Zhangjiagang PDSD14000 Disc Separator System Manual

Operating Instruction of Disk-Type Separator
System Manual
Operating Instruction of
Disk-Type Separator units
(Manual of Frequency-Conversion
Gravity Disk System)
Page 1/ 27 Zhangjiagang Peony Machinery Co., Ltd

System Manual
This operating instruction or any part thereof shall not be reproduced or distributed by any
means or method without prior written permission of Zhangjiagang Peony Machinery Co., Ltd.
The total 3 operating instruction manuals of separator:

General Manual: Information for general Introduction;
Service Manual: Information related to specific type of separator;
System Manual: The operating instructions contain the system manual for specific system as the relative
information only when the separator used as a part of the complete system provided by Zhangjiagang Peony
Machinery Co., Ltd.

System Manual
Contents
1. Safety......................................................................................................................................... 4
1.1 Safety instruction..................................................................................................................... 4
2. Overviews.................................................................................................................................. 4
2.1 Main Purpose........................................................................................................................... 4
2.2 Product Standard:..................................................................................................................... 4
3. System Components and Introduction.......................................................................................5
3.1 System Components................................................................................................................ 5
3.1.1 Common base....................................................................................................................... 5
3.1.2 Separator............................................................................................................................... 6
3.1.3 Electrical control box............................................................................................................ 6
3.1.4 Heating unit...........................................................................................................................6
3.1.5 Piping system........................................................................................................................ 6
3.1.5.1 Names and functions of the valves are as follows............................................................ 6
3.1.5.2 Oil transfer pump............................................................................................................... 8
3.1.5.3 Slag pump.......................................................................................................................... 8
3.1.5.4 Oil Filter............................................................................................................................. 8
3.1.5.5 Heating unit, see 3.4.......................................................................................................... 8
3.1.5.6 Instrument Elements.......................................................................................................... 8
Name.............................................................................................................................................. 8
Characteristics................................................................................................................................ 8
4. Installation and Adjustment....................................................................................................... 9
4.1 Requirements for Installation of Unit:..................................................................................... 9
4.2 Requirements for Installation of External System Piping of Unit.......................................... 9
5. Adjustment of Control Box Parameters before Operation........................................................ 9
5.1 Description............................................................................................................................... 9
5.2 Introduction of Control Box.................................................................................................. 10
6. Operation..................................................................................................................................18
6.1 Operating procedures............................................................................................................. 18
6.1.1 Starting................................................................................................................................ 18
6.1.2 Shutdown............................................................................................................................ 18
6.1.2.1 Automatic Cleaning......................................................................................................... 18
7. Maintenance and Repair.......................................................................................................... 19
Alarm: Oil transfer pump failure................................................................................................. 19
Alarm: Material temperature lower than set-point...................................................................... 19
Alarm: Low clean oil pressure alarm.......................................................................................... 20
Alarm: Material temperature higher than set-point (high temperature alarm)........................... 20
Alarm 11: High clean oil pressure alarm..................................................................................... 21
Alarm: No slag discharge alarm.................................................................................................. 21
Alarm: Abnormal speed alarm (optional).................................................................................... 21
Alarm: First class vibration alarm (optional).............................................................................. 21
Alarm: Vibration alarm (optional)............................................................................................... 22

System Manual
1. Safety
1.1 Safety instruction
The separator is a high-speed rotating equipment and the drum will produce a
tremendous centrifugal force due to high-speed rotation during normal operation;
slightly improper operation or assembly may cause damage to the equipment while
severely improper may cause casualties and other serious accidents.
If the system is used for heavy fuel or lubricating oil, it must be heated to a
certain temperature to achieve the desired state of the material separation. The
temperature of heating medium and heated material is very high, so the operator
shall be careful to prevent accidental scalding when using it; please check the
assembly of the system before operation to prevent the liquid spilling or splashing
that may cause damage or injury.
In order to ensure the safety of the operating personnel and equipment, the
operator shall strictly comply with the safety rules (refer to the safety-related
sections of the operating manual for separator provided with the equipment).
2. Overviews
2.1 Main Purpose
The separator unit is an integrated module assembled with the separator,
electric equipment and related components and parts based on the systematic
diagram of the separator confirmed by both parties according to the requirement of
the owner, design institute and shipyard or user.
This unit is used to remove the water and mechanical impurities from the fuel
and diesel in the ship diesel engine, and for separation, purification and
regeneration of the lubricating oil from the lubricating system. It can also be used
for separation and purification of the fuel and oil in the diesel generator unit system
in the land-use power plant. The product can also extend its use for processing
different types of mineral oil products.
The operating system of the unit is an automatic control system.
* The automatic control refers to unmanned operation during normal
operation, but the product during normal operation can be unmanned operation,
and the separator must operate in attended status during start-up and shutdown
phases because the separator product has a certain risk in the phases of the
separator start-up and shutdown.
* If the user modifies the system at his own discretion without prior consent
of the Technical Department of Zhangjiagang Peony Machinery Co., Ltd, the
customer shall be fully liable for all damages and losses arising therefrom.
The separator used in this unit is characterized by minimal vibration and
prolonged operation with high safety and reliability by checking of precisely
dynamical balancing.
2.2 Product Standard:

