copia de 962111 basic operator guideluine

8/9/2019 Copia de 962111 Basic Operator Guideluine

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962 111 Saku SteBeer Filter

Alfa LavalSterile Beer Filter plant

Basic Operator

Guideluine

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962111 Saku BrewerySaku, Estonia

Table of Contents

System and Process................................................................................................................3

Introduction..........................................................................................................................31.1.1 Safety Precautions ...................................................................................................3

1.1.2 System and Application ............................................................................................7

1.1.3 Intended Use ............................................................................................................7

1.1.4 Equipment Supplied with the BSF System ................................................................8

1.1.5 Equipment Supplied with the CIP Station ...............................................................10

Product Description............................................................................................................13

1.1.6 Process Description ................................................................................................13

1.1.7 System Description ................................................................................................14

1.1.8 Specification of Cartridges .....................................................................................151.1.9 General Processing Parameters .............................................................................16

Operation..............................................................................................................................17

Operating the System........................................................................................................17

1.1.10 Initial Operational Set-up .....................................................................................17

1.1.11 Primary General Operations .................................................................................18

1.1.12 General cleaning guidelines .................................................................................18

Starting the System...........................................................................................................20

Stopping the System..........................................................................................................22

Manual activations on the filter module.............................................................................22

Step forward / Step backwards SEMI AUTOMATIC MODE.................................................23

Communication with other plants......................................................................................24

Process Messages..............................................................................................................25

1.1.13 Error Messages .....................................................................................................25

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System and Process

Introduction

1.1.1 Safety Precautions

To avoid injuring yourself and damaging the filtration system and the filter

cartridges, it is important for you to read the safety precautions given belowand to follow them closely.

The instructions use two different symbols to indicate possible hazardsaccording to their type and gravity:

WARNING!This symbol is used to indicate situations in which the dangerof personal injury or severe equipment damage could arise.

ATTENTION!This symbol is used to indicate situations in which equipmentdamage may occur.

IMPORTANT!This additional symbol is used to mark information that is importantin order to achieve economic operation of the system.

The machine has been built in accordance with state-of-the-art-standardsand the recognised safety rules.The machine must only be used intechnically perfect condition in accordance with its designated use and theinstructions set out in the operating manual. Any functional disorders,especially those affecting the safety of the machine, should therefore berectified immediately.

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Observe all warnings!

At the first sign of functional disorders during operation, stop the machineimmediately, lock it and report the malfunction. Have any defects rectifiedimmediately.

WARNING!Never make any modifications, additions or conversions whichmight affect safety without the suppliers approval.

WARNING!Danger of injury from splashing liquids under high pressurecould arise!

Never loosen the clamping pins or cover bolts of thefilter housings during filtration!

WARNING!Danger from electrical power!

Switch off the machine immediately if trouble occurs inthe electrical system.

Work on the electrical systems an equipment of the machine must be carriedout only by a skilled electrician.

The electrical equipment of machines is to be inspected and checked inregular intervals. Defects such as loose connections or scorched cables mustbe rectified immediately.

Before carrying out repairs cut off the power supply. Necessary work on lifeparts and elements must be carried out only in presence of a second personwho can cut off the power supply in case of danger by actuating theemergency shut-off or main power switch.

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WARNING!Danger of injury from the hydraulic and pneumatic equipment! Riskof injury due to hot water, steam or CIP liquid, that may escapefrom the system.

Work on hydraulic equipment may be carried out only bypersons with the necessary knowledge and experience inhydraulic systems.

Always depressurise all system sections and pressure pipes to be removedbefore carrying out any repair work.

Splashed oil may cause injury and fire.

Check all lines, hoses and screw connections regularly for leaks and obviousdamage. Repair damage immediately.Hydraulic and compressed air lines must be laid and fitted properly.

When handling oil and grease, observe the product related safetyregulations.

WARNING!Improper use of the filter cartridges can lead to severe injuriesor destruction of the filter cartridges.Before cleaning the filtration system, always read the operating

instructions for the filter cartridges!

WARNING!Danger of injury from splashing liquids under high pressurecould arise!

Never loosen the clamping pins or cover bolts of the filter holder duringfiltration!

Always depressurise the system before changing a filter!

