Armaturenwerk Hötensleben
OPERATING/INSTALLATION INSTRUCTIONS (Translation)
Container cleaning device Jet Cleaner TANKO MX125
Armaturenwerk Hötensleben GmbH
Schulstraße 5 - 6 39393 Hötensleben, Germany Telephone:
+ 49 (0) 39405 92-0 + 49 (0) 39405 92-111
Fax:
E-mail:
info@awh.eu
Homepage:
http://www.awh.eu
ID no.: 664BAMX0000EN - 2016/03 Rev. 0
A member of Neumo Ehrenberg Group
Jet Cleaner TANKO-MX
NOTE
These instructions are an essential part of the device and must be available to operating and maintenance personnel at all times throughout its entire life cycle. The safety notes contained therein must be observed! If the device is resold, the instructions must always be transferred to the new owner.
Translation The operating instructions must be written in an official European Community language acceptable to the manufacturer of the machinery in which the partly completed machinery will be assembled, or to his authorized representative. If any discrepancies arise in the translated text, the original operating instructions (German) are to be consulted for clarification, or the manufacturer is to be contacted.
These instructions and all illustrations contained therein are protected by copyright. Any use beyond the confines of copyright law is not permissible and liable to prosecution without the prior written approval of the publisher. This applies in particular to reproductions, translations, microfilming, and storage and processing in electronic systems. © 2016 - Armaturenwerk Hötensleben GmbH. All rights reserved.
Jet Cleaner TANKO-MX
CONTENTS List of Figures .....................................................................................................................III List of Tables .......................................................................................................................III Abbreviations and Units .................................................................................................... IV 1 Introduction......................................................................................................................1 1.1 M EANS OF P RESENTATION .............................................................................................1 1.1.1 Explanation of Signal Words...............................................................................1 1.1.2 Explanation of the Warnings...............................................................................2 1.1.3 Pictograms and Symbols....................................................................................3 1.2 W ARRANTY AND L IABILITY ..............................................................................................4 1.3 P RODUCT N AMES AND T RADEMARKS ..............................................................................4 1.4 R ELATED D OCUMENTS ..................................................................................................4 2 Safety................................................................................................................................5 2.1 I NTENDED U SE ..............................................................................................................6 2.2 S PARE P ARTS , R EPLACEMENT P ARTS AND A CCESSORIES ...............................................9 2.3 D UTIES OF THE O PERATING C OMPANY .........................................................................10 2.4 R EQUIREMENTS FOR P ERSONNEL ................................................................................12 2.4.1 Personal Protective Equipment ........................................................................13 2.5 I DENTIFICATION M ARKING ............................................................................................14 2.5.1 Type designation ..............................................................................................14 2.5.2 Type Plate ........................................................................................................14 3 Construction and Function ...........................................................................................15 3.1 C ONSTRUCTION ..........................................................................................................15 3.1.1 MX125 Construction.........................................................................................15 3.2 G ENERAL F UNCTION D ESCRIPTION ...............................................................................15 3.2.1 Function of the MX125 .....................................................................................17 3.3 T ECHNICAL D ATA ........................................................................................................18 3.4 C LEANING A GENTS ......................................................................................................20 4 Transportation and Storage ..........................................................................................22 4.1 P ACKAGING ................................................................................................................23 4.2 T RANSPORTATION .......................................................................................................23 4.3 S TORAGE ...................................................................................................................24 5 Installation......................................................................................................................25 5.1 S AFETY N OTES FOR I NSTALLATION ...............................................................................25 5.2 I NSTALLATION .............................................................................................................27 5.2.1 Interfaces .........................................................................................................28 5.2.2 Installation Position ..........................................................................................29 5.2.3 Installing the Device .........................................................................................30
