ALFA CE jp fo AG ease Safety 4 Separation System System Description 2 face ea re eee eee eee Operating Instructions 3 io Parameter List 4 fs S002" agit state tenon yg anlcr ons OF? re raga oes ott Alarms and Fault Finding 5 Only foreseeable conditions have been taken int | consideration. No warnings are given for ‘Situations arising from unintended usage of the 7 system components and tools. Installation System 6 Reference Ee eee A Service Manual 7 PERC areca cals (isninspnsas reese eo soon Spare Parts Catalogue 8 ‘System Manual No, 1817365-02 Document No. 578343-02 Product No. 867889-03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 2006.wg Freader’s Comments Form Dear reader, Itis our ambition to produce manuals which are as useful and instructive as possible. If you have any comments, positive or negative, please write them down on this form and send the form to us by fax or mail, or leave it with your local Alfa Laval representative, Alfa Laval Tumba AB, Technical Publications, SE-147 80 Tumba, Sweden. Fax: +46 8 530 310 40 Your Name: Company: ‘Address: City: Country: E-mail ‘System Manual information: System Product No... Book No. 8 Is it easy to find what you are looking for by using the table of contents? Are the chapter and section headings clear and adequate? Is the information presented in the correct order for your purposes? Does the information in the manual cover your needs? Is it easy to understand the instructions in the manual? Is the terminology easy to understand? qaqaaqaag qaQaaquaaaz Are the illustrations easy to understand? Other comments: Date: 1810852-02 Rev. 3) SA Separation System Safety Printed May 2002 Book No. 1810737-02 V4 Solutions beyond technalagy Alfa Laval‘SA SEPARATION SYSTEM SAFETY 1 SAFETY INSTRUCTIONS. 1 Safety Instructions Important - read this! The centrifugal separator includes parts that rotate at very high speeds, generating huge forces. It is therefore essential for the safe operation of this separator system that you read and understand this manual, ‘including the warning signs and safety precautions presented in this manual. Failure to do so may cause a fatal accident. 1.1 Key Factors for Safe Operation ‘The separation system is designed and supplied for a specific function (type of liquid, rotational speed, temperature, density, etc.). The system must be used for this function only, and strictly within Alfa Laval’s specifications Incorrect operation or maintenance may result in a heavy unbalance, reduction of material strength, etc. that could lead to serious breakdown with fatal injury or damage to property. For safe operation, strictly follow the instructions for installation, operation and maintenance in this manual. 1810737-02 ‘ZX _DANGER:1 SAFETY INSTRUCTIONS The follor operation: g is compulsory for safe 1 Never start up a separator before the bowl is completely assembled, and all fastenings securely tightened 2 Never discharge a vibrating separator. Always stop with the emergency stop button. 3 Never begin to disassemble @ separator before it has come to a complete standstil 4 Always set the discharge intervals according to instructions in the instruction book. 5 Never ignore alarms. Always eliminate the cause before resuming operation 6 Never use the separator for other liquids than those specified by Alfa Laval, 7 Never operate a separator with a different power supply frequency than stated on the machine plate. 8 Clean the operating system regularly to avoid sludge discharge malfunction. @ Ensure that personnel are fully trained and competent in installation, operé maintenance. and emergency procedures 10 Use only Alfa Laval genuine spare parts and the special tools supplied. 2 1810737-02 SSA SEPARATION SYSTEM SAFETY‘9A SEPARATION SYSTEM SAFETY 11 SAFETY INSTRUCTIONS 1.2 Warning Sign Definitions Below are definitions of the warning signs used. Danger - serious injury or death Example: ‘This type of safety sign or instruction —_—— indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work. Warning - serious injury or death Examp! This type of safety sign or instruction indicates a potentially hazardous situation which, if not U jp WARNING we avoided, could result in death or serious injury. Disintegration hazard | unusually strong vibration occurs, press the Emergency Stop button and leave the room. Do not enter the room after an emergency stop while the separator is still rotating. Caution - minor or moderate injury Example: This type of safety sign or instruction indicates a situation which, if not avoided, could result in poe minor or moderate injury. \ ‘CAUTION’ used without the safety alert Burn hazard symbol indicates a potentially hazardous ‘Various machine surfaces can be hot and cause| situation which, if not avoided, could result in burns. equipment damage. 1810737-02 31 SAFETY INSTRUCTIONS ‘5A SEPARATION SYSTEM SAFETY 1.3 Summary of Safety Hazards Below follows a selection of the warnings which have been used in the text of this instruction manual to ensure safe installation, start-up, operation, stop, and maintenance. Further ‘warnings are to be found in the appropriate places throughout the manual. ‘Start-up Be especially observant during start-up. If there is any abnormal vibration, immediately stop the separator and investigate the cause. Clean the bow! if it contains sediment. wari Breakdown hazard Assemble the separator completely before start. All couplings, covers, and guards must be in place and properly tightened. Failure to do so may lead to breakdown. Continued on next page 4 1810737-02SA SEPARATION SYSTEM SAFETY 1) SAFETY INSTRUCTIONS ee \ {a WARNING | Electrical hazard Follow local regulations for electrical installation and earthing (grounding). Disintegration hazard Ifthe system is operated from a position from which the separator is not visible, a vibration ‘sensor must be fitted. Breakdown hazard Check that the power frequency is in agreement with the machine plate. Ifincorrect, resulting overspeed may cause breakdown. Breakdown hazard Use the separation system for the purpose, and. within the limits, specified by Alfa Laval. Failure to do so could cause a violent breakdown. Breakdown hazard Always observe the separator during start-up after, ‘assembly If strong vibration occurs, stop by using the Emergency Stop button and evacuate the room. If power cable polarity has been reversed, the rator wil rotate in reverse, and vital rotating parts can loosen. 50Hz? oH? 1810737-021 SAFETY INSTRUCTIONS Operation Disintegration hazard Ifthe system is operated from a position from which the separator Is not visible, an unbalance sensor must be fitted, Breakdown hazard If strong vibration occurs, press the emergency stop button and evacuate the room. Never discharge a vibrating separator. Vibration ‘may then become violent and result in breakdown. Noise hazard Use ear protection if nol Breakdown hazard Nover rset an alarm without first finding and remedying the cause, Burn hazard ‘Avold contact with hot surfaces. Process pipes, various machine surfaces, and processed liquid can be hot and cause buns. = Slip hazard Check all connections for leakage Oil leakage may make the floor slippery. levels are high. ‘SA SEPARATION SYSTEM SAFETY 6 4810737-02‘SA SEPARATION SYSTEM SAFETY peo) ‘Stop TION Breakdown hazard Stop the separator by means of the control unt, and not by turning off the motor. Never attempt to clean the bow! by manual discharge In connection with stop. Emergency stop 1 SAFETY INSTRUCTIONS = integration hazard If unusually strong vibration occurs, pros Emergency Stop button and leave the room Do not enter the room after an emergency stop while the separator Is still rotating. integration hazard Do not start the separator after an emergency stop without first remedying tho cause of the emergency. ‘Make sure that the bow Is clean before restart. 1810737-021 SAFETY INSTRUCTIONS SA SEPARATION SYSTEM SAFETY Maintenance Entrapment hazard Make sure that rotating parts have come toa complete standstill before starting any dismantling ‘work. The rotation Indicator lamp, where applicable, must be off. Disintegration hazards Always contact your Alfa Laval representative if you ‘suspect that the depth of the corrosion damage ‘exceeds 0.5 mm (0.2 mm for bow body and bow! ‘hood) or if cracks have been found. Do not continue to use the separator until it has been inspected and clearance for operation by Alfa Laval. Disintegration hazard Pits and spots forming a line may indicate cracks beneath the surface. Al forms of cracks are a potential danger and are totally unacceptable. Replace any part where corrosion can be ‘suspected of affecting its strength or function. Disintegration hazard All forms of cracks are potentially dangerous as they reduce the strength and functional ability of components. Always replace a part if cracks are present. Disintegration hazard Erosion damage weakens parts by reducing the thickness of the material Pay special attention to the pillars between the sludge ports in the bow! wall. Replace parts if erosion is suspected of affecting strangth or function. 8 1810737-02SA SEPARATION SYSTEM SAFETY 1) SAFETY INSTRUCTIONS Entrapment hazard To avoid accidental start, switch off and lock power supply before starting any dismantling work. ‘Make sure that the separator has come to a complete standstill bofore starting any dismantling work. isintegration hazard ‘Separator parts that are either missing, worn beyond their sate limits, or Incorrectly assembled, may cause severe damage or fatal injury. Disintegration hazard Do not weld nor heat parts that are subject to high- speed rotation. Breakdown hazard ‘Assemble the separator complotoly before restart. Alll couplings, covers, and guards must be in place | and properly tightened. Fallure to do so may lead to breakdown. 1810737-021) SAFETY INSTRUCTIONS SA SEPARATION SYSTEM SAFETY 10 1810737-02‘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 Aifa Laval company. Published by: Alfa Laval Tumba AB Marine & Diesel Equipment ‘SE - 147 80 Tumba Sweden © Copyright Alfa Laval Tumba AB 2002.SA Separation System i System Description Printed ‘Apr 2002 Book No. 1810738-02 V1 Solutions beyond techaolouy Alfa LavalContents 4 System Overview 4.4 Oil Flow 4.2. System Layout 4.3. System Components 2 The Process 2.1 Principle 2.2 Process Cycle Start 2.3 Discharge. 2.4 Increased Water Content bona A sya 14810738-021 SYSTEM OVERVIEW ‘SA SEPARATION SYSTEM SYSTEM DESCRIPTION 1.3 System Components Control unit EPCSO Combined regulating valve (RV4) and shut-off valve (v4) Clean oi cca Operating” Temperature water Operating ar wansmitter — ft cin.tr2) ate renscucer 1 Pressure Oil intot wransmiter, oi init (PT) Pressure ransmiter, oiloutlet (P74) valve (V1) Pressure transmitter, water (PTS) Drain valve 03) 1810738-02‘SA SEPARATION SYSTEM SYSTEM DESCRIPTION 2 The Process 2.1 Principle 2 THe PROCESS During the separation process, sludge and water accumulate at the periphery of the separator bowl. oi Sludge and water Sludge and water are discharged at preset time intervals. During discharge, the oil inlet is closed. Excessive water can also be drained from the separator bowl between discharges. ‘The cleaned oil leaving the separator is tested for traces of water. Any increase in water is detected by the water transducer. Water —~ Water wansducer The signal from the water transducer is continuously transmitted to the control unit, in which a reference value is stored. The control unit compares the transducer signal with the reference value. A significant deviation from the reference value will cause draining of water. 6 6 1810738-02 o2 THE PROCESS ‘SA SEPARATION SYSTEM SYSTEM DESCRIPTION 2.2 Process Cycle Start First the oil pump, separator, and heater are started (ee) ‘The temperature transmitter (IT) and the ‘ speed transmitter (ST) signal the EPC-50 {Vt © F 4 control unit continuously. When the correct separator speed and the correct temperature ; are reached, a sludge discharge Is carried out to x ensure the bowl is empty. The control unit then. 2 starts the process cycle. 1 The change-over valve directs the oil to the (aaeea recirculation line. Conditioning water is 7 added to the separator bow! until the ‘ pressure sensor in the oil outlet senses pressure and signals the control unit 2 The control unit registers the time taken for water addition. This water flow reference value is later used to calculate the correct amount of conditioning water and displacement water to be added. 3 The separator discharges. oo 6 1810738-02SA SEPARATION SYSTEM S¥STEM DESCRIPTION 2 THE PROCESS 4° Using the flow rate calculated in paragraph 2 above, the contol unk signals the solenoid valve to open so that the correct amount of conditioning water is acided to the separator bowl 5 The change-over valve opens so that oll is directed to the separator bow!. When pressure in the oll outlet is sensed, the 4 pressure sensor (PT) signals the control unit ‘The control unit calculates and stores the time taken to add oil to the bowl The cleaning process is now running. Unprocessed oil is fed to the separator, and clean oil is pumped from the separator. 1810738-02 a2 THE PROCESS: 2.3 Discharge ‘The separator discharges after a preset time has elapsed. The following sequence takes place: ‘SA SEPARATION SYSTEM SYSTEM DESCRIPTION 1 The change-over valve changes to oil recirculation, 2. Using the flow rate calculated in paragraph 2 under 2.2 Process Cycle Start the control unit signals the solenoid valve to ‘open so that displacement water is added to push the oil towards the disc stack. 3° After the calculated time for displacement water addition has elapsed, the separator discharges. 