WARNING!Danger of personal injury to the user or severe damage to thefiltration system could arise!

Before starting up or setting the machine in motion, make sure that nobodyis on risk.

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Maintenance and repair work may only be carried out by

properly instructed technicians.

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1.1.2 System and Application

Alfa Laval products solve filtration problems in all the different areasinvolved, from pre filtration to final filtration.

The static filtration process with filter cartridges is a widely-used process forthe filtration of beverages such as wine, beer, juices and mineral water.It is an effective and economical procedure. Cartridges are available asdepth filters membrane pre filters and membrane final filters. According tothe customer's requirements, an optimal cartridge is available within the

product range.

All the cartridges guarantee high product quality and have a compactconstruction with a large and efficient filter area. The particle-removingdepth filter shows high retention rates and reduces parts of micro-organismsand separate yeast totally. The final membrane filter retains the remainingmicro-organisms that spoil beer.

The filtration process runs in a closed system thus avoiding recontamination.The process is able to run continuously for longer periods of time and it ispossible to make the entire process automatic.

1.1.3 Intended Use

The Beer Sterile Filtration system is designed only for the filtration of beer.Using the machine for purposes other than those mentioned above isconsidered contrary to this designated use. The supplier cannot be heldliable for any damages resulting from such use. The liability for any suchmiss use lies entirely with the user.

Do not attempt to operate the filtration system with accessories or spareparts other than those supplied by the original manufacturer.In the event that the filtration system is tampered with in any way, wecannot assume any responsibility for the performance or safety of thesystem.

Use only materials recommended by the manufacturer (e.g. gaskets orhoses).

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1.1.4 Equipment Supplied with the BSF System

Depending on the intended use, the automatic Beer Sterile Filtration systemwill be supplied with the following equipment:

Tag no. Name Remarks

Filter housings

80F02 pre filter housing line1 (28)

80F03 final filter housing 01 line1 (28)

80F04 final filter housing 02 line1 (28)

80COS01F01 gas filter housing (25)80SS01F02 Steam filter housing

Streamer

80COS01V02 Pressure reducer & streamer, CO2

80AS01V02 Pressure reducer & streamer,

compressed air

80SS01V03 Pressure reducer & streamer, steam

Sterile Filter Service Line

Measuring devices

80F02PT01 pressure gauge inlet pre filter line 01

80F02PT02 pressure gauge inlet final filter line 01

80P01PT01 pressure gauge outlet final filter line

01

8COS01PT01 pressure gauge service line

80F02LS01 level pre filter line 01

80F03LS01 level final filter line 01

flow meter beer inlet If available, value will be

displayed through

communication line.

80COS01-TT01 temperature steam/gas line

80VM01QT01 Conductivity transmitter (phase

separation)

Pump-80-P01 Beer booster pump

Pos. no. Name Remarks

Beer piping valves

80VM01AV06 beer inlet filter line 1

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Pos. no. Name Remarks80F02AV05 Bypass valve 1 final filter

80F02AV04 beer outlet pre filter line 01

80F03AV03 beer inlet final filter 01 line 01

80F04AV04 beer outlet final filter 02 line 01



80F02AV07 Bypass valve 2 final filter

80-F02-AV03 Drain valve Pre filter line 01

80F02AV08 Drain valve final filters line 01

Filter housing valves80F02AV02 venting valve pre filter line 01

80F02AV01 gas inlet valve pre filter line 01

80F03AV02 venting valve final filter 01 line 01

80F03AV01 gas inlet valve final filter 01 line 01

80F04AV02 venting valve final filter 01 line 01

80F04AV01 gas inlet valve final filter 01 line 01

Gas piping valves

80COS01AV01 Steam condense valve steam filter

80COS01AV02 Steam condense valve before sterile

filter

80COS01AV03 Steam condense valve after sterile

filter

80COS01AV01 Automatic Shut off CO2 supply

80AS01AV01 Automatic Shut off compressed air

supply

80SS01AV02 Automatic Shut off steam supply

CIP piping valves

80VM01AV01 CIP circulation valve line 01 VM Located at valve manifold

80VM01AV02 Butterfly Valve CIP inlet line 01

80VM01AV03 CIP supply switch valve towards

inlet/outlet pre filter line 01

80VM01AV04 CIP return valve line 01

80VM01AV05 CIP supply valve line 01

Hand operated valves

80COS01V01 Manual valve inlet CO2 supply

80AS01V01 Manual valve inlet compressed air

supply

80SS01V01 Manual valve inlet steam supply

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Pos. no. Name Remarks80SS01V04 Steam overpressure valve

