A. Laval

Safety instructions
CONTENTS PAGE
Use of hazard information . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . 2
Use of signs . . . . . . . . . . . . . . . 3
Cleaning solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alfa Laval Copenhagen A/S
Doc. No. SI 2011-04-EN2
www.alfalaval.com 1(4)
SAFETY INSTRUCTIONS
Safety instructions
To ensure maximum safety always read this section carefully
before carrying out any work or inspection on the equipment.
If the safety instructions are not followed, there is a risk of personal
injury.
Use of hazard informations
Hazard informations in this documentation have the following significance:
Failure to observe this information results in immediate danger
to life.
Failure to observe this information may result in major personal
injury or loss of life.
Caution! Failure to observe this information may result in minor
personal
injury or damage to the equipment.
Note! Information requiring special emphasis.
2(4) www.alfalaval.com
SAFETY INSTRUCTIONS
General
Only trained personnel are allowed to operate the module. The
module may only be used in accordance with the instructions given
in the manuals delivered with the module.
The module is not to be used to process explosive or inflammable
liquids.
The module is controlled by a process controller and may change
mode of operation without operator intervention. The module uses
high temperatures and pressures.
All personnel must therefore:
stay outside the risk area (see tag Operation Manual)
regard all electrical equipment as live
regard all equipment as hot
use hearing protection
CAUTION! If carbon dioxide (CO2) or nitrogen (N2) is used, be aware
that
these gases displace air and thus obstruct oxygen from entering
the respiratory organs. High concentration creates lethal
danger. Follow the instructions given by the supplier.
Before carrying out any work or inspections:
shut off all service media
switch off power
allow the equipment to cool down and adjust to atmospheric
pressure
inform concerned personnel about the intended work
post warning signs at prominent places
During operation:
parts of the equipment may be hot. Contact with parts may result
in severe burns. Avoid contact.
there is a risk of splashes. Always keep protective devices in
place.
The module operates under pressure. All personnel must therefore:
mind for leakage
mind for jets
To protect the control panel internals keep the doors closed.
Alfa Laval will not be responsible for any breakdown of the
equipment caused by the owners failure to follow the instructions
given in this documentation.
This documentation describes the authorized way to use the
equipment. Alfa Laval will take no responsibility for injury or
damage if the equipment is used in any other way.
General
SAFETY INSTRUCTIONS
An electric shock can injure or kill. Treat all
electrical equipment as powered. Switch off
power before maintenance or repair.
Use of signs
Warning signs are used as below.
Caustic agent
Hot surface
High noise levels
Electrical equipment
Temperatures exceeding 60C may occur.
Do not touch without proper protection.
Substances that may be harmful to body
tissues. Do not touch without proper protection.
Noise levels exceeding 85dBA may occur.
Use hearing protection.
Use of signs
SAFETY INSTRUCTIONS
Cleaning solution
Handling of cleaning solution
Cleaning solution normally contains caustic soda (NaOH) or nitric
acid (HNO3). These chemicals may cause burning of body tissues.
Follow the instructions given by the supplier.
Whenever there is a risk of exposure to these chemicals, always
wear:
safety glasses
protection gloves
shoes and apron made of PVC/PE plastic, or rubber
In case of an accident involving cleaning solution, the basic rule is
to, as soon as possible, rinse the affected area with large amounts
of water.
Due to this, always make sure that the emergency and eye showers,
and also additional washing facilities are ready for use.
Emergency measures
If swallowed
immediately drink large amounts of lukewarm water (to dilute what
has been swallowed), then seek medical attention
If contact with eyes
immediately rinse the eyes thoroughly with lukewarm water at
least 15 minutes (keep eyelids widely apart), then seek medical
attention.
If contact with skin or clothes
immediately remove contaminated clothing.
immediately rinse with large amounts of water. If skin burns appear,
seek medical attention.
thoroughly wash the clothing before worn again.
If inhaled
leave the affected area to get fresh air. If any symptoms remain,
seek medical attention.
Note! Reaction may occur several hours after inhalation.
Cleaning solution
Copyright Alfa Laval
02. General Information

General information
CONTENTS PAGE
MODULE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DOCUMENT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 3
Doc No. GI-ALDOX 2012-01-EN3
GENERAL INFORMATION
Module introduction
To ensure maximum safety, always read the Safety instructions
and relevant instructions before carrying out any work
or inspection on the equipment.
Application
ALDOX is a preassembled skid mounted module designed to
continuously deoxygenate and slightly carbonate water. In the
beverage industry it is employed for the production of oxygen-free
water which is used for the production of soft drinks, purge water
and in high gravity brewing.
Service
In case of problems when operating the module, contact the nearest
Alfa Laval company.
Manufacturer
Maskinvej 5
DK-2860 Sborg/Copenhagen
DENMARK
Name plate
The plate below is an example of the attached plate. The plate contains
the data needed when contacting Alfa Laval Copenhagen A/S
concerning this particular module.
Module introduction
Module introduction GENERAL INFORMATION

Document information
Product documentation
The documentation for this module consists of a TECHNICAL
DOCUMENTATION in one or more binders as outlined in the table
of contents.
An OPERATION MANUAL is enclosed as a part of the TECHNICAL
DOCUMENTATION. The OPERATION MANUAL is intended to be
placed at the operator panel in order to at all times provide the operator
with guidance and information on how to operate the module.
As a consequence of this, certain parts of the different sections are
repeated.
It is important to:
keep the manuals available and updated for the life of the module
pass the manuals on to any subsequent holder or user of the
module
Abbreviations
Abbreviations as follows may be used in this documentation.
CIP Cleaning In Place
Cl2 chlorine
CO2 carbon dioxide
Cu copper
DO Dissolved Oxygen
Fe iron
HE Heat Exchanger
HNO3 nitric acid
I/O In/Output module
K potassium
KMnO4 potassium permanganate
Na natrium, sodium
N2 nitrogen
NaOH sodium hydroxide (caustic soda)
NO2 nitrogen dioxide, nitric dioxide
O2 oxygen
pH determination of acid/base concentration
PBT Pasteurised Beer Tank
PHE Plate Heat Exchanger
PLC Programmable Logic Controller
PU Pasteurizing Unit
Design modifications
The directives in this documentation are in accordance with the
design and construction of the module at the time it was released
by the Alfa Laval production facility.
Document information GENERAL INFORMATION
Document producer
Maskinvej 5
DENMARK
Further copies
Can be ordered from nearest Alfa Laval company. When ordering,
always state the module type and Serial No. as stated on the name
plate.
Copyright 2012
All rights reserved. No part of this documentation may be reproduced
or copied in any form or by any means without the written consent
of Alfa Laval Copenhagen A/S.
Document information GENERAL INFORMATION
03. Installation
Installation
CONTENTS PAGE
INTRODUCTION 1
PREPARATORY WORK . 3
INSTALLATION INSTRUCTIONS 5
Requirements on personnel . . . . . . . . . . . . . 5
Storage . . . . . . . 6
Unloading and transportation, Unpacking and inspection . . . . . . . 7
Connections, Positioning and erection . . . . . . . . . . . . . . . . . . . . . . 8
Assembly and connection, Check after installation . . . . . . . 10
WHEN TO START COMMISSIONING . 11
Doc. No. IM-ALDOX 2010-03-EN1
Introduction
Introduction
Prior to operation
Between the time of ordering and normal running, several phases
must be executed:
preparation of site
installation
commissioning
Preparation of site
Preparation of the site can take place prior to equipment delivery.
For detailed information see Preparatory work.
Installation
Installation covers all work from receipt of the equipment to assembled
and partly tested equipment, for example:
lifting
mechanical erection
testing of parts of the module
For detailed information see Installation instructions.
Commissioning
Commissioning covers testing and tuning of the module to bring it
into commercial production.
To ensure an efficient commissioning the following work must be
completed before the commencement of commissioning:
preparatory work
installation work
Furthermore, all required services must be connected and available.
Raw material to be processed must be available at short notice.
The following personnel are requested to be available for training
purposes and to assist the commissioning engineer:
operators
utility welder and erector
TIG welder
electrician
IMPORTANT!
When to start commissioning is a detailed checklist giving conditions
which must be fulfilled before the commencement of commissioning.
NOTE! You can not start commissioning before this list is completed.
INSTALLATION
Introduction INSTALLATION
Preparatory work
Preparatory work
General
To ensure correct and efficient preparation, always refer to Technical
Data, and Drawing(s) provided with the module.
If you have any questions - please contact Alfa Laval Copenhagen
A/S.
Site
Prior to delivery, the premises should be made ready to receive the
equipment.
Prepare:
floor (quality, load, surface, drainage)
foundations (if applicable)
ventilation (if applicable)
lifting devices (if applicable)
insulation (if applicable)
ventilation (if applicable)
Check that doorways and passages are:
of sufficient width and height to allow the equipment to pass
clear of obstructions
Service media
To facilitate the installation, and save time, the required media supplies
should be installed in advance.
Connections from these service lines to the module should be located
approximately as shown in the layout drawing(s), ready to be
connected and equipped with shut-off valves etc. as indicated on
the flowchart.
The steam line (if applicable) is to be equipped with steam traps and
a pressure controller to ensure a dry steam supply with a constant
pressure.
Ensure the services fully satisfy the specifications in tag Service
Media.
Floor drains
Floor drains are necessary to collect liquid waste from the module.
When preparing floor drains consider the following:
capacities, see tag Technical Data
locations, see tag Drawing(s)
INSTALLATION
Preparatory work INSTALLATION

Installation instructions
Requirements on personnel
Electrician
Certified according to local regulations with at least 3 years experience
of similar installations. Proven skills in reading and working
from drawings and cable lists. Knowledge of local safety regulations
for power and automation. Furthermore, the electrician must ensure
that the electrical installation, including the equipment or device
that work has been carried out on, has been adequately checked
regarding the safety of personnel and property before it is put into
operation.
TIG welder
At least 3 years previous experience of similar types of installations,
including argon gas welding of thin-walled stainless steel. Proven
skills in reading installation drawings.
Utility welder and erector
At least 3 years experience of similar types of installations, covering
arc and gas welding in for example pipes for steam or compressed
air. Proven skills in reading installation drawings.
CAUTION! Unauthorized personnel
Operation by unauthorized personnel may endanger personnel and
property.
INSTALLATION
Storage
To avoid damage to the equipment during storage the following
requirements should be met:
Note! The stainless surfaces may never be exposed to aggressive liquids,
particles (e. g. from grinders), etc..
Storage class A
Type of equipment (as applicable):
- control panels
- electronic equipment
- electronic control equipment
- equipment with built in control equipment
to be stored indoors, warm dry and clean.
Temperature: +10C - +40C
Relative humidity: 20% - 85%
Storage class B
Remaining module parts to be kept dry and clean.
Caution! Noncompliance with these requirements may endanger the
equipment.
INSTALLATION
Unloading and transportation
Unloading and transportation of the crates are made most conveniently
with a fork lift.
Observe the signs gravity centre and arrange the lifting accordingly.
CENTER
GRAVI TY
Unpacking and inspection

To avoid the risk of damaging the equipment, the crates must be
opened and unpacked in the presence of an Alfa Laval representative.
Check the equipment against the packing lists attached to the
crates.
Report any damage to Alfa Laval immediately.
Do as follows:
a) Remove the top.
b) Lower the sides (unfold).
c) Unpack the equipment.
Packing List
INSTALLATION
Connections
Connections are clearly marked on the equipment and in drawing(s)
supplied under tag Drawing(s).
The following mechanical connections are to be made:
- steam supply (if applicable)
- condensate outlet (if applicable)
- cooling medium (if applicable)
- compressed air
- water
- drain
- product inlet
- product outlet
The following electrical connections are to be made:
- electrical supply
- communication signals to adjoining equipment (if applicable)
For detailed information about electrical connections (see tag Control
Panel Documents).
Positioning and erection
For efficient positioning and erection of modules use:
layout drawing(s)
component instructions
flow diagram
Use fork lift trolleys when positioning frame mounted module(s).
Proceed as follows:
a) Position the module(s) .
- use two fork lift trolleys, insert the forks under the ends of the
frame
- position the module(s) with the adjustable feet on the baseplates
Note! Position the module with sufficient space for service and maintenance.
b) Level the module(s) - use a spirit level.
- place the spirit level on the frame, check the levelling
- lift the module with a fork lift trolley or a jack
- adjust the feet
INSTALLATION
c) Raise the column to an upright position with the adjustable feet/
baseplates.
Note! To prevent the column from falling, make sure that it is adequately
kept in place.
Risk of falling objects
Falling objects may severely injure personnel or cause damage to
equipment. Use appropriate lifting device. Use helmet. Do not enter
the area beneath lifted equipment.
d) Adjust the column to a vertical position with the adjustable feet.
e) Adjust the height of the column to fit easily to the pump inlet, also
using the adjustable feet.
Note! If the column leans more than 1% the stripping efficiency might be
affected.
Note! Make sure that the column is safely secured against falling over (if
necessary fix the baseplates securely to the floor).
Installation instructions INSTALLATION
Assembly and connection
Caution! Before welding on the module or equipment in contact with the
module, disconnect the detachable screw terminals for inputs and
outputs on the control equipment in the control panel (if applicable).
Always connect the welding earth as close to the welding point as
possible.
Proceed as follows:
a) Mount and connect all pipes to/from the module(s)
Note! Make sure that all plastic protection caps (if any) at the PHE (if
applicable)
and pipe connections are removed.
b) If necessary, extend pipes for condensate and drainage (as
applicable)
c) Mount and connect probes/instruments
d) Connect electricity (see tag Control Panel Documents)
e) Drain all pipes
Check after installation
To ensure a good quality of the installation the following checks are
to be made.
On the module
all pipe unions are tightly connected
External utility
all pipes to and from the module are connected
all pipe unions are tightly connected
the manual shut-off valves (if any) are working correctly
Drain
drain pipes are connected to drain
Electricity
all electrical cables are connected
Instruments and probes
all instruments and probes are mounted and legible
INSTALLATION
When to start commissioning
Check list to be considered before commencing commissioning
Notes
Preparatory work
Floor preparations completed (if applicable) ____________________________
Foundations completed (if applicable) ___________________________
Ventilation work completed (if applicable) ___________________________
Insulation work completed (if applicable) ___________________________
Doorways and passages checked ___________________________
Service media
Water connected and available (if applicable) ____________________________
Steam connected and available (if applicable) ___________________________
Condensate outlet connected (if applicable) ___________________________
Coolant connected and available (if applicable) ___________________________
Electricity connected and available ___________________________
Compressed air connected and available ___________________________
CIP connected (if applicable) ___________________________
Floor drains
Drain work completed ____________________________
Installation
All equipment positioned and connected ____________________________
Checks described in Check after installation completed
___________________________
Upstream/downstream equipment connected ___________________________
New interfacing plant(s)/module(s) (filling machine etc.)
commissioned/ready to be commissioned at the same
time ___________________________
Communication signals with upstream/
downstream equipment settled (if applicable) ___________________________
All new piping thoroughly flushed to drain ___________________________
When to start commissioning INSTALLATION
When to start commissioning INSTALLATION