GB/T5745 "Marine Disc-type Separator" standard manufacture and
acceptance, or systematic diagram and testing schedule approved by the user.

System Manual
3. System Components and Introduction

3.1 System Components
The separator unit is mainly composed of the common base, separator,
electrical control box, heating unit, piping system (including the control valve) and
other components. See figure below (the picture shows a conventional equipment,
if the customer has specific requirements, the equipment as agreed shall prevail):
分离机系统示意图 / Schematic Diagram of Separator System

污油回油 / Waste oil return
压缩空气 / Compressed air
加热媒介 / Heating media
加热媒介 / Heating media
污油 / Waste oil
净水 / Clean water
渣质 / Slag
净油 / Clean oil
污水 / Waste water
渣质(选配) / Slag (optional)
3.1.1 Common base

For supporting the separator, fuel supply system, heating system, control box,
piping and other equipment.

System Manual
3.1.2 Separator
The separator is the core component of the unit playing a role of completing
the material separation and purification (see the manual of separator).
3.1.3 Electrical control box

The electrical control box is composed commonly of the basic motor starting
hardware and PLC and touch screen (text screen) with running accumulation, it has
automatic control function (but it can also be operated manually), parameters set
on panel and real-time display of device operating conditions. It is equipped with
alarms for high and low temperature, high and low voltage, motor overload, pump
overload and failure to discharge slag, slag accumulation, high vibration, speed
loss and other alarms. When the alarm sounds, the alarm information displays; the
oil passages can be automatically changed over as required and there are external
passive contacts, thus achieving the automatic purification and slag discharge
function of the separation system.
All the functions above or achieved shall be completed through a certain
sensing devices, while the alarm message is completed by the sensors covered by
the contents in the supply scope, if it is equipped with no sensors, partial alarms
described above can't be achieved.
There are more types of electrical control boxes, for specific functions that
can be achieved and operations, please refer to the electrical control box
instructions.
3.1.4 Heating unit

The heaters we are using currently are: shell and tube heater, plate heat
exchanger, electric heater, etc. (see Table I), and some heating units are used for
heating the material or for heat exchange of the separated materials to improve the
energy utilization ratio. All heating units are equipped with temperature control
devices.
Type Heating media

Shell and tube heater Steam, hot oil, hot water
Plate heat exchanger Steam, hot oil, hot water
Electric heater
Table I
The basic set point of the heater: the oil is set between 85-90 degrees, and the
120CST-380CST is set between 95-98 degrees. For specific instructions of the
heater see the manual of separator.
3.1.5 Piping system

The piping system consists of piping, valve, pump and slag pump (optional),
oil filter, high-mounted water tank (optional), heating unit, instrument element and
other components. The instrument components play the role of monitoring the
material pressure, temperature and other parameters.
The following description of various components shall be cross-referenced to
the actual situation, and the components and elements vary depending on the
different requirements of the customers.
3.1.5.1 Names and functions of the valves are as follows
Name Function