Sampling valves

80P01V01 Manual sample valve inlet beerline

80VM01V01 Micro sample valve line 01

Beer routing valves (Manifold)

80VM01AV101 Beer outlet KEG line

80VM01AV102 Beer drain KEG line

80VM01AV103 Beer by-pass valve KEG line

80VM01AV104 Beer inlet KEG line

80VM01AV201 Beer outlet KEG line80VM01AV202 Beer drain KEG line



80VM01AV301 Beer outlet KEG line

80VM01AV302 Beer drain KEG line



1.1.5 Equipment Supplied with the CIP Station

Depending on the intended use, the CIP station for Beer Sterile Filtrationsystem will be supplied with the following equipment:

Valves CIP line

80B01AV06 CIP drain valve line 01

80B01AV03 CIP circulation valve line 01 CIP



80B01AV02 CIP cold water supply line 01

80B01AV01 CIP line01 hot water inlet valve80B01V01 CIP cold water flow regulation valve Manual regulation -> cold

water inlet pressure to be

reduced to 1 barg

80B01AV07 CIP hot water tank HW inlet valve

80B01AV11 Drain valve hot water tank

80F01AV01 CIP filter dearation valve To be opened when startingup CIP station and once every

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water flush phase during

cleaning

Instruments CIP line

80-B01-QT01 CIP return L01 conductivity

80-B01-QT01 CIP return L01 temperature

80-B01-FS01 CIP return flow switch

80-W01-TT01 CIP Line 01 temperature heater

regulation

80-B01-FT01 CIP Line 01 flow supply

80-W01-PI04 CIP Line 01 PI inlet heater

80-W01-TI04 CIP Line 01 TI inlet heater

80-W01-PI03 CIP Line 01 PI outlet heater

80-W01-TI03 CIP Line 01 PI outlet CIP filter

Heater sub components

80-W01-AV01 CIP Line 01 steam supply valve

80-W01-AV02 CIP Line 01 steam regulation valve

80-W01-V01 CIP Line 01 manual valve at inlet

80-W01-V07 CIP Line 01 manual valve at outlet

80-W01-F01 CIP Line 01 Y filter at inlet

80-W01-PI01 CIP Line 01 PI inlet steam

80-W01-PI02 CIP Line 01 PI inlet heater

Caustic dosing sub components

80-B11-LSL01 CIP low level caustic concentrate tank

80-B11-P01 CIP L01 caustic dosing pump

80-B11-R01 CIP L01 caustic dosing valve

Hot water tank sub components

80-B01-LSH01 CIP high level hot water tank

80-B01-LSL01 CIP low level hot water tank

80-B01-TT02 CIP temperature hot water tank

80-B01-CM01 CIP spray ball hot water tank

80-B01-AV21 CIP supply spray ball

Main CIP components

80-B01 Hot Water tank

80-B11 Caustic concentrate tank

80-B01-P02 CIP line 01 supply pump

-80-W01 CIP Heater

-80-F01 CIP Filter

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Product Description

1.1.6 Process Description

The complete filter unit is made up of one filter line, consisting of a pre filter housing

Sartofine followed by two final filter housing s with Sartocool filter cartridges. In the

automatic mode the two final filters are active; if the integrity test prior to production, fails

on one of the filters, we can still use the other final filter.

The differential pressure is constantly monitored and should not exceed 0.8 bar. If the

maximum (variable) switch over pressure is reached for the active filter a warning is givento the operator and the operator can decide to continue the production mode for a certain

time (to finish a batch for instance) or to start the regeneration. Besides this, it is as well

possible to run the filter lines in the manual mode.

Before filling, the system is pressurised with CO2. The filter housings are fully drained and

filled with CO2.

The beer is fed to the filter unit from the BBT cellar by the beer pumps in the BBT cellar from

line 1, 2 or 3. These pumps are controlled via an external (existing) control system.

