The S-Separator

Technical information for mineral oil treatment

Inside view

This technical information deals with the S-Separator which provides the highest separation efficiency for mineral oil treatment ever achieved.

3 4

Summary The Alfa Laval S-Separator Systems

Conventional cleaning with purifier systems Separation results with purifiers Limitations common to conventional purifiers Limitations common to conventional clarifiers

The ALCAP technology

Operating principle Medium free water contamination High free water contamination Transducer MT 50 operating principle Dielectric constant approximate values

11 14 16

The separator
Design features

Flow diagram Separation performance

Factors influencing separation efficiency System layout Separation efficiency test method Separation Performance Standard

19

Remote operation

The Alfa Laval S-Separator

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The Alfa Laval S-Separator

Summary
The Alfa Laval S-Separator is an automated single-stage separation system for the cleaning of fuel oil and lubricating oil.

Based on the well established ALCAP technology, this compact system consists of a high-speed separator and ancillary components together with control system and starter box. It can be delivered in a fully integrated modular design on its own base plate or, to facilitate delivery, as six individual components that can be assembled on site. Available in a full range of sizes and in different congurations, the S-Separator delivers higher cleaning efficiency than previous models and drastically reduces operation and maintenance costs. Innovations include: a compact separator bowl which reduces sludge production and loss of oil, a new disc stack design to ensure optimal ow patterns and separation characteristics, the non-threaded CentriLock spring lock ring which is easy to snap on and pop out, and, the CentriShoot discharge system, which replaces the sliding bowl bottom with a patented, exible discharge slide that is xed within the bowl body. The purpose of this document is to provide technical information about the Alfa Laval S-Separator system. This includes information about the separation process, advances in system design, system benets and a description of equipment.

reduces sludge by up to 75 percent, and minimizes wear and tear on the bowl. Compared to previous separator models, the spare parts inventory has been reduced and the service intervals prolonged. Easy-to-access, easy-to-operate equipment provides automatic, start-and-forget systems that are designed for remote control and operation. No adjustments required to the gravity disc or other system components for continuous optimum separation efficiency despite uctuations in density and viscosity. Proven key components provide more uptime, high reliability, consistent performance and low maintenance. Longer service intervals. Longer-lasting construction prolongs service intervals and reduces spare parts consumption by up to 50 percent compared to conventional systems.

Benets Highest separation efficiency available. In laboratory tests, the Alfa Laval S-Separator removes over 85 percent of all 5-micron particles to ensure fuel and lubricating oils do not contain harmful contaminants. This effectiveness measures up to the Separation Performance Standard. Low installation costs. Compact, modular, exible design saves space and reduces installation costs. Faster, more secure commissioning with full technical support during design, installation and startup even for retrots. Big savings on operation and maintenance costs. The S-Separator provides continuous monitoring of clean oil,
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The Alfa Laval S-Separator

The Alfa Laval S-Separator Systems

The Alfa Laval S-Separator is the principle component of a range of highefficiency mineral oil separation systems. Based on proven ALCAP oil treatment technology, the Alfa Laval S-Separator combines fuel oil and lubricating oil treatment into a single separator, thanks to software that makes it possible to set the relevant parameters in the process controller.

The Alfa Laval S-Separator.

The Alfa Laval S-Separator system can handle: Heavy fuel oils with high densities up to 1010 kg/m3 and viscosity up to 700 cSt/50C. Handling of higher viscosity is available upon request. Lubricating oils for all diesel engine types.

1. as the Alfa Laval Separator Ancillary (SA) system, which consists of six individual components that can be assembled on site to facilitate delivery, or, 2. as the Alfa Laval Separator Unit (SU), which is a fully integrated modular system on its own base plate. Both systems include:

Distillates and light diesel oils (MDO). The Alfa Laval S-Separator systems consist of a separator and its ancillary components, together with control system and starter box. It can be delivered in two ways:
4 Alfa Laval Marine & Diesel Equipment

an high-speed S centrifuge, an EPC50 process controller, an MT 50 transducer (capacitive transmitter), and, ancillary equipment.

The Alfa Laval S-Separator

SU Separation Unit Easy to work with but occupying only a minimum volume, the plug-and-play Separation Unit integrates a separator and ancillaries with a control cabinet and starter box. With all components pre-installed on a single base plate, you save installation time, materials and space.

