Foaming Instruction

SECTION 4.
INSTRUCTIONS FOR
FREEZE DRYING PLANT
TYPE CONRAD™ 600 XL Eco
FOAMING SYSTEM H4J1
Please read the safety, installation, operation, maintenance and service instructions
provided in this instruction thoroughly. All plant personnel must be familiar with these
instructions. Failure to follow these instructions may result in injury, fatal accident and
plant damage.
0610-0jjj
zzzz en
032-7024-1-01
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GEA Process Engineering
Published by:
GEA Process Engineering A/S
Gladsaxevej 305
2860 Søborg
Denmark
Authorized representative/support:
Please visit our web site at: www.gea.com
Original instructions.
Copyright © 2017 GEA Process Engineering A/S. All rights reserved.
0610-xxxx CONRAD™ 600 XL eco
4009 en Foaming System
TABLE OF CONTENTS PAGE
1. DESCRIPTION OF THE FOAMING SYSTEM .................................................................1

1.1 General.............................................................................................................................1
2. SAFETY ............................................................................................................................2
2.1.1 Persons responsible for safety .........................................................................................2
2.1.2 General safety issues .......................................................................................................2
3. ENVIRONMENTAL PROTECTION .................................................................................3
3.1 Disposal ...........................................................................................................................3
4. TECHNICAL DATA ..........................................................................................................4
4.1.1 Main data ..........................................................................................................................4
4.1.2 Fines melter unit sketch ....................................................................................................4
4.1.3 Foaming unit sketch..........................................................................................................5
4.1.4 SSHE unit sketch ..............................................................................................................5
5. INSTALLATION ...............................................................................................................6
5.1 General.............................................................................................................................6
5.1.1 Storage .............................................................................................................................6
5.1.2 Placing ..............................................................................................................................6
5.1.3 Installation of pipe system ................................................................................................6
5.1.4 Handling of components ...................................................................................................7
5.1.5 Pressure test of the foaming system ................................................................................7
6. OPERATION.....................................................................................................................8
6.1 List of components.........................................................................................................9

6.1.1 Set points ........................................................................................................................18
7. MAINTENANCE .............................................................................................................19
7.1 Safety during maintenance..........................................................................................19

7.2 Cleaning .........................................................................................................................19
7.2.1 Hand-Cleaning ................................................................................................................19
7.2.2 CIP (Cleaning in Place) ..................................................................................................20
7.3 Regular check points ...................................................................................................20
8. SPARE PARTS ..............................................................................................................21
8.1.1 Ordering of spare parts ...................................................................................................21
8.1.2 Spare parts .....................................................................................................................21
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1. DESCRIPTION OF THE FOAMING SYSTEM
1.1 General
See drawing no. 1149467: P/I-Diagram Foaming System
The main purpose of the FOAMING SYSTEM is to produce a stable, foamed extract
with the correct specific density that gives a dark finished product with good solubility.
The viscosity must be low enough for trouble free feeding to the CAB-Freezing
System.
Fresh extract is pumped from the Extraction and Concentration Plant into the Fines
Melter Tank C8001 where it is mixed with fines from the Granulation System.
By means of water circulation in the heating jacket of fines melter tank the temperature
of the fresh extract / melted fines mixture is kept at about 15°  T  20C.
Finesmelter Tank C8001 is placed on load cells K8002 for measuring the level in the
tank. Level is measured by K8002 and maintained by regulating the amount of fresh
extract supplied by pump in the tank farm.
In Fines Melter Tank the Agitator G8003 secures a thorough mixing of fresh extract
and melted fines so that an even temperature is obtained.
From the Finesmelter tank C8001 Fines and Extract Feed Pump G8001 pumps the
extract to the surface scraped heat exchangers.
The speed of extract pump G8001 is controlled by pressure transmitter K8105 by

means of a pre adjusted feed amount to the surface scraped heat exchangers. There
are respective set points and alarm points for normal feed besides high and low
pressure of feed. Extract Feed is pumped through Flow meter K8101 which measures
the flow and controls the speed of pump G8101 to give a flow equal to the set point.
From Flowmeter K8101 the extract continues through 1st Stage SSHE E8104 where it
is cooled down to about 0°  T  +5C. The extract temperature from surface scraped
heat exchanger SSHE E8104 is measured by temperature transmitter K8104 and
automatically cooled in the surface scraped heat exchanger from it’s cooling system if
temperature is too high. The extract continues through Foamer G8105 or G8106 where
foaming gas is injected into the extract and on through the 2nd Stage SSHE E8107
where the foamed extract is stabilized by being cooled down to about -6°  T  -4C.
The extract temperature is measured and controlled by temperature transmitter K8107
(as temperature transmitter K8104 first stage) before being conveyed through a Mass
Flowmeter K8108 and a backpressure holding pump G8110 to the feeding nozzle of
the CAB Freezing System.
The Mass Flowmeter K8108 measures the density of the extract and control of the
Foaming Gas Regulator Q8213 takes place according to these measurements.
A Backpressure Holding Pump G8110 ensures a constant pressure in the system in

