth If any damage is found contact Alfa Laval Gamajet Equipment immediately During reassembly Alfa Laval Gamajet Equipment recommends the gearhead be lightly repacked u...
Страница 21: ...and check their fit in the 23 The external ring may be a tight fit with the inside of the 23 Once installed however the body of the 33 should turn freely Also the internal O ring should be free from damage compression set or deterioration Clean any deposits from inner bore of 23 and examine for excessive wear Light scoring is acceptable but the 23 should be replaced if the inside diameter exceeds ...
Страница 22: ...Input Shaft Lower Bearing Housing 49 Insert the 49 into the 10 To ease installation of this assembly into the 27 extend the 30 slightly so the engagement of the Input Pinion 26 with the top gears of the 27 is visible Once they are engaged push the 10 assembly into the 1 making sure to align the Planetary Gearhead Pin 35 with the slot in 1 Place the Rotor 46 over the end of the 30 Install the Rotor...
Страница 23: ...33 onto the 22 Lubrication of the internal O ring is recommended To prevent the internal O ring from being cut by the windows in the 22 twist the 33 as it slides over the 22 Push the Nozzle Housing 23 drawing 12 onto the nose of the 22 If a new set of 33 has been installed there will be a slight resistance as the external ring of the 33 is inserted into the 23 Rotate the Tee Housing Assembly sligh...
Страница 24: ...re 5 5 55 bar 80 800 PSI Cleaning Pattern 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 EPDM PFTE FKM ...
Страница 25: ...chnical data during installation operation and maintenance Inform personnel about the technical data 7 2 Performance Data It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data ...
Страница 26: ...portant to observe the technical data during installation operation and maintenance Inform personnel about the technical data 7 3 Dimensions Dimensions A B C D E F G mm 325 282 178 42 44 43 52 in 12 79 11 1 6 99 1 66 1 7 1 67 2 05 ...
Страница 27: ... specifications TRAX Simulation Tool TRAX is a unique software that simulates how the Alfa Laval GJ BB 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 de...
Страница 28: ...8 Parts List and Service Kits 28 The Drawing shows Alfa Laval GJ BB Tank Cleaning Machine 8 1 AL GJBB View GJBB00 ...
Страница 29: ...ings 1 2 3 4 5 6 7 Drawing 1 Gearhead Upper Bearing Housing Drawing 2 Gearhead Lower Bearing Housing A Press Fit A Press Fit B Spring Drawing 3 Gearhead Drawing 4 Input Shaft A Press Fit Note The 26 must be completely perpendicular to the 30 shaft or it will not press on correctly and damage the 26 or the 30 ...
Страница 30: ...ing shows Alfa Laval GJ BB Tank Cleaning Machine Drawing 6 Input Shaft Lower Bearing Housing Drawing 7 Geartrain A Press Fit A Drawing 5 B Spring B Drawing 1 C Spring D Drawing 6 E Drawing 4 F Drawing 3 G Drawing 2 Drawing 5 Rotor A Press Fit ...
Страница 31: ...8 Parts List and Service Kits 31 The Drawing shows Alfa Laval GJ BB Tank Cleaning Machine 8 3 Assembly Drawing 8 Drawing 8 Geartrain Housing A Drawing 7 ...
Страница 32: ...ice Kits 32 The Drawing shows Alfa Laval GJ BB Tank Cleaning Machine 8 4 Assembly Drawings 9 10 11 12 Drawing 9 Output Shaft Drawing 10 Stem A Drawing 8 A Press Fit Drawing 11 Stem Cap Drawing 12 Nozzle Housing A Press Fit ...
Страница 33: ... and Service Kits 33 The Drawing shows Alfa Laval GJ BB Tank Cleaning Machine 8 5 Assembly Drawings 13 14 Drawing 13 Tee Housing A Drawing 10 B Large chamfer on flange C Drawing 12 D Drawing 11 E Left Handed Thread ...
Страница 34: ...8 Parts List and Service Kits 34 The Drawing shows Alfa Laval GJ BB Tank Cleaning Machine Drawing 14 Tee Housing A Drawing 9 B Drawing 13 C Left Handed Thread ...
Страница 35: ...14632405 7 109 5 0 Stator 5 0 1 25 5 9614632406 7 109 5 5 Stator 5 5 1 26 9614634701 7 411 Input Pinion 1 27 9614634801 7 413A Gearhead 1 28 9614634901 7 417 Tee Housing Bevel Gear 1 29 9614635001 7 418 Nozzle Housing Bevel Gear 1 30 9614635101 7 422 Input Shaft 1 31 9614635401 7 431 L Tee Housing Lower Bearing 1 32 9614635501 7 431 U Tee Housing Upper Bearing 1 33 9614635801 7 433 Nozzle Housing ...
Страница 36: ...train Housing Flange Outer O ring Viton 2 54 3 9614617303 9 142 K Collar Large O ring Geartrain Housing Flange Outer O ring Kalrez 2 55 9614625601 6 143 Planetary Gearhead Pin 1 56 1 9614627001 6 154 E Output Cap O ring EPDM 1 56 2 9614627002 6 154 V Output Cap O ring Viton 56 3 9614627003 6 154 Z Output Cap O ring Zalak 57 1 9614661902 642 E Input Shaft Lower Housing O ring EPDM 1 57 2 9614661901...
Страница 37: ...SEAL 1 pcs 33 9614635801 7433 NOZZLE HOUSING LAB SEAL 2 pcs 36 9614636601 7456 GHLBH SMALL O RING EPDM 4 pcs 37 9614637001 7461 STEM CAP O RING EPDM 1 pcs 38 9614637301 7463 NZL HSG COVER PLATE O RING 1 pcs 40 9614686501 7751E GJ VII STEM CAP SMALL O RING 1 pcs 47 9614614701 9115 GEARBOX SEAL 1 pcs 48 9614614801 9116 INPUT SHAFT LOWER HOUSING SEAL 1 pcs 53 9614617202 9141E COLLAR SMALL O RING EPDM...
Страница 38: ...SMALL O RING EPDM 4 pcs 37 9614637001 7461 STEM CAP O RING EPDM 1 pcs 38 9614637301 7463 NZL HSG COVER PLATE O RING 1 pcs 40 9614686501 7751E GJ VII STEM CAP SMALL O RING 1 pcs 47 9614614701 9115 GEARBOX SEAL 1 pcs 48 9614614801 9116 INPUT SHAFT LOWER HOUSING SEAL 1 pcs 53 9614617202 9141E COLLAR SMALL O RING EPDM 1 pcs 54 9614617302 9142E COLLAR LARGE O RING EPDM 2 pcs 56 9614627001 6154E COLLAR ...
Страница 39: ...is document no 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...