At the BBTs, the outlet of a BBT is connected to one of the 3 transfer lines from the BBT to

the BSF system. First beer is pushing de-aerated water to drain at the by-pass of the beer

line in the valve cluster. Based on conductivity, (plus a safety timer or a volume counter)

the water to drain is stopped and the inlet valve of the BSF system is opened. The in-coming

beer is distributed within the valve cluster to the filter line.

The pre-filtration housing is first completely filled with beer, while CO2 is vented at the top

of the pre-filtration housing. When high-level of the pre-filtration housing is reached, beer is

routed to the final filtration housings. Here also the housings are completely filled up with

beer while CO2 is vented at the top of the each housing. When high-level on the final

filtration housings reached beer, the filter line is connected to the outlet of the filter unit and

routed to one of the 3 dedicated BBT lines towards the filling machines.

The outcoming sterile filtered beer flows back to the valve cluster and is lined to the fillingmachine towards KEG/CAN/Bottle fillers.

During processing the filling level on top of the housings is automatically monitored and re-

filled if necessary.

The filtration and regeneration process and the differential processing parameters are

controlled by the integrated control system. For screens with a size of at least 10, the

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actual process step (position of valves) is indicated on the operator screen, otherwise only

alarm is given in case of wrong positioning.

The filter unit is designed for the possibility to process beer through the pre-filter only, while

the sterile filter is by-passed.

1.1.7 System Description

The complete automatic filter unit is built up on two mounting frames, one for the filter line

and the beer/CIP distribution valve cluster and one for the CIP unit for the filters.

The main components of the BSF system are: Pre filter and final filter housings,

A distribution valve cluster with pneumatically activated valves,

Water/CIP/gas supply piping with measuring devices and the control system.

The filter housings in the beer line are equipped on the top with level sensors and

pneumatically activated valves for venting and draining.

The inlet and outlet, and the distribution of the different process streams within the

system is done by pneumatically activated valves.

Standard, all product valves are equipped with Top units with open\close position

indicators controlled by the PLC system of the module.

For controlling of the module; following process parameters must be measured. inlet and outlet pressure for the filter housings,

the flow rate and conductivity/temperature of the CIP solution

the level within the housings

the temperature in the CIP line

beer flow

All these features are necessary for an automatic process. In case the necessary equipment

is not installed on the module , it is the responsibility of the customer to foresee the data

with a data link (f.e. beer flow).

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1.1.8 Specification of Cartridges

The depth pre filter removes yeast totally and reduces beer spoiling micro-organisms and

particles. The final filter retains the other particles, colloids and beer-spoiling

micro-organisms.

Type Sartofine SM 5502805P3G

design asymmetrical filter layer

nominal retention 0.65 m

length 1000 mm/30

pH range 1 ... 14

number of cartridges 36 30

Cartridge material polypropylene

Type Sartocool SM 530 28 06 A3

design membrane filter

area 0.7 m2 per 10

pore size 0.45 m

length 750 mm/30

pH range 1 ... 14

number of cartridges 24 40 pieces

Cartridge material Polypropylene and polyethersulfone

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1.1.9 General Processing Parameters

1.1.9.1 Filtration

Processing Parameters

Max. product flow rate 230 hl/h (two final filters)

180 hl/h (one final filter)

product inlet pressure 3 ... 4 bar

initial differential pressure 0.1 ... 0.2 bar

switch over differential pressure 0.6 ... 0.8 bar

compressed CO2 (product removal) 0.5 bar (above system pressure)

compressed CO2 (pressurisation) 3 ... 4 bar

1.1.9.2 Regeneration

Processing Parameters

flow rate 330 hl/h

inlet pressure 3 bar

cold flushing time 4 ... 6 min

warm flushing 65 ... 75 C, 4 ... 6 min (max 85C)

sodium hydroxide cleaning 2 %, 65 ... 75 C, 15 ... 30 min (max

85C)

warm water sterilisation 85 ... 95 C, 30 min

cooling time 1 ... 2 min

compressed air (drain) 0.3 ... 0.5 bar

(above system pressure)

compressed air (integrity test.) 1.2 bar (Sartocool), 10 min

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Operation

Operating the System

1.1.10 Initial Operational Set-up



At the first sign of functional disorders during operation, stop the machineimmediately, lock it and report the malfunction. Have any defects rectifiedimmediately.