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6 Commissioning..............................................................................................................34 6.1 S AFETY N OTES FOR C OMMISSIONING ...........................................................................34 6.2 F UNCTIONAL C HECK / T RIAL R UN .................................................................................36 6.3 S WITCH - ON PROCEDURE .............................................................................................37 6.4 O PERATION ................................................................................................................38 7 Maintenance ...................................................................................................................41 7.1 S AFETY N OTES FOR M AINTENANCE ..............................................................................41 7.2 S WITCH - OFF PROCEDURE ............................................................................................44 7.3 R EMOVAL ...................................................................................................................45 7.3.1 Removing the Device .......................................................................................46 7.4 M AINTENANCE ............................................................................................................48 7.4.1 Maintenance Intervals ......................................................................................48 7.4.2 Tools and Tightening Torque Values ................................................................52 7.4.3 Disassembling the Device ................................................................................53 7.4.4 Assembling the Device .....................................................................................62 7.4.5 Notes on Cleaning............................................................................................72 7.5 S PARE P ARTS AND C USTOMER S ERVICE ......................................................................73 7.5.1 MX125 Spare Parts ..........................................................................................74 8 Faults ..............................................................................................................................77 8.1 S AFETY N OTES FOR F AULT C LEARANCE .......................................................................77 8.2 F AULTS AND R EMEDIAL A CTION ...................................................................................78 8.3 H OW TO A CT IN C ASE OF AN E MERGENCY ....................................................................79 9 Decommissioning..........................................................................................................80 9.1 D ISPOSAL ...................................................................................................................80 Index....................................................................................................................................82 Appendices .........................................................................................................................83 Notes ...................................................................................................................................87
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List of Figures F IGURE 2.5-1: T YPE PLATE POSITION ...............................................................................................14 F IGURE 3.1-1: O VERVIEW OF MX125 ...............................................................................................15 F IGURE 3.3-1: C HART - MX125 FLOW ..............................................................................................19 F IGURE 5.2-1: I NSTALLATION DIMENSIONS OF THE MX125 DEVICE .....................................................28 F IGURE 5.2-2: I NTERFACES OF THE MX125 DEVICE ...........................................................................29 F IGURE 5.2-3: T HREADED CONNECTION INSTALLATION ......................................................................31 F IGURE 7.4-1: MX125 MAINTENANCE POINTS ...................................................................................50 F IGURE 7.4-2: T OOLS FOR MX125...................................................................................................52 F IGURE 7.5-1: I NTERNAL CONSTRUCTION OF THE MX125 ..................................................................74 List of Tables T ABLE 1.1-1: O VERVIEW OF S IGNAL W ORDS .......................................................................................1 T ABLE 3.3-1: O PERATING PARAMETERS OF THE DEVICE .....................................................................19 T ABLE 7.4-1: MX125 INSPECTION AND MAINTENANCE WORK ..............................................................51 T ABLE 7.5-1: MX125 TIGHTENING TORQUE VALUES ...........................................................................74 T ABLE 7.5-2: MX125 PARTS LIST ( STANDARD ) ..................................................................................76 T ABLE 7.5-3: MX125 STANDARD CONFIGURATION .............................................................................76 T ABLE 8.2-1: O PERATING FAULTS – CAUSE AND REMEDY ...................................................................78
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Abbreviations and Units ATEX
ATmosphère EXplosible; Synonym for the ATEX Directive of the European Union; comprises measures for explosion protection for explosive atmospheres Armaturenwerk Hötensleben GmbH BetrSichV Betriebssicherheitsverordnung (German industrial safety ordinance); ordinance AWH
concerning health and safety when using work equipment; German implementation of Directive 2009/104/EC of the European Parliament concerning the minimum safety and health requirements for the use of work equipment by workers at work.
AU
Assembly unit
CCD
Container cleaning device
BS
British Standard
BSP
British Standard Pipe; British thread standard for pipe fittings.
approx.
Approximately
CIP
Cleaning in Place A local (automated) cleaning process without dismantling plant parts. Denotes a procedure for cleaning processing plants, predominantly in sectors with particularly critical hygiene requirements, such as the pharmaceutical industry, food and drink industry or biofuel plants.
DN
DIN-Nennweite (DIN nominal width)
DIN
Deutsches Institut für Normung e.V.; is a national standards organization in the Federal Republic of Germany; The standards of this organization are referred to as DIN standards. Downpipe In the context of these instructions, this colloquial term describes a line or connection in cleaning technology between a media connection [MC] and a cleaning head or cleaning device. This line is generally used to establish the process connection [PC] for connection of the device to the container.
DP
ES
European Standard
IP
Individual part
FDA
Food and Drug Administration (USA food and medication monitor regulation authority)
ISO
ISO
International Organization for Standardization
Jet
Cleaning jet In the context of these instructions, this colloquial term describes a cleaning jet from a jet cleaner [JC] using in cleaning technology. Media connection In the context of these instructions, this colloquial term describes the interface used in cleaning technology for supplying cleaning agent from the supply line to the device.
MC
M
Metric
“ MX ” device series: Jet with media actuator
MX
max.
Maximum
min.
Minimum
NPT
National Pipe Thread; USA thread standard for pipe fittings
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PC
Process connection In the context of these instructions, this colloquial term describes the interface used in cleaning technology for the connection to the process from the device to the container. Système international d’unités; the most widely circulated international system of units for physical variables.