System Manual
Cutoff valve (before Regulate the flow of material in the inlet pipe. Used for
pump inlet) cutting off the flow before pump to achieve flow control.
Cutoff valve (at outlet Regulate the outlet pressure of the clean oil pipe. The
of clean oil) maximum pressure shall not exceed 0.4Mpa, and the
minimum pressure shall not be less than 0.1Mpa.
Air reducing valve (for Filter the compressed air and keep the compressed air
air passage) pressure at 0.5 - 0.8MPa.
3/2 solenoid valve (for Control the three-way pneumatic valve in the oil pipe to
air passage) achieve automatic control of the oil pipe.
Three-way pneumatic Feeds material in the separator in normal operation of the
valve (installed after separator at proper temperature; and achieves oil return in
heating unit) start-up, shutdown, slag discharge and when the separator
operates improperly and different alarms sound.
Temperature control Only when the steam, hot oil or hot water is used to heat the
valve (installed at steam, oil, this temperature control valve can be used to
hot oil or hot water side) automatically adjust the temperature.
1. It uses electric self-operated structure. The temperature set
points are provided on the valve body where the basic set
point is: the oil set between 85-90 degrees and the fuel
120CST-380CST is set between 95-98 degrees. The valve
body determines the oil temperature with its own
temperature sensors, compares it with the temperature set
point, and then adjust the opening of the valve body with the
motor to control the temperature. If the heat source is
relatively stable, a relatively balanced value can be reached
in about 5 minutes. If the automatic adjustment is faulty, the
hand wheel on the valve body can be manually operated to
open or close in a short time. This time, the 220V cable from
this valve to the control box shall be removed to prevent
maloperation.
2. If the valve that performs temperature adjustment with
PLC is used, the program is set in PLC to adjust the opening
of the valve body.
High-temperature ball Only when using the steam, hot oil or hot water to heat the
valve (used in material, it is used for maintenance and emergency operation
conjunction with of the temperature control valve.
temperature control
valve)
Safety valve and The safety valve and temperature meter in the heating unit
temperature meter are used to ensure the safety of the heating equipment.
(used in steam, hot oil or
hot water heater)
Temperature sensor It transmits the temperature of material in real-time to the
(installed between heater electric control box for real-time display of the temperature,
and three-way valve) and compares it with the set-point.
Safety valve (in oil It prevents the pump valve overpressure.
passage)
By-pass valve (after It is used to split the flow after pump to achieve the purpose
pump outlet, at oil pipe of flow control.

System Manual
side, connected to the

return outlet or pump
inlet)
Ball valve (in water It adjusts the flow of the sealing water, opening water and
passage) water sealing water.
2/2 solenoid valve (in It achieves fully automatic control
water passage)
Relief valve (in water It is used to reduce the pressure of the original water with a
passage) pressure reducing ratio of about 5:1, the pressure reduced
shall be between 0.2MPa - 0.5MPa, please refer to the
requirements in the manual of separator.
Y-type water filter (in It is used to filter the impurities in water in advance, to
water passage, optional) prevent the damage to the sealing mechanism for slag
discharge of the separator. The typically used filter screen is
60-80 meshes.
3.1.5.2 Oil transfer pump

The supporting oil transfer pumps we are using currently are the (horizontal)
three-screw pump, gear pump, centrifugal pump: to provide the separating material,
but because of different conditions of the users, the pump type selection is different,
and the pump flow can enter the separator only when it is adjusted by cutting off
the flow before pump or splitting the flow after pump or other methods (operating
according to the actual supporting conditions).
Note: When the pump is used for the first time, the pump oil injection is
required in advance to prevent the pump wearing due to cavitation.
3.1.5.3 Slag pump

The slag-discharge pumps we are using currently include pneumatic and
electric type pumps: used to discharge the impurities from the separator. The
pneumatic pump is equipped with a high temperature ball valve.
Note: For the pneumatic slag-discharge pump (pneumatic membrane valve),
the valve before pump (usually ball valve) must be closed before shutdown or the
manual pump must operate for 2-3 minutes after the valve before pump is closed,
until the remaining material in the membrane valve are fully discharged before
cutting off the power, otherwise it will affect the life of the membrane pump. A
particular attention should be paid to the use of heavy fuel.
3.1.5.4 Oil Filter

Currently we are using the Y-type filter and dual coarse filter to provide
preliminary filtration of the oil in the waste oil tank to remove the large particles of
impurities, preventing damaging the separator piston and main seal ring. Please
pay attention to the regular cleaning of the filter screen, otherwise it may affect the
normal operation of the oil supply pump, if the filter screen is damaged, replace it,
and the filter screen shall be selected according to the type of material.
3.1.5.5 Heating unit, see 3.4

3.1.5.6 Instrument Elements
Name Characteristics
Vacuum gauge (before It is used to determine that the pump doesn't pump

System Manual
inlet of oil transfer material because the oil pump is damaged or the coarse
pump) pre-filter is clogged that needs to be cleaned.
Pressure gauge (at It is used to indicate the pressure at the clean oil outlet.
clean oil outlet of
separator)
Pressure gauge (at There are two types of gauges: high pressure and low
clean oil outlet of pressure, and it can be configured according to the
separator) customer requirement that the alarm signal will be sent
when the pressure of clean oil at the separator outlet is
below 0.1Mpa. For the specific setting method, refer to
the description of pressure switch.
Vibration switch (on It is used to generate an alarm signal or shutdown in the
separator body) case of abnormal vibration.
(optional)
4. Installation and Adjustment