SU Module The plug-and-play SU Module combines a Separation Unit with a heater and feed pump. This makes it a complete oil cleaning system and an optimum solution for protecting your engine. Double and triple congurations are also available, each mounted on a single base plate with all of the interconnecting piping.

Oil block

Water block

Sludge outlet kit

SA Separation Ancillaries A non-integrated solution, the SA separation system lets you minimize your initial investment by assembling it on site. Specialized block components let you determine the arrangement, and each component is pre-tested to ensure a perfectly working system.

Air block

Optional starter

EPC50 control unit

To further simplify the design process, 3-D AutoCAD drawings for all separator congurations are available in electronic format.

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The Alfa Laval S-Separator

Consequently, the purier type of separator restricts the use of available fuel oils. For lube oil cleaning, the conventional puriers are still an option.

Interface position sensitivity

Conventional cleaning with purier systems Conventional cleaning plants are based on purier type separators. Practical operation has clearly proven that the generally accepted maximum density limit for fuel oil is 991 kg/m3 at 15C. This maximum density limit may be exceeded at bunkering, which may result in operational difficulties with the cleaning plant.

840

Fuel density kg/m3 at 15C

950

970

991

Separation results with puriers To achieve optimum separation results using puriers, the interface between oil and water in the bowl must be outside the disc stack. The interface position of a purier is adjusted by means of gravity discs. To get the correct interface position the purier must be tted with a correctly sized gravity disc. This presents an operational dilemma with changing oil properties. With higher fuel densities, maintaining optimum separation results by means of gravity discs becomes increasingly difficult. Factors that affect the interface position are changes in oil density, viscosity, feed ow rate and temperature. With increasing fuel density, the interface position becomes progressively more sensitive to these factors (Figure 1).
Gravity disc capability

Figure 1. Interface positions sensitivity.

840

Fuel density kg/m3 at 15C

950

970

991

Unfortunately, gravity discs experience the same progressive sensitivity to these disturbing factors. The capability of the gravity disc therefore declines progressively with increasing fuel density (Figure 2). Thus, as the interface position becomes more sensitive to disturbing factors, each successive gravity disc has a reduced capacity to cope with them (Figure 3). In practice, problems with the purier develop well before the fuel density reaches 991 kg/m3. Temperature uctuations, inherent in even the best temperature control systems, cause viscosity uctuations. However, a proportional integral (PI) temperature controller will considerably reduce this source of disturbance.

Figure 2. Capability of the gravity disc to cope with disturbing factors.

Interface sensitivity

Gravity disc insufficiency

Purifier problem area

960 PURIFIER 991 + PURIFIER + CLARIFIER 1010 ALCAP FOPX

Fuel density

Figure 3. Purier problem area.

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The Alfa Laval S-Separator

Limitations common to conventional puriers The basic problem in treating heavy fuel oil is the gravity disc: It restricts the use of diesel engine fuels to those with a maximum density of 991 kg/m3 at 15C. Optimum separation depends on selecting the correct gravity disc, which corresponds to the prevailing density, viscosity, feed ow rate and temperature. This becomes an impossible task in practical operation with the uctuation of density and viscosity, particularly with high-density fuels of 991 kg/m3 at 15C and above. Checking and tting the gravity disc is time-consuming and unpleasant. Since the correct gravity disc is dened as the largest disc that does not cause a broken water seal, it can be a frustrating trial-and-error process. Alarms for broken water seals can be frequent. Consequently, the gravity disc selected tends to be undersized and the oil cannot be adequately cleaned in a purier alone. To ensure satisfactory cleaning a second separator is required in series operation. This creates a separation system of a purier followed by a clarier as a safety net. This system, however, is still restricted to oils with a maximum density of 991 kg/m3 at 15C.

Limitations common to conventional clariers The basic problems when treating fuel oil of any density in a clarier are oil losses and limited water handling capability. Oil losses When operating a separator in clarier mode, no displacement water is added prior to sludge discharge. Therefore, not only sludge and separated water are discharged, but a certain volume of oil is discharged, too. Limited water handling capability For optimum separation efficiency separated water must not enter the disc stack. The separated water can only be discharged with the sludge through the sludge ports at the bowl periphery since the water outlet is closed in a conventional clarier (Figure 4). If a clarier is used without a purier in the rst stage and with elevated water content, sludge discharge occurs frequently at short intervals because no other method of discharging separated water exists. Sludge discharge causes turbulence in the bowl and therefore discharging sludge too frequently decreases separation efficiency. Consequently, the water handling capability of a conventional clarier is insufficient for cleaning fuel oil.