Notes
Product
Product is available ____________________________
Personnel
Operator is available ____________________________
Welder and erector are available with short notice ___________________________
TIG welder is available with short notice ___________________________
Electrician is available with short notice ___________________________
04. Commissioning
Commissioning
CONTENTS PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . 1
INITIAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
UTILITY AND FUNCTION CHECKS . . . . . . . . . . . . 5
Preparations . . . . . . . . . 5
Test of heating, Test of cooling . . . . . . . . . . . . . . . . . . . . . . 7
Test of deaeration . . . . . . . . 8
Test of carbonation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Test of alarm and safety functions . . . . . . . . . . . . 11
Doc. No. CO-ALDOX 2010-02-EN1
COMMISSIONING
Introduction
The ALDOX is to be commissioned before it is put in commercial
operation.
Adhere strictly to the steps described below.
Requirements on commissioning personnel:
Skilled process engineer with adequate experience from commissioning
of industrial processes
Knowledge in process controllers
Proven skill in reading flow charts
Knowledge in local safety regulations
property.
Introduction
Introduction COMMISSIONING
COMMISSIONING
Initial checks
Make the following checks:
External utility
connections are in accordance with the requirements set out in
tags Technical Data, and Drawing(s)
Pump(s) and pipes
connections are tightened
Tank(s) (if applicable)
the tank does/do not contain any foreign matter
CAUTION! Risk of jets of service media
There is a risk of leakage from all equipment when pressurised.
Watch out for all kinds of leakage. Stop the testing as soon as
leakage is detected. Close all service media shut-off valves before
rectifying the leakage.
Control cabinet
all switches, overload protections, and automatic fuses are in
OFF position
motor connections, overload protections, fuses, rated currents,
and voltages are correct
no foreign matter is present in the cabinet
Initial checks
Initial checks COMMISSIONING

Utility and function checks COMMISSIONING
Utility and function checks
Preparations
Proceed as follows:
a) Check that all electrical connections are according to the Control
Panel Documents
b) Flush the air supply pipe as follows:
- disconnect the air hose
- slowly open the manual shut-off valve to blow out possible
foreign matter
- blow until the air is clean
- close the manual shut-off valve and reconnect the hose
- again open the manual shut-off valve for compressed air
- check on the pressure gauge that the pressure is 600 kPa (6
bar)
- check for leakage
d) Check that the detachable screw terminals for control input and
output signals are connected in the control panel
e) Check that the main voltage is correct, measure all 3 phases
f) Switch on the mains supply on the panel, all switches, motor
protections, and automatic fuses
g) Check that all valves are working properly by activating the solenoid
valves manually
h) Check direction of rotation on the motor(s) (if applicable) in the
following way:
- Remove the hood from the motor
- Note the correct direction of rotation (marked with an arrow)
- Make a quick start-stop of the motor
- Check that the direction of rotation is correct, if not - call an
electrician
- When the direction of rotation is correct, mount the hood
i) Flush the gas supply pipe(s) as follows:
- disconnect the pipe(s) at the inlet
- slowly open the manual shut-off valve to blow out possible
foreign matter
- blow until the gas is clean
- close the manual shut-off valve and reconnect the pipe
- again open the manual shut-off valve for gas
- check on the pressure gauge that the pressure is correct (see
tag Technical Data)
- check for leakages
CAUTION! This module uses carbon dioxide (CO2). This gas displaces
air
and thus obstruct oxygen from entering the respiratory organs.
High concentration creates lethal danger. Follow the instructions
given by the supplier.

