hy: Alfa Laval MMPxX 403 Separation System 1 Safety System Description Operating Instructions Parameter List Alarms and Fault Finding System Reference Installation Instructions on oOo ao fF Oo DN Separator Manual (incl. fautt finding) Spare Parts Catalogue 9 Component Descriptions (inci. fautt finding) 10 Optional Equipment Alfa Laval Marine & Power Printed Mar 1998 Product No. 1765592-01 Book No. 1817189-02Separation System Safety Printed Nov 1998 Book No. 1810160-02 V4 OER Cem: dak koAlfa Laval reserve 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 Marine & Power AB S$ - 147 80 Tumba Sweden © Copyright Alfa Laval Marine & Power AB 1998.Contents 1 Safety Instructions 14.1 Important Factors Influencing Safety 1.2 Categories of Warning Signs 1.3 Summary of Essential Warnings 1810160-02 21810160021 Safety instructions Safety ( CAUTION Slip hazard Oil leakage may make the floor slippery and cause injuries The bolts on the main flange of the heater must be checked prior to installation and start up. NOTE Be sure to study all relevant documentation supplied and become familiar with the function and operation of the system and each particular unit. 1810160-02 1. Safety Instructions 1.1. Important Factors Influencing Safety The centrifugal separator includes parts that rotate at high speed, generate high centrifugal forces, and take a long time to stop rotating, Materials are carefully chosen and parts are designed with extremely fine manufacturing tolerances, Rotating parts are carefully bal- anced to reduce vibration and wear and tear and to withstand stress and fatigue. ‘The separation system is designed and supplied for a specific function (type of liquid, rotational speed, temperature, density, etc.) and must be used for this function only, and strictly within Alfa Laval’s specifications. Incorrect operation or maintenance is likely to result in an imbalance due to build up of sediment, reduction of material strength, etc. that could lead to serious injury or damage. These compulsory safety instructions apply: ‘© Use the separator only for the purpose and parameter fange specified by Alfa Laval. ‘© Strictly follow the instructions for installation, operation and maintenance Ensure that personnel are fully trained and competent in operation, maintenance and emergency procedures. 1810160-021 Safety Instructions Use only Alfa Laval genuine spare parts and the special tools supplied, NOTE If safety instructions and installation, operating, and maintenance instructions in this manual are not strictly followed, Alfa Laval can not be held responsible for any malfunction or injuries resulting. 1.2 Categories of Warning Signs Pay attention to the safety instructions in this, manual, Below are definitions of the three grades of warning signs used when there is a risk to personnel. p DANGER Type of hazard This type of safety instruction indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. ) WARNING Type of hazard ‘This type of safety instruction indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. _ Safety 1810160-02 Safety p WARNING Disintegration hazard Failure to clean the separator bowl, including operating system, at required intervals or after alarms and stop of bowl may cause imbalance with risk of injury to personnel. Noise hazard Excessive noise can cause damage to hearing if no ear protection is used Burn hazard Physical contact with steam from the valve will cause scalding. Q CAUTION Burn hazard Process pipes, lubrication oil and various machine surfaces can be hot and cause burns. 1810160-02 1. Safety Instructions1 Safety Instructions Safety Safety 1 Safety Instructions j\ WARNING Disintegration hazard Never reset an alarm without first finding and remedying the cause. Operating water shortage may result in sludge discharge failure and cause sludge accumulation and heavy imbalance. If the separator has been operated at overspeed, it could be severely damaged and must be checked before restarting. Contact Alfa Laval for instructions. Each new bunker requires rewiew of the discharge time setting. If the interval between sludge discharges is too long, there is risk of heavy side breakdown, Experience has shown that if intervals between sludge discharges are too long, a compact and hard sludge cake can accumulate. On discharge, this cake may break up and be discharged unevenly causing imbalance in the bowl. If imbalance is excessive, there is risk for serious mechanical damage and injury to personnel. ‘ CAUTION Type of hazard This type of safety instruction indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This sign is used when there is a risk to equipment. NOTE This type of instruction indicates a situation which, if not avoided, could result in damage to equipment. This sign is also used when there is a need to stress important information. NOTE This sign is used to stress important information, e.g, how to read this, system manual. 