order to make the Mass Flowmeter K8108 measure properly. The control of the
pumping speed of the pump G8110 is controlled by the pressure transmitter P8110.
The foamed extract is led to the CAB Freezing System only after a stable flow with
correct density has been achieved.
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1/21 GEA Process Engineering
CONRAD™ 600 XL eco 0610-0137
Foaming System 4006 en
For this purpose a possibility exists for Re-circulating the flow back to the Fines melter
tank C8001 during START of the plant.
Valve Q8129 which normally keeps the by-pass line open to drain now changes to mix
the return flow with extract in the Fines melter C8001.
2. SAFETY
2.1.1 Persons responsible for safety
User:
A user is any natural or legal person that uses the foaming system or at whose request
the foaming system is used.
The user or his safety representative must ensure that:

 All relevant rules and regulations are observed
 Only qualified personnel are working at and with the foaming system
 The operation manuals are available to the personnel for all relevant tasks
 Unqualified personnel are not allowed to work at and with the foaming system.
Qualified personnel:
Qualified personnel are persons who, based on their education, experience, special
training and knowledge of relevant standards and stipulations, safety regulations and
operating conditions are authorized by the person responsible for safety on the plant to
perform the necessary actions and who are able to recognize and avoid possible
dangers.
2.1.2 General safety issues
Warning!
It is of the outmost importance, that any operator of the foaming system
has read and understood the guidelines in the manuals including those
from the sub suppliers.
All electrical installation and/or repair work is to be carried out by a

professional electrician.
NOTE!
The following points should also be noted and adhered to during the installation,
operation and maintenance of the plant:
 Maintenance on the refrigerant-cooling part of the Foaming System may only be

performed by specialists.
 Always check that all manual valves are in the correct position before starting
operation as the positive displacement extract pumps will create very high
pressures and cause breakage of the safety membranes if the discharge is not
free.
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3. ENVIRONMENTAL PROTECTION
Many countries have legislated in the area in the attempt to reduce pollution and
protect the environment. These environmental protection acts that are to be observed
concern all sectors of the industry.
It is the obligation of the end user, to ensure that local environmental rules are adhered
to, with regards to disposing of consumables and other waste products from the
process.
Especially, please be aware of the following liquids:
 Lubricants
 Waste water
Lubricants:
Wherever possible, food approved lubricants (FDA; USDA H1) are used.
At change of oil, the waste oil must be collected in a vessel and sent to an authorized
destructor.
Waste water:
Waste water from cleaning of the plant can contain considerable amounts of coffee
extract, and therefore the water must be led to a waste water treatment plant.
3.1 Disposal
What? Where?
Transport Pallets To be returned to manufacturer or

materials forwarding agent.
Packaging Cardboard to paper recycling.
Plastic to plastic recycling or
residual waste.
Lubricants Oil, grease To be disposed of according to
local regulations.
Components Motors Electrical Should be returned to the motor
supplier or other specialist for
disposal.
Actuators Steel Should be returned to the supplier
Seals or other specialist for disposal.
Electrical
Valves Cast iron Housing and seals to be dismantled
Sealing and disposed of separately.
Piping and Mild Steel To be sent to scrap yard for
fittings recycling.
Instruments Stainless steel Should be returned to supplier or
Plastic other specialist for disposal.
Special waste
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CONRAD™ 600 XL eco 0610-0137
4. TECHNICAL DATA
4.1.1 Main data
Electricity supply:
Agitator Fines Melter Pmotor kW 1,5
G8003 Umotor V 3 x 380, 50 Hz
In A 2,81
Start VAR
Water Circulating Pump Pmotor kW 0,75
G8050 Umotor V 3 x 380, 50 Hz
In A 2,0
Start DOL
Extract Feed Pump Pmotor kW 15
G8001, Umotor V 3 x 380, 50 Hz
G8101 In A 28,5
Start VAR
Water circulating/CIP Pump Pmotor kW 4,0
G8002, Umotor V 3 x 380, 50 Hz
G8102, In A 8,5
G8103 Start DOL
Back pressure Pump Pmotor kW 2,2
G8110 Umotor V 3 x 380, 50 Hz
In A 4,7
Start VAR
Rotor SSHE Pmotor kW 15
G8104, Umotor V 3 x 380, 50 Hz
G8107 In A 28,5
Start VAR
For distribution of compressed air to the pneumatic actuators, please see the
pneumatic diagram 1149463.
4.1.2 Fines melter unit sketch
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4.1.3 Foaming unit sketch
4.1.4 SSHE unit sketch
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CONRAD™ 600 XL eco 0610-0137
5. INSTALLATION
5.1 General
5.1.1 Storage
If the Foaming system is not installed immediately, suitable storage conditions must be
provided.
Up to a year: Dry, frost-free, dust-free rooms protected from sunlight.