j) Flush the water supply pipe as follows:
- disconnect the pipe at the inlet
- open the inlet valve (if applicable)
- slowly open the water supply
- flush until clean
- close product supply
- reconnect the pipe
k) Flush the steam supply pipe as follows (if applicable):
- disconnect the pipe before the steam regulating valve
- aim the pipe in a safe direction
- slowly open the steam supply
- flush until clean
- close the steam supply
- when the pipe has cooled down, reconnect
l) Flush the cooling medium supply pipe as follows (if applicable):
- disconnect the pipe before the cooling medium regulating
valve
- prepare to collect and properly dispose off the waste cooling
medium
- slowly open the cooling medium supply
- flush until clean
- close the cooling medium supply
- reconnect the pipe
m) Test for leakages as follows:
- open manual water shut off valve (let all other service media
shut off valves remain closed)
- activate drain valve via the solenoid valve. This is done to flush
through the module to get rid of all solids that may have entered
during installation
- start CIP (see tag Operation Manual)
- check that the water flow increases to preset value. The flow
is indicated on the control panel
- check for leaks
- if any leaks are found, stop CIP (see tag Operation Manual),
relieve the pressure, and repair the leak (a common reason for
leaks in unions are missing seal rings)
- repeat the test as described above until no leaks are found
- let flush continue for 10 minutes
- stop CIP (see tag Operation Manual)
- deactivate the drain valve from the solenoid valve.
Test of heating (if applicable)
a) Start CIRCULATION (see tag Operation Manual).
b) Check that the water flow increases to preset value. The flow is
indicated on the control panel.
c) Slowly open the steam supply.
d) Check that the temperature after the plate heat exchanger
increases
to preset value (see tag Parameter List). The temperature
is indicated on thermometer and on the control panel.
e) Let circulation continue for approximately 10 minutes.
f) Check periodically that the heating temperature remains constant
and that the control valve does not fluctuate. If it does, see tag
Maintenance, trouble shooting chart.
Test of cooling (if applicable)
c) Slowly open the cooling medium supply.
d) Check that the temperature decreases to preset value (see tag
Parameter List). The temperature is indicated on thermometer
and on the control panel.
e) Let circulation continue for approximately 10 minutes.
f) Check periodically that the cooling temperature remains constant
and that the control valve does not fluctuate. If it does, see tag
Maintenance, trouble shooting chart.
Test of deaeration
Before this test can be done it is necessary to degrease the module
properly to get rid of protecting oil, debris and deposits. Perform a
complete CIP (see tag Operation Manual).
c) Slowly open the gas supply to the column.
d) Check on the flow indicator that the gas flow is normal (see tag
Technical Data).
To set the gas flow:
- The desired gas flow is found by reducing the gas flow stepwise
until the DO (dissolved oxygen) content in the outgoing water
exceeds the guaranteed value. This is the minimum ratio gas/
water. Normal gas flow should be set slightly above this value to
ensure correct amount of DO content in the outgoing water.
- The needed flow of gas to the column is proportional to the water
flow.
e) Let recirculation continue for 10 minutes.
f) Connect an DO analyzer to the sampling valve. The DO content
is to be close to zero as the same water is circulated through the
module. If the measured DO content is too high, see tag Maintenance,
trouble shooting chart.
g) Start PRODUCTION (see tag Operation Manual). Make sure
that there is no risk to overfill the receiving buffer tank.
h) Continue production for approximately 15 minutes. Check on the
DO analyzer two times per minute. If the measured DO content
is too high, see tag Maintenance, trouble shooting chart.
Note ! Do not supply CO2 to the carbonation point (if applicable) during
these measurements as traces of O2 in the CO2 gas will affect the
measurements (the measured value will be too high). The needed
gas flow to the column is also depending on the temperature according
to the graph below.
This means that if the temperature of the water to the column is
varying, minor adjustments of the gas flow are required to get optimum
running condition.
The flow of CO2 to the column is normally set to solubility plus 5%.
If the CO2 flow is too low, the deaeration effect is low and water
leaving the column will contain too much oxygen. If on the other
hand the CO2 flow is too high this will not improve the deaeration
and the excess gas is lost as it is vented to atmosphere.
Test of carbonation (if applicable)
a) Start PRODUCTION (see tag Operation Manual). Make sure
b) The flow is indicated on the control panel.
c) Connect a carbon dioxide analyzer to a sampling valve as close
to the buffer tank as possible (where all CO2 is dissolved completely).
d) Slowly open CO2 supply for the carbonation.
e) Check on the flow indicator that the gas flow is normal (see tag
Technical Data).
f) Continue production for 1 minute.
g) If necessary adjust the flow of CO2 for the carbonation, after
measuring the CO2 content in the outgoing water. Note that the
CO2 flowmeters measure on volume. The mass rate of CO2 (kg/h)
depends on the pressure at the injection point. This pressure
should therefore be kept constant. If the measured content is
incorrect, see tag Maintenance, trouble shooting chart.
Note ! As the water after the column is precarbonated to the solubility value
for the present temperature, the additional carbonation is done from
this value up to the requested final CO2 value. If the deaeration temperature,
and consequently the precarbonation level, is changed,
this means that the final CO2 addition might need a correction.
Test of alarm and safety functions
Low level in balance tank (if applicable)
there is no risk overfilling the receiving buffer tank.
b) Slowly close the water supply.
c) Check that an alarm is activated when the water level in the
balance
tank is below the level switch.
High level in column (ALDOX with balance tank)
a) Remove the relay for P21 from its socket to prevent pump P21
from starting.
b) Start PRODUCTION (see tag Operation Manual). Make sure
c) Check in column sight glass that the water level is increasing and
that an alarm is activated when the water level is approximately
10 cm above the sight glass top.
High level in column (ALDOX without balance tank)
a) Open the inlet valve manually from the solenoid valve.
b) Open the flow regulating valve manually from the flow controller
picture (see tag Operation Manual).
c) Check in column sight glass that the water level is increasing and
that an input is activated when the water level is approximately
10 cm above the sight glass top.
Low gas flow to column
b) Slowly close the gas supply.
c) Check on the flow indicator that an alarm is activated when the
flow is approximately 5-10% lower than normal. Adjust the switch
position if necessary.
Low CO2 flow to carbonation (if applicable)
b) Slowly close the CO2 supply.
c) Check on the flow indicator that an alarm is activated when the
flow is approximately 5-10% lower than normal. Adjust the switch
position if necessary.
High and mid level in buffer tank
b) Check that the ALDOX switches to circulation when the high
level signal is achieved.
c) Empty the tank until below mid level switch, and check that the
mid level signal goes out.
Low heating temperature (if applicable)
b) Slowly close the steam supply.
c) Check that an alarm is activated when the temperature is
approximately
2C below the preset value (see tag Parameter List).
High outlet temperature
b) Slowly close the cooling medium supply.
c) Check that an alarm is activated when the temperature is
approximately
2C above the preset value (see tag Parameter List).
05. Operation Manual
Operation manual
CONTENTS PAGE
GENERAL INFORMATION 1
SAFETY INSTRUCTIONS 5
Use of hazard informations . 5
Use of signs 6
Cleaning solution, Stripping gas 7
GENERAL DESCRIPTION . 9
Denominations (example of design) 11
PROCESS DESCRIPTION . 15
Working principle . 15
ALDOX description 16
CONTROL PANEL . 17
Denominations 17
Operator panel 18
Main picture, Operation picture . 21
Service picture, Date & time picture 22
Controller picture . 23
Supervision of fault 24
Fault list . 25
Cont.
Doc. No. OM-ALDOX-SP 2012-02-EN4
Operation manual
CONTENTS PAGE
GENERAL INFORMATION 1
SAFETY INSTRUCTIONS 5
Use of hazard informations . 5
Use of signs 6
Cleaning solution, Stripping gas 7
GENERAL DESCRIPTION . 9
Denominations (example of design) 11
PROCESS DESCRIPTION . 15
Working principle . 15
ALDOX description 16
CONTROL PANEL . 17
Denominations 17
Operator panel 18
Main picture, Operation picture . 21
Service picture, Date & time picture 22
Controller picture . 23
Supervision of fault 24
Fault list . 25
Cont.
Doc. No. OM-ALDOX-SP 2012-02-EN4
Operation manual
CONTENTS PAGE
Cont.
OPERATION . 27
Preparations 27
Sterilization 28
Circulation . 29
Production . 30
Stabilization/Shut down . 32
Carbonation . 33
Emergency stop, Start after emergency stop 34
CLEANING . 35
SETTINGS 37
Inspection/change of register value(s) 37
Changing the controller setpoints 39
General information OPERATION MANUAL
General information
To ensure maximum safety, always read the Safety instructions
and relevant instructions before carrying out any work
or inspection on the equipment.
Service
In case of problems when operating the module, contact the nearest
Alfa Laval company.
Manufacturer
Maskinvej 5
DENMARK
Name plate
The plate below is an example of the attached plate. The plate contains
the data needed when contacting Alfa Laval Copenhagen A/S
concerning this particular module.
Product documentation
The documentation for this module consists of a TECHNICAL
DOCUMENTATION in one or more binders as outlined in the table
of contents.
This OPERATION MANUAL is enclosed as a part of the TECHNICAL
DOCUMENTATION. The OPERATION MANUAL is intended
to be placed at the operator panel in order to at all times provide
the operator with guidance and information on how to operate the
module. As a consequence of this, certain parts of the different
sections are repeated.
It is important to:
Keep the manuals available and updated for the life of the module
Pass the manuals on to any subsequent holder or user of the
module
Abbreviations
Abbreviations as follows may be used in this documentation.
CIP Cleaning In Place
Cl2 chlorine
CO2 carbon dioxide
Cu copper
DO Dissolved Oxygen
Fe iron
HE Heat Exchanger
HNO3 nitric acid
I/O In/Output module
K potassium
KMnO4 potassium permanganate
Na natrium, sodium
N2 nitrogen
NaOH sodium hydroxide (caustic soda)
NO2 nitrogen dioxide, nitric dioxide
O2 oxygen
pH determination of acid/base concentration
PBT Pasteurized Beer Tank
PHE Plate Heat Exchanger
PLC Programmable Logic Controller
PU Pasteurizing Unit
Design modifications
The directives in this documentation are in accordance with the
design and construction of the module at the time it was released
by the Alfa Laval production facility.
Document producer
Maskinvej 5
DENMARK
Further copies
Can be ordered from nearest Alfa Laval company. When ordering,
always state the module type and Serial No. as stated on the name
plate.
Copyright 2012
All rights reserved. No part of this documentation may be reproduced
or copied in any form or by any means without the written consent
of Alfa Laval Copenhagen A/S.
Safety instructions OPERATION MANUAL
Safety instructions
To ensure maximum safety always read this section carefully
before carrying out any work or inspection on the equipment.
If the safety instructions are not followed, there is a risk of personal
injury.
Hazard informations in this documentation have the following significance:
Failure to observe this information results in immediate danger
to life.
Failure to observe this information may result in major personal
injury or loss of life.
Caution! Failure to observe this information may result in minor
personal
injury or damage to the equipment.
Note! Information requiring special emphasis.
Safety instructions
An electric shock can injure or kill. Treat all
electrical equipment as powered. Switch off
power before maintenance or repair.
Electrical equipment
Hot surface Temperatures exceeding 60C may occur.
Do not touch without proper protection.
High noise levels Noise levels exceeding 85dBA may occur.
Use hearing protection.
Caustic agent Substances that may be harmful to body
tissues. Do not touch without proper protection.
Use of signs
Warning signs are used as below.
OPERATION MANUAL
Safety instructions
Cleaning solution
Handling of cleaning solution
Cleaning solution normally contains caustic soda (NaOH) or nitric
acid (HNO3). These chemicals may cause burning of body tissues.
Follow the instructions given by the supplier.
Whenever there is a risk of exposure to these chemicals, always
wear:
Safety glasses
Protection gloves
Shoes and apron made of PVC/PE plastic, or rubber
In case of an accident involving cleaning solution, the basic rule is
to, as soon as possible, rinse the affected area with large amounts
of water.
Due to this, always make sure that the emergency and eye showers,
and also additional washing facilities are ready for use.
Emergency measures
If swallowed
immediately drink large amounts of lukewarm water (to dilute what
has been swallowed), then seek medical attention
If contact with eyes
immediately rinse the eyes thoroughly with lukewarm water at
least 15 minutes (keep eyelids widely apart), then seek medical
attention
If contact with skin or clothes
immediately remove contaminated clothing
immediately rinse with large amounts of water. If skin burns appear,
seek medical attention
thoroughly wash the clothing before worn again
If inhaled
leave the affected area to get fresh air. If any symptoms remain,
seek medical attention
Note! Reaction may occur several hours after inhalation.
Stripping gas
CAUTION! This module uses carbon dioxide (CO2) or, if applicable,
nitrogen
(N2). These gases displace air and thus obstruct oxygen from
entering the respiratory organs. High concentration creates
lethal danger. Follow the instructions given by the supplier.
OPERATION MANUAL
Safety instructions OPERATION MANUAL
General description OPERATION MANUAL
General description
Application
ALDOX is a preassembled skid mounted module designed to
continuously deoxygenate and slightly carbonate water. In the beverage
industry it is employed for the production of oxygen-free water
which is used for the production of soft drinks, purge water and in
high gravity brewing.
Operator:
Trained in food/brewery processing and process controllers.
property.
Operator station
In front of the control panel.
Risk area
One meter around the equipment due to jets/splashes of harmful
liquid
Risk area:
One meter around the equipment.
3
7
1
Principle layout
1. Stripping column
2. Control panel
3. Control/regulating valve(s)
4. Flow meter(s)
5. Pump(s)
6. Frequency converter
7. Plate Heat Exchanger
3
1
2
4
5
6
3
4
2
Denominations (example of design)
Control panel
The control panel contains all equipment necessary for indication
of process status, supervision of process performance, and control
of automatic functions.
The ALDOX automation is based on a PLC.
The controller features:
- Process sequence control
- Timers
- Control loops
- Graphic display
- Alarm handling
Heat exchanger
The water is heated and cooled in the heat exchanger, which has
been specially designed for food applications. For the working pressure,
see tags Technical Data and Heat Exchanger. The plates in
the heat exchanger are designed for maximum heat transfer and
minimum pressure drop.
General description
Controlling/regulating valve
Sanitary electro-pneumatic modulating valve(s) controls/regulates
the flow(s).
Flow meter
The flow is measured with electromagnetic flow meter. These instruments
measure accurately, are wear free and corrosion resistant,
cause no additional pressure drop, and have no moving parts or
parts which intrude into the meter tube.
Centrifugal pump
The pump(s) is/are highly efficient and economical, meeting the
requirements of sanitary and gentle product treatment. Designed
for CIP with emphasis on large internal roundings and cleanable
seals.
OPERATION MANUAL
Stripping column
Deaeration is achieved by stripping with carbon dioxide or nitrogen
gas in a specially designed column. The design allows for both a
very low oxygen content in outgoing water and a low gas consumption.
Required gas flow to the column is only slightly above the gas
solubility.
Process description
Process description
Working principle
The water is routed via the liquid distributor in the top of the column
and travels downward counter currently with CO2. The internal material
ensures a large effective contact area between water and gas.
This means both highly efficient oxygen removal and very low gas
rates. The majority of the CO2 added to the column is dissolved in
the water. The virtually oxygen-free pre carbonated water is collected
at the bottom of the column.
The operation is fully automatic and fail-safe. In case of an operating
failure, such as loss of stripping gas or water, the module will go into
circulation until the working conditions are normal again.
The control panel, equipped with a PLC, controls the module operation.
It is operated locally via buttons on the panel. The control
panel is prepared for remote control of the module.
OPERATION MANUAL
Process description
ALDOX description
Production
The water enters the ALDOX via the inlet regulating valve and after
passing the plate heat exchanger, where it is heated, first regeneratively
and then finally by steam, enters the top of the column where
it is distributed over the internal material. In the column the water is
deaerated in counter flow by CO2 or N2 (the column incorporates a
level control). The deaerated water is pumped to the PHE where it
is cooled, first regeneratively and then finally by a cooling medium.
Carbonation can be done by injection of CO2 (optional). The water
then flows to a buffer tank via the outlet valve.
Recirculation
This mode of operation is used during start up and when there is a
minor fault in the process.
Water flow as for production with the exception that water is routed
back to the inlet.
Cleaning
The ALDOX controls the cleaning sequence. Cleaning is made by
an external cleaning station supplying the cleaning solutions. The
cleaning is then started from the control panel.
A cleaning sequence should consist of at least the three steps below.
- Circulation with hot cleaning solution
- Draining of the module
- Rinsing with water
Recommended cleaning intervals (depending on water quality):
- Lye cleaning once or twice a week.
- Acid cleaning once a month to avoid deposits on the stainless
steel surfaces.
OPERATION MANUAL
Control panel
Control panel
Denominations
The front of the control panel is equipped with the following equipment:
1. Mains switch (control panel and motors)
2. Indication lamps
Fault indication (yellow)
- Flashing light indicates unacknowledged alarm
- Steady light indicates acknowledged alarm.
Information (white)
- Indicates operator action
Operation indication (green)
- Indicates that a function is selected
3. Operator panel
OPERATION MANUAL
1
2
3
Control panel
Operator panel
The main parts of the pictures are as below.
Note! The following pictures are examples and may vary depending on
the design.
Display
1. Indication of the ALDOX steps
2. Accumulated volume in production, press to reset
3. ALDOX step number
4. Date and time
5. Present process values, when pressed, the controller is displayed
(if applicable). If the controller is in manual mode the
value is flashing
6. Indication of the oxygen content
When a function is activated its symbol changes to green.
Push-buttons
A. Displays the OPERATION picture
B. Displays the TREND picture
C. Displays the ALARM picture
D. Displays the SERVICE picture
E. Displays the item numbers (automatically disappearing after 10
seconds)
By pressing, for example, FC11 (Flow controller) the controller picture
is displayed.
OPERATION MANUAL
ABCD1
2
4E3
5
6
Control panel
Push-buttons
When a function is selectable, it appears as a push-button. If the
function has been selected the background is green.
Selectable Selected
Step symbols
Different color codes on the symbols indicate different status.
When a sequence is selected but not yet started the symbol background
is white.
When the sequence is started but yet not active the background
color is splitted diagonally, with the lower part green.
When the sequence is activated the background color changes to

green.
Control panel
All steps are indicated with different symbols as below.
Sterilization CIP drain
Production CIP Forward
Circulation CIP Circulation
Stop/Stabilization Production preselected
Parameters
Parameters can be changed by pressing the desired parameter,
which displays a numeric key pad. If a password/username has to
be entered (if applicable) this has to be entered first.
Password/username
There are three password/username levels.
Preset Preset
password username
Level 1 Maintenance 1234 M
Level 2 Supervisor/Management 9999 S
Level 3 Alfa Laval Service - -
OPERATION MANUAL
21(39)
www.alfalaval.com
Operation picture
The functions inside the frame have to be
confirmed, with either 1 to start or 0 to
stop, within 10 seconds from pushing.
1. CIP forward
2. CIP drain
3. Stop/Stabilization
4. Carbonation (if applicable)
5. Sterilization
6. Production
7. Circulation
8. CIP Heating
9. CIP circulation
10. Return to MAIN picture
Main picture
When a function is activated its symbol
changes to green.
1. Displays the flow controller
2. Displays the cooling temperature controller
3. Indication of the oxygen content (if applicable)
4. Displays the OPERATION picture
5. Displays the TREND picture
6. Displays the ALARM picture
7. Displays the SERVICE picture
8. Indication of the ALDOX steps
9. Indication of time in ALDOX step
10. Displays the column level controller
11. Displays the heating temperature controller
12. Indication of accumulated volume in
production, press to reset
Control panel OPERATION MANUAL
Service picture
1. Saving of changes
2. Register number, counting up or down
3. Selection of register number
4. Indication of present register value
5. Displays the CONTROL PANEL picture
6. Displays the PASSWORD picture
7. Displays the DATE & TIME picture
8. Lamptest
9. Selection of Local/Remote operation
Date & time picture

1. To select a new time
2. To select a new date
3. Synchronize date/time between Touch
Panel and PLC
4. Display of days since last CIP
5. Display of days since last Sterilization
6. Return to SERVICE picture

