Alfa Laval GJ 7, Instruction Manual

Page 1: ...Instruction Manual Alfa Laval GJ 7 Covering Standard Machines First published 2015 08 ESE032025 EN1 2015 08 Original manual ...

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Page 3: ...0 5 3 Cleaning Solution Leakage 12 5 4 Poor Cleaning Performance 13 5 5 Recommended Cleaning 14 6 Maintenance 15 6 1 General Maintenance 15 6 2 General dismantling set up 16 6 3 General dismantling 17 6 4 Inspection and Service of Components 18 6 5 Reassembly 21 7 Technical Data 23 7 1 Technical Data 23 7 2 Performance Data 24 7 3 Dimensions 25 7 4 Trax Simulation Tool 26 8 Parts List and Service ...

Page 4: ... 001 to BZ 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 Opera...

Page 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 ...

Page 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...

Page 7: ...ing the stators and 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 Chapter 7 Technical Data 3 2 Intended Use It is to be verified by the end user that the tank cleaning machine is in conformity with respect to tank vessel or container size in which it will be used th...

Page 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 material Step 3 Inspect the tank cleaning machine for visible transport damage Inspection ...

Page 9: ...wn however the Alfa Laval Gamajet will function at any orientation We do not recommend attaching the machine to a hose while in the inverted or horizontal orientation This form of mounting is not rigid and thus will not maintain the Alfa Laval Gamajet s position should the unit become unbalanced due to clogging of the nozzles In addition we do not recommend using a Triple Nozzle machine with a fle...

Page 10: ...n come from hard water dirty heating coils line sediment and well water A supply of clean wash fluid to the Alfa Laval GJ 7 and more importantly the vessel is a must Step 9 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 the Alfa Laval GJ 7 PD pumps are ...

Page 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...

Page 12: ...ashers a high level of dirt in the initial wash fluid This procedure will lessen the buildup of debris inside the Alfa Laval GJ 7 and potential for premature wear of components Every Alfa Laval GJ 7 that ships is accompanied by a Birth Certificate This document indicates how the machine performed in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval Tank Eq...

Page 13: ...rvice of Components Worn output shaft lower seal pos 25 Section 6 4 Inspection and Service of Components Worn Tee Nozzle housing bearing pos 35 36 Section 6 4 Inspection and Service of Components Bent stem pos 3 Section 6 4 Inspection and Service of Components Loose nozzle tee bearing cup pos 32 34 Section 6 4 Inspection and Service of Components Do Nozzle pos 5 and Tee Housing pos 4 both index wh...

Page 14: ...A newly overhauled Alfa Laval GJ 7 may fail to operate when first returned to service If the machine seems otherwise fine try running it with at least one Nozzle removed The reduction in pressure and additional flow will invariably be enough to overcome the extra resistance of new Bearings and Seals Fifteen minutes of operation should loosen the machine to run normally with the Nozzles reinstalled...

Page 15: ... Worn Bearing Cups Inspect the Bearing Cups 34 and 32 for excessive wear grooved or scored particularly near the inside flange where they contact the Bearings and Seals 61 59 and 36 Replace any that show distinct grooves Worn Static Seal Contact Surfaces Inspect the Bearing and Seal contact surfaces of the Stem 3 and the nose of the Tee Housing 4 If these are worn or grooved new Bearings and Seals...

Page 16: ...tion is at the proper temperature Plugged Nozzles Inspect the orifices in the nozzle 5 for 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 Gamajet Configuration Determine if the deposit being cleaned requires greater jet impact or longer jet dwell time slower rotation for more thorough scr...

Page 17: ...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 Danger of burns Step 3 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 18: ...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 8 Minor Service Kit 8 9 Major Service Kit Ordering spare parts Contact your local Alfa Laval Sales Company ...

Page 19: ...hat could adversely affect the seals and O rings during the prolonged contact of storage Step 3 DAILY INSPECTION Before every shift ensure that the Name Plate 6 is tight The Tee Housing 4 should not have any axial play If it does retighten the Tee Housing Bevel Gear Screws 44 that hold down the Bevel Gear 17 Also the Stator 9 and the orifices in the Nozzle Housing 5 should be inspected for debris ...

Page 20: ...ft Bearing Housing 57 Remove the Gear Train Assembly from the body by tapping on the Ouput Shaft at the Base end of the machine with the handle of a screw driver Step 4 Nozzle Housing Unscrew the Name Plate Screw 6 with a 1 4 6 35 mm slotted screwdriver Pull the Nozzle Housing 5 off the nose of the Tee Housing Remove the inner Nozzle Housing Bearing Seal 36 Tip Use a small slotted screwdriver to g...