1810160-02 1810160-021 Safety Instructions 1.3 Summary of Essential Warnings DANGER Disintegration hazard Using the separation system outside limits specified by Alfa Laval could cause breakdown. Do not start the separator after an emergency stop without first remedying the cause of the emergency. After an emergency stop the separator bow] must be manually cleaned before starting up again. If the interval between sludge discharges is too long, there is a risk of heavy side breakdown. If the separator is not assembled and connected properly it may lead to disintegration. If power cables have been altered always check the rotation direction, If the separator rotates in reverse vital rotating parts could unscrew. Excessive vibration may cause breakdown. Safety i i 1810160-02 Safely 1 Safety Instructions DANGER Disintegration hazard Do not discharge a vibrating separator, Vibration can increase if only part of solidified sludge is discharged. Do not enter the room after an emergency stop while the separator is still rotating, Running the separator at overspeed due to wrong frequency may cause disintegration. If the separator rotates in reverse vital rotating parts could unscrew. Entrapment hazard Do not switch on without all covers and guards in place. Do not begin maintenance work while the machine is still rotating. 1810160-02ky: Alfa Laval MMPX Separation System System Description Printed Mar 1998 Book No. 1810028-02 V4 EMER EEUU aioeAlfa Laval reserve 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 Separation AB Marine & Power Division S- 147 80 Tumba ‘Sweden © Copyright Alfa Laval Separation AB 1998.3 The MMPX Process MMPX System Description 3.3 Defi Preset time between sludge discharge sequences (Parameter value) ion of Terms Water seal (Parameter value) Displacement water Purifier Clarifier 10 When this time has elapsed after a sludge discharge, the next discharge is initiated. Water, added to the separator bowl to prevent oil from escaping at the water outlet, Used only in purifiers. Water, added to the separator bowl to displace the oil and ensure there is no loss of oil at sludge discharge. A separator that cleans the oil from water and sludge with continuous evacuating of separated water. ‘A separator that cleans the oil from sludge and traces of water. 1810028-02 Contents 1 Scope 2 System Overview 21 System Layout 2.2 The Oil Flow 3 The MMPX Process. 3.1. Purifying 3.2 3.3 re10028-021810028-02 MMPX System Description 3 The MMPX Process 3.2 Clarifying ‘When the MMPX separator is used as a. clarifier, the water inlet to the separator bowl is closed, ‘The separator is equipped with a clarifier disc, which seals off the water outlet. Process Cycle 1. The feeding of unprocessed oil to the centre of the separator bow! starts. 2. During the separation process sludge accumulates at the periphery of the separator bowl, Cleaned oil is fed from the separator by the integrated paring disc. If the unprocessed oil contains water, it is accumulated between the oil and the sludge. 3. After the preset time between discharge sequences, the oil feeding stops. 4, A sludge discharge is initiated, ‘The next process cycle starts with resuming of the oil feeding. 1810028-023 The MMPX Process MMPX System Description 4, After the preset time between discharge sequences, the oil feeding stops. 5. Displacement water is added to the bowl. ‘The displacement water eliminates the risk of oil loss at the following sludge discharge. 6. A sludge discharge is initiated while the displacement water is still flowing. ‘The next process cycle starts with adding of water for a new water seal. 8 1810028-02 1 Scope The MMPX separation systems are designed for cleaning of lubricating and fuel oils in marine and power applications and can handle the following types of oil: © distillate * marine diesel oil intermediate fuel oil © heavy fuel oil with a maximum viscosity of 600 cSt © detergent lubricating oil © R&O lubricating oil 1810028-0214 Scope MMPX System Description 3 The MMPX Process The terms used in this process description are explained in section “3.3 Definition of ‘Terms” on page 10. For information about parallel and serial systems, sce the “Installation Instructions” for the relevant MMPX system, 3.1. Purifying ‘When the MMPX separator is used as a purifier, a water seal is added to the separator bow! through the water inlet. ‘The separator is equipped with a gravity disc, chosen according to factors as oil temperature, density, and feed rate. This choice decides the position of the interface between oil and water seal. ‘The gravity disc leaves the water outlet from the