2
1
5 6 7 8 9 10
43
1
3456
2
Control panel
Controller picture
1. Selection of the output signal, if in
manual mode
2. Sets the controller in manual mode
3. Selection of the I-time
4. Selection of the gain
5. Bar graph and numeric display of the
output signal
setpoint
input signal (measured value)
8. Displays the controller parameter picture
9. Displays the controllers TREND picture
OPERATION MANUAL
2
1
8 9 10
76543
Supervision of fault
When a fault occurs, the signal lamp FAULT starts to flash and a
fault window appears in the display.
When button ACKNOWLEDGE is pressed the FAULT lamp goes
steady or is extinguished when the fault has disappeared.
By pressing the ALARM button the alarm list is displayed showing
the last occurred faults. Each fault can be displayed three times
with different codes.
A. Active alarms
C. Cleared alarms
K. Acknowledged alarms
Caution! Fault indication
Always investigate the cause of a fault indication, or damage to the
equipment may occur.
Control panel
Fault list
Supervised faults can be found in the Function Description.
A list with preset values for timers etc., used to supervise the process
is found in the Parameter List.
Note! Some of the listed faults belong to optional equipment and might
not be applicable.
General causes of faults:
No air supply to valves
Solenoid valves not working
Output signal on I/O unit not working
I/O unit not working
Only authorized personnel are allowed to adjust or renew/repair
equipment.
Note! For further details, see the tag Maintenance, Trouble shooting
chart.
OPERATION MANUAL
Operation
Operation
Preparations
1) Check that required utilities are available.
- Service media, open manual shut-off
valves (as applicable)
- Gas pressure, open manual shut-off
valve (if applicable)
- Electricity, switch on main supply
2) Check/adjust the air pressure according
to Technical Data.
3) Check/adjust the gas pressure according
to Technical Data.
4) Perform lamp test.
- On the MAIN picture press the SERVICE
button.
Note! Perform a lamp test at least once a day.
5) On the SERVICE picture, press the
LAMP TEST button to perform the lamp
test.
OPERATION MANUAL
Note! The following pictures are examples,
some variations may occur.
Operation
Sterilization
Caution! Do not proceed if personnel are present
in the risk area
If the OPERATION picture isnt displayed:
1) Press the OPERATION button on the
MAIN picture.
2) Start the sterilization by pressing the
STERILIZATION button followed by the
START button.
3) The ALDOX is now being filled with
water and starts heating the water. See
Function Description for explanation
of the STERILIZATION operation.
4) When step 108 is reached the sterilization
is completed.
2.
1.
OPERATION MANUAL
Operation
Circulation
in the risk area
MAIN picture.
2) Start the circulation by pressing the
CIRCULATION button followed by the
START button.
3) The ALDOX is now being filled with
water. See Function Description for
explanation of the CIRCULATION operation.
4) The water is now circulated in the module.
1.
2.
OPERATION MANUAL
2) Start the production by pressing the
PRODUCTION button followed by the
START button.
3) The ALDOX is now in production. See
Function Description for explanation of
the PRODUCTION operation.
4) Automatic changeover from circulation
to production takes place if PRODUCTION
button has been pressed earlier.
When the module is in circulation mode,
preselection is shown by the PRODUCTION
PRESELECTED symbol.
5) Changeover from circulation to production
is made only when gas flow
to column has been maintained for a
certain time. During this preset time it is
assumed that the DO level in the water
has adjusted to the specified level.
Operation
Production
in the risk area
Before starting check that:
- the setpoints are correct
- the gas flow to the column (see Technical
Data)
- receiving tank(s) is/are ready
MAIN picture.
OPERATION MANUAL
1.
2.
Operation
6) Production will continue until pressing
CIRCULATION or STABILIZATION button
followed by the STOP button, or if
a fault occurs.
OPERATION MANUAL
2.
1.
1.
2) Start the stabilization by pressing the
STABILIZATION button followed by the
START button.
3) The heating and cooling media are
shut off and the water in the module is
circulated for a certain time to balance
out levels in the column and to equalize
temperatures.
4) Pump(s) stop(s) and valves return to
deactivated position.
5) Close all manual shut off valves (if applicable).
Stabilization/Shut down
MAIN picture.
Operation
1.
2.
OPERATION MANUAL
Operation
Carbonation (if applicable)
MAIN picture.
2) Start the carbonation by pressing the
CARBONATION button.
3) Carbonation will continue until the CARBONATION
button is pressed again.
OPERATION MANUAL
Operation
Emergency stop
In case of emergency, shut off the mains power supply with the
switch located on the control panel.
This stops the ALDOX in the following way:
- pump(s) stop(s), power supply interrupted
- valves take safe positions to avoid leakage
- stop messages to upstream/downstream equipment
The equipment may contain hot caustic liquid. Handle with utmost
care to avoid exposure.
Start after emergency stop
1) Make sure the cause of the emergency is eliminated.
2) Switch on mains power supply.
OPERATION MANUAL
Cleaning
Chemical hazard
Cleaning solutions contain caustic soda
(NaOH) or nitric acid (HNO3). These chemicals
may cause severe burnings. Use protective
clothing as outlined in the SAFETY
INSTRUCTIONS.
Before starting check that:
- The ALDOX is in OFF
- The water and steam shut-off valves
(if applicable) are open
- The shut-off valve on the cooling
medium outlet side on the heat exchanger
(if applicable) is open (to
allow for heat expansion)
- The upstream/downstream equipment
is connected for CIP
MAIN picture.
Cleaning
2) Start cleaning by pressing the CIP FORWARD
button followed by the START
button.
3) The module is now ready for CIP circulation
over the CIP station.
4) Start the CIP station. The circulation
intervals are controlled from the CIP
station. Flip sequences for the valves
are initiated when the signal CIP FLIP
is received from the CIP station (if applicable).
2.
1.
OPERATION MANUAL
7) After circulation with detergent the
module should be rinsed with water to
drain. Water rinse should continue until
the rinse water is free from traces of
detergent.
8) When the external CIP station has finished,
press the CIP FORWARD button
followed by the STOP button. Then the
ALDOX goes to OFF.
9) Close all manual shut-off valves.
Cleaning
5) If flip signalling isn't available, cleaning
of the circulation loop on the ALDOX
can be done manually. Start circulation
by pressing the CIP CIRCULATION button
followed by the START button.
6) Let circulation continue for 1 minute
before returning to forward flow.
2.
1.
1.
2.
OPERATION MANUAL
Settings
Settings
Alarm limits, timers etc. are stored in registers
in the control system. Before changing
these settings, a password/username has
to be entered. For a complete listing of the
registers, see tag Parameter List.
Caution! A change of setting(s) change(s) the way
the ALDOX works. (If no new value
is entered, the old value remains unchanged).
Inspection/change of register
value(s)
If the SERVICE picture isnt displayed:

1) Press the SERVICE button on the MAIN
picture.
2) Press the REGISTER button.
3) If no valid password/username has been
entered, key in the correct password/
username followed by ENTER.
4) Key in the register number to be inspected/
changed. The number can be
between 100 and 320. After entering the
number press ENTER.
OPERATION MANUAL
Settings
5) If the register is to be changed, press the
VALUE button, enter the desired value,
and press ENTER.
6) To save the new value press the SAVE
button.
OPERATION MANUAL
Settings
Changing the controller setpoints
To change the controller setpoint, for example
on the LC21 (Column level controller).
1) Press the LC21 button on the MAIN
picture.
3) Press the button for the setpoint to be
changed.
4) If no valid password/username has been
entered, key in the correct password/
username followed by ENTER.
5) Enter a new value followed by ENTER.
A) Setpoint during production.
B) Setpoint during CIP.
C) Fixed setpoint/output used in some of
the steps.
2) Press the CONTROLLER SETPOINTS
button.
OPERATION MANUAL
ABC
06. Maintenance
Maintenance
CONTENTS PAGE
INTRODUCTION . 1
Requirements on personnel . . . . . . . . . 1
PREVENTIVE MAINTENANCE 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools and repair guide, Spare parts . . . . . . . . . . . . . 6
Doc. No. MA-ALDOX 2010-02-EN2
MAINTENANCE
Introduction
Information presented in:
Preventive maintenance
Lubrication
Trouble shooting chart
are mainly collected from Component Instructions, where you can
find more information regarding these topics for components.
Mechanic
Skilled mechanic with at least 3 years experience of industrial maintenance.
Proven skill in reading engineering drawings.
Electrician
Certified according to local regulations with at least 3 years experience
of similar installations. Proven skills in reading and working
from drawings and cable lists. Knowledge of local safety regulations
for power and automation. Furthermore, the electrician must ensure
that the electrical installation, including the equipment or device
that work has been carried out on, has been adequately checked
regarding the safety of personnel and property before it is put into
operation.
property.
Introduction
Introduction MAINTENANCE
Preventive maintenance MAINTENANCE
Preventive maintenance
General
Preventive maintenance primarily consists of visual inspection of
the equipment followed by necessary adjustments.
Following inspection and maintenance intervals are recommended:
Intervals
Equipment Daily Weekly Monthly Yearly
Air regulator(s) x
Automatic valve(s) w. Actuator x
Control valve(s) w. positioner/actuator x
Gaskets x
Manual valve(s) x
Non return valve(s) x
Pipes x
Probe(s) and instrument(s) x
Pump(s) x
Regulating valve(s) x
Unions x
Gaskets
Exchange at least once a year or as soon as a leakage is suspected.
Pipes
Check for leakage. Exchange if necessary.
Unions
Check for leakage. Tighten regularly.
Troubleshooting chart
The following chart gives an outline of the most frequently occurring
faults, their causes and ways of eliminating them. A complete listing
with preset values for timers etc. are found in the tag Parameter
List.
Effect Possible cause Elimination
1. High oxygen level in outgoing
water
1. Air leakage in union after column
at pump or PHE
Tighten union
2. Analyzer malfunction Check/calibrate analyzer
3. Gas flow to column too low for
set water flow
Check/increase gas flow
4. Waterflow to column too high Check/reduce water flow
5. Deaeration temperature too low Check/raise temperature
6. Too much O2 added in carbonation
(low gas quality)
Measure oxygen level without
carbonation
7. Stripping gas quality too low Check quality of gas
8. Water level in column too high
or too low
Check level in column (normally
about 10-20 mm below
sightglass). If too high or too low,
check level control system.
9. Cl2 or other chemical disturbing
the O2 analyzer
Check water quality
2. High level in column 1. High pressure in receiving tank Reduce tank pressure
2. High pressure drop in pipes
between module and buffertank
Check for restriction in pipework
3. Freezing in plate heat exchanger
due to too cold coolant
Raise coolant temperature
4. Freezing in plate heat exchanger
due to instable coolant
temperature
Stabilize coolant temperature
5. High level switch not working Check/replace switch
6. Level control not working Check level control system
7. Pump P21 not running Check relay/freq. converter
8. Too high flowrate Adjust flowrate
3. Low level in balance tank (if
applicable)
1. Water supply not enough Check/increase water pressure
2. Balance tank float not working Check float
3. Low level switch not working Check/replace switch
Effect Possible cause Elimination
4. Low heating temperature (if
applicable)
1. Steam pressure too low Check/increase steam pressure
2. Condensate pipe blocked Check/clean condensate pipe
3. Pt100 sensor not working Check/replace Pt100 sensor
4. Temperature transmitter not
working
Check/replace temperature transmitter
5. Steam control valve not working
Check/repair steam control valve
6. Too much condensate in the
steam
Check/repair the steam trap before
regulating valve
7. To high flowrate Adjust flowrate
5. High outlet temperature 1. Coolant temperature too high Check/lower coolant
temperature
2. Coolant flow too low Check/increase coolant flow
3. Pt100 sensor not working Check/replace Pt100 sensor
4. Temperature transmitter not
working
Check/replace temperature transmitter
5. Coolant control valve not working
Check/repair coolant control valve
6. Coolant quality/ concentrationnot
according to specification
Adjust/exchange coolant
6. Unstable heating temperature
(if applicable)
1. Unstable heating medium Check/adjust heating media
2. Air supply to valve too low Check/adjust air supply
3. Controller settings are wrong Adjust controller settings
4. Unstable water flow Adjust controller settings
7. Unstable outlet temperature 1. Unstable cooling media Check/adjust cooling media
2. Air supply to valve too low Check/adjust air supply
3. Controller settings are wrong Adjust controller settings
4. Unstable water flow Adjust controller settings
8. Incorrect carbonation (if applicable)
1. Water flow too low Check/adjust water flow
2. Water temperature too high Check/adjust temperature
3. CO2 gas flow too low/high Check/adjust gas flow
4. CO2 is measured at a position
where all gas is not dissolved
Measure at a suitable place
Tools and repair guide
Necessary repairs are described in the Component Descriptions.
Spare parts
To help you maintain your equipment in good running order, Alfa
Laval can supply spare part kits designed to suit your needs.
For enquires or orders contact your nearest Alfa Laval representative
or Alfa Laval Copenhagen A/S, Sborg/Copenhagen, DENMARK.
For detailed specification of components and spare parts, see the
Recommended Spare Parts/Component Descriptions.
07. Decommissioning
DECOMMISSIONING
DECOMMISSIONING
Electrician
Certified according to local regulations and experience of similar
decommissioning. Knowledge of local safety regulations for power
and automation.
De-erector
Experience from similar work. Proven knowledge in local and international
safety regulations concerning decommissioning, dismantling,
and disposal.
To ensure maximum safety, read the Safety Instructions before
carrying out any work on the unit.
Dismantling
For efficient dismantling use:
installation drawing(s)
component descriptions
flow diagram
CAUTION! Pipes may contain corrosive/caustic media and/or
equipment
may fall down.
Doc. No. DC 2010-03-EN1
08. Flow Chart