SI
SN
Serial number
WAF
Width across flats; gap between two parallel surfaces which indicates the size of a wrench. “ Technische Regeln für Betriebssicherheit ” (German technical rules for operational reliability and safety); These rules put the “ Betriebssicherheitsverordnung ” (BetrSichV) into concrete terms with regard to the identification and assessment of hazards and the derivation of suitable measures.
TRBS
WP
Wear part
AS
Assembly
JC
Jet cleaner
v eff.
Abbreviation for the physical variable of effective vibration velocity
Terms Stationary device: The device remains fitted on the container for a long period, even during the production process. Mobile device: The device is mounted on and removed from the container several times in a short period, and can also be used for cleaning several containers.
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Units of Measure
The following indicated factors are for orientation and conversion of the Si units to common units of measures for the American market.
bar
Unit of measure for pressure p [bar] All specifications of stand for positive pressure [bar] [bar g ] unless otherwise expressly described. Conversion: 1 bar = 14.50376 … psi [pound-force per square inch] Unit of measure for temperature T [degrees Celsius] Conversion from Celsius to Fahrenheit: °C x 1.8 + 32 = °F [degrees Fahrenheit]
°C
h
Unit of measure for time t [hour]
kg
Unit of measure for mass m [kilograms] Conversion: 1 kg = 2.20462 …
lb [Latin libra; pound]
l/min
Unit of measure for volume flow rate V [liters per minute] Conversion: 1 l/min = 0.06 m 3 /h
1 l/min = 0.26417 … gpm (us) [gallons per minute (us)] 1 m 3 /h = 4.40286 … gpm (us) [gallons per minute (us)]
lx
Unit of measure for illuminance E v [Lux]
m
Unit of measure for length l [meters] Conversion: 1 m = 3.28083 …
ft [feet]
mm
Unit of measure for length l [millimeters] Conversion:
1 mm = 1 / 25.40005 in [inches] = 0.03937 in [inches]
Nm
Unit of measure for moment/torque M [newton meters] Conversion: 1 Nm = 0.737 lbft [pound-force + feet] Unit of measure for speed n [revolutions per minute] Conversion: 1 rpm = 1 revolution per minute
U/min
μm
Unit of measure for length l [micrometers]
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1 Introduction These operating/installation instructions (referred to hereinafter as the instructions) are a component part of the device. They provide you with all the information required for smooth operation of the TANKO ® MX jet cleaner (referred to hereinafter as the device). The instructions must be read, understood, and applied by all persons employed to carry out installation and assembly, maintenance, cleaning and troubleshooting on the device. This applies in particular to the listed safety notes.
After studying the instructions, you will be able to – assemble, install and operate the device safely, – clean and service the device correctly and – take the correct measures if a fault occurs.
In addition to these instructions, generally valid, statutory and other binding regulations in regard of the prevention of accidents and in regard of environmental protection in the country of use must also be observed. The instructions must be kept at the location of use of the device so that it is available in legible condition at all times. If the device is resold, the instructions must always be transferred to the new owner. Download the instructions if necessary from the http://www.awh.eu/de/downloads internet page.
1.1 Means of Presentation
1.1.1 Explanation of Signal Words The warnings are introduced with a signal word which describes the extent of the hazard. The meaning and their classification in case of hazardous situations are explained in the following overview.
Signal Word
Meaning
Consequences of Failure to Observe
Hazard with a high level of risk Hazard with a medium level of risk
Death or severe physical injuries
DANGER
Death or severe physical injuries
WARNING
Hazard with a low level of risk
Minor or moderate physical injuries
CAUTION
Hazard with a low risk
Risk of material damage
NOTE
Table 1.1-1: Overview of Signal Words
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1.1.2 Explanation of the Warnings Section-related Warnings The section-related warnings do not just apply for one particular action but rather for all actions within a section. In addition, the pictograms and symbols indicate a specific danger.
DANGER
This warning warns of a hazard with a high level of risk! Failure to observe it can lead to death or severe physical injury. Measure(s) to prevent the danger
WARNING
This warning warns of a hazard with a medium level of risk! Failure to observe it can lead to death or severe physical injury. Measure(s) to prevent the danger
CAUTION
This warning warns of a hazard with a low level of risk! Failure to observe it can lead to minor or moderate injury. Measure(s) to prevent the danger
NOTE
This warning warns of a hazard with a minor level of risk! Failure to observe it can lead to material damage. Measure(s) to prevent the danger
Embedded Warnings The embedded warnings apply to specific actions and are integrated directly into the action before the specific action step. The embedded warnings are structured as follows. Signal word Type and source of danger. Possible consequences in case of failure to observe. Measure(s) to prevent the danger
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Further Means of Presentation
The “ Info ” symbol provides useful information, additional tips and recommendations.