Over a year: Please contact the manufacturer.
5.1.2 Placing
Sufficient space around the components for inspection, operation, cleaning and
maintenance is recommended. Please see recommended arrangement on the
installation drawings 1178445 and 1170683.
5.1.3 Installation of pipe system
All pipes and fittings must be clean inside. After cutting the cutting edge must be
removed and scaling inside the pipes must be cleaned.
Cuttings should always be made at 90° to the pipe axis to ensure parallel pipes and
proper welding. To facilitate the welding the pipe must be sharpened after cutting.
For cutting of stainless steel pipes flame cutting must not be used. Preferably a
mechanically cold saw should be used for cutting the pipes.
When welding on flanges it must be ensured that the flange has a 90° angle to the
pipe axis. Otherwise it will be difficult to tighten the flanges and a lot of stress will be
created in the pipes.
The pipes should be measured out carefully according to arrangement drawing and
actual conditions on site. Pipes must not be forced in position as it will create stress or
even breaking of the pipes.
The pipes need to have a 1 % slope to ensure that any moisture present can be
drained from the drainage points.
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Welding must be executed by certified welders to ensure a safe system with a

minimum of leaks.
As the foaming system is entirely in stainless steel only TIG/Argon welding must be
used. After welding the surface must be treated with a suitable acid agent to retain the
stainless surface.
When bolting together flanges remember to grease bolts with a suitable grease i.e.
copper grease or molycote.
NOTE!
Only food grade gaskets should be used.
A sufficient number of pipe supports must be used to ensure that load is not applied to
pumps and valves.
5.1.4 Handling of components
When installing components such as pumps and valves it must be checked that
protection covers are removed and that components are clean inside before installing.
It must be checked that direction arrows on pumps and valves are according to the
flow diagram.
The circulation pumps and valves must be protected against welding drops and scaling
from grinding during installation. Components should be handled with care as bearings
and shaft seals could be damaged by mechanical shocks.
When butterfly valves are installed they must always be slightly opened - about 10 %.
If not the rubber seat may be squeezed when the flanges are tightened.
5.1.5 Pressure test of the foaming system
Before a pressure test of the pipe system is executed all valves to the open must be
closed.
Air is filled into the system until a pressure of approx. 2.0 bar g is obtained. All welding
and connections in the plant are then carefully leak tested by means of soap water.
Any leaks found are marked for later repair.
When pressure has been released from the system all the marked leaks are repaired.
After repairs have been done, a new pressure test is made as before.
This procedure is repeated until no more leaks can be located.
As a final test fill system with water and circulate this through all parts of the system.
NOTE!
The tanks in the system shall be omitted, when pressure testing pipe systems
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CONRAD™ 600 XL eco 0610-0137
6. OPERATION
Before starting up the Foaming system check that all pipes have been properly
connected and that all manual valves are set in the correct position for production.
The foaming system is started from the MAIN FACEPLATE of the control system with
all equipment in AUTOMATIC mode on the individual faceplates.
PRODUCTION MODES:
STOP
START (RECIRCULATION)
EXTRACT ON
If STOP is ON the complete system is stopped. Pumps and valves can be operated in
MANUAL (with all interlocks active) or in MAINTENANCE, where no interlocks are
active.
Before starting the system the Fines Melter (C8001) should be filled with extract to
normal level, and the heating jacket water system should be switched on.
After pressing the START button on the main face plate the system
AUTOMATICALLY starts-up in the following way and extract is by-passed back to
Fines Melter(C8001) until flow, pressure, density and temperature is correct.
 Pressure Transmitter P8110 measures the pressure in the system and regulates
the pumping speed of the Backpressure Holding Pump G8110 to ensure a constant
pressure of about 3 Barg in the system.
 Foaming Gas Regulator Q8213 is opened about 10% and a small amount of
foaming gas is injected into the Foamer in operation G8105 or G8106.
 When Flowmeter K8101 registers a flow of 500 kg/h the rotors of SSHE E8104,
G8104 and SSHE E8107, G8107 are started in normal operation.
 Cooling of extract now starts by placing refrigerant suction regulating valves
G31Q6002 and G32Q6002 in normal operation.
 When the temperature after 2nd stage SSHE E8107, measured by Temperature
Transmitter K8107 gets below 0 °C, the amount of gas to the Foamer is increased
to normal by changing setpoint to “normal” value.
When density and temperature is correct system is MANUALLY switched to

EXTRACT ON and extract is now led to CAB-FREEZER.
The condition for changing to EXTRACT ON is;

 CAB-Freezer is in operation
 Granulation System is in operation
If production has to be STOPPED the procedure depends of the length of expected

stop.
At short stops up to about 5 minutes flow is changed to RECIRCULATION while all

other parameters are maintained.
At expected stops up to 30 minutes flow should be changed to RECIRCULATION and
foaming gas flow is reduced to a minimum.
If stop is expected to last more than 30 minutes the foaming system should be stopped
completely.
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6.1 List of components
Text reference to other systems:
CAB FREEZER SYSTEM: = L1

GRANULATION SYSTEM = M1
Prefix for all numbers: = H4J1
E1J1 Extract Supply Pumps to Fines Melter Tank