4 Conditioning water is then added, and a new separation cycle begins. 8 1810738-02 (SSA SEPARATION SYSTEM SYSTEM DESCRIPTION 2.4 Increased Water Content If the water transducer senses increased water content in the oil, the following takes place: 2 THE PROCESS 1 The water drain valve (V5) opens for a number of seconds. 2 The water drain vaive closes again, and the transducer signal is evaluated Bf there is still an increase in water content, the drain valve opens again. If the water content is still high after the drain valve has opened five times, a discharge is initiated 4 |fthe water content has decreased, the separation cycle returns to normal, 1810738-022 THE PROCESS ‘SA SEPARATION SYSTEM SYSTEM DESCRIPTION 10 1810738-02oO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 2002.SA Separation System Operating Instructions Printed ‘Apr 2005 Book No. 1810799-02 V2 Solutions beyond technology Alfa LavalContents 4 Operating. 2 4.4 Before Startup 2 1.2 Operators Panel. 5 4.3. Startup 6 1.4 Manual Startup. z 1.5 During operation. 1 1.6 Stop. 14 4.7 Emergency Stop 15 1.8 After Emergency Stop 16 1.9 Cleaning In Placo 18 1.10 Automatic Operation. 19 1.41 Remote Operation.......... 21 4.12 Emergency Operation 22 1.12.1 Manual Operation of the Separation System 22 1810739-021 OPERATING ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS: 1 Operating 1.1 Before Startup 1 Check that the separator is correctly assembled and connected to power supply of correct voltage and frequency. The EPC 50 Control Unit must be ON. Broakdown hazard ‘Assemble the separator completely betore start. All couplings, covers, and guards must be in place and. properly tightened. Failure to do so may lead to breakdown. WARNING Nye Electrical hazard Follow local regulations for electrical installation and ‘earthing (grounding). broakown hazard erect nt per requ agama ih y ‘the machine plate. If incorrect, resulting overspeed SO Hz? = may cause breakdown, corey } } Le WARNING = Use the separation system for the purpose, and within the limits, specified by Alfa Laval. Failure to do ‘80 could cause @ violent breakdown, 2 1810739-02‘SA SEPARATION SYSTEM! OPERATING INSTRUCTIONS 4 OPERATING 2 Check the oil sump level. If necessary, top up Until oil starts to run from the oil-filing hole. “NOTE ‘Too much or too littl oll can damage the separator bearings. Rotation Direction ‘To check the rotation of the bowl, do a quick start/stop. The motor fan must rotate in a clockwise direction. AUTION It power cable polarity has been reversed, the separator will rotate in reverse, and vital rotating parts can loosen. NOTE ‘To make this check, the Mode Selector Switch should be in the CIP position. 1810739-025 OPERATING ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS Air Valve Block Use the pressure gauge situated in the air valve block to check that the air supply is correct, (600 - 700 kPa or 5 - 7 Bar) For further information concerning air, see chapter 1 Technical Data in the Installation System Reference booklet. Operating Water Pressure Check that the operating water pressure is sufficient (200 — 600 kPa or 2 ~ 6 Bar). For further information concerning water, see chapter 1 Technical Data in the Installation System Reference booklet. 4 1810739-02‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS + OPERATING 1.2 Operators Panel General principle for changing control parameters ‘The ‘Enter’ button is used to: ~ enter into a parameter list = enter into a parameter — acceptistore a new parameter value. ‘The ‘W or the ~’ buttons are used to change the value flashing in the display window. Process parameters Set the process parameters to suit the installation as follows: 1. Push ‘Enter’, Parameter no. 1 in the process parameter list is shown You have now come to the process parameter list. Go through the list and set parameters. 2 When the parameters have been set, ‘End I/O" (flashing) shows. Push ‘+. 'Standst.’ now shows in the display. For information on how to set discharge intervals, see chapter 3 Process Parameters in the Parameter list booklet. NOTE Make sure that the operators panel is ‘active’ (LED. green) before operating. 1810739-021 OPERATING 1.3 Startup ‘The control panel mode switch has three positions: ‘MANUAL, ‘AUTO’, and ‘CIP’ ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS The ‘MANUAL mode is for use on all Separation Systems, ‘The ‘AUTO’ mode is for use on systems supplied for fully automatic control and/or fully automatic remote control. The following general rules apply for use of the ‘AUTO’ mode: + The EPC 50 must have control of the oil feed pump. * The EPC 50 must have control of the heater. * The EPC 50 must have control of vibration monitoring. ©The cover interlock must be fitted. ‘The ‘CIP’ mode is for use with Cleaning in Place equipment. See . 6 1810739-02 j i‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 1.4 Manual Startup ‘The first startup must always be carried out manually. Before startup make sure that all the main supply valves for air, oil, and water are open. Open heating media supply valve if applicable. Switch on the power supplies. Make sure the mode selection switch is in the ‘MANUAL position. 41 Start the oil feed pump from the pump starter. 2. Itnecessary, vent air from the heater through the relief valve (if applicable). Switch on the heater from the operator panel (if applicable). ‘The operators panel must be’ active’ to allow operation. 3 Press the ‘SEPARATION’ button to activate the EPC-50. 1810739-021 OPERATING {8A SEPARATION SYSTEM OPERATING INSTRUCTIONS Before the separator can be started, a number of questions scroll across the display which have to be answered: ‘Has the bowl been dismantled? + = YES, - = NO’ 4 Ifthe bow! has been dismantled press the ‘+' button. If no work has been carried out on the bowl, press the ~' button. The start sequence begins and the text ‘Start’ appears in the display. ‘NOTE If this is the first start, answer 'YES". “Assembled according to manual? += YES, -= No" 5 Ifthe bow! has been dismantled and assembled according to the instructions in the Service Manual, press the '+' button. "Bowl cleaned? + = YES, - = NO’ 6 [tthe bow! has been cleaned press the "+" button. ‘An automatic calibration of the system is cartied out. See display. 7 Push the separator start button. 8 1810739-02‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS. 1 OPERATING 8B Listen and observe. Vibration may occur during start up, when passing critical speeds. This is normal and should pass without danger. If vibration increases, or continues at full speed, press the emergency stop button and stand clear unti the vibration stops. The separator, feed pump, and heater are stopped when the emergency stop button is pushed. The emergency stop will only reset when the speed sensor indicates zero speed. Once the zero speed signal has been received, the alarm reset button can be pushed. The message ' Switch power onfoff.” will be displayed. This refers to the EPC 50 power indside the control cabinet, The cause of vibration must be determined and corrected before starting again! See the Alarms and Fault Finding booklet. Broakdown hazard Always observe the soparator during start-up after, ‘assembly. If strong vibration occurs, stop by using ‘the Emergency Stop button and evacuate the room. NOTE Ifthe system is equipped with a vibration sensor, and has control of heater and feed pump, the Auto Start can be used. 1810739-02+ OPERATING ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 9 The separator speed, and ‘Start.’ are shown alternately in the display until the separator is at full speed, 10 Check the oil feed temperature by pressing the ‘+ button until ‘TT is shown on the display. 14 Wait until the oil feed temperature is correct: Heavy fuel mode 98 °C Lube oil mode 95 °C (trunk engines), or 90°C. (otoss-head engines) Diesel oil mode 40 °C 12 When the separator has reached the correct speed, and the oil is at the correct, mocataee temperature, press the process start/stop en a button on the operator panel to start the separation process. 13 Adjust the backpressure to the normal running value. Normal running backpressure is determined at commissioning. See the Installation System Reference bookiet 10 1810739-02‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 1.5 During operation Operator panel information Observe the operator panel information: * Heater operation LED lit (green) ‘+ Separator system operation LED lit (green) ‘© Activated valve LED lit (green) During normal operation, the ALCAP trigger signal is shown on the left of the display, and the time to next sludge discharge is shown on the right. Any alarm is indicated on the display. For further information see the Alarms and Fault Finding booklet. ‘NOTE Regularly check connections. Tighten If necessary. 1810739-02 1"OPERATING ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS NOTE ‘The values displayed in the examples below are not recommendations. More operational information may be read as required, by pressing the ‘+’ button repeatedly. ‘To return to normal display, ie. the trigger value, and time to next sludge discharge, continue pressing the ‘+’ button. ‘© Oilfeed temperature. For the correct, separation temperature see the installation System Reference booklet © Qilpressure, oil inlet © Oilpressure, oil outlet ° Pressure, water outlet * Water transducer value © Speed MT 89 Rpm 0300 ‘* Accumulated operating time in hours Run time 5h 12 1810739-02 i z‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING WARNING a Noise hazard Use ear protection if noise levels are high. = Broakdown hazard ‘Never reset an alarm without first finding and remedying the cause. pee Burn hazard ‘Avold contact with hot surtaces. Process pipes, various machine surfaces, and processed liquid can be hot and cause burns. | Slip hazard ‘Check all connections for leakage. ll leakage may make the floor slippery. 1810739-02 131 OPERATING ‘5A SEPARATION SYSTEM OPERATING INSTRUCTIONS 1.6 Stop To stop the system: 1 Stop the system by pushing the ‘SEPARATION’ button on the operators panel. ‘The yellow LED for separator stop sequence staris to flash. A sludge discharge is initiated. The stop sequence LED changes to steady yellow, and the green LED for separation system operation goes out, when the sludge discharge is completed 'Stop' is displayed If the heater is controlled by the EPC 50, itis switched off automatically. When the oil feed temperature has started to drop, the oil feed pump is switched off automatically. When the separator comes to a complete standstill, ‘Standst. is displayed Breakdown hazard Stop the separator by means of the control unit, and not by turning off the motor. power \ Never attempt to clean the bowl by manual discharge In conneetion with stop. 14 1810739-02‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING If the system is switched off for reasons other than high vibration, it is not necessary to wait for the separator to slow down before restarting the process. WARNING Breakdown hazard ‘The system must not be restarted with the separator rotating if high vibration alarm has been given. 1.7 Emergency Stop Ifan emergency situation occurs, press the emergency stop button and evacuate the room, Do not return until the separator has come to a complete standstill. Disintegration hazard If unusually strong vibration occurs, press the Emergency Stop button and leave the room Do not enter the room after an emergency stop while the separator is still rotating. NOTE In order to be able to restart, the system must be at standstil, and then the EPC power switched off ~ on. 1810799-02 151 OPERATING ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1.8 After Emergency Stop ‘Separator standstill Dismantling work must not be started before all rotating parts have come to a complete standstill. Entrapment hazard Mako sure that rotating parts have come toa complete standstill before starting any dismantling work. The rotation indicator lamp, where applicable, must be off Avoid accidental start Entrapment hazard ‘To avoid accidental start, switch off and lock power supply before starting any dismantling work. Make sure that separator has come to @ complete standstill before starting any dismantling work Remedy the cause ‘The cause of the emergency must be remedied before attempting to restart the separator. If the cause is not found, an overhaul must be performed on the separator, and alll moving parts thoroughly checked nae Disintegration hazard Do not start the separator after an emergency stop without first remedying the cause of the emergency. Make sure that the bow! is clean before restart. 16 1810739-02‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS. 1 OPERATING i 5 Separator reassembl ‘The separator must be fully reassembled with all covers and guards in place and tightened before unlocking the power supply and starting the system. Breakdown hazard Assemble the separator completely before restart. All ‘couplings, covers, and guards must be in place and properly tightened. Failure to do so may lead to breakdown. 1810739-02 71 OPERATING 1.9 Cleaning In Place ‘The use of Cleaning In Place (CIP) equipment is recommended for best separation results. For further information on the CIP equipment, see the CIP booklet, bookno. 1817261. Before connecting the CIP equipment to the Separator, the switch on the control cabinet must be turned to the CIP position. This is to avoid accidental pumping of oil when the pipeline is, opened up. For instructions on how to connect the CIP equipment to the Separator, see the Service Manual booklet. For recommended CIP intervals see chapter 1 Technical Data in the Installation System Reference booklet. 