– Texts which follow this mark, are bulleted lists. Texts which follow this mark, describe measures for prevention of the danger. 1. Texts which follow this numbering, describe the first step of a task which is followed by further numbered steps which have to be performed in the specified order. (1) Numbers in brackets reflect the item number in the parts list. “ ” Texts in inverted commas are (direct) quotes from documents (e.g. directives or standards) or words, word groups and parts of a text with a special meaning. Important, significant information is shown with additional bold type , in italics or CAPITAL LETTERS for emphasis of individual words or phrases. 1.1.3 Pictograms and Symbols The following pictograms and symbols are used as a supplementary measure in these instructions to clarify the sources of dangers and measures. They can appear at all levels of danger.
Warning about dangerous electrical voltage
Warning about explosive atmosphere
Warning about a hot surface
Warning about hand injuries
Warning about corrosive substances
Unauthorized access prohibited
Wear protective clothing
Warning about substances which are a water hazard
Wear safety shoes
Wear hand protection
Wear safety goggles
Wear a hard hat
Wear hearing protection
Wear a welding mask
Isolate from voltage before work
Obey instructions
Secure against power being switched back on Return for recycling
Protective grounding connection required
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1.2 Warranty and Liability
The commitments agreed in the contract of supply and delivery, the general terms and conditions and the terms of delivery of Armaturenwerk Hötensleben GmbH (referred to hereinafter as AWH) and the statutory regulations valid at the time the contract was concluded shall apply. Warranty and liability claims in the case of personal injury and damage to property shall be excluded in particular if these can be attributed to one or more of the following causes: – Improper or incorrect use of the device, – Improper assembly and installation, commissioning, operation and maintenance of the device, – Failure to observe the instructions in the instructions regarding assembly and installation, commissioning, operation and maintenance of the device, – Constructional modifications to the device (conversions or other modifications to the device must not be made without previous written approval from AWH. In case of infringement, the device will lose its EC conformity and the operating authorization), – Use of spare parts that do not meet the specified technical requirements. – Improperly performed repairs, – Disasters, the effects of foreign objects and force majeure. Exclusion of Liability AWH reserves the right to make alterations to this document at any time and without prior notice. AWH provides no guarantee (neither expressed nor implied) with regard to all information in this document, including but not limited to the implied warranty of merchantability and suitability for a particular purpose. Furthermore, AWH does not guarantee the correctness or completeness of information, text, graphics or other parts in this document.
1.3 Product Names and Trademarks
The product names and trademarks included in these instructions are brands or registered trademarks of the respective owners. TANKO ® and AWH ® are registered trademarks of Armaturenwerk Hötensleben GmbH.
1.4 Related Documents
The following documents contain possible supplementary information for these instructions: – Manufacturer's declaration and/or certificates of conformity – Certificates – Additional documents for any attached or upstream components, e.g. Drawings, technical data, information on accessories etc. – Supplements to these instructions (e.g. special versions) – AWH catalog, product data sheet
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2 Safety The device has been built in accordance with state-of-the-art technology and the recognized rules of safety. Nevertheless, use of the device may represent a danger to the life and limb of the operating company and third parties or a risk of impairments to the device and other objects of material value as a result of its function. The following basic safety notes are intended to prevent injury to personnel and material damage. The operating company must ensure that the basic safety notes are complied with and followed. These instructions contain basic notes on installation, operation, maintenance and servicing of the device which must be complied with. Anyone involved in installation, operation, maintenance and servicing must have read and understood these instructions. The safety systems and safety notes described in these instructions must be adhered to.
WARNING
Failure to comply with these instructions, incorrectly performed installation and repair work or incorrect operation could lead to damage to the device and to dangerous situations! There is a risk of death or severe physical injuries. All work on the device must only be carried out by a specialist and in compliance with: – the corresponding detailed operating and installation instructions, – the warning and safety signs on the device, – regulations and requirements specific to the plant, – national/regional regulations for safety and the prevention of accidents. Never install damaged devices or components.
The figures in these instructions are for basic understanding and are primarily representations of the principles involved. They may differ from the actual design of the device.
For maintenance and repair, we recommend a training course provided by the manufacturer or a person authorized by the manufacturer.