Figure 4. Conventional clarier water discharge.

Water outlet closed

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The Alfa Laval S-Separator

The ALCAP technology

Operating principle Dirty, pre-heated oil is continuously fed to the S-Separator, which essentially operates as a clarier. Clean oil is continuously discharged from the clean oil outlet. Separated sludge and water accumulate at the periphery of the bowl. When separated water approaches the disc stack, traces of water start to escape with the cleaned oil. This minor increase in water content of the cleaned oil is detected by the transducer MT 50, which is installed in the clean oil outlet. Increased water content in the cleaned oil is a sign of reduced separation efficiency not only of water, but of solid particles too.
Figure 5. Low free water contamination.

Oil

Sludge and water

The transducer continuously measures changes in water content. No absolute values of water content or volume are involved. The transducer measures the deviation from a non-calibrated reference value and transmits a signal to the EPC50 process controller for interpretation. Measurements that fall within the permissible deviation values are known as the trigger range.

MT
The EPC50 process controller stores a new reference value after the transducer stabilization time that follows every sludge discharge sequence has elapsed. During the reference time the best possible separation result is obtained. At the trigger point, which is when the water content in cleaned oil reaches its maximum allowable deviation of approximately 0.2 percent, the EPC50 process controller initiates an automatic discharge of the water that has accumulated in the separator bowl.
Disc stack Water transducer

Water

Figure 6. High free water contamination.

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The Alfa Laval S-Separator

Depending on the amount of water in the oil, water is discharged either through the water drain valve, or with the sludge through the sludge ports at the periphery of the bowl.

Transducer

MT
Medium free water contamination When separated water approaches the disc stack the transducer signal triggers the EPC50 process controller to open the water drain valve.

High free water contamination When excessive amounts of water are present in the feed and if the water drain valve activation does not provide sufficient drainage, the EPC50 process controller automatically initiates a sludge discharge.

Figure 7. High free water contamination water drain valve activated.

Transducer MT 50 operating principle The transducer includes a cylindrical capacitor through which the full ow of cleaned oil passes, forming a dielectric medium. The working principle of the transducer exploits the large difference between the dielectric constants of mineral oil and water.

Dielectric constant approximate values Mineral oil 24 Water 80 The dielectric constant of oil contaminated with water increases when the water content of the oil increases, and vice versa. Changes in the dielectric constant of the cleaned oil are very sensitive, convenient measures of changes in its water content.
Figure 8. High free water contamination sludge discharge.

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The Alfa Laval S-Separator

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The Alfa Laval S-Separator

The separator
With its unique design features, the centrifugal separator incorporated in the range of S-Separators is the most advanced separator ever produced for the marine and power industries.

Longer intervals between service have a positive effect on overall life cycle costs compared to those of previous separator models. All components, from the simple belt drive to the design of the new bowl, have been thoroughly tested both in laboratory trials and in rigorous eld tests under normal and forced operating conditions.

Drive The separator is driven by an electric motor via a at belt to the spindle that is supported in the frame by bearings and special composite springs. No tensioning of the drive belt is required. This conguration provides reliability and long intervals between service.

Bowl The bowl, which is xed at the top of the spindle, contains the most advanced changes found in the separator. Fluid dynamics studies have been extensively used in the design to ensure the best possible ow patterns. This is especially true in the case of the disc stack, which has been optimized to provide high separation characteristics and to help keep the bowl free from sludge deposits. The bowl has a simple paring tube, instead of the conventional heavy phase paring disc, that oats on the surface of the heavy water phase. This patented paring tube system minimizes oil losses and enables use of the same bowl conguration on all fuel and lube oil types. As with all bowls using ALCAP technology, no adjustments are necessary and no gravity discs are tted. Because of its high speed and advanced design, the bowl is appreciably smaller than those of previous separator models for a given capacity requirement. This compact bowl is a factor that contributes to the small overall size of the separator.

Figure 9. The S-Separator.