Before starting the system for the first time, the following visual checksshould be performed.

Check the supply piping connections.

Check the filter housings.

Check the internal piping, fittings, cabling.

Check the manual setting of the valves.

Check the position indication of the valve positioner(local and on the operator screen if existing).

Check the signal output of the measuring device.

Check the process signal input/output.

Check the pressure-hold test of the system (2 bar).

Check the rinsing of the system without cartridges to detect leakage.

Check the installed cartridges.

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1.1.11 Primary General Operations



At the first sign of functional disorders during operation, stop the machineimmediately, lock it and report the malfunction. Have any defects rectified

immediately.

Every time you start the system up, the following checks and proceduresmust be performed:

Check the compressed air supply for the valves (6 ... 7 bar).

Check the compressed air supply for integrity test (2 bar).

Check the product supply/CIP supply.

Check the electrical supply: 400 Volt.

1.1.12 General cleaning guidelines

Always flush directly after filtration; after every 16 hours of production run if the maximum allowed pressure drop over the cartridges is not exceeded a hot water cleaning should be performed.

After each 2.-3. production runs, a CIP procedure with caustic mustbe selected.

In order to avoid contamination always run a sterilisation procedure beforeand after a longer stand still period.

Flush before reaching the maximum differential pressure.

Use only cleaning solutions recommended by the manufacturer.

Pre-set sufficient time spans for flushing and cleaning cycles.

Use only drinking water or de-ionised water for flushing and cleaning.

Check the temperatures and flow rates.

Follow all operation and safety instructions.

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WARNING!Danger of injury from the Beer Sterile Filtration system.

Use care in handling of warm water, steam, caustic solutions and acid.

Wear protective clothes and safety glasses.

Detergents, disinfectants, and preservatives contain aggressive chemicalsand may develop hazardous vapours and gases. Do not inhale these vapoursand avoid skin contact.

Do not mix these different solutions.

Housing bells should be carefully attached to lifting tackle and secured whenremoved to change the cartridge.

Use safety-orientated ladders and working platforms.

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Starting the SystemBefore starting up or setting the machine in motion, make sure that nobodyis at risk and that all checks and procedures mentioned above have beenperformed.

Turn on the main switch on the control box.

Check the parameter setting.

The program selection is done in the Program Selection bar.

The operator has the possibility to choose between 9 programs.

Possible automatic programs are :

Production

Prefiltration (filtration only using the prefilter)

Regeneration with caustic

Regeneration without caustic

Steaming Service line

Integrity Test on Filter 1

Integrity Test on Filter 2

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Once an automatic Program is selected, the related START push button willcolor green to visualize the selected program on the FILTER or CIP screen.

By pushing the START button, the system will start and communicate withother parts of the brewery automatically.

The Program selection button lights green to indicate that a program isselected; as long as a program is running, no other program can be

activated. When no program is active, the status line indicates NO PHASEACTIVE.

Hold or continue the selected program

Once the program is started, the Status bar indicates what subroutines areactive.

In case there is an alarm on the valve, The valve indication box on top of thewindows colours red. The valves colors red as well.

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Stopping the System

You have to stop the system at the end of operation and at the first sign offunctional disorder during operation.

Start a CIP procedure within the next 2-3 hours

Run a rinsing procedure in case Cleaning will take place during the nextmorning.

Manual activations on the filter module

Manual valve activations are done from the selected #module# screen. Thisby clicking on the valve on which manual manupilation needs to be done.

When clicking on a valve, a window pups up that indicates in green that thevalve is in automatic position. By pushing the hand button, the valve goesover to the hand mode. At this moment, it takes over the status of theautomatic mode.

The green color of the1 button at the wright site of the hand buttonindicates that the valve is manually manipulated. When the valve is switchedof manually with the 0 button, only the yellow color that indicates themanual mode is drawn around the manual mode push buttons.At the same time, the line selection button is colouring yellow to indicatethat a manual activation is active on the line.

To go back to automatic mode, the Automatic button must be pushed.To close the manual manipulation box, the exit button must be used.

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Step forward / Step backwards SEMI AUTOMATICMODE

With the step forward button, it is possible to Step forward through theprogram.This Program may only be used by maintenance personnel or in case offailure of an instrument what results in blocking of the program. Thereforethe button is password protected.