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2.1 Intended Use
DANGER
Risk of injuries from fire/explosion when using the device in an explosive atmosphere. Use of the device in an Ex area (potentially explosive atmosphere) is PROHIBITED, UNLESS expressly intended for that purpose! There is a risk of death or severe physical injuries. Adhere to the type plate of the device (see section 2.5.2 Type Plate) and the respective operating instructions .
WARNING
Risk of hazardous situations caused by use going beyond intended use and/or other types of use of the device! There is a risk of death or severe physical injuries. Only use the device for the intended use. – Only ever use the device in accordance with the specifications contained in these instructions and the specifications on the device’s type plate. – All the specifications in these instructions must be adhered to at all times. – Always keep the operating instructions at the location where the device is used. – Keep all signs on the device in legible condition. – Only use original spare parts. Modifications or conversions to the device are NOT permitted.
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WARNING
Danger from the incorrect use of materials/agents! The materials/agents to be used for the intended operation of the device are procured and utilized by the operating company for the device. The selection of materials/agents is the responsibility of the operating company. There is a risk of death or severe physical injuries. The proper treatment of these materials/agents is solely the responsibility of the operating company. When selecting the materials/agents, make sure that the permitted technical parameters of the device are NOT exceeded. The cleaning agents and media must be approved for all of the materials of the device (e.g. washers, bushings) and for the substances in the container being cleaned which come into contact with them. Adhere to the specified chemical limitations for use in the material data sheets. Adhere to the safety data sheets supplied by the manufacturers of the materials and media, in particular for hazardous substances: – Comply with the hazard and disposal instructions. – Set out protective measures and compile operating instructions for hazardous substances. – This also applies to hazardous substances that may arise during work processes.
Refer to the order confirmation / parts list from AWH for the materials used in the device.
The TANKO-MX is a rotating cleaning device and belongs to the group of jet cleaners. The device is driven by the cleaning agent. The device is used for cleaning the interiors of containers with and without installed equipment. For the purpose of these instructions containers are enclosed, depressurized tanks, silos, barrels, containers, pipes, etc., which are provided with an outlet that ensures a free flow of the supplied cleaning fluid. The pressure in the container to which the device is attached may not exceed a maximum of 0.5 bar (7.25 psi). The device was developed, engineered and built exclusively for industrial and commercial use. It must not be used for private use. In all cases, the operating company must check whether the device is suitable for its application. The device can be used in containers inside and outside of buildings in compliance with the limitations for use (see section 3.3 Technical Data ).
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In the process, the following must always be observed: Only operate the device when installed inside an enclosed container. Never direct the cleaning jet or torrent from the device at persons. Protect the device from freezing (e.g. risk of frost from possible residual water). The device is designed for fixed pipe installation only. Installation on a hose is PROHIBITED. Use a suitable filter system in the supply line for the cleaning agent. Operate the container only within the approved parameters, e.g. pressure and temperature, (see section 3.3 Technical Data ). Only cleaning agents which are compatible with the materials of the device (see section 3.4 Cleaning Agents ) may be used. The preferred installation position for the device is vertical with the cleaning head pointing downwards. Other installation positions are possible (see section 5.2.2 Installation Position ). The device may generate vibrations when cleaning the container. Any vibrations going beyond this must be avoided (see section 7.4.1 Maintenance Intervals ). The device is NOT suitable for the following applications: The device is NOT suitable for private use. The device is NOT suitable for ATEX applications. The device is NOT suitable for use outside of containers. Holding the device with your hand during operation is PROHIBITED. The device must NOT be immersed in the product of the production process (NOT even partially). This can cause the product to enter into the device. The spray openings may become blocked. The free movement of the actuator may be obstructed. The device must NOT by operated with air over a long period as the cleaning agent is used for lubrication of the bearings. The device is intended exclusively for the purpose outlined above. Any other use beyond that described here or alteration of the device without written approval from the manufacturer is considered IMPROPER use. The manufacturer accepts NO liability for damage arising from this. The operating company is solely responsible for the risk. The device must not be put into operation until it has been assured that all the safety devices are fully functional and the plant in which the device is installed meets the safety requirements of all relevant European directives (e.g. the Machinery Directive).
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2.2 Spare Parts, Replacement Parts and Accessories
WARNING
We expressly draw attention to the fact that replacement parts and accessories not supplied by AWH have NOT been checked or approved by AWH. The installation and/or the use of such products could therefore under certain circumstances result in changes with negative results to the properties of the device specified by its design and the higher-level plant. Armaturenwerk Hötensleben GmbH is not liable for any damage arising from the use of non-original parts or non-original accessory parts. Standard parts can be obtained from specialist dealers. Section 7.5 Spare Parts and Customer Service includes a list of spare parts Risk of damage, malfunction or complete failure of the device! Incorrect or faulty spare/replacement parts and accessories puts the functional safety and reliability of the device at risk. There is a risk of death or severe physical injuries. The failure of components or a device malfunction can cause material damage and consequential damages. Only use the manufacturer's original spare parts.