4.1 Requirements for Installation of Unit:
When installing the separator unit, an adequate space shall be left for repair
and maintenance of the separator.
Because the units differ each other, and the user's requirements are deferent,
the basic principle is: a circumferential space of at least 400mm-600mm around the
separator unit is required for maintenance and operation.
The unit can be welded or bolted directly.
4.2 Requirements for Installation of External System Piping of Unit
The external system piping of the unit includes waste oil and clean oil pipes,
used to control the water pipe, sewage pipe, sludge pipe, steam and condensate
water pipes. The separator is connected to the waterway, pipes, and slag outlet with
hoses to isolate the separator from the vibration of external piping.
If no sewage pump is provided, the pipe from slag outlet of the separator to
the slag tank should be vertical.
5. Adjustment of Control Box Parameters before Operation

5.1 Description
Most of the parameters of all control boxes are adjusted properly in place in
factory according to the user's requirements and the requirements of the test
program, therefore further adjustment by the customer is not required, and all
parameters shall not be lost even if due to a power failure of internal PLC or other
reasons.
If the parameter data are modified in debugging process or according to other
needs of the user, the parameters are lost due to internal PLC power failure or other
reasons, please re-adjust based on the preliminary parameters. Therefore, the
parameters adjusted in the process shall be recorded avoiding parameters missing.
Since the parameters for fuel processing, oil processing or other material
processing differ from each other, the company will adjust the corresponding data
properly in place in the factory according to the actual demand for the product, if
the user uses the fuel program for oil processing or the oil program for fuel
processing in actual application, the user shall be liable for relevant losses arising

System Manual
therefrom.
Some parameters in the program can be revised by the user, but the revision of
most of parameters is not allowed and the parameters are protected with password,
so the relevant revisions must be performed by professionals, if the customer
forces to decipher the code, our company shall not assume the liabilities for the
consequences caused therefrom.
5.2 Introduction of Control Box
When starting the control box for the first time or restarting it after a power
failure, a welcome page will be displayed on the screen system as shown below:
按下进入系统键，可直接系统当前的时间及日期，此
进入主系统操作届面时间由 PLC 给定，用户无法
Press the ENTER key to 修改
enter the main system The current system time and
operating interface date, the time is given by PLC
directly that can't be revised by the
user

System Manual
Click the “ENTER” key to enter the process monitoring interface:
停机按钮
Shutdown button
密封测试选择按钮
Seal test selector
button
程序停止按钮
Program stop button
程序启动按钮
Program start button
届面切换按钮
Interface switching button
报警状态显示栏
Alarm status display box
独立密封测试按钮
Individual seal test button
运行时间记录
Running time record
运行状态显示栏
Running status display box
可返回系统主届面
Return to main interface

System Manual
Click the "Process Monitoring" to enter this interface, which is the status
display interface, when "Waiting" is displayed, click "Program start" to enter
separate cycle phase, if the program is required to stop at any time, single click the
"Program Stop", and the "Shutdown" is to enter the slag discharge phase after the
implementation of the current separation cycle, and then the separator, the pump
loses power to stop operating, and the temperature control valve is automatically
closed; when the "Seal Test" is "Yes", i.e. the separator drum shall be detected for
sealing before each separation cycle, if it is "NO", the detection phase shall be
skipped.
And the "Individual Seal Test Button" can independently implement the
program to determine whether the drum is sealed as the separator start is completed;
when the program running is completed, the processing is in continuous waiting
phase, and manual operation of program implementation is required to carry out
material separation. This program is conducive to determine whether the separator
is sealed to avoid loss of material. In this process, the program will calculate
automatically the operation time of the water sealing water, and can introduce
the calculated running time of the water sealing water into the water seal
parameters in the current pressure condition, that is more favorable to the
normal operation of the separator, therefore it is recommended to implement
this program after each start of the separator.
The interface button describes the operation method and precautions of the
interface:
可返回主届面
Return to Main Interface
This button can be used to return back to the main interface from any interface,
and can also use the interface switching button to switch over among a variety of
interfaces.
This program contains five sub-interfaces, namely: process monitoring
interface, real-time data interface, manual operation interface, parameter setting
interface and alarm inquery interface.
The five sub-interfaces can be switched over at any time by pressing the
interface switching button.
Process Monitoring Interface