18 1810739-02 ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS.‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 4.10 Automatic Operation For automatic operation, the system must be equipped for automatic start. Make sure the mode selection switch is in the ‘AUTO’ position and Pr3 has the correct setting. NOTE If local eontrot is needed (for example in an emergency situation), turn the switch to manual ‘mode. This will automatically override the Pr3 setting. ‘NOTE ‘The first startup must always be carried out manually. ‘The system can thereafter be run automatically as ong as no changes are made to it between runs. 4 Press the ‘SEPARATION’ button i 19 Bofore the separator can be started, a number of questions scroll across the display which have to be answered: 1810739-021 OPERATING ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS ‘Has the bow! been dismantled? + = YES, - = NO’ 2 Ifthe bow! has been dismantled press the ‘+ button. It no work has been carried out an the bowl, press the ~ button. The start sequence begins and the text ‘Start’ appears in the disolay. ‘Assembled according to manual? + = YES, -= No" 3 Ifthe bow! has been dismantied and assembled according to the instructions in the Service Manual, press the '+" button. “Bowl cleaned? NO" = YES, 4 Ifthe bowl has been cleaned press the '+" button, ‘An automatic calibration of the system is cartied out. See display. ‘To stop the process, press the ‘SEPARATION’ button (see d Ifthe system is to be restarted, the system valves can remain in operating positions. 20 1810739-02‘5A SEPARATION SYSTEM OPERATING INSTRUCTIONS. 4.11 Remote Operation Remote Operation NOTE After maintenance, the system must be started locally. If in Remote, and ‘+' is pushed in answer to the question ‘Has the bow! been dismantled? the system reverts to local control. Follow the instruetions in chapter 1810739-02 1 OPERATING 241 OPERATING SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1.12 Emergency Operation In the event of a water transducer failure, the system can still be operated by setting parameter Pr 4 in the EPC to standby mode (see the Parameter List booklet). The transducer is then disabled and the time to discharge automatically changes to 15 minutes. ‘Ne’ (not, connected) is shown on the display. All Aleap functions are disabled. Water is removed only during a discharge. A reminder alarm is activated after 24 hours. If the system oil contains plenty of water, and the oil density is less than 991 kg/m®, emergency operation as described below is possible. 4.12.4 Manual Operation of the Separation System In the event of extemely high water content, the system can be run manually by a competent engineer using the following instructions 1. Ensure all oil system manual valves are in the correct position, 2 Set the selection switch on the control unit to the MANUAL position. 3 Fit a jumper between terminals X9:1, and X9:2 in the EPC. 4 Start the feed pump, Start the separator. 6 Heat the oil to the correct separating temperature, Where there is a Heatpac® EHM electric heater, use jumpers in the power unit to bridge terminals X12.11 -X12.6, X12.11-X12.9, and X12.11 -X12.7. Switch on the heater and use the switch to regulate the temperature Nore Remove the jumpers after emergency operation. 22 1810739-02‘GA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 7 When the separator is up to speed and the correct oil low and temperature are achieved, close the bowl. Open SV15 for time specified in timer Ti60 (See Parameter List booklet), Walt for 1 seconds. Open SV16 for time specified in timer Ti62, The bowl is now closed, 8 Temperature, flow, and backpressure must remain constant throughout. @ Remove the water outlet pipe at D. 1810739-02 231 OPERATING ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 40 Screw in screw A to move the paring tube to its innermost position, 14 Open SV10 as follows: ‘Time | Amountbow! {secs.) | filled titre) SA 811/816/8217806 a | ov SA s2o/e2siesoeat/ess/ea6 | 40 4 SA Bd0/841/845/646 nm |19 SA 850/851/855/856 a | 30 ‘SA 850/61/865/066 so | 45, ‘SA 870187 1/875/876 40 70 SA 9901881/885/886 45 110 12 Open SV1 to open oil feed V1 13 Open SVS. This will open the water outlet valve V5. 14 Carefully screw out screw A until water starts to come from D. 15 Lock screw A in position. Breakdown hazard During operation open SV16 for about § seconds ‘very 10 to 15 minutes to ensure that the bow! remains closed. 24 1810739-02‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING Discharge 4 Close oil feed V1 using SV1 2 Close water outlet V5 using SVS. 3 Open SV10 to add displacement water as follows: Time | Amount bow! (sees) | filled titre) ‘SA 8117016/621/826 eo [03 ‘SA 820/825/801831/835/696 | 42 13 SA 840/841/845/646 79 2a SA 850/851/8551056 “4 | 40 SA 260/861/865/866 so | 54 ‘SA 870/871/6751676 ar 34 ‘SA B90/881/885/886 |e 150 4 Open $V15 until a discharge is heard (about 3 seconds). a Wait 15 seconds. o Open SV16 for time specified in timer Ti62. 1810739-02 25+ OPERATING ‘SA SEPARATION SYSTEM OPERATING INSTRUCTIONS 7 Open SV10 as follows: - Time | Amount bowi (soos. | filled (ire) SAB RTORLATES «0 [or sa s2oreesiesoresvessies6 | 40 | 4,1 SA eioreasreAs,846 7m | 10 SA 850/85 1/85/8565, 30 }a0 SA e60/861/865/866 so | 45 SA 870/871/8781876 4/70 SA 880/86 /886/086 45 | 110 8 Open Vi 9 Open V5. 10 Maintain backpressure at normal setting throughout [ WARNING Breakdown hazard Discharging of the bowl, and supervision of the operation, Is now completely manual and under the direct responsibility of the engineer who has placed the ‘separation system in the manual control mode. 26 1810739-02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 2005.S-type Separation System a pe Parameter List OSA Printed ‘Sep 2008 BookNo. 181057202 V 12Contents 1 Parameter Setting Installation Parameters Process Parameters Factory Set Parameters aanon Sequence Diagram 5.1 Separation Sequence. 1810572021 PARAMETER SETTING 1 Parameter Setting The parameters are set in the operator panel for the different separator systems, and for different conditions within the systems. There are three parameter types: Installation, Process, and Factory Set parameters. ‘The parameters are initially set at installation. ‘The process parameters can also be set as required during operation. Parameters not in use are not displayed. ‘The parameter list in this booklet is valid for Separation Units (SU) and SA systems. General principle ‘The ‘ENTER’ button is used to: — enter into a parameter list ~ enter into @ parameter = accepiistore a new parameter value The ‘+’ or the ~’ buttons are used to change the value flashing in the display window. 2 1910572-02 S-TYPE SEPARATION SYSTEMPARAMETER LISTS-TVPE SEPARATION SYSTEM PARAMETER LIST To change parameters, proceed as follow: 41 Push the ‘ENTER’ button, “Time to discharge P1_ 60’ is shown, ‘P1 is the parameter, and ‘60’ is the set value, The ‘1’ of the ‘P1’ is flashing, 2 Push the ‘+’ button until the number of the parameter you wish to program appears in the display window. The chosen parameter number is now flashing. 3 Push the ‘ENTER’ button. The chosen parameter number is now shown on the left side in the display. The parameter value is shown flashing on the right side of the disolay. ‘Schematic ‘diagram with position LEDs Display window — ~push- + push» Enter bution button push- button 4 Push the +’ or 1 PARAMETER SETTING * button to change the parameter value. 5 Push the ‘ENTER’ button. The new value is stored. The parameter number is now flashing 6 Push the '+’ or ~’ button to go to the next parameter to be changed. 7 Toleave the list, push the ‘+’ and the ‘—" buttons at the same time. Tre display shows ‘Standst’ or, when in operation, the trigger value to the left, and time remaining to discharge on the right LED for heer een ven Heater oni | pustbrton LED for control program running —Igr0en) ~., LED for stop sequence running (yellow) OS sedge discharge push LO LED for common LED showing main alarm (reo) thispanel active | Alarm reset 1810572-02 31 PARAMETER SETTING The following lists are available for viewing from a menu in the EPC-50 control unit: © Install (parameters) * Factory (parameters) © Alarms ° Test For detailed information see each list. ‘To open the menu and select a list, proceed as follows: 4 Push the ‘ENTER’ button. The process parameter list is now open. 2 Push the '+' button until ‘End! is displayed. 3. Push the ‘ENTER’ button and the '+’ button at the same time. ‘Install’ will show flashing on the display. 4 Use the '+' button to select a list. 5 Use the ‘Enter’ button to enter into the selected list. 6 To leave the list, push the ‘+’ and the ~" buttons at the same time. 7 To leave the menu, press the ‘+’ button repeatedly until ‘Exit’ is displayed. Push the "ENTER’ button, 4 1810572-02 S-TYPE SEPARATION SYSTEM PARAMETER LISTS-TYPE SEPARATION SYSTEM PARAMETER LIST 2 INSTALLATION PARAMETERS 2 Installation Parameters ‘The installation parameters must be set before the initial start-up and before process parameters are set. These parameters rarely need to be adjusted again. If a new parameter value is to be stored, it is necessary to go through the whole list, and confirm at the end. NOTE Alfa Laval cannot be held responsible for injuries and damage caused by usage of parameter values which are not in proximity to the factory values sot by Alfa Laval. Parameter | Factory set | Plant set Range Description Ses Int en en= English Language. All information displayed p= oe pai ae io ee ee soe ate i ea Ing 836 811, 816 ‘Separator size eae ac circa 300, 830, 831, 835, 896 «SIZE Are Sot automaticaly according oumeese Se aa papel pono See on sty ita eee Pelee lalae I Meraraae elu ee eee communication each system must be given its own identity (1 oF 2 or 3 etc) 1810572-02 52 INSTALLATION PARAMETERS |S-TYPE SEPARATION SYSTEM PARAMETER LIST Parameter | Factory set | Plant set Range Description value value iné. Yes No ‘Speed sensor Yes In? No No Vibration sensor Yes Ing No No OP remote, Yes ing Yes No Water transducer Yes nts No No ‘Sludge pump used Yes In16 No No VO expansion board usad Yes int7 c C3 Celsius or Fahrenheit F Inte No ‘No (no heater) Heater type EL, (electrical heater) ‘Steam (steam heater) Int9 16 7, 8, 14, 16, 22, 24,36, 40, El heater size 50, 56, 65, 72, 86, 96,98, Activated when El. is selected in 100, 110, 112, 126,128, in tg 180, 144 kw In 20 120 (0-999 seconds ‘Stoam-valve run time ‘Actvatad when Steam is selected in ints 1810572-02S-TYPE SEPARATION SYSTEM PARAMETER LIST 2 INSTALLATION PARAMETERS. 1810572-02 Parameter | Factory set | Plantset | Range Description value value in22 15 (0-30 seconds: ‘Alarm delay time n23 15 0-240 seconds (Change-over vaive V1 temp. alarm delay Prevents false alarm due to any fluctuations in temperature caused by valve actions. nag No No Change-over valve V1 action at extra Yes alarm When the exire alarm input is used, action at alarm can be none (No) or feed off (Yes). in 25 Yes No Power fail alarm used Yes If this alarm is not required, set the parameter to ‘No* In 26 No No ‘Type of computer communication ExiPC = Fieldbus Roan mse! Net = Internet in27 ° 0-255 Internet IP address, part 1 in 28 ° 0-255 Internet IP address, part 2 In29 ° 0-255 Internet IP address, part 3 Ingo ° 0-255 Internet IP address, part 4 nat No No Feed pump controled Yes Feed pump hes to be connected by EPC when running in auto mode. naz mh mn Flow rate in mith per hour or usam US gallons per hour. ‘The food flow measurement, based fon init pressure, can be displayed in one of these ways.{3 PROCESS PARAMETERS ‘-TVPE SEPARATION SYSTEM PARAMETER LIST 3 Process Parameters ‘The process parameters can be adjusted easily and as often as required, even during operation, to meet changes in the operating conditions, e.g. time between sludge discharges, oil temperature, alarm points, \ Note, Regularly check the condition of the bowl. If there Is ro noticeable amount of hard sludge in the sludge ‘space, the discharge interval may be increased by 30, ‘minutes ata time. The total discharge interval must not exceed three times the factory set value in order to avoid an uneven bulld-up of sludg Factory set Range Description value value Prt 120 = 800 minutes Time to discharge Pr HF380 MDO=Marine Diesel Ol Oil type. GO = Gas Ol Fxx= Intermediate Fuel Oil (xxx represents viscosity in Cst at Hoc = Heavy Fuel Oil LOTP = Lubricating Oi for ton Engines LOCH = Lubricating Oi for (Grose Head Engines Pr OPlos OP oc = Local OF in control OPrem = Remote OP mind = Remind using Sattbus ExIPC = Extern Computer Board Remote switches Pra on si. Pes 00 lot used (041 to 10.0%1000 hours 50°C) Control location OPloc is standard. OPrem, EXPO and Rem$W are shown only when Intallod Alcap On/Standby IMT50 function disabled when in ‘standby (Stb). Discharge every 15 minutes (overrides Pri). No dieplacoment water added. Countdown service timer ‘Action isto be taken whon the timer reaches 0, 8 1810872-02‘S-TVPE SEPARATION SYSTEM PARAMETER LIST 3 PROCESS PARAMETERS Parameter | Factory set | Plant set | Range Description value value | Pre ° ‘0= service time elapsed “Type of service 1-9 = Service text 1.9 When service timer PrS reaches 0, an alaim Is given and a message shown rr ° Information Keys to special functions used by service engnesr When P17 ie set to 1 during normal ‘operation, the actual timer is displayed ithe + button is pressed ‘once. Pri0 30 0.06.0 bar High oll pressure limit 0.0 = ol prossure sensor (cleaned oil outlet) disabled Pett 10 0.060 bar Low oil pressure limit Pri2 55 0.0-6.0 bar High water pressure limit 0.0 = water pressure sensor (water oute! disabled Pra 02 0.06.0 bar ‘Low water pressure limit Prig 80 0.0-6.0 bar High feed pressure iit (0.0 = food pressure sensor disabled Pris: 0.20 (0.00 - 6.00 bar Low feed pressure limit Low pressure indicates insufficient flow. The lon pressure limit must be higher than any static pressure and lower than normal pressure. Pre 105°C 0- 118°C or HFOILO high temp. limit 0-258 °F (= Tomp sensor disabled Pei7 85°C 0-118°C or HFOILO low temp. lint 0-285 °F 1810572-023 PROCESS PARAMETERS S-TYPE SEPARATION SYSTEM 2ARAMETER LIST Factory set [Plant set | Range Description value value Prt@ 95° 0-110 Cor HFOILO setpoint” 0~200°F ‘Setpoint for feed temperature is vale ‘Temp sensorisebied only when temperature controller is Installed in the EPC. Pri9 40° 0-115 "Cor DO high temp. tit 0-255 °F Pr20 0-115 °Cor DO tow temp. limit 0-255 °F Prat 30°C 0-110 °Cor DO setpoint”? 