The pumps and control of the pumps is not controlled from the Freeze-Drying control
system.
The signal from the weighing transmitter K8002 registers 0 – 100 % filling in the Fines
Melter Tank C8001 can be utilized for control of the pump.
The function of the pump is to pump the necessary amount of fresh extract from the
Extraction Plant to the Fines Melter Tank to maintain the preset level in the Fines
Melter Tank C8001.
P8001: Flow, Fresh Extract

The Flowmeter P8001 measures the amount of fresh extract supply to the Fines Melter
Tank C8001.
The flow in kg/h is shown on the screen.
The amount of extract is accumulated and displayed as the actual value and the total
value on the screen. The counter can be reset from the display.
K8002: Load Cells Fines Melter Tank

The weighing system K8002 consists of two load cells with a capacity of 1000 kg each
and a transmitter.
The level in the Fines Melter is shown on the screen and set points can be selected
from the display.
When the low level alarm (LL) from the Load Cell K8002 is ON, the agitator G8003
STOPS
G8002: Cleaning water Pump

The pump G8002 flushes cleaning water from finesmelter C8001 through the piping
sys-tem to the buffer tank C8101.
When the pump is started, Solenoid Valve Q8002 is activated.
Pump can only be started in MANUAL mode.
P8003: Temperature, Fresh Extract

The temperature element P8003 is a type PT 100 and registers the temperature of the
fresh extract supply to the Fines Melter Tank C8001.
The temperature is for display only.
F8003: Safety Switch Fines Melter Tank Lid

The tank lid on the Finesmelter Tank C8001 is fitted with a safety switch F8003.
When the lid is CLOSED the signal is ON, and when the lid is OPEN the signal is OFF.
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CONRAD™ 600 XL eco 0610-0137
G8003: Agitator, Fines Melter Tank C8001

The agitator G8003 has an ON / OFF function.
A frequency converter G8003-T01 controls the speed. The rotational speed is

manually selected from the agitator faceplate.
The agitator is ON in START and EXTRACT ON Modes.
P8004: Extract Temperature, Fines Melter

The temperature element P8004 is a type PT 100 and is placed in the Finesmelter
Tank.
P8004 is for display and alarm only, while regulation of extract temperature is executed
based on temperature measurements from sensor K8051 placed in the pipeline from
the Finesmelter. Alarm set points can be selected from the display.
P8005: Pressure after Pump G8001

The pressure transmitter P8005 has an output of 4–20 mA corresponding to a
pressure range of 0 to 10 barg.
The pressure is shown on the screen and alarm set points can be selected from the
display.
Q8012: Shut-off Valve Cleaning Water Fines melter

The pneumatically operated valve Q8012 has an on/off function and is controlled by a
(NC) solenoid valve.
The valve is equipped with two proximity sensors:
 -B01 for OPEN position and -B02 for CLOSED position.
When put in AUTOMATIC mode the valve is always CLOSED.
Q8015: Shut-off Valve, Cleaning Liquid, Fines Melter Agitator

The (NC) solenoid valve Q8015 has an on/off function and is used for supplying water
to wash out coffee extract from the shaft sealing box.
When Fines Melter Agitator G8003 is ON the valve is OPEN for 15 sec every 60
minutes.
G8050: Water Circulation Pump, Fines Melter Heating Jacket

The Pump circulates water in a closed circuit through a Heat Exchanger E8050 and
the heating jacket of Fines Melter C8001.
In AUTOMATIC mode pump G8050 is ON when START or Extract ON modes are ON.
In AUTOMATIC mode pump G8050 is OFF when STOP mode is ON.
P8050: Water Temperature, Fines Melter Jacket

The temperature element P8050 is a type PT 100 and is placed in the closed
circulation water system. The temperature element measures the water temperature
before the Fines Melter C8001.
The temperature is shown on the screen and alarm set points can be selected from the
display.
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Q8051: Steam Control Valve, Fines Melter Heating Jacket

The two-way valve Q8051 controls the temperature of the extract in the Fines Melter
as measured by the temperature element K8051 by regulating the steam supply to the
plate heat exchanger E8050.
The valve is controlled by a pneumatically operated actuator with positioner operating

from 0% to 100% for a control output of 4 – 20 mA.
The position of the valve is indicated on the screen and the set point can be selected
from the display.
K8051: Melted Fines Temperature

The temperature element K8051 is a type PT 100 and is placed in the outlet pipe from
Fines Melter Tank C8001.
Extract temperature is shown on the screen and set points can be selected from the
display.
K8101: Flowmeter
The Flowmeter K8101 measures the amount of extract from pump G8101. The flow in
kg/h is shown on the screen.
Further the flowmeter is used in the regulation of pump G8101 to maintain the flow at
the required set point which is set manually on the display.
The amount of extract is accumulated and displayed as the actual value and the total
value on the screen.
The counter can be reset from the display.
K8108: Flowmeter – Density Control

The Flowmeter K8108 measures density of the extract and control of Foaming Gas
Regulator Q8213 takes place according to these measurements.
The Flowmeter has an output of 4 – 20 mA for a range of 500 - 2000 g/l and the
density in g/l is shown on the screen.
The desired ratio coffee extract / foaming gas (density) can be selected from the
display.
Stop!
The extract pumps G8001, G8101 and G8110 must not be started in
dry condition.
Running without extract or water filling will damage the shaft seals
G8001: Fines and Extract Feed Pump

TWO pump operation with G8001 and G8101
The pump transports the melted fines/extract mixture from Finesmelter Tank C8001 to
the heat exchangers E8150 and E8151.
The speed of the pump is controlled by a PID regulator through the frequency
converter G8001-T01 according to deviation from set point of the pressure in the
extract pipe by pressure transmitter P8005.
Set points can be selected from the display.