bow! open. Process Cycle L.A specific amount of water is added to the separator bowl to form a water seal. 2. The feeding of unprocessed oil to the centre of the separator bowl starts, 3. During the separation process sludge and water accumulate at the periphery of the separator bowl. Cleaned oil is fed from the separator by the integrated paring disc. Excessive water leaves the bowl through the water outlet to the sludge tank. 2 1610028-02 1810026-022 System Overview 2.2 The Oil Flow The unprocessed oil is fed by a positive displacement pump, operating at a constant flow. Depending on the oil type, the oil may need to be heated Afier the heater the change over valve directs the oil to the separator. The separated oil passes the manually operated back-pressure regulating valve to the receiving tank. The oil can also be directed back to the tank, bypassing the separator, This is the case when the oil temperature is outside the preset range, during separator start and stop procedures, and during alarm conditions, MMPX System Description 1810028-02 2 System Overview In the MMPX process, heated oil is fed through the MMPX separator to clean the oil from solid particles and water. An MMPX system comprises: © An MMPX separator, * Ancillary equipment including a control unit, * Optional equipment such as an oil feed pump and an oil heating system. ‘The MMPX separating systems can be operated as single, parallel or serial systems. ‘An MMPX separator operates as a purifier or as a clarifier, ‘When operating as a purifier, cleaned oil eaves the separator through the oil outlet, separated water leaves through the water outlet, and sludge accumulates at the periphery of the separator bowl. When operating as a clarifier, cleaned oil leaves the separator through the oil outlet while separated water and sludge accumulate at the periphery of the separator bowl. In both cases, the control unit initiates a sludge discharge at preset intervals. Sludge and water are then discharged through sludge ports at the periphery of the bowl and collected in an intermediate tank or a sludge tank, 1810028022 System Overview MMPX System Description MMPX System Description 2 System Overview 2.1 System Layout lem] Symbol | Designation Function : Pneumaticaly controlled | Leads the unprocessed oll tothe separator or back The MMPX system layout is illustrated by the KY change over valve to the tank (recirculation). following symbol diagram. 3 ok Separator Cleans the oil by removing water and solid 4 A particles. High pressure switch Senses high prescure in the ol outlet. 5 (For system without intermediate tank) Low pressure switch ‘Senses low pressure in the oil outlet. 8 Pressure gauge Displays the pressure in the oil outlet. 7 Manually controlled Regulates the clean oil back pressure, 8 {SS4 | reguiating vaive Solenoid vaive block, water | Distributes separator opening and closing water, 9 bd water seal water, and displacement water. £ Contro| unit ‘Supervises the separator system. : 10 The MMPX system The inlet and outlet arrows indicate the following: A Unprocessed oil inlet D Water inlet B Cleaned oil outlet E Sludge outlet C — Oilrecirculation ttem | Symbol | Designation Function OD Displacement pump Feeds unprocessed oil to the separator. 1 AY Heater Heats unprocessed oil to separation temperature. 2 4 1810028-02 1810028-02 5ky: Alfa Laval MMPxX Separation System Operating Instructions Printed Nov 2000 Book No. 1810029-02 V5 ENEMA: aki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 Marino & Power AB SE - 147 80 Tumba ‘Sweden, © Copyright Alfa Laval Marine & Power AB 2000.Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents with fatal injuries. In order to make the information clear only foreseeable conditions have been considered, No warnings are given, therefore, for situations arising from unintended usage of the machine and its tools. A Summary of the safety information is found in the Safety chapter under divider 1.2 Operating MMPxX Operating Instructions Dismantling work must not be started before all rotating parts have come to a complete standstill, A DANGER Entrapment hazard Do not begin maintenance work while the machine is still rotating. A DANGER Disintegration hazard After an emergency stop the separator bowl must be manually cleaned before starting up again. ‘The separator must be reassembled and all covers and guards in place before unlocking the power supply and starting the system, Q DANGER Entrapment hazard Do not switch on without all covers and guards in place. 