Teagasc/IMQCS Recommendations for the …

1 1 Teagasc/IMQCS Recommendations for the installation andtesting of milking machines2 table of ContentsRecommendations for the installation and testing of milking machines1 Performance Tests for Access for Airflow measuring Vacuum measuring Additional IMQCS requirements for test points and isolation 112. Safety and hygiene .. 123. Additional IMQCS requirements for materials4. User s Installation Instructions for 175 Vacuum Vacuum Vacuum Regulation Regulation Regulation characteristics and effective Vacuum Vacuum Pumps - Influence of Prevention of reverse flow through vacuum Additional IMQCS requirements for vacuum Additional IMQCS requirements for Vacuum Regulator Vacuum Examples of location of sensing points for vacuum Additional IMQCS requirements for vacuum Vacuum Vacuum gauge 22 Airlines-internal diameter and Additional IMQCS requirements for Sanitary Leakage into the vacuum Additional IMQCS requirements for sanitary trap(s).

2 236. Pulsation Design data that shall be included in the user s Pulsator Pulsation rate, pulsator ratio and pulsation chamber vacuum Additional IMQCS requirements for pulsation 267. Milk Design of Additional IMQCS requirements for Additional IMQCS requirements for washlines-milkline Additional IMQCS requirements for milk transfer lines- recording jar Additional IMQCS requirements for milking vacuum/wash lines-recording jar Additional IMQCS requirements for milk recording Air Milk Diversion of Control of releaser milk Delivery 338. Milking Additional IMQCS requirements for milking Teatcup Teatcup Vacuum Air vent and Vacuum in the milking Milk recording Recorder Attachments to the milking Long milk 3749. Additional IMQCS requirements for milk pumps and milk Vacuum system- Mechanical tests (ISO 6690).

3 General requirements and Preparation before Vacuum Test of vacuum regulation Regulation Regulation Tests of regulation Effective reserve for Vacuum Vacuum pump Vacuum pump exaust back Vacuum regulator Vacuum gauge Vacuum drop in Leakage in vacuum 4511. Pulsation Pulsation rate, pulsator ratio, pulsation vacuum phases and vacuum drop in pulsator 4712. Milk Slope of Milk system Milking Teatcup or cluster fall-off air Leakage through shut-off valves of milking Air vent and leakage into teatcup or Measuring the vacuum in the Measurement of the vacuum drop from accessories attached in the long milk Airflow at the end of the long milk 53 table 1 - Midi-level milkline plants with two 54 table 2 - Midi-level recording jar plants with two table 3 - Double up low level milkline plants with one 4 - Double up midi-level milkline plants with one 57 table 5 - Double up midi-level recording jar plants with one 58 table 6 - Recommended sizes of diversion 59 AppendicesAppendix A - Measurements and 61 Appendix B - Test report and inspection - service check 67 Appendix C - Laboratory and parlour tests of vacuum in the milking unit.

4 76 Appendix D - Milk 805 Recommendations FOR THE INSTALLATIONAND TESTING OF MILKING MACHINESR ecommendationsRecommendations6 Recommendations for the installation and testing of milking machinesIntroductionThis manual has been prepared by the Irish Milk Quality Co-Operative Society(IMQCS). IMQCS has its registered office at 84 Merrion Square, Dublin 2. Theorganization was incorporated in 1989 with the aim to improve milk qualitystandards in Ireland, to ensure that Irish milking machine installation andtesting standards exceed the best international standards. This manual combines Irish Milk Quality Co-operative Society (IMQCS)Guidelines and ISO standards (International Standards Organisation) (ISO5707 (2007), ISO 6690 (2007) and ISO 3918 (2007) into a reference guide forall milking machine installers and advisers in the Republic of Ireland. Themanual also contains information on some equipment and topics related tomilking machines which are outside the scope of the ISO standards.)

5 TheIMQCS guidelines and ISO standards have been developed to ensure bestpractice in the installation and testing of milking machines and are not a basis of the manual is compliance with existing standards, directives andlegislation and agreed installation practices for the fitting of new milkline andrecorder parlour plants for manual applies only to the main milking facility (which is usually aparlour) and does not apply to new bucket plants. Where possible andpracticable the Recommendations shall be applied to existing IMQCS has informed each person who is listed in its Register of CertifiedMilking Machine Testers and Installers of the importance of complying withthese Recommendations . IMQCS is not in a position to police adherence tothese Recommendations and cannot accept any responsibility for any loss ordamage of any nature which might be incurred by non-compliance with use of shall indicates that a clause is mandatory for compliance withthese Recommendations , whereas, should clauses are recommended onthe grounds of good term manufacturer is used in these Recommendations to refer to theoriginal equipment manufacturer (OEM) and installer is the actual is in contrast to CE documentation in which the installer is defined asthe manufacturer.