Untreated oil Clean oil outlet Water outlet

CentriLock

Paring tube

Seal ring Discharge ports Discharge slide

Figure 10. Separator bowl.

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The Alfa Laval S-Separator

Figure 11. CentriShoot discharge system.

Figure 12. CentriLock lock ring.

STEP ONE:

CentriShoots discharge slide is xed at the centre. During separation it covers the discharge ports. CentriLock can be removed with only an Allen key. No sledgehammer is necessary.

STEP TWO: During sludge discharge, the edge of the slide exes downward, exposing the ports.

CentriLock lifts out and snaps in easily without any threads to wear. Threaded lock rings must be removed with a sledgehammer. Over time, metal-to-metal wear between bowl and lock ring lead to expensive bowl repair or replacement.

STEP THREE: After discharge, the slide moves gently back into position, closing the ports. Closing is done hydraulically, without any springs.

Discharge system The separator operates with the new CentriShoot discharge system. The sliding bowl bottom of previous models has been replaced by a discharge system that uses a patented, exible discharge slide that is xed in the bowl body. During discharge, only the outer periphery of the disc exes downward exposing the discharge ports. The frame of the separator easily absorbs the impact forces in the sludge. Because of the smaller bowl volume, longer intervals between sludge discharges and more accurate controls, the new system provides efficient sludge removal but with less oil loss, lower water consumption and less total waste production than previous models.

CentriLock lock ring In the new separators, a simple snap-in spring lock ring, for which patents have been applied, has replaced the traditional threaded lock ring, the lock ring spanner and the sledgehammer. The bowl is assembled and then compressed, using the mechanical disc stack compression tool that comes with the S-Separator. This enables the spring lock ring to snap easily into place. Removal is equally simple. An Allen key loosens grub screws set into the outer wall of the bowl and the lock ring pops out.

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The Alfa Laval S-Separator

Inlet/outlet parts The inlet/outlet parts of previous models consisted of several parts that required individual assembly. These individual parts have been replaced in the new separator by a single housing to which the inlet/outlet hoses are connected. When opening the separator, the hoses are disconnected rst and secured to one side for reconnection. The entire housing can then simply be removed as a single piece.

EPC50 process controller The control cabinet for the separator unit combines the motor starters and the process controller into a single unit. However, the separator ancillary system requires the process controller to be installed in a separate cabinet. Maximum reliability and user-friendliness were among the major design considerations for the new EPC50 process controller. In addition, the EPC50 introduces several new functions that are now available due to changes in the instrumentation. Pressure transmitters have replaced pressure switches in the ancillaries unit, providing a higher degree of accuracy and reliability. They also supply the process controller with a continuous stream of information. Instead of the message codes used in previous systems, the new unit provides information in clear language in a rolling text window. Eight different languages are provided as standard, enabling the operator to select the language of choice at the initial start-up. Further support for the rolling text messages is provided in the Instruction Book. In rigorous tests over many years, the process controller has proven to be stable and the light-emitting diode (LED) display legible under conditions of high humidity and temperatures of 55C and above. The EPC50 has been granted approval from many classication societies.

Ancillaries The system can be delivered either pre-assembled as a single compact pre-tested unit that includes the separator and ancillary unit mounted together, or as loose blockmounted components with the separator and ancillaries as individual units.

Ancillaries system Good engineering principles have yielded improvements in the new ancillaries unit compared with the ancillary systems supplied with previous models. Instead of having to connect several different components, the new ancillary system consists of three blocks. The main block consists of the inlet and outlet connections, control and regulating valves, temperature and pressure transmitters, and the water transducer built into a single block. The two smaller blocks for operating water and air are connected as the unit is built. Six pipe connections are required for the S-Separator: Oil inlet Clean oil outlet Oil recirculation outlet Operating water Operating air Sludge outlet.

Sludge Removal Kit for use with the Separation Unit Thanks to the new discharge system it is no longer necessary to have a large sludge tank under the separator. Instead, a very small intermediate sludge tank can be mounted on the base plate between the separator and the ancillaries unit. The intermediate sludge tank is equipped with a level switch and an air-operated pump that pumps away the sludge after each discharge. The tank is also equipped with a connection for a small vent pipe to the nearest tank ventilation. The Sludge Removal Kit provides exibility in the placement of a separation unit.

