Alfa Laval ALF-S Installation, Operating & Safety Manual

ALF Filter

Model : ALF-R, ALF-S, ALF-P

Standard (Steel) : ASME VIII or EN 13445

Standard (Glass fiber) : ASME X or EN13121

Valid for : 10S/15S/20S/30S

: 20P/30P/40P

: 20R/30R/40R/50R/60R/80R

English EN

Original manual

ALF Instruction Manual UM_Filter_100B03

ALFA LAVAL COPENHAGEN A/S

Installation, Operating & Safety Manual

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

The instructions given in this manual are intended as a general

instruction to Alfa Laval Filter type ALF

Alfa Laval reserves the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvement of this

publication would be gratefully appreciated. Please forward this information to the address below.

If further clarification regarding this manual is required, please contact your local Alfa Laval

representative.

Copies of this publication can be ordered from your local Alfa Laval Company.

This instruction replaces all previous manuals including

ALF instruction manual UM_Filter_100B01

ALF instruction manual UM_Filter_100B02

Published by: Alfa Laval Copenhagen A/S

Maskinvej 5

DK-2860 Søborg

Denmark

This manual and its content must not be copied, reproduced, transmitted or disclosed to any third

party without consent of Alfa Laval Copenhagen A/S.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

Table of contents

1. Contents

1.

Contents ............................................................................................. 3

2.

Safety Instructions and Warnings ....................................................... 5

2.1

General Safety Regulations ............................................................... 6

2.2

Safety Regulations during Installation ................................................ 6

2.3

Safety Regulations during Operation and Maintenance .................... 6

2.4

Noise Emission .................................................................................. 6

2.5

Modifications and Reconstruction ...................................................... 7

3.

Storage guidelines ............................................................................. 8

3.1

Storage .............................................................................................. 8

3.2

Standstill ............................................................................................ 8

4.

Installation .......................................................................................... 9

4.1

Guidelines ......................................................................................... 9

4.2

Unpacking ......................................................................................... 9

4.3

Lifting ............................................................................................... 10

4.4

Foundation ...................................................................................... 11

4.5

Mechanical Installation .................................................................... 11

4.6

Electrical Installation ........................................................................ 15

4.7

Parts position ................................................................................... 16

5.

Main Components ............................................................................ 18

5.1

TYPE ALF-R .................................................................................... 18

5.2

TYPE ALF-S .................................................................................... 19

5.3

TYPE ALF-P .................................................................................... 20

6.

Operating instructions ...................................................................... 21

6.1

Field of Application .......................................................................... 21

6.2

Operating Principle .......................................................................... 21

6.3

Operating precautions ..................................................................... 21

6.4

Normal Operation ............................................................................ 23

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

6.5

ALF Filter Start, Operation and Shut down – 2Touch ....................... 25

6.6

ALF Filter Start, Operation and Shut down – S7 Panel .................... 28

7.

Maintenance .................................................................................... 31

7.1

Introduction ...................................................................................... 31

7.2

Safety Instructions ........................................................................... 31

7.3

Removal and Insertion of the Filter Basket ...................................... 33

7.4

Alfa Laval “Combined Shaft Puller and Pusher” ............................... 35

8.

Trouble Shooting. ............................................................................. 36

9.

Spare Parts ...................................................................................... 38

9.1

Ordering Spare Parts ....................................................................... 38

9.2

Alfa Laval Service ............................................................................ 38

10.

Index ................................................................................................ 39

11.

APPENDIX A: Tables ....................................................................... 40

12.

APPENDIX B: Control Panel 2Touch ............................................... 43

12.1

Control Panel - 1 Filter ..................................................................... 43

13.

Appendix C: ALF Control Panel S7 .................................................. 63

13.1

Control Panel

-

1 Filter ..................................................................... 63

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 5 of 67

2. Safety Instructions and Warnings

The following symbols in this manual point out safety precautions. It means your

attention is needed and your safety is involved.

WARNING

This symbol is used to indicate the presence of a hazard, which can or will

cause severe personal injury, if the warning is ignored.