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2.3 Duties of the Operating Company
The device is used in the commercial sector. The operating company is thus subject to the legal obligations of occupational safety. In the EEA (European Economic Area), the national implementation of Framework Directive 89/391/EEC on carrying out measures for improving safety and protecting the health of employees during work, as well as the associated individual Directives and among these in particular Directive 2009/104/EC regarding the minimum regulations for safety and health protection in connection with the use of machinery by employees at work, shall be observed and complied with in their current valid versions. As a basic rule, the operating company in Germany must observe the Industrial Safety Regulation (BetrSichV). In other countries, the respective national guidelines, statutes and country-specific regulations regarding occupational safety and the prevention of accidents must be adhered to. At the same time, the following, non-exhaustive instructions apply in particular: – The operating company must ensure that the device is only used for its intended use (see section 2.1 Intended Use .) – The operating company must keep informed of the locally applicable occupational health and safety regulations and, in addition, use a risk assessment to determine the hazards resulting from the specific working conditions at the location of use of the device. This must then be implemented in the form of operating instructions for the operation of the device. – When using hazardous materials, protective measures must be specified in accordance with the safety data sheets and operating instructions shall be compiled for hazardous materials. Personnel must be appropriately briefed about this. This also applies to hazardous substances that may arise during work processes. – A continuous risk assessment must be carried out for workplaces, including temperature conditions for the medium and the place of use (falling). The measures must be recorded in operating instructions and personnel must be instructed accordingly. – Supervisors must monitor compliance with the measures specified in the operating instructions. – Throughout the entire operating period of the device, the operating company must check whether the operating instructions he has compiled reflect the current legislation and adapt them as necessary. – The operating company must clearly regulate and specify the responsibilities of personnel (e.g. for operation, maintenance and cleaning). – The operating company must only allow sufficiently qualified and authorized personnel to work on the device. – The operating company must ensure that all employees handling the device have read and understood the instructions. Furthermore, he must provide personnel with training at regular intervals with certification and inform them about the hazards. – The operating company must provide sufficient workplace lighting at the plant in accordance with the locally applicable regulations for occupational health and safety in order to prevent hazards occurring as a result of poor lighting. – The operating company must provide personnel with personal safety clothing and equipment and make sure that this is used (see section 2.4.1 Personal Protective Equipment ). – The operating company must make sure that the danger area of the higher-level plant in which the device is installed is not accessible to unauthorized persons.
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– The operating company must make sure that there is nobody is allowed to work on the device whose ability to react is impaired by drugs, alcohol, medication or similar. – The operating company must take appropriate measures to inform groups of persons who are not intended to come into direct contact with the device (e.g. visitor groups) about the potential dangers involved. – The operating company is responsible for making sure that the device is only ever operated in perfect condition. – Wherever high pneumatic pressures occur, there is a possibility of sudden failure of or damage to the lines and connections. This poses a hazard. The operating company must instruct operating and maintenance personnel at least once a year on the possible hazards. – The constructor of the overall plant must install the switching and safety devices required for setting up, inspection, shutting down (including emergency shutdown), operating, maintenance, cleaning and repair, and provide proof of their installation. – The operating company must design the disconnection of the energy sources on the higher- level plant technically in such a way that the Switch-off procedure described in section 7.2 can be adhered to. – The operating company must define and adhere to the intervals for inspections and control measures in accordance with the environment and media used. – The operating company must provide fire safety devices, e.g. the appropriate quantity of suitable hand-held fire extinguishers of the appropriate size, in easily accessible places and provide employees with training on fire safety. – Warnings in the documentation for externally supplied assembly units must be adhered to and incorporated into the risk assessments for the specific workplace. Connections: Before operating the machine with the device, the operating company must make sure that the local regulations are observed for assembly and installation and commissioning, if these tasks are performed by the operating company.