Page 21: ...of 22 with your index finger to keep it in place This is done to prevent the accidental disassembly of the Gearhead 26 inside of 8 A thin spacer from the Gearhead may stick to the underside of the input assembly If it does remove it and place it back on the top of the Gearhead Pull and twist the Output Shaft Seal Housing 14 from the Gearhead Housing 8 Loosen the Output Shaft Set Screw 39 with a 0 ...

Page 22: ...g if 24 is still good If not remove the old one by prying it out of the 14 and replace it Check the Housings 8 and 14 for scoring or scratches in the areas of 24 and 49 contact Drawing 15 16 Nozzle Housing If the unit is a Standard Version with a tapered Nozzle Housing inspect the orifices in the 5 for debris The inside diameter must be smooth round and free of damage especially any nicks for maxi...

Page 23: ... should still have a bead In the case of the 61 replace if it has worn even with the main body of the bearing section Replace the 59 if it has worn even with the outside diameter of the seal s heel Inspect the interior of 61 and 59 for loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring replace as required Clean any deposits from tee hous...

Page 24: ...e threaded holes in the top of the 3 Apply a small amount of a mild thread lock to the four Phillips Pan Head Screws 44 and screw them in tightening them in a star pattern Needle nose pliers will help insert the small screws The 4 should not have any axial play Turn to drawing 10 Ensure that the Output Shaft Lower Seal 25 is in the Idler Shaft Base 29 spring side out Then repeat the procedure in t...

Page 25: ... assembly O ring side first over the 12 and push and twist it into the Gearhead Housing 8 until it is flush and fully seated The captured air will try to push the ends of the assembly off so quickly insert this assembly into the Stem 3 and proceed to the next section Drawing 14 Stem Cap Place the Stem Cap 2 on the 57 making sure the screw holes are aligned Using a 3 32 2 4 mm Hex Key screw the ste...

Page 26: ...PSI Recommended pressure 5 5 55 bar 80 800 PSI Cleaning 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 PTFE FKM EPDM and...

Page 27: ... c l e a n i n g Flow Rate Flow Rate Cleaning Time 0 7 0 8 Noz It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data 7 2 Performance Data Flow Rate Impact Throw Length Inlet Pressure Cleaning Time 0 100 Noz ...

Page 28: ...rtant to observe the technical data during installation operation and maintenance Inform personnel about the technical data 7 3 Dimensions Dimensions Dimensions A B C D E F G mm 176 115 27 17 42 43 48 in 6 9 4 5 1 1 0 7 1 7 1 7 1 9 ...

Page 29: ...are that simulates how the Alfa Laval GJ 7 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 containing different cleaning simulations covering a vari...

Page 30: ...8 Parts List and Service Kits 27 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine 8 1 AL GJ 7 View GJ0700 ...

Page 31: ...rts List and Service Kits 28 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine 8 2 Assembly Drawings 1 2 3 4 Drawing 1 Rotor Shaft Bearing Housing Assembly Drawing 2 Output Shaft Seal Housing Assembly ...

Page 32: ...s List and Service Kits 29 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 3 Gearhead Installation Drawing 4 Rotor Shaft Lower Bearing Housing For Low Pressure Applications refer to Appendix A ...

Page 33: ...8 Parts List and Service Kits 30 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine 8 3 Assembly Drawings 5 6 7 Drawing 5 Rotor Shaft Assembly Drawing 6 Rotor Assembly ...

Page 34: ...rvice Kits 31 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 7 Gear Train Assembly For Low Pressure Applications refer to Appendix A A Drawing 6 D Drawing 5 B Drawing 1 E Drawing 3 C Drawing 4 F Drawing 2 ...

Page 35: ...8 Parts List and Service Kits 32 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine 8 4 Assembly Drawings 8 9 10 11 Drawing 8 Stem Assembly ...

Page 36: ...8 Parts List and Service Kits 33 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 9 Tee Housing Assembly Drawing 10 Idler Shaft Base Assembly ...

Page 37: ...8 Parts List and Service Kits 34 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 11 Body Assembly A Drawing 8 B Drawing 9 C Drawing 10 ...

Page 38: ...8 Parts List and Service Kits 35 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine 8 5 Assembly Drawings 12 13 14 Drawing 12 Idler Gear Assembly Drawing 13 Idler Shaft Base Assembly ...

Page 39: ...8 Parts List and Service Kits 36 The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 14 Installing Gear Train into Body A Drawing 7 C Drawing 12 B Drawing 11 D Drawing 13 ...