P&ID
Symbol Legend
09. Technical Data
Technical Data ALDOX

Doc No: CA0277-103 1(2)
Manufacturer Alfa Laval Copenhagen A/S
Maskinvej 5
Denmark
Module type ALDOX
Flow diagram 9680024799
Order No. CA0277
Customer SAB Miller - CDM, Maputo, Mozambique
Application
The module is designed and tested for the following applications:
- Automatic deaeration and pasteurization of water.
Capacity 150-300 hl/h
Deaeration level 10 ppb (after stripping column)
Temp program 10/25-77-80-12/27-2C
Electric power Outlet pump: 15.0 kW, 400 V, 50 Hz
Control panel: 1.0 kW, 400 V, 50 Hz
Noise (max) 85 dB(A)
Consumption rates at 300 hl/h
(peak consumption can be up to 2-3 times the normal consumption)
Media Data Consumption
Water 300 kPa (3.0 barg) 300 hl/h
Steam 800 kPa (8.0 barg) 180 kg/h
Coolant (30% Prop Glycol) In : -3.5C 56 000 kg/h
Out : 11C
CO2 for deaeration 600 kPa (6.0 barg) 7.5 Nm 3/h
Gas purity: min. 99.98%
Instrument air 600 kPa (6.0 barg) 5 Nl/min
Technical Data ALDOX
Doc No: CA0277-103 2(2)
Material - Frame and pipe work
AISI 304 stainless steel
- Control panel
AISI 304 stainless steel
- Plate heat exchanger
Frame of AISI 304 stainless steel
Plates of AISI 316 stainless steel
Unit dimensions Length: 4070 mm
Width: 2500 mm
Height: 5200 mm
10. Drawing(s) Layout
A-A ( 1 :20 )
B-B ( 1 :20 )
1
1
2
2
3
3
4
4
5
5
6
6
AA
BB
CC
DD
This document and its contents are our exclusive
property and must not be copied, reproduced,
transmitted or communicated to any other party
or used for purposes not expressly permitted by us.
Only to the extent expressly
agreed by us this document
may constitute a contractual
obligation on our part.
(Inventor made from:Template-2009-01) C:\Vault_Workingfolder\01. Projects\030 CA Brewery Projects\02. B Orders
(Modules)\ALDOX\CA0277 Aldox-SP 150-300hl_h\9680024874-R00.idw
Date Revision text Drawn Checked Approved
Location
Date Drawn
Size
Scale
Sheet
Drawing No
Dimensions without tolerances:
Proj. No Proj. Type Proj. Name
Title
Rev
Rev
No
ISO
Alfa Laval Copenhagen A/S Method E ISO 2768-M or ISO 13920-B
20-08-2012 DKSOKNNA 1
A1
1:20
9680024874 00
CA0277 Brewery SAB Miller - CDM
Layout ALDOX-SP 150-300 hl/h
A
BAB
00 Released first time 11-09-2012 DKSOKNNA DKSONND DKSOAHN
145
2000
315
2954
3000
258,5
324
1154
1200
310
300
STEAM Inlet DN40
GLYCOL Outlet DN100
GLYCOL Inlet DN100
CO2 Inlet DN25
190
1,03
506,5
434
90
DAW / CIP Outlet DN65
WATER / CIP Inlet DN65
2110 ~
QE31
FO31
AV21
SC21
AV32 AV11 AV33
FT21
TT41
AV34
AV12
R21
K61
PCV/PI01
LP01
TI61
5201 ~
LS21 LT21
AV41
FT11
K21
P21
TT21
COND. Outlet DN25
FO61 AV61 TT11
W02
W01
TT61
AV23
CM21
AV22
PCV21
AV42
TI41
V35
QT31
TT31
AV63
PI61
PCV61
PI62
AV62
11. Service Media
Service media
Compressed air
Used as instrument air (valves and instruments)
- pressure see tag Technical data
- max oil content 10 mg/l
- max dew point -20C
- solid particles max 0.01 mm
- capacity see tag Technical data
Gas (if applicable)
- type see tag Technical data
- design pressure see tag Technical data
- purity see tag Technical data
Steam (if applicable)
Characteristics
- quality dry saturated steam
- humidity max 5% condensate
- pH 7.0 - 8.0
- chloride max 7 - 8 ppm
- solid particles none
- turbidity max 3 ppm KMnO4
- K and Na max. 0.01 mg/kg
- Fe max. 0.02 mg/kg
- Cu max. 0.003 mg/kg
- NO2 max. 0.02 ppm
- conductivity 0.3 mS
- organic matter no trace
Water
- temperature see tag Technical data
When used as drinking, process, flush, and cleaning water, the
quality shall meet the WHO guidelines or the European EC drinking
water directive.
Cooling medium (if applicable)
- type see tag Technical data
- temperature see tag Technical data
NOTE! To avoid freezing the temperature of coolant medium must never
be below -5C, unless a cooling media circulation loop has been
included in the delivery.
Electricity
Power supply
- voltage see tag Technical data
- max variation on tension 5%
- max variation of frequency 2%
Power supply for control
- voltage 24 V AC (int. supply)
- max variation on voltage -10% - +15%
Service media
Doc. No. SM 2012-06-EN2
12. List of Components

Equipment List
Instrument List
Valve List

Customer: SAB Miller - CDM
Location: Maputo, Mozambique
Project-No.: CA0277
Description: Aldox-SP 150-300 hl/h
Equipment List
Item No. Object description Object details
Type \ Seal \ Impeller Manufacturer Part No. Order No. Sizing Data
Capacity \ Pressure \ Speed
Power data
Voltage \ Type \ Hz \ Conn
Material
Product \ Gasket \ Shaft
Mechanical product connection
Norm \ Conn \ Bore Remarks
Created: DKSOAHN / 2012-08-13
Checked: DKSOAHN / 2012-08-14
Approved: DKSOGJN / 2012-08-14
Document Number: CA0277-105 Equipment list
Revision: 00
Sheet:
1/1
Copyright. All rights reserved Issued for: ,
Filename: dksows0009\31501 Brewery\B Orders Modules\CA0277_Aldox_SP.prj@dksows0009\Engineering\Lists and datasheets (Valve list, Equipment list, Data sheets, I/O list, Load list, Tag list)\CA0277-105
Equipment list
CM21 Spray ball LKRK 2T 64 dia \ --- \ --- Alfa Laval LKM 9611710861 - \ --- \ --- --- \ --- \ --- \ --- \ AISI 316L \ --- \ --- ISO \ OD25
FO31 Orifice \ --- \ --- Scandi Brew, Alfa Laval
Copenhagen A/S 10-0160220-051 - \ \ --- --- \ \ --- \ --- \ SS2333 \ \ --- SMS \ OD51 Drilled with 35 mm hole
FO61 Orifice \ --- \ --- Scandi Brew, Alfa Laval
Copenhagen A/S 10-0160220-051 - \ \ --- --- \ \ --- \ --- \ SS2333 \ \ --- SMS \ OD51 Drilled with 41 mm hole
K21 Deaeration column C 27 \ --- \ --- Scandi Brew, Alfa Laval
Copenhagen A/S
40-600-01-1100 + 40-
600-17-3715 + 40-600-
01-1000
0,0 m3 - 0,0 m3 \ \ --- --- \ --- \ --- \ --- \ --- 1.4301 \ --- \ --- SMS Male P. / SMS Liner \ OD76,1 / OD76,1
K61 Steam trap FT14 4,5 ENP/R-L \ --- \ --- Spirax-Sarco 1475363 - \ PN16 \ --- --- \ \ --- \ --- \ SG Iron (DIN 1693 GGG 40.3) \ Reinforced Exfoliated
Gasket \ --- DIN Flange \ DN25
P21 Centrifugal pump SolidC 4 \ SSS \ 240,0 mm Alfa Laval LKM 9613271171 300,0 hl/h \ 700,0 kPa \ 3000 1/min 400 V \ 3/N/PE ~ \ 50 Hz \ 15,000 kW \ AISI 316L \ EPDM \ C/SiC SMS Male P. \ OD76,1 / OD51
SC21 Frequency converter VLT FC 301 \ --- \ --- Danfoss 131B3661 --- \ --- \ --- 400 V \ \ 50 Hz \ 11,000 kW \ --- \ --- \ --- --- \ ---
W01 Plate heat exchanger TL10P Base \ --- \ --- Alfa Laval Lund AB 30108-08692 0,0 m3 \ \ --- --- \ --- \ --- \ --- \ --- AISI 316 \ NBRP \ SMS Male P. \ OD101,6
W02 Plate heat exchanger TS6M FHC \ --- \ --- Alfa Laval Lund AB 30108-08687 --- \ \ --- --- \ --- \ --- \ --- \ --- AISI 316 \ NBRP \ SMS Male P. \ OD76,1

Project-No.: CA0277
Instrument List
Type Manufacturer Part No. Order No. Output signal(s) Power details
Voltage \ Type \ Hz \ Power \ Conn Range Material
Product \ Gasket Mechanical connection Remarks
Document Number: CA0277-105 Instrument list
Revision: 00
Sheet:
1/1
Filename: dksows0009\31501 Brewery\B Orders Modules\CA0277_Aldox_SP.prj@dksows0009\Engineering\Lists and datasheets (Valve list, Equipment list, Data sheets, I/O list, Load list, Tag list)\CA0277-105
Instrument list
FT11 Electromagnetic flowmeter Promag 10H Endress+Hauser 10H65-
VF0A1AA0A5AA 4-20 mA, frequency, HART 24 V \ DC \ DC \ 0,015 kW \ M20x1,5 0-2000 l/min at v =
10 m/s AISI 316L / PFA \ EPDM ISO Welded \ OD63,5
FT21 Mass flowmeter Promass 40E without Tag and calibrated
to Range Endress+Hauser 40E25-
AFMWAAAAA1AA 4-20mA HART + frequency 0 V \ \ DC \ --- \ M20 acc. to spec. EN 1.4404 (AISI 316L) and EN 1.4539 (AISI
316Ti) \ DIN Male P. \ DN25 - To be updated -
LS21 Level switch Liquiphant T FTL20H Endress+Hauser FTL20H-0UPJ2B 3 wire PNP 24 V \ DC \ --- \ --- \ Pg 11 AISI 316L \ --- DIN Ins. Thr. \ DN25
LT21 Level transmitter Liquicap M FMI51 Endress+Hauser FMI51-A1BTDJB2A1A 4-20 mA (loop-powered with HART protocol) 24 V \ DC \ --- \ --- \ M20x1,5 0-600 mm AISI 316L/FEP \ --- ISO Clamp \ OD51
PI21 Pressure gauge MGS 10 D Nuova fima 41X0373 --- --- \ \ --- \ --- \ 0-10 bar Brass \ Silicone rubber ISO Outs. Thr. \ 1/8
PI61 Pressure indicator with syphon
and cock Spirax Sarco 0273300+0273002 --- --- \ \ --- \ --- \ 0-10 bar Stainless steel \ BSP Outs. Thr. \ DN40/DN38 / 3/8
PI62 Pressure indicator with syphon
and cock Spirax Sarco 0273300+0273002 --- --- \ \ --- \ --- \ 0-10 bar Stainless steel \ BSP Outs. Thr. \ DN40/DN38 / 3/8
QE31 Oxygen sensor M1100 S00 Orbisphere M1100-S00 + 32510.05
+ 29501.0 --- \ --- \ --- \ --- \ SS \ EPDM \ DN40/DN38
QT31 Oxygen analyzer 410M Orbisphere 410M W2C0 0000 24 V \ DC \ DC \ 20,000 VA \ RS485 0-999 ppb \ \ DN40/DN38
TI41 Thermometer TE67F Alfa Laval TE67F911051120 --- --- \ \ --- \ --- \ -20/120 EN 1.4401 (AISI 316) \ DIN/ISO Clamp \ DN40/DN38
TI61 Thermometer TE67F Alfa Laval TE67F911052120 --- --- \ \ --- \ --- \ -20/120 EN 1.4401 (AISI 316) \ DIN/ISO Clamp \ DN40/DN38
TT11 Temperature sensor Omnigrad M TR 44 Endress+Hauser TR44-
BB5AAS2HGP000 4-20 mA PCP 24 V \ --- \ DC \ --- \ M20x1,5 0-100 C AISI 316L \ --- ISO Clamp \ OD38