Figure 13. EPC50 process controller.

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The Alfa Laval S-Separator

Flow diagram
Feed Pump
Feeds unprocessed oil to the separator.

Pressure transmitter, oil

Measures the pressure in the oil inlet, and signals the process controller.

Pressure transmitter, oil

Measures the pressure in the oil outlet and signals the process controller.

Heater
Heats unprocessed oil to the separation temperature.

Pneumatically controlled
changeover valve Leads the untreated oil to the separator, or back for recirculation.

Transducer
Continuously monitors changes in water content in the oil outlet and signals the process controller. Provides a separation efficiency check.

Temperature transmitter
Measures the oil temperature and signals the process controller.

Process controller
Supervises the S-Separator.

Untreated oil inlet

TT

PT

Oil return

Optional

Conditioning water Opening water Water inlet Closing water

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The Alfa Laval S-Separator

Regulating valve
Regulates the back-pressure in the clean oil outlet.

Separator
Cleans the oil by removing water and solid particles.

Pneumatically controlled
shut-off valve Closes the clean oil outlet.

Pressure transmitter, water

Measures the pressure in the water drain outlet and signals the control unit.

Solenoid valve block, water

Distributes separator opening/closing water and conditioning water.

Drain valve
Opens when water is drained from the separator.

EPC50 Control Unit

PT

MT

Clean oil outlet

PT

Water outlet

Separation Unit

Sludge outlet to sludge tank or Sludge Removal Kit

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The Alfa Laval S-Separator

Separation performance
Catalytic nes introduced during the renery process of heavy fuels can cause premature wear of components and engine breakdown. Therefore, good separation performance is imperative.

Factors inuencing separation efficiency Several factors inuence separation efficiency, such as: Separation temperature Separation viscosity Feed rate Utilization of the disc stack Densities of the light phase (oil) and heavy phase (water) Size and number of solid particles in the feed Amount of water in the feed Chemical characteristics of the oil

splitting the feed rate equally between the two separators is recommended to maintain sufficient separation efficiency. Series operation will not improve the separation efficiency to the same degree as parallel operation. Consequently, the S-Separator cannot be operated in series conguration. Lube oil is not subjected to variations in viscosity and density, therefore a correctly sized separator in single-stage operation that is properly operated fulls the requirements to achieve the desired separation result.

System layout Single-stage operation is the normal operating mode, which generally provides sufficient separation efficiency. Fuel oil varies considerably in terms of viscosity, density and the amount of solids, water and other characteristics present. On those occasions when the fuel oil contains elevated levels of abrasive wear particles and/or water, parallel operation

Separation efficiency test method One of the major challenges facing the development team was the lack of a reliable method for testing the separation efficiency of the new separator during the various stages of the development work. This required a method that closely approximated normal operating conditions, but would provide accurate and reproducible results to establish a standard separation efficiency test method.

Separation vs. flow rate 100

80

pa

rti

cle

Separation [%]

60

40

20

0 0 1 2 3 Flow rate [m /h]

3

Figure 14. Separation of plastic particles versus ow rate in an older Alfa Laval model.

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The Alfa Laval S-Separator

In the early 1980s, Alfa Laval carried out separation efficiency tests using a typical fuel oil. Both before and after separation, the levels of contaminants, expressed as aluminium and silica, were measured both by weight and by particle size using a particle counter. These tests indicated separation efficiencies for particles greater than 5 micron in the region of 70 to 80 percent for ALCAP separators. The tests also showed that a single ALCAP separator could replace the traditional purier/clarier in series operation. Instead of catalyst nes, monodisperse spherical plastic particles size 5 micron are used. This is relevant with respect to the tolerances found in fuel injection and engine lubrication systems. These particles are produced to very exact dimensions and densities. In typical laboratory tests, the prepared mixture of synthetic oil and plastic particles is heated to a temperature that provides the same viscosity as fuel oils (380 and 700 cSt @ 50C) when heated to the normal separation temperature of 98C. The material is then fed through the separator at different feed rates, and samples are taken at xed intervals after a discharge. The method demonstrated that the test could produce consistently reproducible results for a given set of conditions. The test therefore was considered suitable as a highly accurate test method to determination separation efficiency. Typical data from test results show a gradual decrease in separation efficiency as ow rate increases (Figure 14).