0-240°F ‘Setpoint for fad temperature is valid only when a temperature controller is Installed in the EPO, Pr22 40 10-00% P-constant”) Preset value based on experience with Alfa Laval Hestpac heaters. Pr23 12 0.1 10.9 minutes constant") Proset value based on experience with Alta Laval Heatpac heaters. Pr2a o 0-9 Heater conto! location = disabled “To be set when more than one EPC temperature contrallar can be used for one heater. Pr25 2 (0-240 seconds ‘Sludge tank alarm delay (during Ti 68) Pr 40 60 (0-100 discharges Test of sludge in bow! Prat 15 0-100% Max. decrease of displacement water *) Parameter appears only when heater board installed. 10 1810872-02S-TYPE SEPARATION SYSTEM. PARAMETER LIST 4 FACTORY SET PARAMETERS. 4 Factory Set Parameters 85 if Pr2= TPLO Bit Pr2=CHLO. 0 = water transducer disabled Parameter | Factory set | Plant set | Range Description value value Fad ‘See table on page 0.4 = 99.99 ire Conditioning water volume to be fed after ischarge Fas 02 00-99 bar PTS pressure increase or decrease. | (Test during 7159, TI 64, 11:70, TI71, ‘Ti 82) Signal thatthe bows filed. Fato ‘See table on page (0 14000 rpm High spaced (0 = sensor disabled Is set depending on separator size Fatt ‘See table on page (0 14000 rpm Low speed Is set depending on separator size Fat2 300 (02000 rpm ‘Speed decrease during discharge Fats ‘See table on paga 00-25 ‘Shutdown limitfor separator spindle 2 0.0 = sensor gisablod amine Fat? ‘See table on page | 00-25 ration alarm prewarning Fate 0s 00-25 Vibration sensor adjustment zero ‘point, Zero point should be within 15 2Fat8 Fa20 8.011 Pr2 = fuel oll 0.01 - 10.0 pF ‘Alcap tigger factor 0.6 if Pr2 = lube oll This is the amification factor for the transducer sighal 60 thet the proper trigger range is achieved. Fa2t 100 0-250 % ‘Trigger limit HFO Fa22 100 0-250% Trigger limit LODO Fa2a 110 if Pr2-=tuel oll 0-999.9 pF Alarm limit for high water transducer value. 1810872-02 114 FACTORY SET PARAMETERS S-TVPE SEPARATION SYSTEM PARAMETER LIST lo reduction jeduction alter every tiga jeduction after 2 consecutive triggs Reduction after2trigas within 3 discharges 4 = Reduction after triggs within 4 aischarges Parameter | Factory set | Plant set | Range Description value value Fa2a 70 (0 999.9 pF ‘Alarm imi for low wator transducer value Fa25 25 (0-250 seconds Pulse time for open drain valve Fa26 5 (0-30 seconds Drain pause time. With the valve closed, the system waits for the result ofthe draining Fa27 70 = 100% “The limt below whieh the triggor value must be to interrupt draining. Fa28 5 0-20 Limit for number of HEO crainings. It the trigger value hasnot fallen below the value of Fa 27 after Fa 28, an ‘alarm Is giv, Fa29 5 0-40 ‘Tost of water transducer tigger gic aisatled signal every x discherge. («= 0-100) Fa30 250 0-300 % “Tigger level during T164, 7165, 7171, We Fa3t 2 0-4 Reduction of Ti72 due to trigger signals during Ti 64, 7165, 12 1810872-02S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS Parameter | Factory set | Plant set | Range Description value value Fas2 10 00-10 Radustion of Ti 72 in DO made. Timer Ti 72 is reduced by Fa 32 Fass 2 0-10 Limit for number of LO erainings. Wa higher no. of d-ainings than Fa 33 ‘takes place within one separation period (Ti 68), an alarm will be given. Fasa +0.00 HFO temperature adjustment, MT 50 ‘Temperature compensation for the ‘water transducer, HFO made." Faas 40.00 2.00 42.00 LO temperatura adjustment, MT 50 0=-2.00 ‘Termperature componsation for the 200-0100 water transducer, LO mode.) 400 = +2.00 Fass 40.00 -2.00-+2.00 DO temperature adjustment, MT 50 0=-2.00 ‘Temperature compensation for the water transducer, DO mode." Fas7 20 Flush water every x dish. Fase 00 SAV response time Faat 5 1-30 minutos Closing wator pulse time Time between zlosing water pulses ‘The transducer value can be influenced by temperature variations. This ean be compensated for by using this parameter, Proceed as follows: Note the transducer value. N.B. The transducer value must be steady (no water in oil) in order todo this test. At normal stable running temperature, decrease the temperature by 10 °C. At stable new temperature, read the temperature and transducer value. Example: ‘Temperature decrease = 10°C ‘Transducer value change = + 1 (from 82.6 to 83.6) ‘Since the transducer value increased, this must be compensated by making Fa34 negative. Fa34= (10x 10)/10°C=- 1.0 1810572-02 134 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST Parameter | Factory set | Plant set Range Description value | value Fad No No Vé activated in Tie Yeo ‘To get a faster pressure response when oll fee fs the tow (s2@ 164) valve V4 could be closed ves. Faao 4.00 0.00-2.00 ‘The flow indicated on the controler can be adjusted. Faas See table on 0-18 seconds Delay for close of Vat leak test, age ‘Automatically aojusted during test. ri68) Faas See able on 0~18 seconds Delay of PT4 pressure reference page °? value registration duing the automatic adjustment of pressure range for leakage test (see Ti 66). Faas 10 0-4 bar Acceptable PTA decrease during leakage test Alarm forleaking bow ifthe pressure decreases more than Fa 48 during leakage tot Faa7 30 0-4 bar PT4 high int during eskage test | Faas 10 0-4 bar 4 low limit curing leakage test Faao 5 0-10 Max, no. of eakage teats o establish the test pressure win high-low | limits (NOTE _ For parameters Fa 90~Fa 95, see page 14 1810572-02‘-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS. Timer Sequence Parameters (separation start, sludge discharge, stop) Parameters for timers are listed under Factory, but are called ‘Ti’ When expected feedback from a timer is given, the timer is interrupted and the next timer starts, If feedback is not received within the preset time, an alarm is given. ‘Timers for start are 50 - 59. ‘Timers for operation are 60 - 69. ‘Timers for discharge are 70 - 79. ‘Timers for stop are 80 - 89. ‘Timers 50, 51, 52 and 87 are intended for the ‘fully automatic’ system (Auto mode) with pump, and heater controlled by EPC 50. If pump and heater are started independent of EPC and Alfa Laval starter, X6:4 - X40 must be connected to a free closing contact at the external pump contactor. Increasing tomperaturo is the only process condition needed for timers 51 and 52. The program skips directly to timer 55 when not ‘fully automatic’. 1810572-02 154 FACTORY SET PARAMETERS ‘S-TVPE SEPARATION SYSTEM PARAMETER LIST Parameter | Factory set | Plantset | Range ] Description value value 7180 60 2 = 800 seconds Feed pump on Tis 6 (0-80 seconds Food prossure feedback tise 4 0-60 minutes, ‘Separator star-up (Speed feedback) ‘Speed above low lrit (Fa 11) expected, Condition of belt, couping, rotor bearings, height adjustment, and speed sensor supervise. 7153 18 (0-60 minutos Healer on temp. feedback) ‘Temperature above low limit (Pr 17, Pr 20) expected to confirm that the heater works normaly 188 © (0-30 minutes | Max, time for Standky mode. During satay ‘Standby’ mode, the system is waiting fr an order to start the process sequence. The process sequence is started with a push of the start button When 7158 =0 the process starts without delay Tis6 80 0.1 -5.0 seconds Discharge if Ti 59 has expired after alarm. Ti87 18 (0-90 seconds 158 See table on (0-60 seconds age 16 1810572-02‘S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS Parameter Factory set value T1593 T60 Ti61 Tie2 170 ‘See table on age 18 ‘See table on page (0300 secands (0.1 ~ 30.0 seconds 0-30 seconds (0-60 seconds ‘Waterflow ral calibration At start throe quostions are displayed: + Bow ciemantied? ‘© Assemblec according to manual? ‘= Bowi cleanod? When the answer tothe third question is Yes, calibration of the ‘ator flow rate through SV 10 takes place. SV 10s open unt pressure in the water outiat increases (Fa 6). ‘The water volume is defined for each ‘separator size Based on this and the time taken toil the bowl, the EPC. calculates the water flewrato, When the answer is No, this means that stored caibration data willbe sed and consequently the program performs TI 63. Discharge ‘= when starting, the operating system needs some extra water to ‘support the operating slide before ‘losing the bow. (This Is nat 2 proper discharge, since the bow is empty), after a power fallure to prevent a pporlad between discharges greater than Pr. Pause: system Close bowl raining of operating 1810572-02 74 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST Parameter | Factory set | Plant set | Range value value Te 720 Second, calculated Conditioning water added Based onthe calibration o ho water ‘tow ate, the EPG calculates the time to which Ti 68s set, 0 thatthe correct volume of eondtioning water | is added tothe bow. Data concerning the bow is activated wien size of separator is choosen (in), The preset vas is jus for start. ler the caleuiaton, the coroctvaluo for 7163 is sot automaticaly. Ties © 0-60 seconde Ol feed on. Max 60 sece Ties 15 0-20 seconds Water transducer puse control time “Testo the signal from the water transducer. his shews water inthe «il the displzcomonttime prior to | next discharge will be reduced, Tis Seo tabie on 0-90 eeconde Bowl leakage chock a (See also Fa 44 — 49) 67 60 0-300 secones Time for stabilisation ofthe transducer signal. When the time has elapsed the EPC stores the actual transducer vaio as a ‘eforonco for changos in water | content 18 1810572-02‘S-TYPE SEPARATION SYSTEM PARAMETER LIST 4 FACIORY SET PARAMETERS. Factory set value Plant sot value Description Ties 1170 v7 72 1173 wW74 720 (= Prt) 15 20 180 10 30 ‘300 minutes 0-80 seconds 0-120 seconds Seconds, calculated (max. '300 seconds) (0-30 seconds 0.1 -5.0 seconds Time between discharges. Thisis the same as Pr 1.f one Is changed, the other one is automaticaly changed. During 7168 the water transcucer supervises changes of the water Content in the cloan ol Ifthe trigger value is greater than 100, the drain valve (VS)opens. For details see Fa 25-28. Cil feed off. Oil outet prossure bolow low limi (Pr 1°) expected. Displacement of ol. During T171, V4 's closed untiincreasing pressure Is sensed, indicating displacement ‘water has entered the baw! Displacement water (SV 10). ‘Opening of the drain valve to wash ‘out any ll from the paring tube and Piping. Discharge 1810572-02 194 FACTORY SET PARAMETERS S-TVPE SEPARATION SYSTEM °ARAMETER LIST Parameter Factory set value Plant set value Range Description 1175 Tist Thea T183 Tis 15 Soe table on age 160 10 (0-20 seconds 0-60 seconds ‘Seconds, calculated 0-30 seconds 0-30 minutes Pause = Draining of operating sysiem Discharge feedback as shown by decreased speed, Fa 11) If the speed sonsor is out of orcer/ disabled, feedback is automatically taken over by timer Ti 64. (I time close to 0 there wasino discharge). Draining of operating eystem takes place during TI75. ‘Alter TI 75, the program returns to 7162, provided stop is not ordered. however any value or timer Influencing tha water calibration has been changed, the program returns toT158. When stop is ordered the discharge precedes the stop sequence. Close bow! Hoater off ‘Addition of water unt 80% of bow! volume, or increased pressure is ‘sonsed in the oll outst (Fa 8). This is to keep the bow filed during stop sequence, pening of the drain valve to wash ‘out any ail from the paring tube and the pipe. Temperature decrease ‘Tho EPC switches the separator motor off Decreasing ol feed temperature ‘greater than 5 °C expected, 17185 = 0, no temperature contol 20 1810872-02‘S-TVPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS Parameter Factory set value Plant set value Range Description Ties me7 Tiss Fa90 Fast Fa92 3 60 30 0-30 minutes Decreasing spaed expetied (Fatt) (0-300 seconds Pump of In Auto mode, the EPC switches the fad pump of. By doing so after ‘witching off the separator furtner ol ig fed tothe heator (whichis already ‘switched oft help cooking 30— 60 minutes “The EPC is waiting for zero speed. {slong as the separator is rotating sta speed greator than 6 revsimin. (1 pul re, the speeds displayed aternating with Stop! Speed loss tan 6 roveimi. i csplayed as 0 When speed Ohes been displayed for 1 minute (aternating wit Stop’), “Standst! wil be displayed. 