The process monitoring interface includes the real-time status display of the
separator, program start (separator starts automatic operation) button, and program
stop (separators stops automatic operation) button, as well as automatic shutdown
button.
Real-Time Data Interface

It can display the real-time data of separator in any running status and the
running status of the external control valve, and the related real-time data needs to
be supported by various external control elements, if the customer has not installed
the corresponding control device or sensor, the content displayed in the upper part

System Manual
of this interface will be null value.
Manual Operation Interface

It enables manual operation of external valve in most conditions, and the
manual operation time is just the time of the contact on the screen pressed. Also, if
the system is equipped with slag pump for customer by Luzhou, this interface can
operate the slag pump running.
Parameter Setting Interface

It can set the parameters required for separator running
Alarm Inquiry Interface

Any alarms are recorded in PLC for query, but the number of records is
limited by the capacity of PLC itself.
运行状态显示栏
Running Status Display
This display bar shows the operating state of the separator, they are: Waiting,
Preparation for running, Separating, Slag Discharging, and Stopping
Waiting: refers to that when the separator is started, the pump is started, and
the temperature is in the preset range, this Waiting status appears. The display of
this status also represents that the separator is ripe currently for pressing the
program button to start.
Preparation for Running: the separator operates for sealing, water sealing
water entering, slag-discharging, as well as a series of preparations performed
before feeding material.
Separating: conducts material separation.
Slag Discharging: stops feeding, and discharging slag
Stopping: Stops the separation process, and cuts off the power to separator
and pump.
实时数据届面
Real-Time Data Interface
Press Real-Time Data under the screen, the following contents can be seen,

System Manual
and display in real time the current operating status of separator and system.
In this interface, the running state of all valves and controllers are visible, and
the light on indicates in running status.
At the same time, it also displays the separator speed, vibration amplitude,
heavy phase pressure, separator current, oil temperature, outlet pressure, separation
cycle and other parameters. All the contents above are displayed only when the
corresponding sensing devices are installed, otherwise the display will be null; the
installation of the sensors shall be recognized as in delivery condition in the
technology status confirmation, and the adding sensors to the installation in the late
period may be necessary to change the pipes or involve a larger cost.
During normal operation or regular inspection, the prolonged display of

this screen is recommended.
手动操作届面
Manual Operation Interface

System Manual
There are manual operation buttons of all control valves that can be used to
carry out manual fault diagnosis, artificially manual operation in normal separation
cycle is not recommended, so as to avoid the occurrence of unpredictable
accidents.
There is also a control button of residual slag pump in this interface to carry
out artificially independent operation in the existence of slag pump, so that the slag
pump can run in cycling operation. Or independently starts operating.
参数设定届面
Parameter Setting Interface
General Range of Parameters

Name Time (s) Name Time (s)
Water seal 10-30 Water sealing test 1 15-30
Sealing 3-11 Water sealing test 2 1-3
Opening 3-8 Water sealing stop 1-3
Waiting 10-30 Minimum outlet 0.5-1bar
pressure
Starting time 630-810 Heavy phase pressure 0.5-2.5bar
comparison
Water draining 15 Separation current 0.5-1.5bar
comparison
Pre-sealing 5-10 Slag pump start Adjust according
actual conditions
Separation cycle 600-7200 Vibration alarm ----
Vibration Shutdown ----
Times of water sealing 10-15
Minimum temperature 0-80oC
Maximum temperature 110-125oC