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2.4 Requirements for Personnel
The device must only be operated, maintained and repaired by persons with the appropriate qualifications. These persons must be familiar with these instructions and act in accordance with them. The respective authorizations for personnel must be clearly defined. The following qualifications are designated in the instructions for various fields of activity: Expert/Specialist Personnel An expert is a person whose professional training, knowledge and experience and knowledge of the relevant standards and regulations enables them to carry out work on the device and identify and prevent potential risks independently. Instructed person An instructed person has been briefed and, if necessary, trained by the operating company or an expert in a briefing on the assigned tasks and possible hazards in case of improper actions, and instructed on the necessary safety devices and protective measures. Only personnel with the following specific knowledge must be employed for work on the device: – Assembly/disassembly: Industrial mechanic or comparable vocational qualification, practical experience in the assembly/disassembly of devices. The person must be familiar with the construction, mechanical installation, maintenance of the device and fault clearance on the device and have the following qualifications: – Vocational training and final qualification in the field of mechanics (e.g. mechanic or mechatronics technician) – Welding work: Welder qualification in pipeline engineering or similar qualification. – Electrical work: Electrician; person with appropriate specialized training, knowledge and experience, enabling them to identify and prevent risks which may be caused by electricity. – The person must be familiar with the electrical installation, commissioning, fault clearance on and repair of the device and have the following qualifications: – Vocational training and final qualification in electrical engineering (e.g. electrician, electronics engineer or mechatronics technician) – Several years of vocational experience in the field of electrical engineering – Cleaning: Instructed person Work performed in other areas transportation, storage, operation and disposal must be performed exclusively by personnel who have received suitable instruction. All of the personnel listed above must wear protective clothing in accordance with their respective activities.
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Jet Cleaner TANKO-MX
2.4.1 Personal Protective Equipment Personal protective equipment must be used in accordance with the respective task when working on the device in order to minimize health hazards.
Protective Work Clothing Protective work clothing is tight-fitting work clothing with low resistance to tearing, with close-fitting sleeves and without protruding parts. It is mainly used for protection against getting entangled in moving components. Do not wear any rings, necklaces or other jewelry. Safety shoes Wear slip-resistant safety shoes for protection from heavy, falling objects and to prevent slipping on slippery surfaces. Protective gloves Wear protective gloves to protect your hands against friction, grazes, getting pricked or deep cuts and against coming into contact with hot surfaces or chemical substances. Protective goggles Wear protective goggles for protection against media escaping at high pressure and against flying objects.
Hard hat Wear a hard hat for protection against falling or flying objects.
Hearing protection Wear hearing protection to protect yourself from an increased sound pressure level (≥ 85 dB(A)). Welding mask Wear a welding mask for protection from damage to the eyes or skin due to the welding arc and from burning caused by flying particles during welding.
Personal protective equipment must be provided by the operating company and must meet the valid requirements.
Furthermore, both the national regulations and, if necessary, the internal instructions from the operating company, must be observed.
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Jet Cleaner TANKO-MX
2.5 Identification Marking 2.5.1 Type designation Example: Jet Cleaner
TANKO – MX125 – G14
1) Brand of the
cleaning devices
TANKO
2) Type:
M edia actuator X
Installation opening 125 mm
3) Size:
G for “ gleitgelagert ” (with slide bearing)
4) Variant:
5) Number of nozzle carriers: 1 6) Number of nozzles: 4
2.5.2 Type Plate
The information only applies to devices with types indicated on the title page of these instructions.
The marking is applied to the device according to the following illustration.
1 Device type plate
In case of inquiries, the data on the type plate of the device are important for proper and speedy processing: – Manufacturer – Type designation – Year of manufacture
– Article number – Serial no. [SN]
1
Figure 2.5-1: Type plate position
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Jet Cleaner TANKO-MX
3 Construction and Function For the development of the device, importance was attached to simple shape and functional design for the operating company. The outer appearance of the device is harmonious and compact. The design has been protected to safeguard the innovation. – EU Community Design No. 002772095-0001
3.1 Construction
3.1.1 MX125 Construction The container cleaning device comprises the following main components: 1 AU actuator unit 2 AU cleaning head
1
2
Figure 3.1-1: Overview of MX125
3.2 General Function Description
The jet cleaner of the TANKO-MX series is a cleaning device design with an internal actuator. The materials of the device are stainless steel and plastic. The bearings do not require additional lubrication as they are flushed with cleaning agent during operation and thus simultaneously lubricated and cooled. The actuator unit is driven by the cleaning agent which flows through it. The cleaning agent flows from the media connection, through an inflow disk and into the device and drives the impeller which is solidly connected to a rotor shaft. The cleaning head is connected to the actuator unit in such a way that the generated torque is transmitted directly onto the integrated bevel gear unit. The gear unit comprises one fixed bevel gear wheel and one circulating bevel gear wheel. The circulating bevel gear wheel drives the nozzle carrier (with nozzles).