0 ~ 9999 days Set runtime, S20 chaptor 4 Change of Creu Boardin the Service Manual bookie 0-99°0 Break point, cod stat 0-210°F “The temperature upto which gain factor Fa92 is active. Above this tomperature normal gan (Pr 22) active. Gain factor, cot start This factors used to increase the normal P-bana (Pr 22) when tampereture isbolow that defined in Faot Ex. Normal P-band = 90, Fa 82 = 40 gives an actua P-band below Fa 91 of 0.40x30= 12 1810572-02 244 FACTORY SET PARAMETERS S-TYPE SEPARATION SYSTEM PARAMETER LIST Parameter] Factory set Range Description value Fae Sesu ‘SBSU (Gatbus on REZIB) | Communication ype ASCII (ASCII protocol) PRINT (Printer output) Fao 26 12,24,4.8,96,192, or | Serial communication Baudrate 84 channel A (4.8 = 4800) Fa9s No No Communication patty channel A oud Even Fase 2.01 Pr2-=tuel 0.41~10.0pF ‘cap trigger range during ischarge oil osifPr2 =tube | oll Parameters depending on separator size Separator size FaS [Fai0 [Fatt |Faté [Fai7 [Fada [Faas S017, S816, 8200, Se2,S26 fore [19800 |t¥000 joao fozo [2 5 $ 820, $ 625, $300, $80,431, [03 11000 |e900 [030 ozo 2 5 $ 895, § 096 8 400,8.40,041,8045,8040 |o4 |oco0 |eooo |oso joao ja 5 $500, 8850,sa51,sa55,ses6 |o7 Jeaoo |7400 |oso joao |e. 10 s.800,8.860,sas1,s005,se66 loo |7200 |e4o0 oso joao |e 10 s700,8870,sa71,se7s,sa76 |15 |6700 |ss00 oso [ogo 10 40 js000,S 080,Se81,sea5,see [25 {seco [4700 [oso jogo —_|10 10 ‘Separator size Tiss Tie2 [Ties |tiei | Tiso S811, § 818, $200, S 621, S626 5 5 6 10 6 30 '$ 820, S 825, S 800, $ 880, $ 831,835, |15 6 18 10 18 30 8836 $400, S 840, S841, S 845, S 848 16 5 18 20 18 30 $800, $ 850, $ 851, S 855, $ 856 18 5 18 20 15 40 '$ 600, $ 860, $ 861, S 865, S$ 868 25 16 25 25 25 45 '$ 700, $ 870, $871, $875, $ 876 95 25 35 30 35 45 'S 800, S 880, S 881, S 885, S 886 60 25 eo 30 60 60 22 1810872-02‘S-TVPE SEPARATION SYSTEM PARAMETER LIST 4 FACTORY SET PARAMETERS: 1810872-02 235 SEQUENCE DIAGRAM ‘S-TYPE SEPARATION SYSTEM PARAMETER LIST 5 Sequence Diagram Autostart [Start [Separation [750 Tit [Ts [Ts [TS [Tes [TST [TSB [TED ]Ti6d [Tey [Tie [Tas [Tes [Tas [66 [67 ibs activity ed pump [7 I motor on Fw stabitzoa | i. soparator motor on icator on in) fem inorease Heater max o star time = Discharg svi8 _ Drain ot operating water = | Cosina water isvie = Catioration of ” water flow rato — Isv 10 | Conditioning water SV 10 — Feed on V1 oi outlet » closed, V4 — Leak test Ret. time [Soparation Drain of water; ve Feed off Displacement water isv 10 Water isvi0 Optional ”) studge pump eel 1 nterupted by feedback signal 5) Interrupted by decreasing speed 8) 1 s0c. pulse at 4000 rpm 2) Pulse 1 see. every S min ©) Interrupted by pump of feecoace 10) 8 sec. every 30 minutos 3) Actvated whan nocded 7) Interrupted by Oe panos ss 09 our zz pue ‘o2e iggalbamed tin atin uote et. 562557 Rev. 3 15 1810940-022 DRAWINGS ‘SA 891f896/861/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 Valve Block Oil, DN 25 Assembly Drawing Cable 19 Water transducer | Connection Valve Pressure * Angular coupling Uansmittar Needle valve Non-return valve Nipple Elbow * Fonnection ransmiter ry y Seater 4 / 73 Valve beck led vane henperauwe srcer ipple ao neumatic “ transmitter hange-over valve. P BS Connection fon-return valve Nipple * Screw” Washer” Hexagon plug Elbow Silencer Flexible connec‘on * To be sealed with locking liquid Ref, 567802 Rev. 3 18 1810949-02‘5A 83'/836184 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.2.15 Valve Block Water Assembly Drawing 2 DRAWINGS: Flow valve for SY 10, Flow valve for SV 15 Flow valve for SV 16 [Connection for solenoid valve Flexible connection Flexible connection Quick coupling Non return valve kit of, 667040 Rev. 0 1810949-02 192 DRAWINGS ‘SA 831/836/84 1/845 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.2.16 Valve Block Air, Assembly Drawing ‘Spade connection Valve block Fel, 568048 Rev. 0 is 20 1810949-02‘SA.831/836/84 1/845 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.2.17 Control Unit EPC 50 Dimension Drawing 2 DRAWINGS Separator interlock indication (optional) Sludge valve interleck indication PC connection (optional) at - r al 2 Emergency stop, Operating panel AY separator separator Los Plugged holes for extra cable ganas "Technical Ba ‘Artiertinpeatce | Wax 65S Proacten eset Pos Natesalinessnat | Sheet tel Power spol 100,18, 0230 VAC 6060 He ‘Operating vatage 2a Ac soso He Power censurpten | 70VA(.200,VA‘e 10) Wiig 1959 = = == oplonat Ff, 568904 Rev. § 1810949-02 242 DRAWINGS ‘5A 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.2.18 Starter Dimension Drawing et, 868025 Rev. 1 22 1810949-022 DRAWINGS. ‘SA 831/536/84 1846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.3 Electrical System Layout womememns ervey ead ccs men EI Ff, 568029 Rev, 1 23 1810949-022 DRAWINGS: ‘SA 83/8904" /246 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.4 Electrical Diagrams 2.4.1 Cable List No. | Type Connectionpoint | Instruction | Connection point | Remarks A B Power cables (currents according to order) 1 MPRXCX | sx4 | Mains supply Starter Fuse20A 1 MPRXCX | 3x10 | Meine supply Startor Fuseas A 1 MPAXCX | 3x16 | Mains supply Starter Fuses0A 1 MPRXCX | 9:25 | Mains cupply Starter Fuse63.A 1 | maxx | sx¢5 | Mains supply Starter Fuseao A 2 | MPRXOX | 2x15 | Starter EPC s0 3 | MPRXoX | 3x15 | Starter ‘Soparator motor 3 | MPRXCX | 3x25 | Starter Separator motor a MPRxcx | 3x4 | Starter Separator motor }9 MPRXCX | 3x6 | Starter ‘Separator motor 3 MpAxcx | 3x10 | Starter Separator motor |3 | mprxcx | axe | starter Separator motor 3 | MPRXCx | 3x25 | Starter Separator motor 71 | MPRXOX | 2x1.5 | Starter Soparator motor MPRXCX | ax1.6 | Startor Food pump 04-638 MPRXCX | 9:25 | Starter Food pump 63-160 72__| MPRXCX | 2x15 | Starter Foed pump Pet, 565081 Rev. 1 24 1810949-02‘8A 891/890/641/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS No. | Type Connectionpoint | Instruction | Connection point | Remarks A B Signal cables 11 | RFE-HF | tx2x0.75 | EPC50 svt 12 | RFE-HF | 1x2x0.75 | EPC 50 sv4 13 | RFE-HF | 1x2x0.75 | EPC-50 sv5 14] RFE-HF | 1x2x0.75 | EPC SO svi 18 | RFE-HF | 1x2x0.75 | EPC-SO svis 16 | RFE-HF | 1x2x0.75 | EPC 50 svi6 17 | RRE-HF | 1x2x0.75 | EPC 50 sso PT 18 | RFE-HF | 1x2x0.75 | EPC50 ssc Pra 19 | PUR-cable | 4x0.94 | EPC-50 SSC+EMC | MT a 20 | RFE-HF | 4x2x0.50 | EPC SO SSC+EMC | ST,(YT,SS) 21 | RFE-HF | 1x2x0.75 | EPC 50 ssc PTS 22 | RFE-HF | 1x2x0.75 | EPC 60 ‘SUM Alarm 23 | RFE-HF | 4x2x0.75 | EPC 60 ssc Tre 50 | RFE-HF | 4x2x0.75 | EPC 50 Starter S10 | RFE-HF | 4x2x0.75 | EPC 50 Starter 820 | RFE-HF | 1x4x0.75 | EPC 50 Starter Options (as ordered) si | RFE-HF | 1xax0.75 | EPC SO SsC+EMC | Rem, OP unit [92 | RRE-HF | 1x4x0.75 | EPC So Fem, Temp. al 33° | MPRXCX | 5x15 EPC 50 Fem. Start’Stop 940 | RFE-HF | 1x4x0.75 | EPC 50 SSC+EMC | Comm. module 95 | RFE-HF | 1x4x0.75 | Starter GS, Valve switah 36 | RRE-HF | 112x075 | EPC 50 L, Sludge Level 97 | RFE-HF | 1x2x0.75 | EPC 50 ‘8V6, Sol. Valve For pneumatic sludge pump 36] MPRXCX | 4x15 EPC 50 Syst, Emergency » 40 | RFE-HF | 4x2x0.75 | EPC 50 Power unit 45 | RFE-HF | 1x2x0.75 | Starter Power unit 41 | RRE-HF | 1xx0.75 | EPC 50 Steam reg. valve 44 | RRE-HF | 1x2x0.75 | EPC 50 Shutoff valve ®) This cable cannot be longer than 25 m to avoid voltage drop. ®) Cable with moulded connector included in Alfa Laval delivery. Rot. 568031 Rev.1 1810949-02 252 DRAWINGS ‘SA 891/696/861/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE Other equivalent and approved cables may be used. Cable areas are calculated with correction factor 0.7. Cables used are Shipboard Cables, designed according to IEC 92-3. Flame retardant according to IEC 882-3/A. Halogen-free according to IEC 754-1 Code designations for cables obtainable through cable producers Helkama, Finland, and Acatel, France. Where SSC is indicated it should be a Signal Shielded Cable with the shield properly connected to earth as shown in the electrical drawings. For other connections, an armoured cable may be used provided the armour is connected to earth, as shown in the electrical drawings, and gives sufficient EMI protection. Copper wire armouring is normally used. 26 1810949-02‘SA 831/89684 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.4.2 Interconnection Diagram, Starter 2 DRAWINGS Mains suppy 3x230 400, 440, 486, 875 oF 680 VAC Select correct voltage on transformer TE Separator motor ‘Space hoator 230 VAC Separator motor optional Contactor response, separator ! Feed pump motor optional Space heater 230 VAC Separator motor optional Contactor response, soparator ‘Systems emergency stop —. {(Coniral voltage off) = Power supply to EPC 60 (Sheet 5) 230V AC, SOBOHZ HALYVIS et, 568020 Sheet 1, Rev. 4 1810949.02 272 DRAWINGS ‘SA 831/896/8¢ 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.4.3 Interconnection Diagram, Starter, cont. replaces jumper in terminals injomal connections To EPC 50 (s To EPC 50 (sheet 5) ‘Separator emergency stop (optional, external) ‘Sludge valve interlock sitet ‘optional YBLYVIS Remote stop Feed pump Remote start Feed pump intertock Heater interlock 7 Potential ree contact, max. 250 (Feed pump running = contact closed) | “ripped mat nal Potential free NC contacts, max. 250 0.5 A Emergency Shut Down (ESD) signal (optional) Emergency Shut Down (E80) feedback ‘To EPC 50 (sheet 3) Ref, 568080 28 Sheet 2, Rev 4 1810949-02‘$A 831/696/041/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS 2.4.4 Interconnection Diagram, Transmitters MT Water transducer “Termination jumper. Only at ‘sattbus end units. Remote OP urit “Termination Jumper. Only at Ssattous end units, Temp. sensor, 2xPT 100 TT (Alarm) TT2 (Control) Pra 09 Od3 LINN TOHLNOO PTS: Speed sensor (Cabie included in separator delivery) » Speed transmitter g B BS Vibration transmitter @ 3 (Optional Separator interlock switch optional uoqzouato a ; z Ls © Level Switch Sludge Tank (Optional) Ref, 568030 Sheet 9, Rev. 4 181004902 292 DRAWINGS ‘9A 831/856/841/846 SEPARATION SYSTENS INSTALLATION SYSTEM REFERENCE 2.4.5 Interconnection Diagram, Solencid Valves Sipe alarm pn FS scorns ope atl Max SOVRCDGT9R ov er Stage Ect} —@it sono ” Frou Suge Pum i (Optra) ! sv ner \ Stee got +} OH sva ie | Giloutet cane -—@+4 sys Water outlet svio Water seal 09 Od LINN TOHLNOO svis Opening water svis Ciosing water vk one peau ous Rol. 668030 Shoot 4, Rev. 4 30 1810949-02A 63186664145 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS 2.4.6 Interconnection Diagram, Solen: Valves cont. | » | 8 i meal § systems emergency stop (Control votage of ; i < ' z : ca e | ° From starter (sheet 2) 4 poi TRERESEREESEEEESEEEEEOE S 5 2 5 5 ae Ss Boon Boo B3 B & Z & afer 88 i 3 = 2 ok 8 i & m 2 [key & 5 : 2 é < Ua ia 1 8 a B Ge St & i fa 8 8 é | g from staror (sheet 2) From starter (sheet 2) mnt ‘| fe * Replaces jumper in terminals 7 ¥ soot 6 Ff, 68000 Sheet 5, Rov 4 491094902 312 DRAWINGS ‘SA 991/996/04 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.4.7 Interconnection Diagram, Optional Equipment i Q 1 3° e | 4 oO 8 ge CG | 8s z | ae a Ee a vige 8 ‘Remote alasm indication High temp, indication ‘Low temp. indication Pot, free contacts Max. 50 V AC/DC, 1.08 Contact closes at alarm. Remote opaation Remote mode selected (output 24 VAC) Sep. status indication (output 24V AC) Separation StartStop ‘uavoR NoISNKIKS-ON Note Jumper X71 10 X71:3 10 void false alarm when not used, Ret. 568030 Sheet 6, Rev. 4 32 1810949-022 DRAWINGS ‘94 831/896104 846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.4.8 Transformer Connection Diagram ~ yes onpooioig ew), Bhat yeanou oun, eseyd au — Joy eur | ows ure 33 1810949-02 el, 31880-6337-0 Rev. 22 DRAWINGS ‘SA 831/836V64 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2.4.9 Circuit Diagram, Power Circuits Mains supply ‘Separator Space heater (Cptional) Feed pumo {optional} ‘Space heater (optional) Ref, §68028 Sheet 1, Rev. 0 34 1810949-022 DRAWINGS: ‘9A 891/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE jiagram, Separator Starter and Feed Pump 2.4.10 Circuit $ ji : ‘| rn essa uss Ret. 568028 Sheet 2, Rev. 0 35 1810949-02‘SA 83 /836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS it Diagram, Remote Start Interlock (optional) ircuil 2.4.11 Ci spoveru soresedog "pu ej ny reyes xy yous pisos | voneiain | | ef, $68028 Sheet 3, Rev. 0 1810949-02 36SASS VS0N04 1846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 onawnas 2.4.12 Circuit Diagram, ESD-relay and Trip Contacts (optional) 3 i 3 ; Bi i ‘6 Fe 868028 Sheet 4, Row 0 1810849-02 372 DRAWINGS: ‘SA 8518961841846 SEPARATION SYSTEMS INSTALLATION SYS"EM REFERENCE 38 1810949-02‘SA 891/896 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 3 REMOTE OPERATION SYSTEMS 3 Remote Operation Systems iG Disintegration hazard If the system is operated from a position from which the separator is not visible, a Remote Operation System must be installed, including vibration sensor and frame cover interlock switch. Connection to steering system via PROFIBUS or MODBUS fioldbus systems. PROFIBUS or MODBUS communication protocol can be used to connect an EPC 50 Control Unit to a central steering system. The EPC 50 Control Unit uses a PROFIBUS DP or MODBUS RTU. Every node, or EPC 50 Control Unit, on the bus has a unique address, and can use 200 bytes for data exchange. An interface board is needed to connect an EPC 50 Control Unit to the respective fieldbus system. This is mounted on the I/O card. Remote fieldbus connection for EPC 50 Control Unit is for use in those cases where the user wants access to data and operation information from the control cabinet, and supervision and/ or remote control from his own steering system, 1810949-02 39{3 REMOTE OPERATION SYSTEMS ‘9 83/836 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE PROFIBUS MODBUS Userinterface | To bearranged by | Tobe arranged by customer. customer, Cable Cable for PROFIBUS | Cable for MODBUS. aquired and installed | aquired and installed by customer. by customar. Manual Hardware and software | Hardware and software Instructions exist instructions exis Board Part no. 31830-6659-1 | Part no. 31830-8558-1 40 1810949-02‘5A 831/896 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 9 REMOTE OPERATION SYSTEMS: 1810949-02 a4 SPECIFICATIONS 4 Specifications 4.1 Cables Cable Identification All cables are to be marked to simplify identification and fault finding. ‘94 891/836V84 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE Specifications ‘The following specifications apply to cables connected to and from Alfa Laval equipment. Follow the instructions given in the cable list. Examples of cable types that can be used: Steel armoured cable. Copper armoured cable with a separate earth core, Stee! armoured and shielded signal cable; pair twisted or parallel Shielded signal cable; pair twisted or parallel. 