181002902 Contents 1 Scope 1 2 Operating 3 2.14 Start up Check List 3 2.2 Startup 5 2.3 Intervals Between Sludge Discharges 2.3.1 Background 2.3.2. Recommended intervals between sludge discharges 7 23.3 Fuel oil cleaning 8 2.3.4 Lubricating oil cleaning 9 2.3.5 Bowlinspection n 2.4 Intervals Between Bowl Cleaning 2 25 — Operating Check List 14 2.6 Check of Gravity Disc Size During Operation 18 2.7 Stop 19 2.8 Emergency Stop 21 2.9 After Emergency Stop 21 te10020-021810029-02 MMPX Operating Instructions 2.8 Emergency Stop If an emergency situation occurs press the ‘emergency stop button and evacuate the room. Do not return until the separator has come to a complete stop. ) DANGER Disintegration hazard Do not enter the room after an emergency stop while the separator is still rotating. 2.9 After Emergency Stop ‘The cause of the emergency must be remedied before attempting to restart the separator. If the cause is not found a major service must be performed and all moving parts thoroughly checked. DANGER Do not start the separator after an emergency stop without first remedying the cause of the emergency, To avoid accidental start, switch off and lock the power supply before dismantling. Consult the “Separator Manual” and the “Alarm List” about emergency procedures. 1810029-02 2 Operating 2120 2 Operating MMPX Operating Instructions 9, In order to empty the bowl, restart the separator drive motor from the separator starter and let it run for about 30 seconds. 1810029-02 1 Scope ‘The MMPX separation system is designed for cleaning of fuel and lubrication oil for marine and power diesel engines. 1810029-021 Scope MMPX Operating Instructions 1810029-02 MMPX Operating Instructions 2 Operating 2.7 Stop To stop the system: 1 Stop the system from the control unit: A sludge discharge is initiated, Separator stop sequence operation LED flashes (yellow), ‘The LED changes to steady when the sludge discharge is completed. Stop the heater from the control unit. If the heater is not connected to the control unit it must be switched off independently. ‘Wait until the oil feed temperature starts to drop, read the temperature on the control unit display by pressing the alarm reset button, If the temperature sensor is not linked to the control unit read the temperature indicator situated after the heater. Stop the oil feed pump at the pump starter. Observe when the separator is switched off by the control unit, i.e. when the starter ammeter reading drops to zero. Apply the brake after the EPC 41 display shows OFF. ‘Wait until the separator has come to a complete stop (3-5 minutes; depends on size). Release the brake. 1810029-02 192 Operating MMPX Operating Instructions 2 Operating 2.6 Check of Gravity Disc Size During Operation 1. Carry out a discharge (for uninterrupted time during check). 2. Close the isolating valves for both 2.1 Start up Check List pressure switches PS41 and PS42 (to avoid pressure alarms during check), Separator 3, Note the normal backpressure in the oil 1, Check that the separator is assembled and outlet. connected correctly. 4, Close regulating valve RV4 completely. DANGER 5. Check that oil flows out through the Av sludge outlet. Disintegration 6. Re-open regulating valve RV4. hazard 7. Check to sce if oil is still flowing out If the separator is not assembled and through the sludge outlet, Also observe connected properly it may lead to the backpressure. disintegration, If oil is still flowing out, the gravity disc is the correct size. ‘The backpressure is low. Go to item 8. 2. Check the oil sump level: it should be If there is no oil flowing out, the gravity above the min, line on the sight glass disc is too small. The backpressure remains normal. Stop the separator and fit a larger NOTE gravity disc. Restart and repeat the test. Too little oil can lead to damage of the 8. Reset the system: separator bearings. © Carry outa discharge. Reset normal backpressure in the oil outlet using regulating valve RV4. Open both pressure switches PS41 and Starter PS42, 3. Power on. 18 1810029-02 1810029-02 32 Operating MMPX Operating Instructions Control Unit 4, Ensure that the mode selector switch points to L (local), 5. Power on. ‘The display reads “OFF”. 6. Close the door. 7. Check that the direction of rotation of the bow! corresponds with the sign on the frame; do a quick start/stop and look at the motor fan rotation, ) DANGER Disintegration hazard If power cables have been altered always check the rotation direction, If the separator rotates in reverse vital rotating parts could unscrew. Air Valve Block 8. Ensure that there is correct air supply by reading the pressure gauge situated on the valve block; see “System Reference”. Plant set value: min. max. | 1810029.02 MMPX Operating Instructions 2 Operating Avoid contact with hot machine surfaces. 