Good correlation was also found between this method and separation tests carried out at 98C on a sample of fuel oil containing catalyst nes. It is known that separation efficiency is a function of capacity and that, if capacity is raised, then separation efficiency will decrease. To maintain separation efficiency when capacity is increased, improvements must be made to the separator in order to provide the desired separation efficiency at the increased capacity (Figure 15). Despite the fact that modern bunkers often have good quality and contain low amounts of catalytic nes, underdimensioning separation systems is inexcusable. Occasionally, highly contaminated bunkers or bunkers with poor separation characteristics may occur. Other parameters, such as separation temperature and the cleanliness of the disc stack, uctuate. To maintain a safe margin against poor separation performance, even during such conditions, a separation system, which is amply over-dimensioned for easy treatment of bunkers, is required. This may be regarded as an insurance fee that pays off during demanding conditions, such as when other systems do not perform satisfactorily and lead to costly engine wear and unreliable operation. Similar reasoning applies for lube oil systems. Although the characteristics of the oil do not vary much, other parameters can have noticeable inuence on the separation efficiency. It is important to dimension the system for the worst-case scenario. Otherwise unacceptable engine wear can result.

100 a 80 Decrease in separation efficiency due to increased recommended capacity without improved design. b 40 Increased rec. cap c

Separation [%]

60

Imp ed rov

20

Old rec. cap

ld

Flow

Figure 15. Illustration of the effect of increased ow design in a separator. a) Old point of operation. b) After increasing capacity without change in design. c) Improved design gives high efficiency of increased ow.

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The Alfa Laval S-Separator

Separation Performance Standard Establishing a separation performance standard enables: Fair comparison of different separators, Good reliability of the diesel engine, and, Economical operation of the diesel engine. Of all the contaminants contained in residual fuels, the most damaging are catalytic nes. These are hard, abrasive, irregularly shaped particles of aluminium silicate, which must be removed, or at least reduced, to acceptable levels before the fuel oil is injected into the engine. If cat nes remain, they can lodge in injection pumps, piston rings and cylinder liners, causing serious wear that can over time lead to breakdowns. According to ISO 8217 standards, the maximum allowable cat nes in bunkered fuel is 80 parts per million (ppm). However, because engine builders typically stipulate a maximum of 15 ppm in fuel oil, fuel oil is rigorously cleaned by centrifugal separation before it enters the engine. Currently, fuel oil separator selection is based on the Maximum Recommended Capacity (MRC) tables provided by the manufacturers. It is known that separation efficiency is a function of the separator ow rate. Generally, the higher the ow rate, the higher the number of particles that remain in the oil, and the lower the separation efficiency. But as the ow rate is reduced, particle removal increases and cleaning efficiency improves. It is, however, essential to know at what capacity adequate separation efficiency is reached in the typical case. There is no recognized reproducible method for measuring the relationship between capacity and separation performance. Therefore no one can be absolutely sure that separators chosen according to the MRC actually provide safe removal of harmful catalytic nes from the heavy fuel oil before injection into the engine. Fuel system suppliers do not believe that it is possible to compensate for poor separation or to provide adequate back up to ensure separation performance by installing a ne lter downstream of the separator. The lter would only capture particles of 10 micron or more, while smaller cat nes that remain would pass through the system. Centrifugal separators can remove particles as small as two micron. In cooperation with several classication societies, Alfa Laval has provided a de facto standard for independent verication of separation performance based the DNV-approved Dyno Test Method. This is an alternative to specifying separator performance based on the MCR; the new standard is expressed as Certied Flow Rate (CFR). A separators CFR is the throughput rate at which 85 percent of 5 micron monodispersed plastic particles, which simulate harmful catalytic nes, are removed from the test oil, which simulates a high viscosity fuel oil. The CFR represents a safe level for continuous, efficient separation and provides the industry with independent verication of separation perfor18 Alfa Laval Marine & Diesel Equipment