The pump is ON in START and EXTRACT ON Modes
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CONRAD™ 600 XL eco 0610-0137
G8101: Extract Feed Pump

The pump G8101 transports extract from heat exchangers E8150 and E8151 through
1st Stage SSHE E8104, Foamer G8105 or G8106, 2nd Stage SSHE E8107 and the
Backpres-sure Holding Pump G8110 to the feeding nozzle for CAB Freezer.
converter G8101-T01 according to the chosen set point.
SETPOINT: SP 15-2500 kg/hr
The pump speed set point is manually selected from the PID controller faceplate.
G8102: Cleaning water Pump

The pump G8102 flushes cleaning water from where through the piping system to the
Finesmelter C8001 or the drain at the Recirculation/Drain Valve Q8129.
When the pump is started, Solenoid Valve Q8102 is activated.
Pump can only be started in MANUAL mode.
P8102: Pressure after Extract Feed Pump G8101

The Pressure Transmitter P8102 has an output of 4–20 mA corresponding to a
display.
G8103: CIP Pump for Plate Heat Exchangers E8150 & E8151
The CIP Pump G8103 has an on/off function.
The CIP Pump is ON in START and EXTRACT ON modes.
Q8103: CIP Pump valve Plate Heat Exchangers E8150 & E8151
The CIP Pump Valve Q8103 has an on/off function.
The CIP Pump Valve is ON in START and EXTRACT ON modes.
P8103: Temperature before SSHE E8104

The Temperature Transmitter K8103 is a type PT 100 and is placed in the pipe system
before 1st Stage SSHE E8104.
The extract temperature as measured by K8103 is shown on the screen and further
used in the PID-control of the refrigerant regulation suction valve G31Q6002.
Set point for the PID-controller for refrigerant regulation suction valve G31Q6002 as
well as alarm set points can be selected from the display.
P8104: Temperature in Chilled water for HEX E8150 & E8151

The Temperature Transmitter P8104 is a type PT 100 and is placed in the pipe system
after 1st Stage SSHE E8104.
Set point for the PID-controller for refrigerant regulation suction valve G31Q6002 as
well as alarm set points can be selected from the display.
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G8104: Rotor, SSHE E8104, 1st Stage

The rotor G8104 in scraped surface heat exchanger SSHE E8104 has an on/off
function. The speed of the scraped surface heat exchanger rotor is controlled by the
frequency converter G8104-T01.
The rotational speed of the rotor is manually selected on the rotor faceplate.
The scraped surface heat exchanger is ON during START and EXTRACT ON modes.
G8107: Rotor, SSHE E8107, 2nd Stage

The rotor G8107 in scraped surface heat exchanger SSHE E8107 has an on/off
function.
The speed of the scraped surface heat exchanger rotor is controlled by the frequency
converter G8107-T01.
The rotational speed of the rotor is manually selected on the rotor faceplate.
The scraped surface heat exchanger is in operation during the START and EXTRACT
ON modes.
Stop!
The rotors of the SSHE´s must not be started in dry condition.
Running without extract or water filling may damage the scraper blades
G8110: Backpressure Holding Pump

The pump G8110 ensures that the extract from Extract Feed Pump G8101 through 1st
Stage SSHE E8104, Foamer G8105 or G8106, 2nd Stage SSHE E8107 is held under
constant pressure
converter G8110-T01 according to the chosen set point for the back pressure.
The pump speed set point is manually selected from the PID controller faceplate.
P8110: Pressure after SSHE E8107

The pressure transmitter controls the pumping speed of the Backpressure Holding
Pump G8110 in order to maintain a constant pressure in the system between Extract
Feed Pump G8101 and Backpressure Holding Pump G8110
display.
Q8110: Shut-off Valve Sealing Liquid SSHE E8104

The (NC) solenoid valve Q8110 has an on/off function.
The valve is OPEN when SSHE E8104 (G8104) is ON.
P8111: Pressure after Backpressure holding Pump G8110

display.
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CONRAD™ 600 XL eco 0610-0137
P8113: Pressure after SSHE E8104

display.
Q8120: Shut-off Valve Sealing Liquid SSHE E8107

The valve is OPEN when SSHE E8107 (G8107) is ON.
Q8127: Extract Feeding/Recirculation Valve

(NC) solenoid valve (-K01).
In OPEN position the extract flows to the CAB Freezing System, and in CLOSED
position extract is recirculated back to the Fines melter C8001 through the recirculation
pipe.
When the valve is in OPEN position the recirculation pipe may be cleaned by flushing
with warm water, which is then led to drain through valve Q8129.
When put in AUTOMATIC mode the valve is CLOSED, i.e. recirculation during the
modes STOP and START.
When put in AUTOMATIC mode the valve is OPEN, i.e. extract to CAB Freezing
System during the mode EXTRACT ON.
In AUTOMATIC mode the valve is CLOSED, i.e. extract is recirculated during the
following ALARM condition
Q8128: Shut-off Valve Cleaning Water

(NC) solenoid valve.
Q8129: Recirculation/Drain Valve

(NC) solenoid valve (-K01).
In OPEN position recirculation line is connected to Fines Melter Tank C8001.