0 CAUTION Burn hazard Process pipes, lubrication oil and various machine surfaces can be hot and cause burns. Use ear protection if noise levels are high. p WARNING Noise hazard Excessive noise can cause damage to hearing if no ear protection is used. 1810029.02 Ky 172 Operating MMPX Operating Instructions Check the back pressure: read the pressure gauge situated by the low pressure switch on the clean oil outlet line. Plant set value: ‘Check the intermediate tank level by looking at the level indicator on the tank. Empty, if necessary, by opening the left hand valve on the air block. However, the control unit normally empties the tank after each discharge. If excessive vibration occurs press the emergency stop bution and evacuate the room, A DANGER Disintegration hazard Do not discharge a vibrating separa- tor. Vibration can increase if only part of solidified sludge is discharged. Check all connections for leakage, A Oil leakage may make the floor slippery and cause injuries. CAUTION Slip hazard 16 1810029-02 MMPX Operating Instructions 2.2 Startup starter, 2 Operating 1. Start the oil feed pump from the pump 2. Switch the heater on from the control unit. If the heater is not connected to the control unit it must be switched on independently. ZB 3, Start the separator from the starter unit, 4, Listen and observe. Vibration may occur during start up, when passing critical rpm (revolutions per minute). This is normal and should pass without danger. If vibration increases, or continues at full speed, press the emergency stop button. ‘The cause of vibration must be determined and corrected before starting again! ( DANGER tegration hazard Excessive vibration may cause breakdown. 1810029-02no Operating MMPX Operating Instructions Ensure that the separator is at full speed. At full speed the starter ammeter reading has decreased from a high starting value to a low steady value; the idling value (slightly lower than the normal operating value). Cheek the oil feed temperature on the control unit display by pressing the alarm reset button. If the temperature sensor is not linked to the control unit read the temperature indicator situated after the heater. Wait until the oil feed temperature is correct: lube oil; + for cross head engines 90°C + for trunk piston engines 95 °C fuel oil; + for the correct separation temperature see the “Technical Data” in the “System Reference”. Start up the system from the control unit. Operation LED lit (green). v 1810029.02 MMPX Operating Instructions 2 Operating Observe the control unit front panel information: © heater operation LED lit (green): only if the heater is connected to the control unit. © separator system operation LED lit (green). * activated valve LED lit (green). During normal operation the time to next sludge discharge is shown on the right of the display. More information may be read, as required, by pressing the alarm reset button repeatedly (the values are always shown to the right): 1. the oil feed temperature. For the correct separation temperature see the “Technical Data” in the “System Reference” If the temperature sensor is not linked to the control unit read the temperature indicator situated after the heater. 2. the oil feed temperature (if a second sensor for heater control is connected). 3. the accumulated operating time! in hours. N.B. The values displayed in the pictures to the right are examples and not recommendations. Continue pressing until the display returns to normal: i.e. the time to next sludge discharge. 1. How to interpret the displayed figures as hours: (000 ~ 999 = actual value in hours 1000 - 9990 hours 10000 — 99900 hours 100000 = 999000 hours 1810029-02 152 Operating MMPX Operating Instructions 2.5 Operating Check List Compulsory 200 hour Service A compulsory service must be carried out when the system has completed 200 hours of operation after installation or after a gear has been replaced. 1. Check that all units are in good condition and function correctly. 2. Change the oil in the separator oil sump. Consult the “Separator Manual”. The level should be above the min. line on the sight glass. NOTE Neglecting or delaying an oil change may result in damage to separator bearings. 3. Tighten all connections. During operation: Check visually that there is oil in the sump. NOTE Too little oil can lead to damage of the separator bearings. Check that the starter ammeter reading is the normal low and steady value, 14 s810029-02 MMPX Operating Instructions 2 Operating 2.3. Intervals Between Sludge Discharges 2.3.1 Background N WARNING Disintegration hazard Experience has shown that if intervals between sludge discharges are too long, a compact and hard sludge cake can accumulate. On discharge, this cake may break up and be discharged unevenly causing imbalance in the bowl. If imbalance is excessive, there is risk for serious mechanical damage and injury to personnel. Recommendations are given regarding initial intervals between sludge discharges for different applications. The setting may subsequently have to be changed after actual inspection of the bowl. 2.3.2 Recommended intervals between sludge discharges Many factors influence accumulation and hardening of sludge between the discharges. so the appropriate interval depends on local conditions. However, in order to have a reasonable starting point the following table shows recommended initial discharge intervals and operating times to first inspection. 