System Manual
All parameters are well adjusted in the factory, so further adjustment is not
required, and when the on-site debugging is completed, it is recommended that all
operators record all the setting data, in order to avoid loss of data in the late period.
The high-pressure water of the operating water is stabilized between 2.5-3.0 bars
and the low-pressure water is maintained in the range of 0.5-1.0 bars; for the
material separation temperature, the heavy fuel is 95-98oC, lubricant is 85-95oC
and the diesel separation is at room temperature.
Explanation of different parameters:
Water seal: the time to carry out drum water sealing or oil transfer operation,
the time will be fuzzily calculated automatically according to the site water
pressure or real time water pressure, and will assign the calculated value to the
water seal time while modifying the original parameters. If no "Sealing Test" is
conducted, the program will run as by manual input parameters. When performing
sealing test for the first time, more tests are required by modifying the value in
"Sealing Test 1" to the low value, and the program will automatically be corrected
in order to achieve the calculated value of optimum site conditions.
Sealing: used for running time of the operating water for drum water sealing.
Opening: used for running time of the operating water for opening drum or
producing slag discharge action.
Waiting: used for waiting time for speed self-repair of drum or other internal
running processes.
Starting Time: the time control of the separator from start to full speed state.
(The time shall be increased by at least 60 seconds on the basis of actual starting
time, otherwise it may cause actual operation fault)
For the frequency-conversion starting separator, the starting time must be set
to be greater than the time of the frequency converter from 0Hz to actual common
frequency that is usually 10 minutes, but 11 minutes is recommended.
Water draining: used for the time for draining water in the initial phase of the
material separation of the separator.
Pre-sealing: used for the time to conduct drum evacuation and sewage
discharge operation after the separator starting is completed.
Separation cycle: the running time of the separator from material separation to
slag discharge operation.
Water Sealing Test 1: the time for adding water sealing water for the first time
when conducting "sealing test", the time shall be counted initially according to the
following method, and when the separator starting is completed, manually add
water sealing water, manually force to open the drain valve while starting timing
until the water is drained out from the drain valve outlet, the time minus 5 seconds
can be regarded as the setting value of the water sealing test 1.
Water Sealing Test 2: the time for accurately adding water when conducting
"Sealing Test", the time is usually set to 1S.
Water Sealing Stop: means the interval time between two "Sealing Test 2"
when conducting "Sealing Test".
Minimum Outlet Pressure: used for determining the pressure value of
unsealed drum, this value is generally set at 0.5-1bar.
Heavy Phase Pressure Comparison: used for determining the value of water
sealing water content of material components in the drum, this value is generally
set at 0.5-1.5bar.
Separation Current Comparison: used for determining the normal slag
discharge when the drum is operating for slag discharge.

System Manual
Slag Pump Start: used for the running time of the slag pump when the pump is
running.
Vibration alarm: used for separator vibration unfavorable to separator running
tendency and generates an alarm when it is equipped with vibration alarm device.
Vibration Shutdown: used for separator vibration unfavorable to separator
action and generates an alarm to perform separator shutdown operation.
Times for water sealing: Maximum times allowed to add "Water Sealing
Water 2", if exceeded, the drum is regarded as not sealed.
Minimum Temperature: minimum temperature for material separation
Maximum Temperature: maximum temperature for material separation
The following is a record table of real operating parameters, they are recorded
according to actual condition:
Name Time (s) Name Time (s)
Water seal Water sealing test 1
Sealing Water sealing test 2
Opening Water sealing stop
Waiting Minimum outlet
pressure
Starting time Heavy phase pressure
comparison
Water draining Separation current
comparison
Pre-sealing Slag pump start
Separation cycle Vibration alarm
Vibration Shutdown
Times of water sealing
Minimum temperature
Maximum temperature
报警查询届面
Alarm Inquiry Interface

System Manual
This interface retains the last 20 alarm records including the alarm time, and
the causes and status of the alarms, and can perform timely adjustment and
judgment operations.
6. Operation
6.1 Operating procedures
6.1.1 Starting
Note: The following procedure is implemented without setting the system
parameters, if necessary, set the system parameters in reference to the
(descriptions for parameters setting).
1. Check before starting (refer to the "Check before Starting" in the Manual of
Separator)
The check contents include brakes, oil level, motor direction and valve switch
and others.
2. Open the master control valve in the control waterway; it is appropriate to
control the pressure in waterway between 0.3-0.5Mpa.
3. Open the master compressed air control valve: Set the compressed air pressure
to 0.5-0.8MPa.
5. Open the flow control valve in clean oil pipe.
6. Open the master control valve in heating pipe.
7. Turn on the mains switch of the electrical control box.
8. The screen can be used to start operating after about a minute.
9. Press the "Oil Transfer Pump Start" button on the control box to start the oil
transfer pump, now the system is in Backflow status displayed in the temperature
control valve instrument.
10. When the temperature parameters are displayed, press the "Separator Start"
button on the control box to start the separator.
Please Note: when the frequency-conversion starting separator is started, unless
special requirements are necessary, it is generally converted automatically into
common frequency and the frequency converter is disengaged.
11. When the separator is started, and the material temperature is at separation
temperature, the waiting status display will appear.
12. A sealing test is recommended, if no any problem, when returning to Waiting
status, press the Program Start Button.
13. Adjust the flow adjusting valve in the inlet pipe, and adjust the clean oil outlet
pressure to between 1.5-2.0bar.
6.1.2 Shutdown
Press the Shutdown button, then the separator will automatically cut off the
material and conduct drum cleaning
6.1.2.1 Automatic Cleaning
1. Turn off the Mains switch on the control box.
2. Close the flow control valve in oil outlet pipe.
3. Close the flow control valve in oil inlet pipe.
4. Close the master control valve in heating pipe.
5. Close the master control valve in compressed air pipe.
6. Close the master control valve in control waterway.