In CLOSED position the valve will drain the recirculation line
When put in AUTOMATIC mode the valve is always in OPEN position.
K8104: Temperature after SSHE E8104

The temperature element K8104 is a type PT 100 and is placed in the pipe system
after 1st Stage SSHE E8104.
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Set point for the PID-controller for refrigerant regulation valve G31Q6002 as well as
alarm set points can be selected from the display.
K8107: Temperature after SSHE E8107

The temperature element K8107 is a type PT 100 and is placed in the pipe system
after 2nd Stage SSHE E8107.
Set point for the PID-controller for refrigerant regulation valve G32Q6002 as well as
alarm set points can be selected from the display.
Q8150/Q8151/Q8152/Q8153/Q8154/Q8155 Valve for CIP/Coffee extract

Valves for CIP/Coffee extract Q8157 to Q8155 has an on/off function.
Q8157/Q8159 Valve for Chilled water to Heat Exchanger E8150/E8151

Valves for CIP/Coffee extract Q8157/ Q8159 has an on/off function.
P8201 & P8202: Foaming Gas Pressure & Foaming Gas Supply Pressure
display.
K8208: Foaming gas flow measuring

The measuring device K8208 measures the flow of Foaming Gas which is led to the
foamers.
Rate of flow in normal litres per minute is displayed on the screen.
Q8212: Foaming Gas Shut-off Valve

The valve is OPEN in START and EXTRACT ON modes.
Q8213: Foaming Gas Flow Controller

The flow controller Q8213 controls the flow of Foaming Gas to be injected into the
extract flow in Foamer G8105 or G8106, to obtain the required density of the foamed
extract, as measured by Flowmeter K8108.
The set point for density in g / l can be selected from the faceplate.
Foaming Gas flow regulator Q8213 is ON in START and EXTRACT ON modes.
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CONRAD™ 600 XL eco 0610-0137
Q8215/ Q8216: Shut-off Valve protecting the N2/Air dosing unit

The (5/2) solenoid valve Q8215/Q8216 controls the pneumatic operated ball valve
Q8217/Q8218. If the pressure measured by P8113 is > or = P8201 the valve closes
the ball valve Q8217/ Q8218.
Q8301/Q8302/Q8303 : Valve for activating aromasystem

The valves Q8301/Q8302/Q8303 has an on/off function and is used for activating
opening/closing the aroma system in variants.
The valves is controlled from the control system
G31Q6003: Hot Gas Supply Valve, SSHE E8104

The (NC) solenoid valve H1G31Q6003 has an on/off function.
G31Q6001: Liquid refrigerant-Supply Valve, SSHE E8104

The (NC) solenoid valve G31Q6001 has an on/off function.
Valve G31Q6001 is OPEN when SSHE E8104/G8104 is running.

If SSHE E8104/G8104 is stopped valve must be CLOSED.
G31Q6002: Refrigerant-regulating Valve, SSHE E8104

The regulating valve controls the amount of refrigerant that evaporates in the SSHE in
order to maintain the correct extract temperature.
A PID regulator giving 4-20 mA corresponding to an opening from 0% to 100% controls

the valve. The PID regulator adjusts the valve position in order to maintain a
temperature after SSHE E8104 equal to the set point for the temperature transmitter
K8104. When the temperature set point is exceeded the valve is opened, and when
the temperature is below the set point the valve is throttled.
During START mode the PID controller is set in AUTO mode when the rotor G8104 of
the SSHE E8104 is started.
Unless when START or EXTRACT ON modes are ON the valve is CLOSED.
G31K6002: Suction Pressure for refrigerant separator G31C6000

The pressure transmitter G31K6002 has an output of 4–20 mA corresponding to a
pressure range of 1,9 to 5,2 bar abs.
The measurement is used in the PID-control of the suction pressure maintained by the
refrigerant regulation suction valve G31Q6002.
Set point for the PID-controller is the extract temperature measured by K8104
G31Q6005: Drain Valve, SSHE E8104

G32Q6001: Liquid refrigerant-Supply Valve, SSHE E8107

Valve G32Q6001 is OPEN when SSHE E8107/G8107 is running.