CAUTION

Certain passages of the text will be marked with a caution mark. This mark

indicates the presence of hazard, which will or can cause property damage if the

instructions are not observed.

NOTE

This type of instruction indicates a situation, which, if not avoided, could result in

damage to the equipment.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 6 of 67

2.1 General Safety Regulations

The following general safety rules must be followed on every occasion:

• The installation and operating manual contains vital information that must be

considered during all handling of the ALF filter. All personnel who are in

contact with the equipment must read the operating and installation manual.

The operating manual should be kept available near the equipment.

• If the safety regulations are not followed, there is a risk of injuries as well as

damage to the machinery and the surrounding environment. If these safety

regulations have not been followed, Alfa Laval cannot be claimed responsible.

If manuals are translated to local language the unit complies with the European

Machinery Directive 2006/42/EC and EN ISO 12100-1/2:2003 standards.

For countries within the EU and the associated EFTA countries, manuals MUST

be available in local language before installing and operating the unit.

2.2 Safety Regulations during Installation

Only authorized and qualified personnel should carry out the installation.

All work on the machinery must be performed when it is not in operation and

the main power supply is switched off.

All local regulations regarding transport and lifting must be followed at all

times.

2.3 Safety Regulations during Operation and Maintenance

Never open the filter during operation

Never put hands, other parts of your body or foreign objects into the

machinery without making sure the mains supply has been switched off

2.4 Noise Emission

Peak level sound pressure level occur when the filter is flushing and back

flushing.

In an indoor installation the sound pressure level will be significantly higher due to

the reflection of sound from walls and surroundings.

In order to minimize the sound pressure level at the machinery, it is

recommended to install in a room with low reflection of sound.

WARNING

Always wear ear protection when working next to a filter in operation. High

sound pressure levels can occur at flushing or back flushing

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 7 of 67

2.5 Modifications and Reconstruction

Please note that the machinery must not be altered or modified in any way if not

directly approved by Alfa Laval.

Use of original spare parts and accessories guarantee a safe operation. Use of

parts from other manufacturers can lead to premature failure of the machinery,

cause damage to the machine and surrounding area and jeopardize the

warranty.

WARNING

Noise hazards

• Use ear protection in noisy environments.

Crush hazards

• Do not work under hanging load.

• Wear head protection during installation and maintenance of the

equipment.

Cut hazards

• Wear gloves when handling machined parts.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 8 of 67

3. Storage guidelines

3.1 Storage

Unless otherwise agreed, Alfa Laval delivers the equipment ready to be put in

operation upon arrival and after installation.

If it is necessary to store equipment for a longer period (1 month or more), certain

precautions shall be made in order to protect and prevent unnecessary wear of

the equipment.

Filters shall be stored preferably in their packing case (ALU Pack) & in the

original wooden box and in an environment protected from rain, dust, sands &

direct sun. Storage temperature shall be maintained between -10 to +60

0

C (14 to

140°F) and the relative humidity between 15 and 95% RH.

NOTE

There should absolutely not be any ozone producing equipment in the

storage room, like operating electric motors or arc welding. Ozone destroys

many rubber materials.

Do not store organic solvents or acids in the storage room.

Avoid heat and ultraviolet radiation.

3.2 Standstill

If the machinery is to be out of operation for a period of 3 days or more, the

following precautions shall be taken:

• Drain the filter

• Flush the filter with potable water

Note

If the filter(s) is out of operation for more than three (3) days, then filter(s) shall

be drained and flushed with potable water in order to avoid corrosion on the

internal metallic parts.

3.2.1 Restart

• Visually check outside for defects

• Close Drain valves (option)

• Ensure proper venting of pipe system to avoid air pockets in system

• After start up - monitor the operation of the unit for approx. 10 minutes

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 9 of 67

4. Installation

4.1 Guidelines

For details on Dimensions, Connections, Loads, Service area, etc.: See the

order specific dimension drawing.

The ALF filter is either a complete machine or a partly completed machine

depending of what components the ordered filter consist of.

NOTE

It is the responsibility of the party that commissions/installs the filter to ensure

that the instructions given on the declaration of incorporation/ declaration of

conformity are followed prior to the first startup of the filter.