By pushing this button, the Program will step one fase further in thesubroutine.

For the same reason, the step backward button is created. With this button

it is possible to step one fase backwards

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Communication with other plants

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Error display Cause Remedy

differential pressure

drop on filter higher

than the set value

System Warning or

System Hold

depending on the scale

of the differential

pressure drop

The blocking of the

cartridge

increases.

Press the key ACK toconfirm the errormessage.

Check theset valueforthe differential pressure(range 0.5-0.8 bar)between the inlet andoutlet of the filterhousings.

Finish the productionand start regeneration.

Check the pressuresensors.

Replace the cartridge.

compressed air

pressure too low

System Warning

Too low air

pressurePress the key ACK toconfirm the errormessage.

Check the air supplyCheck the air filter If not - Check the mainsupply to the filter system

malfunction valve

no.##

System Warning

The valve does not

work correctly.

The positioner

does not work

correctly.


Check the pneumaticvalves within the system.

Check the positioner.

Check the pneumatichoses and connections.

Check the compressed airsupply.

Restart the program.

CIP flow too low

System Hold

The pump speed is

too lowPress the key ACK toconfirm the error

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Error display Cause RemedyThe feed supply

line is closed.

The cartridges for

water supply is

blocked.

message.

Check the regulatingvalve.

Check the externalpiping.

Check the CIP pump.

Check the inlet pressureof the caustic waterhousing (clean or replacethe cartridge).

Pressure in Line bigger

than 10 bar

System Hold

Too high feed

pressurePress the key ACK toconfirm the errormessage.

Check feed pressurecoming from BBT

Check blocking on outletsite of the line

integrity test of filter

line has failed

System Warning

The compressed

air pressure loss of

the corresponding

line was above the

set maximum

value.

The cartridges are

not wetted

correctly.

One or more

cartridges are

defect.

Press the key ACK to

confirm the errormessage.

The integrity test can berepeated by the operator

Cartridges must bechecked in case ofrepetive failure

Ground fault alarm ASI

BUS

System Warning

Ground fault on

the ASi bus or

ground faultdetection relay

broken


Replace relay in case ofbroken relay

Find fault on ASI bus

Emergency alarm

System Hold

Emergency relay

defective or

Emergency button

Press the key ACK toconfirm the error

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Error display Cause Remedypushed message.

Replace the relay ifdefective

Release the theemergency button ifemergency situation isresolved

Fuse alarm

System Hold

Fuse fault Press the key ACK toconfirm the errormessage.

Replace fuse

Maximum production

time elapsed

System Warning

Filter line too long

time in productionPress the key ACK toconfirm the errormessage.

Switch over to other filterline in case productionmust continue for aperiod loner than 2 hours

Reset the count downtime in case productionmust continue on thesame filter line

Maximum production

time elapsed + x hours

System Hold

Filter line too long

time in production

and count down

time not reset in

time


Switch over to other filterline in case production

must continue for aperiod longer than 2hours

Reset the count downtime in case productionmust continue on thesame filter line

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Error display Cause RemedyMaximum production

runs exceeded ;

regeneration with

caustic necessary

System Warning

To many

production runs

without CIP with

caustic

regeneration


Perform a CIP with causticregeneration on the filterline after stop ofproduction on the line

Status bytes instrument

NOK

System Warning

Profibus PA fault

on the instrumentPress the key ACKtoconfirm the error

message.Solve the cause of the PAerror message

Work switch pump

System Hold

Work switch pump

in save position or

defective


In case of broken workswitch, replace the switch

In case of work switch insave position ; finalise thework on the pump beforecontinuing of theproduction

Fault pump ( drive )

System Hold

Fault on pump Press the key ACK toconfirm the errormessage.

Identify reason of faultand correct it

The repeatedintegrity test of

filter2 has failed

The compressedair pressure loss

of the

Press the key ACK to confirmthe error message.

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Error display Cause Remedycorrespondingline was abovethe setmaximum value.

The cartridgesare not wettedcorrectly.

One or morecartridges aredefect.

the process goes on (or break the process)

Change cartridges.

Test cartridges.

The repeatedintegrity test offilter1 has failed

copia de 962111 basic operator guideluine

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