42 1810949-02‘SA 83183654 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPEGIFICATIONS 4.2 Cable Routing Recommendations Power cables carry the power supply to motors, heaters, ete. Any distance between signal and power cablos lectrical noise transfor. reduces olectrical noise transfer. ©0® 606 Examples of recommended routing of various cable types. + Power cables and signal cables routed ona Power Sonal cable rack should be separated. © Saltbus cables should be routed away from power cables. If the space is limited, cables can be routed in tubes. .3 Oil, Water, Steam, and Condensate Piping For piping to and from Alfa Laval equipment, see the specifications below. Specifications The correct pipe size must be used in the oil system. The number of bends in the oil pipes must be minimized. ‘The suction height must be as low as possible, The oil feed pump must be of positive displacement type. ‘The pump must be positioned close to the oil tank The heater must be installed close to the separation system to maintain correct feed oil temperature. The recirculation line should be connected either directly to the settling tank (HFO) or to the oll outlet line from the separator (LO). The oil outlet line from the separator must be connected to the system tank for lube oil, or the service tank for {uel ol 1810949-02 434 SPECIFICATIONS ‘SA 831/826/84 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4.4 Ambient Temperature Limitation Specification Leading classification societies state in their regulations for engine room equipment that the maximum ambient temperature permissible is +55 °C, To meet this regulation, it is essential that electrical and electronic components have good ventilation, and temperature control. 44 1810949-02‘SA 83 1/8365 1/646 SEPARATION SYSTEMS INSTALLATION SYSTEM FEFERENCE 4 SPECIFICATIONS 4.5 Sludge Removal Kit (Optional Equipment) If you have a Sludge Removal Kit, this must be connected to a ventilation pipe. ‘NOTE, ‘The sludge removal pump must be set to the correct ‘speed ~ circa 60 strokes/min, otherwise the lifetime of the diaphragm, valve balls, and air motor will be severely shorten {WARNING Health Risk ll mist and vaporized oil constituents from hot olly, | sludge may be dangerous to health and must not be Inhaled. A pipe or hose must be drawn from the flange to the nearest oil tank ventilation pipe. ‘The pipe /hose must have the same diameter as, the flange opening, ‘The pipe/hose must be as straight as possible, with a steady upward incline, ‘The connection to the oil tank ventilation pipe must point upwards as shown. NOTE ‘tan vertistion For HFO separation, It is not recommended to make the connection to the separator room ventilation system. For LO separation, connection to the separator room ventilation system should be made only if the separator room ventilation Is adequate. Use the optional connection hose (part no, 568023-80, -81, oF 62) for this purpose. This hose is designed to entrap oil drops in the vent hose, and lead the oil back to the | | ‘Sludge Removal Kit tank. | 1810949-02 454 SPECIFICATIONS ‘5A 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE NOTE Impurities gather in the Sludge Removal Kit tank. Regularly check the tank and level switch. See Instructions below. Proceed as follows: ‘+ From the Control Panel, run the sludge pump manually for a few seconds, ‘+ Undo the four screws at the top of the sludge tank and remove the sludge pump. + lFnecessary, clean the level switch and the inside of the tank using diesel oil. ‘© Check the seals and gaskets, and change if necessary. ‘* Loosen the hose lip and check the inside of the ventilation hose, Clean if necessary. ‘To avoid breakdown of the Sludge Removal system, the sludge pump must be regularly overhauled as follows using spare parts kit 1766702-81. * Replace the diaphragms and the O-rings with those delivered in the spare parts kit. ¢ Perform a 4000 hour Inspection Service, For Service and Overhaul intervals, see i 46 1810949-02‘9 83186184 /846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS. 4.6 Sludge Tank Sludge tank volume per separation system should cover approximately up to 2 days storage at a discharge interval of 2 hours (for discharge volumes see technical data). A manhole should be installed for inspection and cleaning. ‘The tank should be fitted with a sounding Pipe. The tank floor, or most of it, should have a slope (B) of minimum 15° The sludge outlet pump connection should be Positioned in the lowest part of the tank. Ahigh level alarm switch, connected to the sludge pump, should be installed A heating coil should be used to keep the sludge warm and fluid while being pumped out ‘Tank ventilation must follow the classification rules for evacuation of gases. ‘There should be a ventilation pipe to fresh air, The ventilation pipe should be straight. If this isnot possiole, any bends must be gradual. ‘The ventilation pipe must not extend below the tank top, A sludge tank with partition walls must have ventilation pipes in all compartments, or cutouts in the upper edge, to allow vapours to travel through the tank entation ape ‘see pe comectan q Stuige ote i N]. ps eae nee] | lun hoist ssn Mir iopo 15° om 1810949-02 47{4 SPECIFICATIONS. ‘SA 831/836) 846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE ‘The number of ventilation pipes, and their minimum dimension, depend on the size and number of separators connected to the same tank. See table below. ‘Type 1 system 2aystems ‘SAB11,SA816 | 1 xZ50mm 11x 250mm SA 821, SA826 | 1xQ75mm 1x 275mm SA831, SA836 SA 841, SA846 Saasi,Sa856 | 1x@t00mm — | 1x@100mm SA861, SA866 sAa7i,sasre | 1x@t0omm — | 1xGi25mm SA.881, SA 886 ‘The separation system generates almost no air during operation. At any discharge, the maximum volume of air produced is the same as the bowl volume (see technical data). 48 1810949-02‘SA 89/8848 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS. 4.7 Sludge Piping Specitication © The sludge pipe from the separator to the sludge tank should be vertical, Ifa vertical pipe is not possible, the deviation (A) from the vertical line must not exceed 30°. + The sludge pipe must not extend below the tank top. NOTE 1 ‘An extended sludge pipe will obstruct ventilation and | create back pressure that could cause separator problems. 1810949-02 494 SPECIFICATIONS ‘9A 891/896/84'1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE If more than one separator is connected to the same sludge tank, a butterfly valve should be installed in each sludge pipe. NOTE Ha butterfly valve Is not used, the bowl and the ‘operating system may be affected. + Ifa butterfly valve is used, it should be ‘equipped with an interlocking switch (connected to the separator starter) to prevent the separator from being started when the valve is not fully open. 50 1810949-02‘SA 831/536/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS 1810949.02 5‘5 COMMISSIONING AND INITIAL START ‘SA 83 /836\641/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 5 Commissioning and Initial Start 5.1 Completion Check List It is essential before starting up the separation system that all units are in good operating condition and that all pipelines and control equipment are properly connected to assure correct operation. Use this check list as a guide for completing the system installation: Breakdown hazard ‘Check that the power frequency is in agreement with ate. I incorrect, resulting overspeed down. 41 Check that transport seals are removed from all pipes, 2. Use flushing filters to prevent pipe work debris from being pumped into the separation system. NOTE ‘The flushing filters must be removed attor i flushing. ial 3 Check that all separators are in proper working condition. Follow the manufacturer's instructions, 4 Make sure that separators are lubricated accordance with instructions. NOTE Make sure that the spindle bearings are prelubricated 5 Separators are delivered without oil in the oil ‘sump. For information on oil fling and oil type, see the Service Manual booklet. 52 1810949-02‘SA 83 /836/861/246 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE | NOTE ‘Too much, of too little oil may result in damage to separator bearings. Neglecting an oll change may resul ‘separator bearings. damage to 6 Power on, 7 With the mode selector switch in the CIP postion, check that the separator rotation direction corresponds with the arrow on the frame by doing a quick start/stop (1-2 seconds.) and looking at the motor fan rotation. owes lf power cables have been installed incorrectly, the ‘separator will rotate in reverse, and vital rotating parts can unscrew. 8 Check the pump function and direction 9 Ifa Sludge Removal Kits used, check that the sludge pump speed is set to circa 60 strokes/min.It necessary, adjust the throttling valve (positioned after solenoid valve sv 6) 1810949-02 5 COMMISSIONING AND INTIAL START'5 COMMISSIONING AND INITIAL START ‘SA 831/856/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 5.2 Initial Start-up Use this check list for initial system start up: 4 Check that there is oil in the feed oil tank. 2 Check water and air supply. See “System Data” 3 Check power supplies to the control unit and that the voltage is in accordance with data in “System Data” 4 Check all parameter settings in the control unit. See Installation Parameters in the Parameter List booklet. 5 Check the separator. NOTE © Atways lubricate the bearings betore start-up. NOTE The Control Unit is supplied with stendard configuration parameters. You may have to make ‘some changes to suit your installation. 7 Start the separation system as described in the Operating Instructions dooKiet 8 Start up step by step, checking that the machine and units function properly. 9 Establish system pressures. The delivery height pressure is the pressure in the cil pide work down stream from the separation system, due to the pipe bends and the height (head) to the cleaned oil tank. If the cleaned oil tank is below the separation system the delivery height pressure may be very low. The oil paring disc pressure will have to be greater than the delivery height pressure for any oil to flow. Proceed as follows: ‘© Ensure the valves in the oll system are in the correct positions. «The oll should be at separation temperature. Cont. 54 1810949-02‘SA 831/836V841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE ‘The adjustment screw for the water paring tube should be in the outer position. The paring tube should be able to move freely. * Ensure that V5 is closed. * Fully open the back pressure regulating valve Rv4 ‘+The shut off valve V4 should be open. Open SV15 for 3 seconds to prime the operating slide. ‘+ Open SV16 for 15 seconds to close the bow. ‘© Open SV10 for 1 minute to put water into the bow. ‘+ Feed oil to the separator at the normal flow rate by opening SV1 Note the pressure in the oil outlet PT4, both on the pressure gauge and in the EPC50 display. This pressure is P min. * Gradually close the back pressure regulating valve RV4. The pressure on PT4 will increase. ‘The water pressure (PTS) decreases slightly as the paring tube moves inwards. The water pressure will suddenly drop when oil passes from the oil paring chamber to the water paring chamber. Note the pressure of PT4 both on the pressure gauge and in the EPC50 display. This pressure is P max. © Open Rv4. Stop the oil feed to the separator and note the pressure in the oil outlet. This is the delivery height pressure P del. * Stop the heater + Stop the separator. * Stop the feed pump when the heater has cooled. 1810949-02 5 COMMISSIONING AND INTIAL START 555 COMMISSIONING AND INITIAL START ‘SA 831/830/84 1/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 5.2.1 Calculating Operating Pressure ‘© Caloulate the normal back pressure level during operation as follows: * Calculate the value for low pressure alarm setting (Pr 11) as follows: Prin + Prormal 2 om press, © Calculate the value for high pressure alarm setting (Pr 10) as follows: Prormat + Pmax 2 igh poss. Adjust the back pressure to Prormat Set Pr 11 to give alarm at pressure decreasing below the Prow prose, Value. Set Pr 10 to give alarm at pressure increasing above the Phign ress, Value. 