System Manual
7. Maintenance and Repair

For the specific contents about maintenance and repair of separator in the
separator unit, refer to the maintenance contents (in the Manual of Separator
provided with the equipment).
The pipes of separator unit shall be regularly cleaned to ensure the pipe is
unblocked; always check the rubber hose connections in the unit, if aged or
emulsified, the hose must be replaced immediately to prevent the pipeline leaking.
Check the electrical control equipment regularly to prevent the lines aging,
avoiding short circuit.
Check the instrument components regularly, if damaged, the component shall
be replaced immediately to ensure the normal operation of the unit.
(* Note: The unit configuration involved in this document is a full

configuration, and the actual unit shall be configured and system
designed according to the specific requirements of the customer in
the technical agreement)
Common alarms
Alarm: Oil transfer pump failure

Alarm Description of Failure Resolution
The pump fails to start Start the pump
Check the thermal
Pump overload protection and circuit
breakers
Oil transfer pump The pump is clogged Check the pump
failure The filter before pump is
Clean the filter
clogged
The valve before pump fails Check the piping and
to open valves
Electrical wiring failure Check the wiring
Alarm: Material temperature lower than set-point

Alarm Description of failure Resolution
The oil temperature is too
Check the inlet oil
low before entering the oil
temperature
heater
The material feeding Check the material
Material temperature is amount is too high feeding amount
lower than set-point Check the heating
The heating medium
medium temperature and
temperature is too low
valve
The low temperature Check the low
set-point is on the low side temperature set-point

System Manual
Temperature control valve Check the temperature

failure control valve
Heater failure Check the heater
Heater dirty Clean the heater
Temperature sensor is Check the temperature
damaged sensor
Steam trap accumulates
Clean up the steam trap
water
Alarm: Low clean oil pressure alarm

The opening of back pressure valve Check the back-pressure
is too large valve settings
The material feed amount is on the Check the material feed
low side amount
The clean oil low pressure set-point Check the low pressure
is on the high side set-point
The operating water pressure is too Check the operating water
high, and the drum is unsealed pressure
The supplementary sealing time is Check the supplementary
too long, and the drum is unsealed sealing time
Low clean oil
Water seal is damaged Check the sealing time
pressure alarm
The drain pin in the drum is Check the water quality
clogged and drain pin
Oil supply pump failure Check the oil supply
pump
The oil inlet three-way valve is not Check the compressed air
open pressure and valve for
damage
The seal ring in the drum is Check the seals in the
damaged drum
Alarm: Material temperature higher than set-point (high temperature

alarm)
The material feed Test the temperature
temperature is too high control valve
The material feed amount is Check the material feed
too low amount
Material temperature is Check the
The high-temperature
higher than set-point high-temperature
set-point is too low
(high temperature set-point
alarm) Heater failure Check the heater
Temperature control valve Check the temperature
failure control valve
Check the temperature
Temperature sensor damage
sensor

System Manual
Alarm 11: High clean oil pressure alarm

The opening of
Check the back-pressure
back-pressure valve at
valve for opening
clean oil outlet is too small
The material feed amount Check the material feed
Clean oil
is too high amount
high-pressure alarm
The set-point of high clean Check the set-point of
oil pressure is too low high clean oil pressure
The material feed Check the feed material
temperature is too low temperature
Alarm: No slag discharge alarm

Drum hydraulic slag discharge
Check the drum hydraulic
system failure, such as seal ring
slag discharge system
damaged and drain pin clogged
The opening water valve is not Check the opening water
properly opened valve
The opening water valve is not Check the connection of
properly connected opening water valve
Select the appropriate current
The current deviation set-point is
deviation set-point based on
No slag too high
the separator model
discharge alarm
Select the appropriate
The operating water flow is too operating water flow and
small pressure based on the
separator model
Current sensor failure Check the current sensor
Poor water quality results in filter Check the water quality and
clogging in waterway water filter
Excessive wear or oil pollution of Check the friction plate of
friction plate separator
Alarm: Abnormal speed alarm (optional)

Description of
Alarm Resolution
failure
High drum Check the electrical system and speed
speed sensor
Abnormal speed
Check the electrical system and speed
alarm Low drum
sensor, belt breakage, excessive wear of
speed
friction plate
Alarm: First class vibration alarm (optional)