Project-No.: CA0277
Valve List
Type \ Act Type \ Diameter Manufacturer Part No. Order No. Actuator details
Rest pos. \ Pneum. conn.
Power details
Voltage \ Type \ Hz \ Power \ Conn
Material
Product \ Other \ Gasket Mechanical product connection Remarks
Document Number: CA0277-105 Valve list
Revision: 01
Sheet:
1/1
Filename: dksows0009\31501 Brewery\B Orders Modules\CA0277_Aldox_SP.prj@dksows0009\Engineering\Lists and datasheets (Valve list, Equipment list, Data sheets, I/O list, Load list, Tag list)\CA0277-105 Valve
list
AV11 Butterfly valve LKB \ LKLA \ Actuator 085 Alfa Laval LKM 9612628342 NC \ R 1/8 (BSP), internal thread --- \ \ --- \ --- \ AISI 304 \ EPDM ISO Welded \ OD63,5
AV12 Regulating valve SPC 2 \ \ Normal Spring Alfa Laval LKM 9612553710 NO \ R 1/8 (BSP), internal thread --- \ \ --- \ --- \ AISI 316L \ EPDM ISO Welded \ OD63,5 Kv 64
AV21 Butterfly valve LKB \ LKLA \ Actuator 085 Alfa Laval LKM 9612628339 NC \ R 1/8 (BSP), internal thread --- \ \ --- \ --- \ AISI 304 \ EPDM ISO Welded \ OD25
AV22 Regulating valve 3510 -7 \ 3277 + IP 3760 \ Actuator 120
cm2 Samson --- NC \ 1/8 NPT --- \ \ --- \ --- \ M20x1,5 1.4571 \ PTFE DIN Flange \ DN25 Kv 0.4
AV23 Butterfly valve LKB \ LKLA \ Actuator 085 Alfa Laval LKM 9612628343 NC \ R 1/8 (BSP), internal thread --- \ \ --- \ --- \ AISI 304 \ EPDM ISO Welded \ OD76,1 Drilled with a 24 mm hole
AV41 Regulating valve 3241 -7 \ 3277 + IP 3730-1 \ Actuator 700
cm2 Samson --- NC \ 1/8 NPT --- \ \ --- \ --- \ M20x1,5 GG-25 / 1.4006 \ PTFE DIN Flange \ DN100 Kv 160
AV62 Regulating valve 3241 -7 \ 3277 + IP 3760 \ Actuator 240
cm2 Samson --- NC \ 1/8 NPT --- \ \ --- \ --- \ M20x1,5 GG-25 / 1.4006 \ PTFE DIN Flange \ DN32 Kv 25
AV63 Ball valve 226 \ LKLA \ Actuator 85 EGO 419561210+961249710
3+9611416300 NC \ R 1/8 (BSP), internal thread --- \ --- \ --- \ --- \ --- AISI 316 \ R PTFE ISO Welded \ DN32/OD38
PCV01 Pressure regulator MS4 LFR \ \ Festo MS4-LFR-1/8-D6-CRMAS
\ --- \ \ --- \ --- \ Aluminium \ BSP Ins. Thr. \ 1/8
PCV21 Pressure regulator Olympian Plus R64G \ \ Norgren R64G-6GK-NMN \ --- \ \ --- \ --- \ Zinc/Brass \ BSP Ins. Thr. \ 3/4
PCV61 Pressure reducing valve BRV73 \ \ Spirax-Sarco 2103493 \ --- \ \ --- \ --- \ SG Iron (DIN 1693 GGG 40.3) \ DIN Flange \ DN32
R21 Non-return valve LKC 2 \ \ Alfa Laval LKM 9612220001 NC \ --- \ \ --- \ --- \ AISI 304 \ EPDM ISO Welded \ OD25
V35 Membrane sample valve SBMSV P \ \ Scandi Brew, Alfa Laval
Copenhagen A/S 20-1108650S-11 --- \ --- \ \ --- \ --- \ 1.4404 \ Q ISO Clip-on/ISO Stub End \ DN6 / DN25
13. Function Description
Function description ALDOX

Doc No: CA0277-112 1(10)
Sequence steps
Step 000 Off Stage
Activities : No activities
Transitions : If STERILIZATION, CIRCULATION or PRODUCTION selected - go to step 101
If CIP FORWARD selected - go to step 201
If CIP CIRCULATION selected - go to step 202
If CIP DRAIN selected - go to step 203
Step 101 Drain Column
Activities : Valves AV21, AV23 and AV33
Valve AV22; Fixed output
Pump P21; Fixed output
Transitions : If OFF selected or FAULT - GO TO OFF - go to step 000
If LT21 < Low level in column 1 (Registers 118) and time Low level in column 1 (Register
254) has elapsed - go to step 103
Step 103 Fill to column
Activities : Valve AV11 if not LS21
Valve AV12; Flow controller FC11; Circulation set point
Valves AV23 and AV33
If LT21 > Mid level in column 1 (Registers 119) - go to step 105
Step 105 Fill to outlet
Valve AV12; Flow controller FC11; Circulation set point
Valves AV21, AV23 and AV33
Pump P21; Level controller LC21; Production set point
If time in step (Registers 200) has elapsed - go to step 106
Doc No: CA0277-112 2(10)
Step 106 Heat
Activities : Valves AV23, AV34, AV61 and AV63
Valve AV62; Heating temperature controller TC61; Sterilization set point
Pump P21; Flow controller FC11; Circulation set point
Transitions : If FAULT - GO TO OFF - go to step 000
If STERILIZATION not selected or TT41 > Sterilization outlet temperature (Register 145)
and time Sterilization outlet temperature (Register 295) has elapsed - go to step 107
If STABILIZE/SHUT DOWN selected go to step 116
Step 107 Sterilize
Activities : Valves AV34, AV61 and AV63
Valve AV62; Heating temperature controller TC61; Sterilization set point
If STERILIZATION not selected or time Sterilization time (Register 296) has elapsed - go to
step 108
Step 108 Stabilize 1
Activities : Valves AV21, AV23, AV34, AV42 and AV63
Valve AV33 if LS21
Valve AV41; Fixed output; If time AV41 fixed output in step 108 (Register 315) has not
elapsed (not applicable when coming from step 115 or 121)
Valve AV41; Coolant temperature controller TC41; Circulation set point; If time AV41 fixed
output in step 108 (Register 315) has elapsed or when coming from step 115 or 121
Valve AV62; Heating temperature controller TC61; Production set point
If time in step (Register 201) has elapsed and if TT61 > Low heating temperature (Registers
153) and time Heating temperature attained (Register 308) has elapsed - go to step 111
Doc No: CA0277-112 3(10)
Valve AV33 if LS21
Valve AV41; Coolant temperature controller TC41; Circulation set point
If flow switch FIA21 active and time CO 2 gas filled in column (Registers 240) has elapsed -
go to step 112
If STABILIZE/SHUT DOWN selected - go to step 116
Step 112 Circulation
Activities : Valve AV21 if COLUMN NOT GAS FILLED or AV21 FLIP (On-Register 243, Off-Register 244)
Valve AV33 if LS21
Valves AV23, AV34, AV42 and AV63
Valve AV41; Coolant temperature controller TC41; Circulation set point
If PRODUCTION selected and not FAULT - GO TO CIRCULATION and not high level in buffer
tank - go to step 113
Step 113 Cool
Valve AV41; Coolant temperature controller TC41; Production set point
If TT41 < Production outlet temperature (Registers 143) and time Production outlet temperature
(Register 291) has elapsed - go to step 114 or 115 (If no carbonation)
Doc No: CA0277-112 4(10)
Step 114 Carbonation (if applicable)
Step 115 Production
Valve AV12; Flow controller FC11; Production set point
Valves AV21, AV23, AV32, AV42 and AV63
Valve AV22; Flow controller FC22; Production set point
Valve AV33 if LS21
Valve AV53 if CARBONATION is selected
Pump P21; Level controller LC21; Production set point
If CIRCULATION selected or FAULT - GO TO CIRCULATION - go to step 108
If high level in buffer tank - go to step 117
Valve AV33 if LS21
Transitions : If STABILIZE/SHUT DOWN selected or FAULT - GO TO OFF or if time in step (Registers
203) has elapsed - go to step 000
Doc No: CA0277-112 5(10)
Valve AV33 if LS21
Transitions : If STABILIZE/SHUT DOWN selected or FAULT - GO TO OFF - go to step 000
Step 121 Stand-By
Transitions : If PRODUCTION OFF selected or FAULT - GO TO OFF - go to step 000
If high level in buffer tank and time in step (Registers 206) has elapsed - go to step 000
If not high level in buffer tank and (not mid level or PRODUCTION or if time in step (Registers
206) has elapsed) - go to step 108
Doc No: CA0277-112 6(10)
Step 201 CIP Forward
Valve AV12; Flow controller FC11; CIP set point
Valve AV32
Valve AV62 if CIP HEATING selected; Heating temperature controller TC61; CIP set point
Valve AV63 if CIP HEATING selected
Pump P21 if COLUMN PUMP LEVEL; Level controller LC21; CIP set point
Transitions : If CIP OFF selected or FAULT - GO TO OFF - go to step 000
If remote signal CIP FLIP active and time in step (Registers 209) has elapsed - go to step 211
Step 202 CIP Circulation
Activities : Valve AV11 if not pump level in column
Valve AV34
Pump P21 if COLUMN PUMP LEVEL; Flow controller FC11; CIP set point
Step 203 CIP Drain
Activities : Valve AV33
Pump P21 if COLUMN PUMP LEVEL; Fixed set point
Doc No: CA0277-112 7(10)
Step 211 CIP flip 1, low pressure (if applicable)
Activities : Valves AV23 and AV34
Valve AV61 (if applicable)
Step 212 CIP flip 1, no pressure (if applicable)
Activities : Valve AV33
Step 213 CIP flip 3, low pressure (if applicable)
Activities : Valve AV34 and AV61
Step 214 CIP flip 4, pressure 1 (if applicable)
Valve AV34
Doc No: CA0277-112 8(10)
Valve AV34
EXTERNAL CIP STATION and if time in step (Registers 215) has elapsed - go to step 201
No EXTERNAL CIP STATION and if time in step (Registers 216) has elapsed - go to step 202
Doc No: CA0277-112 9(10)
Object activation
Step P21 AV11 AV21 AV23 AV32 AV33 AV34 AV43 AV61 AV63
0
101 X X X X
103 NH X X
105 X NH X X X
106 X X X X X
107 X X X X
108 X X X H X X X
111 X X X H X X X
112 X G X H X X X
113 X X X X X X
114 X X X X X X
115 X NH X X X H X X
116 X G X H X
117 X G X H X
121 G
201 P NH X HS
202 P NP X HS
203 P X HS
211 P X X HS
212 P X HS
213 P X X HS
214 P NH X HS
215 P NH X X HS
216 P NH X HS
P = If pump level in column NP = If not pump level in column
H = If high level in column NH = If not high level in column
G = Pulsed open if gasfilled or open if not gasfilled W = If water carbonation selected
HS = If CIP heating is selected
Doc No: CA0277-112 10(10)
Fault supervision and resulting actions
Fault Step Resulting action
3. Low water flow rate 103-114, 116 & 117 Fault indication only
115 108 (Stabilize 1) activated
4. High water flow rate ALL Fault indication only
5. High level in column ALL Fault indication only
6. High level in column too
long
ALL OFF position
9. Power failure ALL OFF position
11. Motor trip ALL OFF position
17. High oxygen level too
long
108, 111 & 112-114 Fault indication only
19. High outlet temperature 115 108 (Stabilize 1) activated
22. Low heating temperature 112-114 Fault indication only
25. Low CO2 flow to column 108-121 Fault indication only
26. Low CO2 flow to column
too long
32. High oxygen level 108, 111 & 112-115 Fault indication only
14. Parameter List
Parameter list ALDOX

Doc No: CA0277-113 1(7)
Reg
No.
Register description Preset
value
Unit Changed
value
100 -
101 -
102 -
103 -
104 Low water flow to column 5 %
105 -
106 High water flow to column 95 %
107 -
108 FT11 max range 400 hl/h
109 Flow setpoint ramp value 10 hl
110 -
111 -
112 Low CO2 flow to column 5 %
113 High CO2 flow to column 95 %
114 -
115 -
116 -
117 -
118 Low level in column 1 5 %
119 Medium level in column 1 30 %
120 High level in column 1 95 %
121 -
122 -
123 -
124 -
125 -
126 FT21 max range 40 kg/h
127 -
128 -
Doc No: CA0277-113 2(7)
Reg
No.
value
Unit Changed
value
129 -
130 -
131 -
132 -
133 -
134 -
135 -
136 -
137 Low oxygen level 5 %
138 High oxygen level 50 %
139 Oxygen max range 100 ppb
140 -
141 -
142 Low outlet temperature 1 C
143 Production outlet temperature 6 C
144 CIP outlet temperature 50 C
145 Sterilization outlet temperature 85 C
146 -
147 -
148 -
149 -
150 -
151 -
152 -
153 Low heating temperature 65 C
154 High heating temperature 95 C
155 -
156 -
157 -
Doc No: CA0277-113 3(7)
Reg
No.
value
Unit Changed
value
158 -
159 -
160 Manual compensation Water temp / CO2 0
161 Gas excess compensation CO2 0
162 -
163 -
164 -
165 -
166 -
167 -
168 -
169 -
170 -
171 -
172 -
173 -
174 -
175 -
176 -
177 -
178 -
179 -
180 -
181 -
182 -
183 -
184 -
185 -
186 -
Doc No: CA0277-113 4(7)
Reg
No.
value
Unit Changed
value
200 Time in step 105 15 s
204 Time in step 117 to 112 30 s
205 Time in step 117 to 121 600 s
207 - - s
208 - - s
209 Time in step 201 - 203 to 211 240 s
217 -
218 -
219 -
220 -
221 -
222 -
223 -
224 -
225 -
226 -
227 -
228 -
Doc No: CA0277-113 5(7)
Reg
No.
value
Unit Changed
value
229 -
230 Low water flow to column 5 s
231 Low water flow to column too long 10 s
232 -
233 High water flow to column 5 s
234 -
235 -
236 -
237 Low CO2 flow to column 5 s
238 -
239 Low CO2 flow to column too long 15 s
240 CO2 filled in column 180 s
241 CO2 not filled in column 3600 s
242 -
243 AV21 on pulse 10 s
244 AV21 off pulse 80 s
245 -
246 -
247 -
248 -
249 -
250 -
251 -
252 -
253 -
254 Low level in column 1 2 s
255 Medium level in column 1 2 s
256 High level in column 1 2 s
257 -
Doc No: CA0277-113 6(7)
Reg
No.
value
Unit Changed
value
258 -
259 High level switch column 1 5 s
260 High level switch column 1 too long 15 s
261 -
262 -
263 -
264 -
265 -
266 -
267 -
268 -
269 -
270 -
271 -
272 -
273 -
274 -
275 -
276 -
277 -
278 -
279 -
280 High level switch in buffer tank 2 s
281 Low oxygen level 5 s
282 High oxygen level 5 s
283 High oxygen level too long 60 s
284 AV33 on pulse high level in column 2 s
285 AV33 off pulse high level in column 30 s
286 Freeze flow controller 3 s
Doc No: CA0277-113 7(7)
Reg
No.
value
Unit Changed
value
287 -
288 -
289 -
290 Low outlet temperature 5 s
291 Production outlet temperature 5 s
292 High production outlet temperature too long 60 s
293 CIP outlet temperature 5 s
294 CIP time 600 s
295 Sterilization outlet temperature 5 s
296 Sterilization time 1200 s
297 -
298 -
299 -
300 -
301 -
302 -
303 -
304 -
305 Low heating temperature 5 s
306 High heating temperature 5 s
307 Low heating temperature too long 60 s
308 Heating temperature attained 30 s
309 -
310 -
311 -
312 -
313 -
314 -
315 TC41 on delay in step 108 30 s
15. Control Panel Documents
Index
DanProces Engineering A/S
Glasmagervej 38C, Fensmark, 4684 Holmegaard
Tel. 55 54 80 40 - Fax 55 54 80 41
e-mail: post@danproces.dk
Index
ALDOX-SP 300 hl/h
Order no.: CA0277-111
Page : I1
CDM
Mozambique
Copenhagen A/S
Total : 48
Index I2
Proj. no.: A 20805
El drawings
00
01
05
07
Flow transmitter FT21 08
Flow transmitter FT11
El drawings
Supply voltage 24V DC
Front page
Power supply Motor
Supply voltage 230V - 24V DC 03
Frequency converter SC21 pump P21 11
15
20
21
23
25
Analog output QW256 - QW262 26
Analog output QW752 - QW754
Orbisphere analyzer
Analog input IW280 - IW286
PLC rack
Analog input IW752 - IW758
Analog input IW272 - IW278 22
Digital input I124.0 - I124.7 30
31
32
40
42
43
Remote signal relay contact 60
Digital output Q9.0 - Q9.7
Digital input I125.0 - I125.7
Digital input I126.0 - I126.7
Digital output Q125.0 - Q125.7 41
Layout Layout
Tel. 55 54 80 40 - Fax 55 54 80 41
Index
ALDOX-SP 300 hl/h
Page : I2
CDM
Mozambique
Copenhagen A/S
Total : 48
I1 El drawings
Proj. no.: A 20805
80
81
Pneumatic
91
98
PLC LIST Plc list
Pneumatic
Panel layout
Pneumatic
Component layout
Pneumatic
Pneumatic 90
PLC list 100
101
102
Component list
111
Cable list
-W1-AV12 120
Cable list
PLC list
Component list
PLC list
Component list
Component list 110
-W1-FT11 121
122
123
124
126
-W1-LS32
-W3-SC21
-W1-QT31
-W1-TT21
-W2-QT31 125
El drawings
DanProces Engineering