All electrical installations must be done in accordance with local regulations. A

certified electrician should carry out this job.

During working on the electrical installations the main power supply must be shut

off at all times.

For all signal cabling it is recommended to use screened cables only.

WARNING

Emergency stop must be installed as per local regulations.

4.2 Unpacking

When unpacking, take care not to damage the filter

Make sure that the ALF filter has not been damaged during the transport.

If transport damages are found, please contact local Alfa Laval agent.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 10 of 67

4.3 Lifting

The ALF filter should only be lifted by using proper lifting slings fitted to the ALF

filter as according to the following drawing.

Lifting of filter

s

mounted with lifting lugs.

Lifting lug is present on all according to the

lifting lug table.

Lifting of filter

s

without lifting lugs

Lifting

of

filter

s

for vertical installations:

Lifting lugs on the End cover flange.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 11 of 67

4.3.1 Lifting Lug Table

The following sizes are always supplied with lifting lugs:

ALF 15-S

ALF 20-S ALF 20-R

ALF 30-S ALF 30-R ALF 30-P

ALF 40-R ALF 40-P

ALF 50-R

ALF 60-R

ALF 80-R

Always use approved and certified equipment for the lifting. Refer to dimensional

drawing for the specific ALF filter for the weight of the equipment.

When lifting a filter, then use proper and approved rope slings and make sure

that the filter is prevented from tilting or rotating. Center of gravity is stated on the

dimensional drawing.

The ALF filter must be empty during lifting or transportation in order to avoid

unstable lifts and damage to the ALF filter.

WARNING

Always use lifting slings

with appropriate strength and dimension to handle the

weight of the ALF Filter

Always lift the ALF

filter by the lifting points, as shown above

Make sure that the ALF filter is empty before lifting.

4.4 Foundation

The ALF filters that are equipped with support feet or mounting brackets must be

fastened securely to the floor or a steel structure.

The maximum static foundation load calculation can be purchased on a

foundation drawing on request.

It is important that the foundation is made so that the filter is installed in

completely horizontal or vertical position to ensure correct fitting of piping

In vibrating environments or upon installation in earthquake zones loads on

nozzles and foundation bolting should be considered carefully prior to installation.

4.5 Mechanical Installation

1. Make sure there is a sufficient service area according to below table for pulling

out the flow diverter shaft or filter basket for maintenance purposes.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 12 of 67

Service distance for

Size (R, S, P)

(minimum)

Shaft

(mm above flange)

Basket

(mm from end cover

flange)

10 320 500

15 420 700

20 500 800

30 555 1050

40 650 1300

50 850 1600

60 1150 2150

80 1600

(from shell)

2600

2. Proper Pipe Support shall be considered for the flushing pipe line. Otherwise due

to the high velocity, flushing pipe will be damaged. Suitable support shall be

considered for filter types ALF 30, ALF 40, ALF 50, ALF 60 and ALF 80.

3. Ensure the flow direction is correct. (Refer to section “Operating instructions”).

4. Flushing valve on ALF 20 and larger models are a wafer type butterfly valve. The

pipe work must allow the valve free entry into the pipe, when it turns.

5. Filter shall not be installed with the flow diverter shaft or actuator downwards.

6. Do not mount butterfly valves directly on the filter inlet or main outlet flanges.

There is a risk that the valve disc contacts the flange internals and could not be

opened or closed properly.

7. Non-return valves causes turbulent flows and is not recommended in front of the

filter. Ensure minimum 6 times pipe diameter from the non-return valve to the filter

inlet.

8. Flushing pipe can be connected to pipe system after a heat exchanger in order to

obtain back pressure for the flushing outlet. (See Installation example)

9. Flushing valve shall be tightened until the valve does not leak.

NOTE

Make sure the flushing valve is centred and not excessively tightened. There is

risk that the valve body can break during operation.

10. To avoid water hammer and excessive flow during back flushing initiation,

flushing pipe should be installed so that the pipe can be water filled at all times.

11. Make sure differential pressure (DP) between filter’s inlet & flushing outlet must

not exceed below values.

i. For (ALF 40, 50, 60 & 80) = 2.5 barg.

ii. For (ALF 10, 15, 20, & 30) =3.0 barg.