Page 40: ... Laval GJ 7 Tank Cleaning Machine 8 6 Assembly Drawings 15 16 Drawing 15 Nozzle Housing Assembly For Low Pressure Applications refer to Appendix A Drawing 16 Completing the Assembly For Low Pressure Applications refer to Appendix A A Drawing 15 B Drawing 14 ...

Page 41: ...Y 2 or 3 8 9614681501 7 708 S GEARHEAD HOUSING 1 9 1 9614681601 7 709 3 STATOR 3 0 1 9 2 9614681602 7 709 4 STATOR 4 0 1 9 2 9614681603 7 709 4H STATOR 4H 1 9 4 9614681604 7 709 4X STATOR 4X 1 9 5 9614681605 7 709 5 STATOR 5 0 1 9 6 9614681606 7 709 5H STATOR 5H 1 9 7 9614681607 7 709 MV STATOR MV 1 9 8 9614681608 7 709 SV STATOR SV 1 9 9 9614681609 7 709 SV2 STATOR SV2 1 10 9614681701 7 710 ROTOR...

Page 42: ...CREW 1 40 9614685801 7 743 BASE SCREW 2 41 9614685901 7 744 BASE LOCKWASHER 2 42 9614686001 7 746 ROTOR OUTPUT PINION LOCKWASHER 2 43 9614686101 7 747 ROTOR OUTPUT PINION NUT 2 44 9614686201 7 748 T H BEVEL GEAR IDLER SHAFT BASE SCREW 8 45 9614686301 7 749 DRIVE PIN 2 46 9614686401 7 750 GEARHEAD SCREW 2 47 1 9614686501 7 751 E STEM CAP SMALL O RING EPDM 1 47 2 9614686502 7 751 K STEM CAP SMALL O ...

Page 43: ...OUSING 1 58 9614685301 7 739 LONG CARBIDE BEARING 1 59 9614685001 7 735 S TEE HOUSING LOWER SEAL 1 60 9614680501 7 703 E STEM GUIDE OPTIONAL FOR LP ONLY 1 61 9614684801 7 735 TEE HOUSING UPPER BEARING SEAL 1 62 1 9614687401 760 E ROTOR SHAFT HOUSING O RING EPDM FOR LP ONLY 1 62 2 9614687402 760 V ROTOR SHAFT HOUSING O RING VITON FOR LP ONLY 1 63 9614683901 7 727 SAS ROTOR SHAFT LOWER BEARING FOR L...

Page 44: ...ER SHAFT BUSHING 2 pcs 61 9614684801 7735 GJ 7 TEE HSG SEAL 1 pcs 35 9614684901 7735B GJ VII TH LOWER BEARING 1 pcs 59 9614685001 7735S GJ VII TH LOWER SEAL 1 pcs 36 9614685101 7736 GJ VII NH BEARING SEAL 2 pcs 39 9614685701 7742 GJ VII OUTPUT SHAFT SET SCREW 1 pcs 44 9614686201 7748 GJ VII CAP SCREW 8 pcs 47 1 9614686501 7751E GJ VII STEM CAP SMALL O RING 1 pcs 48 1 9614686601 7752E GJ VII STEM C...

Page 45: ...85101 7736 GJ VII NH BEARING SEAL 2 pcs 39 9614685701 7742 GJ VII OUTPUT SHAFT SET SCREW 1 pcs 44 9614686201 7748 GJ VII CAP SCREW 8 pcs 47 1 9614686501 7751E GJ VII STEM CAP SMALL O RING 1 pcs 48 1 9614686601 7752E GJ VII STEM CAP LARGE O RING 1 pcs 49 1 9614686801 7754E GJ VII ROTOR SHAFT BEARING HOU 2 pcs 50 1 9614686901 7755E GJ VII TEE HOUSING NOSE O RING 1 pcs 52 1 9614687101 7757E GJ VII NO...

Page 46: ...8 Parts List and Service Kits 43 Appendix A AL GJ 7 For Low Pressure Applications ...

Page 47: ...8 Parts List and Service Kits 44 Drawing 4A Rotor Shaft Lower Bearing Housing Drawing 7A Gear Train Assembly A Drawing 6 D Drawing 5 B Drawing 1 E Drawing 3 C Drawing 4A F Drawing 2 ...

Page 48: ...8 Parts List and Service Kits 45 Drawing 15A Nozzle Housing Assembly Drawing 16A Completing the Assembly A Drawing 15A B Drawing 14 ...

Page 49: ...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...