Tel. 55 54 80 40 - Fax 55 54 80 41
ALDOX-SP 300 hl/h Page : 00
Copenhagen A/S
Md.by : AH
Approved : JD
Front page
Filnavn: C:\AH Moduler\onCA0277-111-A20805\Hardware\CA0277-111-V1_1
Last rev. : 04-10-2012 10:03:48 Order no.: CA0277-111
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
El drawings 01
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Power supply
Motor
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
00 03
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Supply voltage
230V - 24V DC
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
01 05
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Supply voltage 24V DC
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
03 07
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
05 08
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
07 11
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Frequency converter SC21
pump P21
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
08 15
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Orbisphere analyzer
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
11 20
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
PLC rack
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
15 21
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Analog input
IW752 - IW758
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
20 22
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Analog input
IW272 - IW278
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
21 23
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Analog input
IW280 - IW286
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
22 25
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Analog output
QW752 - QW754
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
23 26
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Analog output
QW256 - QW262
Revision : 1.1
Last printet : 12-09-2012 07:26:16
Total : 48
25 30
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Digital input
I124.0 - I124.7
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
26 31
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Digital input
I125.0 - I125.7
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
30 32
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Digital input
I126.0 - I126.7
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
31 40
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Digital output
Q124.0 - Q124.7
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
32 41
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Digital output
Q125.0 - Q125.7
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
40 42
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Digital output
Q8.0 - Q8.7
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
41 43
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Digital output
Q9.0 - Q9.7
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
42 60
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Remote signal
relay contact
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
43 Layout
CDM
Mozambique
Proj. no. : A 20805
Layout

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Panel layout
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
Layout 81
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Component layout
Revision : 1.1
Last printet : 12-09-2012 07:26:18
Total : 48
80 Pneumatic
CDM
Mozambique
Proj. no. : A 20805
Pneumatic

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Pneumatic
Revision : 1.1
Last printet : 12-09-2012 07:26:20
Total : 48
Pneumatic 91
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Pneumatic
Revision : 1.1
Last printet : 12-09-2012 07:26:20
Total : 48
90 98
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
Pneumatic
Revision : 1.1
Last printet : 12-09-2012 07:26:20
Total : 48
91 Plc list
CDM
Mozambique
Proj. no. : A 20805
PLC LIST
I/O Connection Function
Tel. 55 54 80 40 - Fax 55 54 80 41
Page
PLC list
-K20.1:22 Fuse control external
I 126.2 -K20.1:24
-K20.1:25
I 126.1
I 126.4 -K20.1:26
I 126.5 -K20.1:27
I 126.6 -K20.1:28
I 126.7 -K20.1:29
IW 752 -K20.1:3
IW 754 -K20.1:6
IW 756 -K20.1:9
IW 758 -K20.1:12
QW 752 -K20.1:17
QW 754 -K20.1:19
I 124.0 -K20.2:2
I 124.1 -K20.2:3
I 124.2 -K20.2:4
I 124.3 -K20.2:5
I 124.4 -K20.2:6
I 124.5 -K20.2:7
I 124.6 -K20.2:8
I 124.7 -K20.2:9
I 125.0 -K20.2:12
I 125.1 -K20.2:13
I 125.2 -K20.2:14
I 125.3 -K20.2:15
I 125.4 -K20.2:16
I 125.5 -K20.2:17
I 125.6 -K20.2:18
I 126.3
-K20.1:23 External input C-F.I126.1
External input C-F.I126.2
Temperature cooling TT41
Temperature heating TT61
Aldox flow FT11
Column level LT21
Regulating valve coolant AV41
Regulating valve steam AV62
Fuse control internal
Spare
Feedback signal P21
Spare
Spare
Spare
Flow pulse FT11
Flow pulse FT21
Spare
Spare
Spare
Level switch LS21
Spare
Tank low level LS33 spare
Tank medium level LS32 spare
I 125.7 -K20.2:19 Tank high level LS31 spare
I 126.0
ALDOX-SP 300 hl/h
Page : 100
CDM
Mozambique
Copenhagen A/S
Total : 48
Plc list 101
Proj. no.: A 20805
Tel. 55 54 80 40 - Fax 55 54 80 41
Page
PLC list
-K20.2:22 Spare
Q 124.2 -K20.2:24
-K20.2:25
Q 124.1
Q 124.4 -K20.2:26
Q 124.5 -K20.2:27
Q 124.6 -K20.2:28
Q 124.7 -K20.2:29
Q 125.0 -K20.2:32
Q 125.1 -K20.2:33
Q 125.2 -K20.2:34
Q 125.3 -K20.2:35
Q 125.4 -K20.2:36
Q 125.5 -K20.2:37
Q 125.6 -K20.2:38
Q 125.7 -K20.2:39
QW 256 -K20.3:3
QW 258 -K20.3:7
QW 260 -K20.3:11
QW 262 -K20.3:15
IW 272 -K20.4:2
IW 274 -K20.4:4
IW 276 -K20.4:6
IW 278 -K20.4:8
IW 280 -K20.4:12
IW 282 -K20.4:14
IW 284 -K20.4:16
IW 286 -K20.4:18
Q 124.3
-K20.2:23 Activation P21
Spare
Spare
Spare
Fault lamp yellow H100-Y
Operation lamp green H100-G
Information lamp white H100-W
Remote signal spare
Remote signal spare
Remote signal spare
Remote signal spare
Remote signal spare
Remote signal spare
Remote signal spare
Remote signal spare
Regulating valve flow AV12
Regulating valve CO AV22
Frequency converter SC21
Spare
Inlet temperature TT11
Column temperature TT21
After regen temperature TT31
Spare
CO flow FT21
Oxygen analyzer QT31
Spare
Spare
Q 124.0
ALDOX-SP 300 hl/h
Page : 101
CDM
Mozambique
Copenhagen A/S
Total : 48
100 102
Proj. no.: A 20805
Tel. 55 54 80 40 - Fax 55 54 80 41
Page
PLC list
-K20.5:2 Activation valve AV11
Q 8.2 -K20.5:4
-K20.5:5
Q 8.1
Q 8.4 -K20.5:6
Q 8.5 -K20.5:7
Q 8.6 -K20.5:8
Q 8.7 -K20.5:9
Q 9.0 -K20.5:12
Q 9.1 -K20.5:13
Q 9.2 -K20.5:14
Q 9.3 -K20.5:15
Q 9.4 -K20.5:16
Q 9.5 -K20.5:17
Q 9.6 -K20.5:18
Q 9.7 -K20.5:19
Q 8.3
-K20.5:3 Activation valve AV21
Activation valve AV23
Activation valve spare
Spare
Spare
Spare
Spare
Q 8.0
ALDOX-SP 300 hl/h
Page : 102
CDM
Mozambique
Copenhagen A/S
Total : 48
101 Component list
Proj. no.: A 20805
Component list
Name Manufacture Type
Tel. 55 54 80 40 - Fax 55 54 80 41
Page
Component list
-A20 Siemens 6AV6647-0AC11-3AX0
-F3-1 Siemens 5SY41 - C4
-F3-3 Siemens 5SY41 - D2
-H100.BASE Telemecanique XVB C21
-H100.G Telemecanique XVB C2B3
-H100.W Telemecanique XVB C2B7
-H100.Y Telemecanique XVB C2B8
-K20 Siemens 6ES7 313-5BF03-0AB0
-K20.3 Siemens 6ES7 332- 5HD01-0AB0
-K20.4 Siemens 6ES7 331- 7KF02-0AB0
-K20.5 Siemens 6ES7 322- 1BH01-0AA0
-K40-2 Phenix 29 66 17 1
-K41-1 Phenix 29 66 17 1
-K41-2 Phenix 29 66 17 1
-K41-3 Phenix 29 66 17 1
-K41-4 Phenix 29 66 17 1
-K41-5 Phenix 29 66 17 1
-K41-6 Phenix 29 66 17 1
-K41-7 Phenix 29 66 17 1
-K41-8 Phenix 29 66 17 1
-K42 Festo 10P-10-5C-D1-R-Y-5C+V
-Q1-0 Telemecanique VZ 15
-Q1-0 Telemecanique VCF4 - (80 AMP)
ALDOX-SP 300 hl/h
Page : 110
CDM
Mozambique
Copenhagen A/S
Total : 48
Component list 111
Proj. no.: A 20805
Name Manufacture Type
Tel. 55 54 80 40 - Fax 55 54 80 41
Page
Component list
-Q1-1 Siemens 3RV1901-1E
-Q1-1 Siemens 3RV1031-4FA10 - (28-40A)
-Q3-1 Siemens 3RV1021-1EA10 - (2,8 - 4,0 A)
-T3-1 Noratel 3-060-100 700
-T3-2 Siemens 6ES7307-1KA02-0AA0
-V3 Procond OY DFHF-6
-X3 Schupa PC 16/2
MMC Siemens 6ES7 953-8LF20-OAAO
ALDOX-SP 300 hl/h
Page : 111
CDM
Mozambique
Copenhagen A/S
Total : 48
110 Cable list
Proj. no.: A 20805
Cable list

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
-W1-AV12
Revision : 1.1
Last printet :
Total : 48
Cable list 121
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
-W1-FT11
Revision : 1.1
Last printet :
Total : 48
120 122
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
-W1-LS32
Revision : 1.1
Last printet :
Total : 48
121 123
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
-W1-QT31
Revision : 1.1
Last printet :
Total : 48
122 124
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
-W1-TT21
Revision : 1.1
Last printet :
Total : 48
123 125
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
-W2-QT31
Revision : 1.1
Last printet :
Total : 48
124 126
CDM
Mozambique
Proj. no. : A 20805