If SSHE E8107/G8107 is stopped the valve must be CLOSED.
GEA Niro
G32Q6002: Refrigerant-Regulating Valve, SSHE E8107

The refrigerant-regulating valve controls the amount of refrigerant media that
evaporates in the SSHE in order to maintain the correct extract temperature.
A PID regulator giving 4-20 mA corresponding to an opening from 0% to 100% controls

the valve. The PID regulator adjusts the valve position in order to maintain a
temperature after SSHE E8107 equal to the set point for temperature transmitter
K8107.
When the temperature set point is exceeded the valve is opened, and when the
temperature is below the set point the valve is throttled.
During START mode the PID controller is set in AUTO mode when the rotor G8107 of
the SSHE E8107 is started.
When put in AUTOMATIC mode the valve is always CLOSED, unless in START and
EXTRACT ON modes.
This corresponds to 4 mA and it must not be possible to open the valve.
G32Q6003: Hot Gas Supply Valve, SSHE E8107

G32Q6005: Drain Valve, SSHE E8107

G32K6002: Suction Pressure for refrigerant separator G32C6000

The pressure transmitter G32K6002 has an output of 4–20 mA corresponding to a
pressure range of 1,9 to 5,2 bar abs.
The measurement is used in the PID-control of the suction pressure maintained by the
refrigerant regulation suction valve G32Q6002.
Set point for the PID-controller are the extract temperature measured by K8107
GEA Niro
CONRAD™ 600 XL eco 0610-0137
G31K6001 /G32K6001: Refrigerant level in separator G31C6000/ G32C6000

The level indicator G31K6001/ G32K6001 controls the level of refrigerant liquid in the
separator G31C6000.
The level is shown on the screen and set points can be selected from the display.
Q8090/ Q8190: Cleaning water Valve by-passing pump G8001/ G8101

The pneumatically operated valve Q8090/ Q8190 is controlled by the solenoid valve
Q8133/ Q8134 and is only activated in case of cleaning.
Q8133: Valve for activating Q8090 when cleaning

The (NC) solenoid valve Q8133 has an on/off function and is used for activating Q8090
when cleaning.

The valve can only be open in MANUAL mode.
Q8134: Valve for activating Q8190 when cleaning

The (NC) solenoid valve Q8134 has an on/off function and is used for activating Q8190
when cleaning.

The valve can only be open in MANUAL mode.
E8127: Heat Tracing extract supply and re-circulation pipes

The Heat Tracing cable E8127 is used for heating up the extract supply pipe and
recirculation pipe in the cold room when the foaming system is not running.
When put in AUTOMATIC mode, the Heat Tracing is always off.
6.1.1 Set points
The various set points in the foaming system must be determined during the start-up of
the plant to give the best possible operation conditions.
GEA Niro
7. MAINTENANCE
7.1 Safety during maintenance
For maintenance works preferably the complete foaming system should be stopped.
Warning!
The below mentioned guidelines should always be followed when doing
any maintenance work on the foaming system.
 Refrigeration specialists only may perform any maintenance work on the cooling
system for the SSHE units.
 Specialists only may perform all maintenance work other than cleaning.
 Before removing pneumatically operated valves, the compressed air supply lines
must be disconnected. The disconnected air hoses must be blocked with plugs or
by tongs and cleaned carefully before reassembly.
 Prior to any maintenance or repair work on the pumps, the power must be
disconnected at the source, and it must be ensured, that the power cannot be
turned on accidentally by locking the safety breaker with a personally kept pad-lock
or similar.
 Only spare parts mentioned in the spare part list or other spare parts approved by
GEA Niro may be used when repairing any part of the system.
 For details on repair and maintenance of specific items, please find sub supplier’s
instructions in the Instruction Handbook
7.2 Cleaning
The Foaming System can be hand-cleaned or CIP-cleaned (Cleaning in Place).

It is recommended to clean the Foaming system as often as possible in order to
maintain a high hygienic standard.
Cleaning Compounds
Always choose a Cleaning Compound that will not interact with the material.
NOTE!
Never use Cleaning Compound containing ACID for cleaning the inner tube of the
SSHE E8104, E8107 and E8150. The ACID will attack the surface and the chrome
plating.
7.2.1 Hand-Cleaning
Flush all remaining extract out of the pipes and equipment with hot water and if
necessary clean with an appropriate cleaning agent and finish with cold water rinsing.
After cleaning, drain all pipes and equipment of remaining water before assembling the
system again.
GEA Niro
CONRAD™ 600 XL eco 0610-0137
7.2.2 CIP (Cleaning in Place)
The Foaming System can be CIP-cleaned using the central CIP-kitchen.