1810029-02 72 Operating MMPX Operating Instructions 2.3.3 Fuel oil cleaning Recommendations Type of fuel Initial intervals be- | Time to first bow! in- tween discharges | spection Distilate (1.5 - 6 o8t/40 °C) 4 hours 1 week Matine Diesel Oil (max, 14 Sv40 °C 2 hours 1 week Heavy Fuel Oil 0.5 hours 2 days Conditions may change completely when bunkers are changed. Therefore, great care must be given to the discharge interval setting for each new bunker. In case the actually used discharge interval exceeds the recommended initial value, the interval setting has to be reduced, according to the table above, when a new, unfamiliar bunker is separated. Use of unstable fuel or mixing of incompatible fuel oils may give precipitation of sludge and overloading of the separator. 8 1810029-02 MMPX Operating Instructions 2 Operating Note: 1. A low pressure/low flow alarm with no apparent external cause (incorrect flow, temperature etc.) is a sign that the bowl needs immediate cleaning. Never neglect to investigate and remedy the cause of such alarms. 2. Cleaning of the operating system is normally required whenever product- wetted parts of the bowl are manually cleaned, 3, In cases where an uneven sludge cake remains in the bowl after a discharge, this, induces a particularly heavy imbalance when not covered by liquid. This may occur in total discharge type separators and when starting separators without previous cleaning. Therefore, always after each stop, inspect the bowl for cleanliness from sludge, and if required clean it before restart, This should be done when the separator has been in operation for 24 hours or more after the last inspection or cleaning. 0 WARNING Disintegration hazard Failure to clean the separator bowl, including operating system, at required intervals or after alarms and stop of bowl may cause imbalance with risk of injury to personnel. 1810029-02 132 Operating MMPX Operating Instructions 2.4 Intervals Between Bowl Cleaning Suitable intervals between cleaning vary according {o the process parameters and installation. The intervals can only be determined by bowl inspections at actual operating conditions. Indicated below are some of the conditions, where experience has shown that the interval between cleaning has to be closely monitored and possibly shortened. General: ¢ Installation not in accordance with Alfa Laval specifications and recommendations, * Poor operating water quality. For fuel oll separators: © HFO with excessive or extraneous contaminants. © Separation of fuel containing stuffing box oil, spent lubricating oil or recovered from sludge tanks. For lubricating oil separators: * Diesel engine condition bad. © Separation of piston rod stuffing box oil in the case of crosshead diesel engines. # Inadequately cleaned piston rod stuffing box oil recycled to system oil. 12 1810029-02 MMPX Operating Instructions 2 Operating 2.3.4 Lubricating oil cleaning © Continuous operation: In a new lubricating oil system the oil is initially clean but as it gets dirtier the interval between discharges will have to be shortened until a “steady state” is reached, Following information refers to systems in “steady state”. Recommended intervals for Crosshead engines Type of oil Type of separator Initial discharge | Time to first bow in- spection Main lubricating oil system ‘hour 1 week MOPX Main lubricating oil system 0.5 hours 1 week MMPX Stutfing box oil 5 min. After each batch | MMPX When separating stuffing box oil, the specialised “MMPX Box Oil Cleaning Plant” is primarily recommended. Please note that the recommended initial discharge interval is 5 minutes and that it must never exceed three times this value. Recommended intervals for Trunk engines Type of oll Initial discharge | Time to first bow in- spection Main lubricating oil system 0.5 hours 2 days © If separator has been out of operation: If the separator has been out of service for 24 hours or longer, while the engine has been running, the interval between discharges has to be shortened. In this case the recommendation is: * Discharge interval 5 minutes until the whole oil volume has passed twice through the separator. * After that resume normal discharge interval. 