56 1810949.02‘SA 831/896/84"/246 SEPARATION SYSTEMS. INSTALLATION SYSTEM REFERENCE 6 SHUT-DOWN AND STORAGE 6 Shut-down and Storage Storage before Inst: ition If the separation system is stored before installation, the following safeguards must be taken: ‘Storage period 4-6 months > 6 months See Action Protect from dust, dit, x x This chapter water, etc Protect with ant-rust x x This chapter ol Ingpection x x (On commissioning Overhaul x (On commissioning 6.1 Shut-down after Use If the separation system is going to be shut down for a period of time, the following safeguards must be taken: Shutdown | 1-6months) 6-48 > ie months period (stand-by) months | Action | Remove bowl x x x Dismanting ana Assombiyin the Sence Manua! Protectrom dust. dit, x x x This chapter water ete. Protect wih ant-ust x x x This chapter ai Inspection x x x On new startup Overhaul x On naw startup 1810949-02 87{6 SHUT-DOWN AND STORAGE ‘5A 83 1836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 6.2 Protection and Storage All system equipment, both the separator and the ancillary equipment, must be stored indoors at 5 - 55°C, ifnot delivered in water-resistant box for outdoor storage. If thore is a risk for condensation of water, the equipment must be protected by ventilation and heating above dew point. ‘The following protection products are recommended: * Anti-rust oil (Dinitral 112 or equivalent) with long lasting effective treatment for external surfaces. The oil should prevent corrosion attacks and give a waxy surface. ‘© Anti-rust oil (Dinitrol 40 or equivalent) thin and lubricating for inside protection. It gives a lubricating transparent oil film. © Solvent, 6.9. white spirit, to remove the anti- rust oil after the shut-down. * Moist remover to be packed together with separator equipment. * Ifthe storage time exceeds 12 months, the equipment must be inspected every 6 months and, if necessary, the protection be renewed. Rubber Parts * Gaskets, O-rings and other rubber parts should not be stored for more than two years. After this time, they should be replaced. ‘Separator Dismantle the separator bowl and take out the O-rings. Clean the bow! with oil and reassemble without the O-rings. Place in a plastic bag with silica dessicant bags and seal the plastic bag. Grease the spindle. 58 1810949-02‘SA 831/536/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE Valves, Pipes and Similar Equipment © Components such as valves need to be cleaned with solvent and treated with anti-rust oll (type 112), * Water pipes should be drained and treated with anti-rust oil (type 112), * Articles made of rubber or plastics (e.g, seals) must not be treated with anti-rust oi 6.3 Reassembly and Start up Clean away the anti-rust oil with white spirit, © Remove all silica gel bags © Pre-lubricate the separator spindle bearings * If stored for 6 months or longer, perform an inspection service (including change of oil in the separator sump). Follow all relevant instructions in the Service ‘Manual and Operating Instructions. woTe Always lubricate the separator bearings before start up. 181094902 65 SHUT-DOWN AND STORAGE 596 SHUT-DOWN AND STORAGE 60 ‘9A 831/556/84 1/845 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 1810949-02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 Sep 2008.Sign pa / Separator Manual High Speed Separator S$ 831 & S 836 Product No, 881202-03-09/2 & 881202-02-09/2 Book No. 578702-02 Rew 2Contents 1 Read TI First 2 Safety Instructions 2A 2.2 2.3 text. Warning sign: Environmental Requirements of personnel. 3 Basic Principles Of Separation 3.1 Separation By Gravity.. 3.2 Centrifugal Separation 3.3 Temperatures 4 Design. 4.4 Overview 4.2 The Drive Section. 4.3 The Process Section 4.4 Sensors 4.5 Separating Function. 4.5.1 The liquid balance in the bow! 45.2. Liquid tow. 4.5.3. Discharge of sludge and water: 45.4 ALCAP™ concept, 5 Operating Instructions 5A 5.2 5.3 5.4 5.5 56.1 5.6 57 Before First Start-up Start After Service. Before Normal Start Start Operating Sludge discharge during operation Stop. Emergency Stop 6 Service, Dismantling, Assembly. 64 614 612 613 614 615 6.2 6.3 634 632 633 Periodic Maintenance. Maintenance intervals, Maintenance procedures Tightening of screws Service kits Cleaning Maintenance Log Dismantling Introduction, Tools Frame hood 57870202 14 18 16 17 7 18 18 19 at 22 26 or 27 28 28 28 34 31 32 32 37 38 40 42. 43 43 43 4a, 44 44 45, 48 48 48 50634 635 636 6.4 644 642 643 644 645 646 647 648 65 65.1 652 653 654 655 656 66 66.1 6.7 ert e72 673 674 675 676 68 68.1 63.2 Bow! Driving device Centrifugal clutch Actions Before Assembly Cleaning nnn Inspection for corrosior Inspection for cracks Inspection for erosion Exchenge of frame feet Lubrication of bow! parts How to lubricate bow! parts with slide lacquer Check for galling on operating siide and bow! body .. Assembly. Centrifugal clutch Driving device, Bow! 7 In and outlet device. Unbalance sensor (optional) ‘Speed sensor Actions After Assembly... Control of machine plates and safely labels .. Change Lubricating oil Check oil eve! lll change procedure. Lubrication chart, Lubricants. Lubricating cis Lifting instructions Lifting the separator. Liffing the bovrl Fault Finding sos 4 TA 7A 742 743 714 TAS 716 TAT 7A8 72 724 722 723 7.2.4 Mechanical Functions, Separator vibration Smell. NOI8@ nn Speed too low. Speed too high Starting power too high Starting power too low Starting time too tong. ‘Separating Functions Bow opens accidentally during operation Bow fails to open for sludge discharge. Unsatistactory separation result Bow fails o close 1578702-02 52 6 78 e2 82 84 85 86 e7 EY 89 91 91 98 12 125 129 131 182 192 134 134 135 135 136 137 140 142 442. 143 45 145 145 146 146 148 oe 46 147 147 147 148, 143. 148 148 149Technical Reference 8.1 Product description 8.2 Technical Data. 8.3 Connection List 8.4 Interface Descript 84.1 Scope 84.2 References 84.3 Definitions, 844 Goal 8.4.5. Description of separator modes. 8.4.6 Remote start araeannese 8.4.7 Handling of connection interfaces 8.5 Demand Specification Water. 8.6 Drawings 86.1 Basic size drawing 86.2 Foundation drawing. 86.3 Interconnection diagram ... 86.4. Electric motor... Installation 9.4 Introduction 9.2 Upon Arrival At The Storage Area 9.2.1 Transport 9.2.2 Protection and storage of gods 9.3 Planning of Instal 9.3.1 Important measurements 93.2 Maintenance service 9.3.3 Connections to surrounding equipment. 9.4 Storage at out of operation 9.5 Before start-up 67870202 151 151 162 153 165 155 155 156 156 187 168 158 165 166 166 167 168 169 171 171 172 172 173 174 174 a 7B: 176 17 177678702021 Read This First This manual is designed for operators, maintenance personnel and service engineers working with the Alfa Laval S 831 & S 836 separator. If the separator has been delivered and installed by Alfa Laval as a part of a processing system, this manual should be viewed as part of the System Documentation. Study carefully all instructions in any System Documentation. In addition to this Separator Manual a Spare Parts Catalogue, SPC is supplied. The Separator Manual consists of: Safety Instructions Pay special attention to the safety instructions for the separator. Accidents causing damage to equipment and/or serious injury to persons or personnel can result if the safety instructions are not followed. Basic Principles of Separation ‘This chapter describes the purpose of separation and separation principles. Design and function This chapter contains a description of the separator. Operating Instructions ‘This chapter contains operating instructions for the separator only.Service, Dismantling, Assembly ‘This chapter gives instructions for the maintenance procedures. It also contains step- by-step instructions for dismantling and assembly of the separator for service and repair. Fault Finding Refer to this chapter if the separator functions abnormally. Ifthe separator has been installed as a part ofa processing system, always refer to the trouble- tracing instructions, in the System Documentation. ‘Technical Reference ‘This chapter contains technical data concerning the separator and drawings. Installation ‘This chapter contains specifications and recommendations concerning separator installation. ‘NOTE A-complete reading of this manual by personnel in ‘contact with the machine Is essential to safety. Do not allow personnel to clean, assemble, operate ‘or maintain the separator until they have read and. fully understood this manual. Ensure that all personnel who operate and service the separator are well-trained and knowledgeable ‘concerning the machine and the work to be carried out.2 Safety Instructions The centrifuge includes parts that rotate at high speed. This means that: + Kinetic energy is high © Great forces are generated * Stopping time is long i 3 Manufacturing tolerances are extremely fine. Rotating parts are carefully balanced to reduce undesired vibrations that can cause a breakdown. Material properties have been considered carefully during design to withstand stress and fatigue. The separator is designed and supplied for a ‘specific separation duty (type of liquid, rotational speed, temperature, density ete.) and must not be used for any other purpose. Incorrect operation and maintenance can result in unbalance due to build-up of sediment, reduction ‘of material strength, etc., that subsequently could lead to serious damage and/or injury. The following basic safety instructions therefore apply: * Use the separator only for the purpose and parameter range specified by Alta Laval. ‘* Strictly follow the instructions for installation, operation and maintenance. * Ensure that personnel are competent and have sufficient knowledge of maintenance and operation, especially concerning ‘emergency stopping procedures. * Use only Alfa Laval genuine spare parts and the special tools supplied.10 ( Disintegration hazards When power cables are connected, always check direction of motor rotation. If incorrect, vital rotating parts could unscrew. If excessive vibration occurs, stop separator and keep bow! filled with liquid during rundown. Use the separator only for the purpose and parameter range specified by Alfa Laval. Check that the gear ratio is correct for power frequency used. If incorrect, subsequent overspeed may result ina serious break down. Welding or heating of parts that rotate can seriously affect material strength. Inspect regularly for corrosion and erosion damage. inspect frequently if process liquid is corrosive or erosive, 2 Safely Instructions ae2 Safety Instructions i) Entrapment hazards ‘Make sure that rotating parts have come to a complete standstill before starting any dismantling work. 3 a To avoid accidental start, switch off and lock power supply before starting any dismantling work a Assemble the machine completely 3 before start. All covers and guards must be in place. j\ Electrical hazard * Follow local regulations for electrical installation and earthing (grounding). To avoid accidental start, switch off and lock power supply before starting any dismantling work. j Crush hazards © Use correct lifting tools and follow lifting instructions. Do not work under a hanging load. 12 Safety instructions i) Noise hazards * Use ear protection in noisy environments. h Burn hazards * Lubrication oll, machine parts and various machine surfaces can be hot and cause burns. Wear protective gloves. )\ Skin irritation hazards When using chemical cleaning agents, make sute you follow the general rules and suppliers recommendation regarding ventilation, personnel protection ete. Use of lubricants in various situations. 122 Safety Instructions \ Cut hazards ‘* Sharp edges, especially on bow! discs and threads, can cause cuts. Wear protective gloves. h Flying objects ‘* Risk for accidental release of snap rings and springs when dismantling and assembly. Wear safety goggles. M Health hazard © Risk for unhealthy dust when handling friction blocks/pads. Use a dust mask to make sure not to inhale any dust. 13; 2 Safety instructions 2.1. Warning signs in text Pay attention to the safety instructions in this manual. Below are definitions of the three grades of warning signs used in the text where thera is a risk for injury to personnel. iS ANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. \ WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Bowne CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. cates a potentially hazardous situation which, if not avoided, may result in property damage. 142 Safely instructions 2.2 Environmental issues Unpacking Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps. Wood and cardboard boxes can be reused, recycled or used for energy recovery. Plastics should be recycled or burnt at a licensed waste incineration plant. Metal straps should be sent for material recycling. Maintenance During maintenance oil and wear parts in the machine are replaced. il must be taken care of in agreement with local regulations, Rubber and plastics should be burnt at a licensed waste incineration plant, If not available they should be disposed to a suitable licensed land fill site. Bearings and other metal parts should be sent to a licensed handler for material recycling. Seal rings and friction linings should be disposed toa licensed land fill site. Check your local regulations. ‘Worn out or defected electronic parts should be sent to a licensed handler for material recycling. 152 Safety instructions 2.3 Requirements of personnel Only skilled or instructed persons are allowed to operate the machine, e.g. operating and maintenance staff. * Skilled person: A person with technical knowledge or sufficient experience to enable him or her to perceive risks and to avoid hazards which electricity/mechanics can create. Instructed person: A person adequately advised or supervised by a skilled person to enable him or her to perceive risks and to avoid hazards which electricity/mechanics can create. In some cases special skilled personnel may need to be hired, like electricians and others. In some of these cases the personnel has to be certified according to local regulations with experience of similar types of work. 163 Basic Principles Of Separation The purpose of separation can be to © free a liquid of solid particles, © separate two mutually insoluble liquids with different densities while removing any solids present at the same time, © separate and concentrate solid particles from a liquid. 