The cleaning liquids are delivered from the CIP-kitchen through the tank farm and
extract feed line into the foaming system.
The Foaming System must be prepared for CIP before starting the CIP-cleaning.
1. Drain the extract out of the system
2. Close slide gate M1Q1226 in fines drop duct to fines melter C8001
3. CIP-kitchen ready and the routes from the CIP-kitchen to the Foaming System is
set up.
The Foaming system can be CIP-cleaned using the following sequences

 Flush with water.
 Wash with Caustic soda at 80°C or hot water at 80°C.
 Finally, rinse with water.
7.3 Regular check points
FOAMING SYSTEM
CONTROL POINTS d w m s y ACTIONS REMARKS
Fines Melter C8001 x Check cold air flow Adjust dampers as
required
x Inspect for leaks If leaking, replace
tightening parts
Agitator Fines melter x Inspect axle packing Repair or replace as
G8003 box required
x Check oil level in If low, refill and check
Gear for leaks
SSHE x See Operation
E8104, Manual
E8107, x See Operation
Manual
Extract Pump x See Operation
G8001, Manual
G8101, x See Operation
G8110 Manual
Water/ CIP Pumps x Inspect for leaks If leaking, replace
G8050 tightening parts
G8002 x Noise and vibrations If abnormal, inspect
G8102 pump
G8103
Foaming Gas dosing x Inspect for leaks If leaking, replace
system tightening part
Pipe connections x Inspect for leaks If leaking replace
packing
Field Equipment x Check calibration
d = daily; w= weekly; m = monthly; s = special, see supplier instructions, or during

routine maintenance; y = yearly
GEA Niro
8. SPARE PARTS
8.1.1 Ordering of spare parts
When contacting the service department of GEA Niro, please inform of full part number
(6 digits) from the spare parts list. This part number unambiguously identifies the
requested spare part.
Refer to the original GEA Niro Plant no. (032-7024) and the supplied machinery.
For contact about service or other information, state machine type, serial number and
year of manufacture. These data appear from the nameplates.
Drives
Type designation appears from the nameplate on the drive.
For ordering of separate parts for a drive renovation, please see the supplier’s
instructions for repair, which are enclosed with this manual.
Pneumatic valves
Pneumatic components can be ordered from GEA Niro or according to the supplier’s
diagram and parts list, which are enclosed with this manual.
8.1.2 Spare parts
The necessary spares in order to ensure reliable operation have to be provided before
commissioning and start-up in accordance with the separate spares catalogue located
in section 4.
GEA Niro

Foaming Instruction

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Foaming Instruction

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SECTION 4.

FREEZE DRYING PLANT

TYPE CONRAD™ 600 XL Eco

FOAMING SYSTEM H4J1

TABLE OF CONTENTS PAGE

1. DESCRIPTION OF THE FOAMING SYSTEM .................................................................1

6.1 List of components.........................................................................................................9

7.1 Safety during maintenance..........................................................................................19

1. DESCRIPTION OF THE FOAMING SYSTEM

See drawing no. 1149467: P/I-Diagram Foaming System

The speed of extract pump G8001 is controlled by pressure transmitter K8105 by

A Backpressure Holding Pump G8110 ensures a constant pressure in the system in

2.1.1 Persons responsible for safety

The user or his safety representative must ensure that:

2.1.2 General safety issues

All electrical installation and/or repair work is to be carried out by a

 Maintenance on the refrigerant-cooling part of the Foaming System may only be

Transport Pallets To be returned to manufacturer or

4.1.1 Main data

4.1.2 Fines melter unit sketch

4.1.3 Foaming unit sketch

4.1.4 SSHE unit sketch

Up to a year: Dry, frost-free, dust-free rooms protected from sunlight.

5.1.3 Installation of pipe system

Welding must be executed by certified welders to ensure a safe system with a

5.1.4 Handling of components

5.1.5 Pressure test of the foaming system

When density and temperature is correct system is MANUALLY switched to

The condition for changing to EXTRACT ON is;

If production has to be STOPPED the procedure depends of the length of expected

At short stops up to about 5 minutes flow is changed to RECIRCULATION while all

6.1 List of components

Text reference to other systems:

CAB FREEZER SYSTEM: = L1

Prefix for all numbers: = H4J1

E1J1 Extract Supply Pumps to Fines Melter Tank

P8001: Flow, Fresh Extract

K8002: Load Cells Fines Melter Tank

G8002: Cleaning water Pump

Pump can only be started in MANUAL mode.

P8003: Temperature, Fresh Extract

The temperature is for display only.

F8003: Safety Switch Fines Melter Tank Lid

G8003: Agitator, Fines Melter Tank C8001

A frequency converter G8003-T01 controls the speed. The rotational speed is

The agitator is ON in START and EXTRACT ON Modes.

P8004: Extract Temperature, Fines Melter

P8005: Pressure after Pump G8001

Q8012: Shut-off Valve Cleaning Water Fines melter

When put in AUTOMATIC mode the valve is always CLOSED.

Q8015: Shut-off Valve, Cleaning Liquid, Fines Melter Agitator

G8050: Water Circulation Pump, Fines Melter Heating Jacket

P8050: Water Temperature, Fines Melter Jacket

Q8051: Steam Control Valve, Fines Melter Heating Jacket

The valve is controlled by a pneumatically operated actuator with positioner operating

K8051: Melted Fines Temperature

K8108: Flowmeter – Density Control

G8001: Fines and Extract Feed Pump

Set points can be selected from the display.

G8101: Extract Feed Pump

G8102: Cleaning water Pump

Pump can only be started in MANUAL mode.

P8102: Pressure after Extract Feed Pump G8101

The CIP Pump is ON in START and EXTRACT ON modes.