NOTE

DP pressure beyond above mentioned values could create serious damage on

the filter basket & other internal parts.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 13 of 67

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 14 of 67

Installation Example

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ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 15 of 67

4.6 Electrical Installation

4.6.1 Electric controlled filters

1. Control panel preferably shall be installed within sight of the filter.

2. Wiring to the control panel must be in accordance to the electrical drawings and

the installation must comply with local regulations.

WARNING

Failure to comply with electrical regulations can cause risk of death by touching

electrified parts.

3. When using electrical actuators with junction box as an option, make sure the

junction box with safety switch is installed in close proximity to the filter. All cables

from the control panel must be wired via the junction box.

4. Before turning on control panel, refer the to Operation instruction section in this

manual.

4.6.2 Pneumatic controlled filters

12. Control panel should be installed within sight of the filter.

13. Connect compressed air hose between control panel and filter (Refer to the

Electrical Diagram). Use polyamide hoses Ø6 mm. Air Connections are provided

in both control panel and on the filter’s actuators.

14. A shut off valve mounted in the air supply in front of the control panel is

mandatory (not part of Alfa Laval delivery)

WARNING

Failure to comply with electrical regulations can cause risk of death by touching

electrified parts.

15. When using pneumatic actuators with junction box as an option, make sure the

junction box with safety switch is installed in close proximity to the filter’s body. All

cables from the control panel must be wired via the junction box.

16. Before turning on the control panel, refer to the Operation instruction section in

this manual.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 16 of 67

4.7 Parts position

Positions:

1. Service Area

2. Pipe Supports

3. Flow Direction

4. Flushing Valve

5. Actuators

6. Shut-Off Valve

7. Bypass Pipe

11. Flushing Pipe

14. Outlet Pipe

17. Shut-Off Valve

P Flushing Outlet Pipe

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 17 of 67

4.7.1 Piping Installation

The piping should be arranged in as short and easily assembled parts as

possible.

Size of piping should be appropriate for the size on the ALF filter (see dimension

drawing).

Choose piping details and associated equipment in materials that will meet the

demands by the specific process application.

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 18 of 67

5. Main Components

5.1 TYPE ALF-R

ALF-R: A pressure vessel of carbon steel Rubber lined inside for corrosion protection containing a

strainer for filtration of water

1.

Filter Body

2.

Filter Basket

3.

Flow Diverter

4.

Flushing Valve

5.

Flow Diverter Actuator

6.

Flushing Valve Actuator

7.

End Cover

8.

Ventilation Connection (optional)

9.

Drainage Connection (optional)

10.

Pressure Transmitter Connection (optional)

11.

Davit for Horizontal Version (optional on some models)

12.

Davit for Vertical Version (optional on some models)

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 19 of 67

5.2 TYPE ALF-S

ALF-S: A pressure vessel of Stainless steel with a rubber lined end cover containing a strainer for

filtration of water

Filter Body

1.

Filter Body

2.

Filter Basket

3.

Flow Diverter

4.

Flushing Valve

5.

Flow Diverter Actuator

6.

Flushing Valve Actuator

7.

End Cover

8.

Ventilation Connection (optional on Size 20 and 30)

9.

Drainage Connection (optional on Size 20 and 30)

10.

Pressure Transmitter Connection (optional)

Alfa Laval Copenhagen A/S

ALF – Installation, Operating and Safety Manual

ALF Instruction Manual UM_Filter_100B03

Page 20 of 67

5.3 TYPE ALF-P

ALF-P: A pressure vessel of Glass Fibre Reinforced Polyester containing a strainer for filtration of

water

1.

Filter Body

2.

Filter Basket

3.

Flow Diverter

4.

Flushing Valve

5.

Flow Diverter Actuator

6.

Flushing Valve Actuator

7.

End Cover

8.

Ventilation Connection (optional)

9.

Drainage Connection (optional)

10.

Pressure Transmitter Connection (optional)

11.

Davit for Horizontal Version (optional)

Support feet (optional on 30 and 40)

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