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Jet Cleaner TANKO-MX
The rotation of the circulating bevel gear wheel around the axis of the fixed bevel gear wheel and the forced rotation around its own axis generates the orbital rotary movement of the nozzles around the cleaning head. The different number of teeth on the bevel gears causes the nozzle position to shift with each revolution of the cleaning head. A cycle is complete when the nozzles are back in their exact initial position after a certain number of revolutions. The orbital movement of the jet creates a closed cleaning pattern on the surface of the container. The mesh size of the pattern depends on the number of teeth on the bevel gears, the number of nozzles and the distance from the container wall. The jet-blast principle of the nozzles concentrates the cleaning agent, generating a high-energy jet. The mechanical cleaning effect depends on the outlet speed, the mass and the angle of impact of the cleaning agent. The intensive cleaning jets dislodge the adhered deposits from the container wall, rinse them off at high speed and discharge them. Very good cleaning results can be achieved using the jet cleaner for soluble substances and if the appropriate jet cleaner is selected for the respective container size. Differently sized devices, variations of head sizes, nozzle quantity and the nozzle bore are available to suit the specific requirement and the size of the container.
Sample applications for jet cleaner type TANKO-JM: Tanks, silos, barrels, containers, pipes, dryers, centrifuges, agitators, vacuum tanks, spraying towers, container washing plants, fermenters, filters, mixing containers and horizontal dryers.
Comment on the Cleaning Process The result of a cleaning process with the device, like all other cleaning processes, depends on multiple parameters. According to the “Sinner’s circle” definition, the four most important parameters for cleaning are: • Chemicals (cleaning agent and product and its concentration) • Mechanics (removal of dirt, establishment of contact with the cleaning agent) • Temperature and • Time (application time of the cleaning agent and duration of the cleaning process). All four factors are interdependent and variable in their magnitude in relation to each other. The desired cleaning results can only be achieved with a well-balanced combination of pressure, flow, application time, temperature and cleaning agent.
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3.2.1 Function of the MX125
The item numbers shown in brackets refer to the Figure 7.5-1: Internal construction of the MX125.
The cleaning fluid enters through the connection cover (01) of the device and flows through the bores of the inflow disk (14) and into the actuator unit at a certain angle. In the process, the fluid meets the rotor impeller (15) which is connected fixedly to the shaft of the spur gear (18). The parts are set in rotation and the spur gear (18) drives the planetary gear. The spur gear with internal gearing (22) of the planetary gear is screwed fixedly to the shaft-axle connection (24) so that the generated torque is transmitted directly from the actuator unit in the direction of the cleaning head. Simultaneously, the cleaning agent flows further through the planetary gear via the bores in the ring gear (22), through the bevel gear for the nozzle carrier (26), and into the shaft-axle connection (24) of the cleaning head. In the cleaning head there is a bevel gear unit which comprises a fixed bevel gear for the housing (23) and a circulating bevel gear for the nozzle carrier (26). The fixed bevel gear for the housing (23) is screwed fixedly to the housing (02). The rotation of the shaft-axle connection (24) and the gearing of the bevel gears force the bevel gear for the nozzle carrier (26) to rotate. The circulating bevel gear for the nozzle carrier (26) is bearing mounted on the driver shaft for the nozzle carrier (25) and connected to the driver shaft by a pin (35). The nozzle carrier (27) is screwed fixedly to the driver shaft for the nozzle carrier (25). The nozzle carrier (27) is therefore driven. The simultaneous rotation of the bevel gear wheel for the nozzle carrier (26) around the axis of the fixed bevel gear wheel for the housing (23) and the forced rotation around its own axis generates the orbital rotary movement of the nozzles (12) around the cleaning head. The fluid flows past the bevel gear wheel for the nozzle carrier (26) and into the nozzle carrier (26) and is distributed to the side bores for the nozzles (12). From there, the fluid passes through the openings of the nozzles (12) and back out again. Any leakages from the cleaning device are used for the device’s self -cleaning. MX125 cleaning times The speed of the cleaning head varies depending on the volume flow rate which is determined in particular by the number of nozzles, the size of the bores in the nozzles and by the pressure of the cleaning agent. - If the entry pressure is 3 - 10 bar (44 - 145 psi), the speed of the cleaning head is 5 - 14 rpm. Fluctuations of 10 to 15% are to be expected due to the design. - A complete cleaning cycle is completed after 43 revolutions. At a speed of 5 rpm, 8.6 minutes are required for a complete cleaning cycle. - In order to determine the cycle time, divide the number 43 by the number of revolutions of the cleaning head per minute. After installation of the device, you have to check the speed of the cleaning head (see section 6.2. Functional Check / Trial Run ).
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