System Manual
Slag accumulation in drum Clean the drum

Material leakage of drum Check the drum
Check the vibration
The vibration sensor is loose
sensor
First class vibration The first class vibration Check the vibration
alarm set-point is too low set-point
The drum component is not
properly assembled or Check the drum
replaced with that of other component
drum
Alarm: Vibration alarm (optional)

The second class vibration
Check the set-point
set-point is too low
Clean the drum, check the
Slag accumulation in drum
main seal ring
Vibration sensor failure Check the vibration sensor
Check the drum, assemble
the drum according to the
Second class vibration
installation manual; check
alarm
The drum component is not whether the drum
properly assembled components are all for this
drum, the parts of different
drums are not
interchangeable
The external vibration is too Test the base and external
high vibration source

System Manual
Annex: Program Logic Schematics
分离逻辑图 / Separation logic diagram

等待阶段 / waiting phase
接通电源、控制箱自检 / switch on the power and start the control box self-test
分离机启动按钮 / separator start button
等待分离机启动完毕 / waiting for completion of separator start process
油泵启动按钮 / pump start button
油温自动调节 / automatic adjustment of oil temperature
油温是否符合要求 / whether the oil temperature meets the requirement
程序启动 / Program start
密封测试 / seal test
运行准备阶段 / running preparation phase
转鼓是否密封 / whether the drum is sealed
等待报警确认 / waiting for alarm confirmed
自动计算水封水量 / automatic calculation of water sealing water flow
控制箱按钮 / control box button
屏幕显示操作框 / operation box of screen display
判断框 / Determination block
过程状态 / Process status
报警 / Alarm

System Manual
运行准备阶段 Running preparation phase

转鼓排渣 / drum slag discharge
密封测试是否打开 / whether the seal test starts
转鼓密封 / drum seal
转鼓密封 / drum seal
转鼓水封 / drum water seal
分离阶段 / separation phase

System Manual
分离阶段 / separation phase

转鼓进料 / drum material feed
分离状态是否正常 / whether the separation status is normal
分离周期是否结束 / whether the separation period is completed
手动排渣按钮 / manual slag discharge button
排渣阶段 / slag discharge phase
停机阶段 / shutdown phase

System Manual
排渣阶段 / slag discharge phase

停止进料 / Stop material feeding
打开水封水 / open the water sealing water
打开开启水 / open the opening water
运行准备阶段 / running preparation phase

System Manual
停机阶段 / shutdown phase

关闭温度自动调节 / close the automatic temperature adjustment
停止油泵 / stop oil pump
停止分离机 / stop separator

Zhangjiagang PDSD14000 Disc Separator System Manual

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Zhangjiagang PDSD14000 Disc Separator System Manual

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Operating Instruction of Disk-Type Separator

Page 1/ 27 Zhangjiagang Peony Machinery Co., Ltd

The total 3 operating instruction manuals of separator:

Machinery Co., Ltd.

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Page 3/ 27 Zhangjiagang Peony Machinery Co., Ltd

2.2 Product Standard:

Page 4/ 27 Zhangjiagang Peony Machinery Co., Ltd

3. System Components and Introduction

分离机系统示意图 / Schematic Diagram of Separator System

3.1.1 Common base

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3.1.3 Electrical control box

3.1.4 Heating unit

Type Heating media

3.1.5 Piping system

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side, connected to the

3.1.5.2 Oil transfer pump

3.1.5.3 Slag pump

3.1.5.4 Oil Filter

3.1.5.5 Heating unit, see 3.4

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4. Installation and Adjustment

5. Adjustment of Control Box Parameters before Operation

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Click the “ENTER” key to enter the process monitoring interface:

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Return to Main Interface

Process Monitoring Interface

Real-Time Data Interface

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of this interface will be null value.

Manual Operation Interface

Parameter Setting Interface

Alarm Inquiry Interface

Running Status Display

Separating: conducts material separation.

Slag Discharging: stops feeding, and discharging slag

Real-Time Data Interface

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During normal operation or regular inspection, the prolonged display of

Manual Operation Interface

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Parameter Setting Interface

General Range of Parameters

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7. Maintenance and Repair

(* Note: The unit configuration involved in this document is a full

Alarm: Oil transfer pump failure

Alarm: Material temperature lower than set-point

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Temperature control valve Check the temperature

Alarm: Low clean oil pressure alarm

Alarm: Material temperature higher than set-point (high temperature

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Alarm 11: High clean oil pressure alarm

Alarm: No slag discharge alarm

Alarm: Abnormal speed alarm (optional)