mance. This makes it possible to compare fuel oil separators based on separation efficiency rather than on throughput capacity. With CFR measured for every separator, customers can specify a unit of the correct size for the task, with the knowledge that the installed unit will suit its intended purpose and eliminate the risk of installing an undersized unit. Because catalytic nes are not available in any standard size distribution, it is impossible to create a standard based on the evaluation of tests using real cat nes, or real heavy fuel oil. Fuel oils also vary in terms of chemical characteristics, which affect the polarity, and physical characteristics such as density and viscosity. Due to these wide variations, it is impossible to obtain repeatable and comparable results from tests made on actual bunkers. The 5 micron monodispersed plastic particles, or Dynospheres, are identically sized, homogeneous, spherical plastic particles, normally used for the calibration of instruments. The development of the Separation Performance Standard is positive for the shipping industry as a whole. For the ship owner, the overall benets are clear: different separators can be compared on equal terms based on a reliable independent international performance standard. The owner may nd that investment in a larger separator is required when basing selection on CFR. This, however, can be compared with buying a separator with an insurance fee against damage to the engine caused by inadequate separation. Analyses indicate that a reduction in engine wear of as little as two percent makes the selection of separators according to CFR a protable investment. At a given ow rate, a larger separator will always provide higher separation performance than a smaller one.

The Alfa Laval S-Separator

Remote operation
Unlike previous systems, the S-Separator has several options for remote operation. This has been made possible due to built-in safety features, such as a speed sensor and a vibration sensor.

Depending on the installation, the alternatives for remote control include: Bus communication that enables up to nine systems to be connected as a network. Installation of the customers own software package enables remote operation. A MODBUS or PROFIBUS board must be installed in each EPC50 process controller. An additional EPC50 control panel (remote operator panel) that can be installed for local operation or for operation from an alternative location. A simple remote operation version that uses two switches connected to an I/O expansion board. A junction box that can be installed on the S-Separator to enable positioning of the control cabinet at a location away from the separator itself. Each alternative provides safety interlocks to prevent accidental operation in un-safe conditions.

REMIND As standard, each complete delivery of the S-Separator includes a REMIND software package for local monitoring only, a short connecting cable and an operating manual. This allows the operator to install the program disks on a laptop computer that is then connected to the EPC50 process controller. REMIND can then review and store the alarm history and the processing parameters in the laptop. This data may be used later to check processing conditions and for troubleshooting. Full instructions for the installation of the various systems are given in Instruction Books.

Figure 16. Remote control network version.

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The Alfa Laval S-Separator

Retrofitting
The Alfa Laval S-Separator is ideal for new building applications as well as for replacing older separator units or supplementing existing cleaning systems. Its compact size easily ts into available space in an existing engine room. It can also be divided into four parts in order to facilitate transport through small passageways. In addition, the pipe connections for the separator units enable greater exibility for the placement of the unit; the units no longer need to be located over the sludge tank or in the same place as the unit it is replacing.

Documentation
Alfa Laval supplies each S-Separator with full documentation either as paper copies or as PDF (Portable Document Format) les on a CD-ROM. Documentation is clearer and easier to understand, thanks to improved graphics. The instruction manual, which can also be made available in most major languages, covers: Safety System description Operating instruction Parameter list Alarms and fault nding System reference/installation instructions Service manual Spare parts catalogue

Classification society approval

Alfa Laval ensures that the S-Separator fullls the requirements of all major classication societies. Upon request, Alfa Laval delivers each S-Separator with an individual test certicate. This includes approval by the society of the main components as well as workshop testing of the complete module. Most key components are also type approved by the leading classication societies.

Spare parts, service and support

Alfa Laval provides spare parts kits for all service and maintenance needs. Global technical service, training and support are available throughout the lifetime of the S-Separator.

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Alfa Laval reserves the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local Alfa Laval company. Published by: Alfa Laval Tumba AB Marine & Diesel Equipment SE-147 80 Tumba Sweden

Copyright Alfa Laval Tumba AB 2004.

Alfa Laval in brief Alfa Laval is a leading global provider of specialized products and engineering solutions. Our equipment, systems and services are dedicated to helping customers to optimize the performance of their processes. Time and time again. We help our customers to heat, cool, separate and transport products such as oil, water, chemicals, beverages, foodstuff, starch and pharmaceuticals. Our worldwide organization works closely with customers in almost 100 countries to help them stay ahead.

How to contact Alfa Laval Contact details for all countries are continually updated on our web site. Please visit www.alfalaval.com to access the information.

EMD00049EN 0410

www.fotoskrift.se

2004