6 In a situation where a main contractor provides a completemilking installation consisting of components from more than onemanufacturer he has responsibility to all CE and ISO standards requirementsfor the complete installation and therefore deemed to be the manufacturerRecommendationsIntroduction7 Recommendationsof the complete installation. If a main contractor provides an individualcomponent ( , pulsation system) in an existing installation he shall beresponsible only for the CE and ISO requirements of that manual has been prepared by;Mr. Seamus GogginIMQCSDr. Edmond HartyIMQCSMr. George KearnsSecretary,IMQCSDr. Eddie O CallaghanEditor, TeagascMr. Alan PearsonIMQCSMr. Sean ReidIMQCSMr. Tom RyanTeagascThe committee wishes to acknowledge the contribution of Margie Egan, teagasc , Moorepark in compiling this PERFORMANCE REQUIREMENTSISO 5707 Milking machine Installations-Construction and Performancespecifies minimum performance and information requirements and certaindimensional requirements for satisfactory functioning of milking machinesfor milking and Tests for complianceThe methods for performance testing referred to in this manual are specifiedin ISO 6690.

7 Access for Generala) Connection points for measuring airflow and vacuum shall be ) Dismantling is acceptable to access connection points. c) All connection points and their location shall be described in the user' Airflow measuring connections (Figure 1)A1: to enable measurement of effective reserve, manual reserve and regulatorleakage:a) For bucket or direct-to-can milking machines connection to be betweenthe regulator sensing point and the first vacuum ) For pipeline milking machines connection to be at or near the receiver(s),upstream of the sanitary trap(s).c) For recorder milking machines connection to be at or near the sanitarytrap(s) on the milking vacuum line(s)A2: to enable measurement of leakage into the vacuum and milk systemsa) Connection to be between the vacuum pump(s) and the sanitary trap(s)or the first vacuum :When not in use, test connections shall not form a trap for shall have the same internal diameter as the airline or ( 2)mm, whichever is Vacuum and airflow measuring connections (Figure 1).

8 The following measuring points shall be provided for a vacuum or an airflow meter:a)Vmat or upstream of the measuring point )Vrnear each regulator sensing )Vpnear each vacuum pump )PeConnection for measurement of exhaust backpressure of the vacuumpump outlet. e) In a pipeline milking machine, Vmcan be any point in the milking system,or upstream of the receiver. In a recorder jar milking machine, Vmcan bein the milking vacuum line or in the nearest convenient recorder jar. In abucket milking machine, Vm = Vrand can be combined with the nearestconvenient vacuum tap. f) All test connections shall be at least five pipe diameters from any bends,air inlet points or other fittings creating air ) If the regulator sensing point is on a branch, there shall be two measuringpoints Vr, one to measure the vacuum drop in the airline upstream of thisbranch and the other one to determine the regulator leakage near theregulator sensing ) Means shall be provided to isolate vacuum pump(s) to measure vacuumpump ) It is necessary that the pulsators can be stopped or disconnected tomeasure leakage into the vacuum system and of air used to 1.

9 Location of test points in ISO standards (ISO 3918) tees +isolation valves (IV) Additional IMQCS Recommendations for test points and isolationvalves a) Airflow test points shall consist of a tee-piece complete with a test valveand nipple the valve and nipple bores shall not be less than means for the connection of airflow meters are acceptableprovided that their operation does not necessitate the use of tools. b) Isolation valves shall be fitted to the main airline near the vacuum pumpon the interceptor side of the test tee-piece and on the sanitary trapairline between sanitary trap and main ) Isolation valve bore shall be equal to the bore of the airline in which it is fitted. d) A separate vacuum pump to operate feeders is preferred but is notnecessary where there is adequate vacuum pump capacity. e) When a separate vacuum is not provided, means shall be provided toisolate ancillary equipment, such as vacuum feeder, ACRs, vacuum gates,water heater controls, teat sprayers, etc.

10 SAFETY AND HYGIENES afety & Hygience1213 Safety & Hygience2. SAFETY AND HYGIENEa) Installations shall comply with the relevant safety requirements given inISO 12100-1 and ISO 12100-2. The electrical components shall comply withthe relevant safety requirements given in IEC ) Installations shall comply with the hygiene requirements given in ) The equipment has to be effective, easy and safe to use and MATERIALSa) All components that are subjected to a vacuum shall be designed andconstructed to withstand a minimum vacuum of 90 kPa, withoutpermanent distortion. b) Materials that may involve danger if damaged, such as glass, shall bedesigned using a safety factor of 5 against external pressure ( , 5 x 90 kPa).c) All materials in contact with milk or cleaning solutions whether used forrigid components (for example, pipelines or recording jars) or flexiblecomponents (for example, joint rings, teatcup liners), shall be constructedto withstand the maximum temperature used in the plant as specified inthe instructions.