Tel. 55 54 80 40 - Fax 55 54 80 41
Copenhagen A/S
Md.by : AH
Approved : JD
-W3-SC21
Revision : 1.1
Last printet :
Total : 48
125
CDM
Mozambique
Proj. no. : A 20805
16. Certificates
Environment declaration
PHE - TL10P - W01
PHE - TS6M - W02
Flow transmitter - Promag 10H - FT11
Mass flowmeter - Promass 40E - FT21
Environment Declaration
Supplier Alfa Laval Copenhagen A/S, Maskinvej 5, 2860 Sborg,
Denmark
Local environment
legislation or regulation
to consider
The plant must be installed and operated with respect to
any local environment legislation. It is the responsibility of
the owner/user to follow all legislation and regulation
including all necessary approval from environmental
authorities before taking the plant into use.
Handling of waste In relation to installation, maintenance and
disposal it is
mandatory to dispose any chemicals, waste oil or grease
or other waste material in a safe way in suitable containers
and in agreement with the local environmental regulations.
Handling of hazardous
materials
Any hazardous material used during installation,
maintenance or disposal must be treated in agreement with
the local environmental regulations. The plant must be
installed and operated with all assemblies in a healthy
condition such that no CIP liquid or other aggressive media
can leak from the plant. It is important that the outlets for
carbon dioxide, nitrogen or any gasses resulting from
chemical reactions during cleaning are arranged such that
they do not constitute a safety hazard.
Noise The plant has a noise emission of maximum 85 dB (A).
Use ear protection when operating the plant.
Discharge of process
water
The plant is designed for processes in a brewery. The
disposal of waste water must be in agreement with the
local environment rules.
Emission to air There is no emission to air from the plant other than
from
the fermentation process (carbon dioxide), gasses added
by the brewery (carbon dioxide, nitrogen) or gasses from
any chemical reaction in connection with cleaning. The air
emission must be in agreement with the local environment
rules.
Risk of soil and
ground water pollution
Provided that the instructions in the Environment
Declaration and the instruction manual are followed there
is no risk for soil and ground water pollution.
Disassembling and
disposal of the plant
Disassembling and disposal of the plant shall be executed
after the local environmental regulations with respect to
each material.
30108-08692/0
2012
189,00 M2
-3/100C
10,0 bar
Manufactur.Year:
Heating Surface:
Design Temp:
Design Pressure:
30108-08692
97/23/EC/3.3
PED34503863-1
O12-38842
CA0277_TL10P
Manufacturing No:
Type Registration No:
Calculation Drawing:
Assembly Drawing:
Manufacturers Order No:
Suppliers Order No:
ORDER REFERENCES AND PRESSURE VESSEL DATA
SUPPLIER
DENMARK
Aldox / Alfa Laval Copenhagen
CUSTOMER
Danmark
DK-2860 SBORG
Maskinvej 5
Att.:Cristina Gracia Lisbona
PLATE HEAT EXCHANGER CERTIFICATE
TYPE: TL10-PBASE
Total Volume: 490,0 L
Article Material specification Heat No TQ No
LIST OF MATERIALS
FRAME PLATE EN 10028-2 P265GH 104039 907512
PRESSURE PLATE EN 10028-2 P265GH 104064 910247
CONNECTION PLATE ACC. DRAWING. 932748 907095
BLIND CORNER EN 10217-7/EN 10028-7 1.4301 CS170728 909351
TIGHT.-BOLT, COMPL EN 10269 1.4923 BJ16/AK58 907833
TIGHT.-BOLT, COMPL EN 10269 AD2000 W7 1.4923 04/AK58 908369
NUT-TIGHTENING EN 12449 CW509L/R340 L48 908513
TUBE EN 10217-7 1.4404 11310 908572
SINGEL CORNER EN 10213-4 1.4408 11678 901923
NIPPLE EN 10272 2007 1.4404 273C0107 904685
CHANNEL PLATES EN 10028-7 1.4401/SA240 316 * *
GASKETS NITRILE PERFORMANCE(NBRP) * *
Alfa Laval Lund AB
Lund, Sweden 2012-09-27
Quality Control Dept.
MANUFACTURER
Designdrawing and Strengthcalculation checked
and approved by Alfa Laval Lund AB. Review of
manufacturing documents, material identification,
manufacturing, internal and external inspection has
been done in accordance with existing
requirements. The result was accepted.
CERTIFICATION
SECONDARY SIDE : 13,0 bar (g)
PRIMARY SIDE : 13,0 bar (g)
HYDROSTATIC PRESSURE TEST
Per Danielsson
Digitally signed by Per Danielsson
DN: cn=Per Danielsson, o=Alfa Laval Lund,
ou=OM-Q, email=per.danielsson@alfalaval.com,
c=SE
Date: 2012.09.27 09:50:45 +02'00'
30108-08687/0
2012
1,20 M2
0/100C
0/145C /
10,0/10,0 bar
Manufactur.Year:
Heating Surface:
Design Temp:
Design Pressure:
30108-08687
97/23/EC/3.3
PED34501068-0
O12-38838
CA0277_TS6
Manufacturing No:
Type Registration No:
Calculation Drawing:
Assembly Drawing:
Manufacturers Order No:
Suppliers Order No:
ORDER REFERENCES AND PRESSURE VESSEL DATA
SUPPLIER
DENMARK
Aldox / Alfa Laval Copenhagen
CUSTOMER
Danmark
DK-2860 SBORG
Maskinvej 5
Att.:Cristina Gracia Lisbona
PLATE HEAT EXCHANGER CERTIFICATE
TYPE: TS6-MFMC
Volume side 1/2: 3,4/4,6 L
Article Material specification Heat No TQ No
LIST OF MATERIALS
FRAME PLATE EN 10028-7 AD2000 W2 1.4432 91309 860274
PRESSURE PLATE EN 10028-7 2007 1.4432 403077 879123
STUD BOLT A2-70 DIN ISO3506-1 3.1B LG-C6 324011
TIGHT.-BOLT, COMPL ASME SA193 B8M CL. 2 BG60/AH81 904436
NUT-TIGHTENING EN 12449 CW509L/R340 L55 907570
TUBE DIN 17458 AD2000 W2 1.4404 035657 632765
NIPPLE EN 10272 2007 1.4404 173D1253 898728
CHANNEL PLATES EN 10028-7 1.4401/SA240 316 * *
GASKETS NITRILE PERFORMANCE(NBRP) * *
Alfa Laval Lund AB
Lund, Sweden 2012-10-01
Quality Control Dept.
MANUFACTURER
Designdrawing and Strengthcalculation checked
and approved by Alfa Laval Lund AB. Review of
manufacturing documents, material identification,
manufacturing, internal and external inspection has
been done in accordance with existing
requirements. The result was accepted.
CERTIFICATION
SECONDARY SIDE : 13,0 bar (g)
PRIMARY SIDE : 13,0 bar (g)
HYDROSTATIC PRESSURE TEST
Per Danielsson
Digitally signed by Per Danielsson
DN: cn=Per Danielsson, o=Alfa Laval Lund,
ou=OM-Q,
email=per.danielsson@alfalaval.com, c=SE
Date: 2012.10.01 11:59:23 +02'00'
17. Recommended Spare Parts
Doc No : CA0277-106.xlsx 1(3)

Recommended spare parts ALDOX
For item Class.* Qty Denomination Alfa Laval ref.No. Type
Valves:
AV21 Automatic butterfly valve LKB-25-W
Actuator with coupling 9611416301 LKLA-NC
Actuator with coupling 9611416304 LKLA-NO
B 1 Service kit valve 9611923028
B 1 Service kit actuator 9611923010
AV## Automatic butterfly valve LKB-51-W
AV## Automatic butterfly valve LKB-63.5-W
AV23 Automatic butterfly valve LKB-76-W
AV42 Automatic butterfly valve LKB-101.6-W
Actuator with coupling 85 9611416306 LKLA-NC
Actuator with coupling 85 9611416307 LKLA-NO
Actuator with coupling 133 9612271306 LKLA-NC
Actuator with coupling 133 9612271307 LKLA-NO
B 1 Service kit actuator 85 9611923010
B 1 Service kit actuator 133 9611923020
AV63 Automatic ball valve EGO 226 DN32/OD38
B 1 Service kit valve 501001918 PTFE
V35 Sample valve 9680124470 Scandi Brew, SBMSV-P
B 1 Diaphragm + bush (20 pc) 9680124378 Silicone
B 1 O-ring 9680122976
B 1 Clip 9680123786
AV12 Regulating valve SPC-2-63.5 Kv64
B 1 Service kit 9611920423
AV62 Regulating valve 9680149289 Samson 3241-7 DN40 Kv 25
B 1 Seat 501001787 Position No. 4
B 1 Plug Kv 25 501001788 Position No. 5
B 1 Threaded bushing 9680148783 Position No. 8
B 1 Spring 9680149572 Position No. 11
B 1 Disk 9680149986 Position No. 12
B 2 Packing 9680149611 Position No. 15
Doc No : CA0277-106.xlsx 2(3)
B 2 Gasket 9680148142 Position No. 17
B 1 Service kit actuator 240 cm2 501001468
C 1 Positioner 3760 501001469
AV41 Regulating valve 9680149279 Samson 3241-7 DN100 Kv 160
B 1 Seat 501001802 Position No. 4
B 1 Plug Kv 160 501001803 Position No. 5
B 1 Threaded bushing 501001804 Position No. 8
B 1 Spring 501001805 Position No. 11
B 1 Disk 501001806 Position No. 12
B 2 Packing 501001807 Position No. 15
B 2 Gasket 501001808 Position No. 17
C 1 Positioner 3730-1 9680148032
AV## Regulating valve 9680149296 Samson 3510-7 DN25 Kv 0.4
B 1 Trim Kv 0.4 501001214 Pos No. 2
B 1 Packing washer 501001215 Pos No. 10
C 1 Positioner 3760 501001469
V## Manual regulating valve 9680147573 Scandi Brew, SBRV-20
O 1 Service kit 9680124423
R21 Non-return valve 9612220001 LKC-2-25-W
PCV21 Pressure regulator 9680126442 Norgren, R64G-6GK-NMN
S 1 Service kit 9680149549
PCV01 S 1 Pressure regulator 9680162668 Festo, MS4-LFR-1/8-D6-CRM-AS
K61 Steam trap 9680123935 FT14-4.5
S 1 Service kit 9680149466
Pumps:
P21 Centrifugal pump SolidC-4/### (5.5-22.0) kW
SC## Frequency converter Danfoss VLT
C 1 Frequency converter 9680126217 FC301, 11.0 kW
PHE:
See plate heat exchanger parts list
Pipes & Fittings:
B 10 Seal ring 25 3131703753 EPDM
B 20 Seal ring 38 3131703772 EPDM
B 20 Seal ring 51 3131703785 EPDM
B 20 Seal ring 63.5 3131703793 EPDM
B 20 Seal ring 76 3131703803 EPDM
B 10 Seal ring 101.6 3131708862 EPDM
T 1 Wrench 25-76 69696
Doc No : CA0277-106.xlsx 3(3)
Measurement:
FIA## C 1 Flow switch 9680126858 Gemu 1252000Z
FT11 C 1 Electromagnetic flowmeter 9680148322 E+H Promag 10H, Weld OD63.5
FT21 C 1 Mass flowmeter 9680177943 E+H Promag 10H, Weld OD63.5
LS## C 1 Level switch 9680126203 E+H FTL20H, OUPJ2B
LT21 C 1 Level transmitter 9680126455 E+H FMI51, Clamp 2"
TI## O 1 Thermometer TE67F911051120 -20/120'C, Bottom, Clamp 1"
O 1 Thermometer TE67F911052120 -20/120'C, Back, Clamp 1"
TT## C 2 Temperature sensor 9680123931 E+H TR44, Clamp 1"
PI## O 1 Pressure indicator 9680123925 0-10 bar, Spirax Sarco
PI21 S 1 Pressure indicator 9680123464 0-10 bar, Nuova fima
Control panel:
See electrical drawings
Equipment ordered from external suppliers:
See spare part list for the component in question
*Classification of the spare parts :
C - Critical components
B - Basic components
O - Ordinary components
S - Special components
T - Tools, instructions
A fault of such a component will cause a serious disturbance in the operation of the module
or process. It is advisable to have this type of component available within a couple of hours.
Components which should be replaced on a regular basis.
The function of a component is related to a part of the plant and is not critical. The
components have a limited lifetime and a certain stock should be kept.
Not considered as spare parts, however necessary for the maintenance of the module.
These components are not likely to malfunction and are available on the local market.

Project Manager : Anders Hakansson
Company : Alfa Laval Copenhagen A/S
Address : Maskinvej - 5, DK - Soborg, Denmark
Tel. direct: : +45 39 53 67 25
Mailto : anders.hankasson@alfalaval.com
Website : www.alfalaval.com
Local Contact : Dragos Dobrescu
Alfa Laval (Pty) Ltd
P.O. Box 187
ZA 1600 Isando
South Africa
Contact us :

A. Laval

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

A. Laval

Uploaded by

Copyright:

Available Formats

Safety instructions

02. General Information

Module introduction GENERAL INFORMATION

Preparatory work INSTALLATION

Unpacking and inspection

When to start commissioning INSTALLATION

Initial checks COMMISSIONING

Utility and function checks COMMISSIONING

05. Operation Manual

Alfa Laval Copenhagen A/S

When the sequence is activated the background color changes to

Production CIP Forward

Circulation CIP Circulation

Stop/Stabilization Production preselected

Date & time picture

Control panel OPERATION MANUAL

If the SERVICE picture isnt displayed:

Copyright Alfa Laval

Copyright Alfa Laval

08. Flow Chart

09. Technical Data

Technical Data ALDOX

10. Drawing(s) Layout

Copyright Alfa Laval

11. Service Media

12. List of Components

Alfa Laval Copenhagen A/S

Alfa Laval Copenhagen A/S

Alfa Laval Copenhagen A/S

Copyright Alfa Laval

13. Function Description

Function description ALDOX

14. Parameter List

Parameter list ALDOX

Copyright Alfa Laval

15. Control Panel Documents

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S

DanProces Engineering A/S