3.1 Separation By Gravity A liquid mixture in a stationary bow! will clear slowly as the heavy particles in the liquid mixture sink to the bottom under the influence of gravity, A lighter liquid rises while a heavier liquid and solids sink. Continuous separation and sedimentation can be achieved in a settling tank having outlets arranged according to the difference in density of the liquids. Heavier particles in the liquid mixture will settle and form @ sediment layer on the tank bottom. Lighter Tiquie FAS Heavier = Tiguid ‘Sediment layer of heavier particies 732 CENTRIFUGAL SEPARATION 43 BASIC PRINCIPLES OF SEPARATION 3.2 Centrifugal Separation Ina rapidly rotating bowl, the force of gravity is replaced by centrifugal force, which is many times greater. Separation and sedimentation is continuous and takes place very quickly. The centrifugal force in the separator bowl can achieve in a few seconds that which takes many hours in a tank under influence of gravity. The separation efficiency is influenced by changes in the oil viscosity, separating temperatures and in throughput. 3.3 Temperatures For some types of process liquids (e.g. mineral oils) a high separating temperature will normally increase the separation capacity. The temperature influences oil viscosity and density and should be kept constant throughout the separation. Lightor liquid — Heavier quid ~<—} Contiugaltrce Viscosity Viscosity is a fuids resistance against movement, Low viscosity facilitates seperation. Viscosity can be reduced by heating. ° ° 4 High viscosity Low viscosity Density difference Density s mass per volume unit. The greater the density difference between the two liquids, the easier the separation. The densty diference can be increased by heating, Low density citference = i) ws High density difference. 184 Design Process section The feed inlet and outlets WF — — — — = — — 7 are situated at the top of 1 Electric motor the separator ‘The rotating bowl is driven ' by the electric motor via & Lp —— — — 44 batt transmission: The liquids cleaned in the rotating separator bow 1 1 1 fdehotarenoos, | ! ' ' ' ' I Sensors 7 ‘he separator is monitored Dyaswodeatocar Chaldnoe sensor anc an introeking teh are caters! + Drive section / The rotating separator + bow! is riven by a flat 1 Bet transmission with friction coupting, I Sludge outlet re rt Separated solids are discharged at ‘The separator rests preset interval. (on vibration damping Lubrication system frame feet Lubricates the bearings criven ‘by the flat bet transmission 1941 OVERVIEW 4 DESIGN 4.1 Overview ‘The separator comprises a process section and a drive section powered by an electric motor: ‘The separator frame comprises a lower body and a frame hood. The motor is attached to the frame. The frame feet dampen vibration. ‘The bottom part of the separator contains a flat, belt transmission, a centrifugal clutch and a vertical spindle. The lower body also contains an oil bath for lubrication of spindle bearings. ‘The frame hood contains the processing parts of the separator; the inlets, outlets and piping. ‘The process liquid is cleaned in the separator bowl. The bowl is fitted on the upper part of a vertical spindle and rotates at high speed inside the frame hood. The bow! also contains the discharge mechanism which empties the sludge during operation. A speed sensor, and the optional unbalance sensor and lock switch, are parts of the equipment for monitoring the separator functions, 204 DESIGN 42 THE DRVE SECTION +2 The Drive Section The separator bowl is driven by an electric motor via a belt transmission. The belt pulley on the motor shaft includes a centrifugal clutch. Flat belt The fat elt transmission has @ ratio which increases the bow! speed saveral times compared with the motor speed | To reduce bearing wear andthe | transmission of bow! vibrations to. | The centrifugal clutch with friction the frame and foundation, the top pads ensures agente sir and ‘bearing of the bow! spindle is | [smooth acceleration, and at the ‘mounted in a spring dampened ‘same time prevents overloading of bearing seat the Belt and motor. | ‘The bearings on the spinale are lubricated By the ol spray produces by an oll pump mounted on the | | | ower end of the spindle ASE EE PPE GCSE EEE EEE 21491 THE PROCESS SECTION 4 DESIGN 4.3 The Process Section The separation process takes place inside the rotating separator bowl. The feed and outlet of process liquid takes place in the in and outlet unit on top of the separator frame hood. Inlet and outlet ‘The inlet and outlet unit consists of the following parts: A connection house for pipe connections. A pipe with a paring disc and a paring tube is located inside the connection house. The pipe has channels for incoming and outgoing process liguid. ‘The paring disc and paring tube pump the cleaned oil and water respectively out of the bowl. The paring tube can move radially. During separation it surfs on the liquid surface. It is balanced by a spring. Under certain operating conditions, the paring tube radial position can be locked in place by two adjustable screws on the connection house. ‘The paring disc and tube are located inside and at the top of the separator bowl. The inlet and outlet device is held together against the frame hood by a nut on the end of the inlet pipe. Height adjusting rings determine the height position of the paring disc and paring tube relative to the bowl. 224 DESIGN 43 THE PROCESS SECTION Pipe oe ‘Spring dex Uncleaned oll sep Cleaned oil Paring tube Paring cise Connection house / 2343 THE PROCESS SECTION 4 DESIGN Separator bowl ‘The separator bowl, with its sludge discharge mechanism, is built-up as follows: ‘The bowl body and bowl hood are held together by a lock ring (Centrilock). Inside the bowl are the distributor and the dise stack. The dise stack is kept compressed by the bowl hood. The discharge slide forms a separate bottom in the bowl body. ‘The upper space between the bow! hood and the top disc forms the water paring chamber and contains the paring tube, which pumps the separated water out of the bowl. The oil paring chamber, with its paring disc, is located inside the top of the distributor. From here the cleaned oil is pumped out of the bowl. The sludge space is in the bowl periphery. The bowl is kept closed by the discharge slide, which seals against a seal ring in the bowl hood. At fixed intervals, decided by the operator, the discharge slide drops down to empty the bowl of sludge. The sludge discharge mechanism, which controls the movement of the discharge slide, is comprised of an operating slide and an operating water device. Passive parts are: nozzle and valve plugs. The operating water cover, beneath the bowl, supplies operating water to the discharge mechanism via the operating water ring. 244 DESIGN 4.3 THE PROCESS SECTION Bowl body Top dise il paring chamber Disc stack Lock ring Seal ring Discharge slide Operating slide 2544 SENSORS 4 DESIGN 4.4 Sensors The separator is equipped with a speed sensor: As options an unbalance sensor and an interlocking kit can be fitted. ‘Speed sensor Monitoring kit (optional) ‘A speed sensor indicates the speed of the separator, The For indication of any abnormal unbalance, the separator can correct speed is needed to achieve the best separating _be equipped with a sensor monitoring he radial position of results and for reasons of safety. Refer to type plate for spead the bowl spindle. particulars. Cover interlocking kit (optional) \When the cover is closed the interlocking circu in the control system is closed which makes it possible to start the separator. _- Cover interlocking switch 264 DESIGN 45 SEPARATING FUNCTION 4.5 Separating Function The separator separates water and solids from the uncleaned oil. Water normally leaves the separator through the water outlet. During sludge discharge, solids (sludge) and water are removed through the discharge ports. 4.5.1 The liquid balance in the bowl ‘The liquid levels in the bow! depend on many factors (bowl geometry, liquid densities, flow rates etc.). To get a picture of how the liquids are distributed in the bowl, imagine that the bowl is at standstill and turned 90° (only influenced by gravity). The bowl can now be compared with a settling tank: ‘SEPARATOR BOWL TURNED 90° Unseperated oi! > Separated oll | water a a ; : paso v i | T r te Y | | = unseparates oit I\ Seas [> water ie ‘SETTLING TANK a74 DESIGN 4.5.2 Liquid flow ‘Unseparated oil is fed into the bowl through the inlet pipe and travels via the distributor towards the periphery of the bowl. When the oil reaches slots in the distributor, it rises through the channels formed by the disc stack, where it is evenly distributed. ‘The oil is continuously cleaned as it travels towards the centre of the bowl, When the cleaned oil leaves the dise stack, it flows through a number of holes in the distributor and enters the oil paring chamber. From here it is pumped by the oil paring disc, and leaves the bowl through the oil outlet. Separated water, sludge and solid particles, which are heavier than the oil, are forced towards the periphery of the bowl and collect in the sludge space. ‘The space between the bow] hood and top disc, as well as the water paring chamber, is filled with oil, which is distributed over the entire circumference via the grooves in the top disc. During normal operation, the water drain valve in the water outlet is closed. 4.5.3 Discharge of sludge and water As the sludge space fills up and water enters the dise stack, traces of water will escape with the cleaned oil. The increase of water content in the cleaned oil is the sign of reduced separation efficiency. ‘This condition is monitored by the process control system, and water is removed from the bowl when minimal levels are recorded, ‘The water is removed by either of two ways: © The water drain valve opens and the water leaves the bowl through the water outlet. + Through the sludge ports at sludge discharge. Which way is decided by the process control system. SEPARATOR MANUAL 4.5.4 ALCAP™ concept When the sludge space is filled up and water enters the dise stack, traces of water will escape with the cleaned oil. The increase of water content in the cleaned oil is the sign of reduced separation efficiency. ‘This condition is monitored by the process control system, and water is removed from the bow] when minimal levels are recorded. 28 578702024 DESIGN 45 SEPARATING FUNCTION DISCHARGE OF WATER THROUGH WATER OUTLET ex Unseparated cll se Separated cil il paring alse cep Water Water paring chamber il paring chamber Holes in cisibutor ee 294.5. SEPARATING FUNCTION 4 DESIGN5 Operating Instructions These operating instructions describe routine procedures to follow before and during the start, running and stopping sequences of the separator. If system documentation is available, always follow the operating instructions therein. If there is no system documentation, the instructions below are to be followed. 5.1 Before ‘st Start-up Technical demands for connections and limitations for the separator are listed in chapter 7 : ‘Technical data Connection list Interface description Basie size drawing Foundation drawing. Before first start: Ensure the machine is installed and assembled correctly and that feed lines and Grains have been flushed clean. Fill oil in the oil sump. See Quality of oil see ‘Make sure that the bearings on the spindle are pre-lubricated. Check the direction of rotation by doing a quick start/stop. The motor fan should rotate clockwise. 3152 START AFTER SERVICE 5 OPERATINGINSTRUCTIONS 5.2 Start After Service Pay special attention to any unusual sounds or vibrations when starting the separator after a service. Different fault symptoms are listed in chapter Pind 5.3 Before Normal Start To achieve the best separation results, the bowl should be in a clean condition. 4 Check that all couplings and connections are > Securely tightened to prevent leakages. Leaking het liquid can cause burns: thatthe lock nut is fully tightened. Ba not forget the washer. the direction of rotation by doing a quick Siat/stop. The motor fan should rotate Clockwise, that all rame hood bolts _~ aswell as the clutch cover are tuly tightened the oll evel and top up it necessary. ‘The separator should be level and at standstill vhen oll is filled.'5 OPERATING INSTRUCTIONS 54 START 5.4 Start 1 Start of separator, ‘a Open the water supply valve. 'b Start the separator by pushing the start button at the starter unit NOTE After every start the separator must always be run ‘continuously for a minimum of 1 hour to ensure proper lubrication.5.4 START 5 OPERATING INSTAUCTIONS Check the separator for vibration. zone | Se jw Normal vi Vibration may occur during start up when passing critical speed. Excessive vibration This s normal and shoul pass I vibration increases, or without danger. continues at full speed, keep bow! filled and stop the separator. ‘The cause of the vibration must be determined and corrected before starting again! Excessive vibration may be due to incorrect assembly or Insufficient cleaning of the bowl. 345 OPERATING INSTRUCTIONS 5.4 START 3 Ensure that the separator is at full speed (after about 60 - 150 seconds), ‘The time by full speed can be checked by studying the ammeter Current increases during start. {0 decrease to a stable Value when ful speed has been reached [4 Performa sludge discharge. ‘@ Add opening water until discharge sound is heard (3.0 seconds) bb Wait 15 seconds, © Add closing water for 15 seconds. 35