1810029-02 cE}2 Operating MMPX Operating Instructions © Intermittent operation: For installations whiere one separator serves one engine which is temporarily stopped the following recommendations apply: If the engine is to be stopped for 24 hours or less: + Operate the separator continuously. If the engine is to be stopped for more than 24 how + Keep the separator in operation for 8 hours after the engine is stopped. + Start the separator 8 hours before the engine is started again, Doing so most of the suspended particles and condensed water will be removed from the system and not settle in the sump tank. For installations where one separator serves more than one engine the following recommendations apply: + Continuous use of the separator whenever possible. + Frequent switches between the engine systems to be cleaned, In a typical case with one separator serving 2-4 auxiliary engines switching after maximum 24 hours of cleaning. + Discharge interval: Engine has been in operation with- | Engine has not been in operation ‘out cleaning of the system oil since last cleaning of system oil Discharge interval 5 min. ‘Normal discharge interval Duration until the whole oil volume. has passed twice through the separator ‘After that resume to normal discharge interval 10 1810029-02 MMPX Operating Instructions 2 Operating 2.3.5 Bowl inspection To check if the initially selected interval is appropriate, the bow] should be inspected after a short test period shown in the previous tables. If sludge space is clean: Interval may be prolonged with steps of 15 minutes, but it must not exceed three times the recommended initial interval. “Sludge space is clean” means that no noticeable amount of hard sludge remains in the sludge space. If sludge space is dirty: Interval has to be shortened. When the bowl is opened for routine cleaning, the sludge space should always be inspected and evaluated, If necessary, the interval between discharges should then be changed accordingly. N.B. Alfa Laval assumes no responsibility for the actual choice of discharge intervals, as these entirely depend on local conditions. 1810029-02 ‘Sludge space in bowl. Parts to be inspected: A 8B. c. D. E Top disc Bow! hood Sludge space Disc stack Sliding bow! bottom aMMPxX Separation System Parameter List List No. \31830-6181-7 Printed Mar 1998 Book No. 1810141-02 V4 Alfa Laval Marine & PowerAlfa Laval reserve 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 Separation AB Marine & Power Division $- 147 80 Tumba ‘Sweden © Copyright Alfa Laval Separation AB 1998,7 Sequence Diagram 7.2 Clarifier mode MMPX Parameter List ‘The duration of the monitoring functions and output signals when the separator is operated as a clarifier is illustrated in the diagram. [Valve [Terminal Activated function |Standby|Starting | Separation |Sludge dlecharge_ [Stopping Relay sequence _|sequence [sequence lsequence [Sensor ‘OFF [Pao [Pam [P54 | Pad | Pet [P70 [Pre [Pre [Pra ||Pea [Pot [POF [ORF 3 [Ws [ads | ws oma [ros [ros [Os [ios] a0e | Ss [rode Mon. functions High intermediate — usa jxre [0 isa x73 |High eve! oo psa2 [x74 — |Lowooll pressure —— x82 xe [Emergency stop! —$—$——— a, xs [x84 | Vibrations! ———— tt X93 |Hoator faut [peeeeeenremrfessne ens eenerennefeten snes etn anenteentmneine TTY X13 | High ofl temperature” a Trt |x11:1-3. | Low oil temperature? —— [Output signals X1:1-2 |Motor starter — 4 [Blocking vibration xs1 [xase [Bice — Mvi |x4:4 Jil separator -_ — Mve {x51 Tank drain — - Displacement! MVI0 X52 Sealing water Mv15. |x8:3. Bowl opening water — Mv16 {x54 Bowl closing water? Cc 24 Emergency stop (XS2) is normally connected on terminal X84. f optional vibration switch (XS1) is installed, it willbe connected on ferminal X84. Emerg the EPC is in stand-by mode (OFF) and t! stopped. yency stop (XS2) will hen be connected on system power supply. If ie emergency stop Dutton is pushed, the separator motor wil be ‘With optional sensor T1 installed PSO will not star if the temperature is too low or too high. During P81 intermittently 2 seconds every 15 minutes. 1810141-02 Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents with fatal injuries. In order to make the information clear only foreseeable conditions have been considered. No warnings are given, therefore, for situations arising from unintended usage of the machine and its tools. A summary of the safety information is found in the Safety chapter under divider 1.7 Sequence Diagram 7.1 Purifier mode ‘The duration of the monitoring functions and output signals when the separator is operated as a purifier is illustrated in the diagram. (Valve | Terminal Activated function [Standby staring Separation] Sludge alacharge [Stepping Relay sequence ‘sequence |sequence lsequence Sensor rE |pan [PE [BSS Tosa wan | wer [Pvo [ore [Pr [Pra ra [Pee [POS OFF Ts [as sos Oss mh oe Telos ]e [we se fee Mon. tnetione High intermediate uss [x73 [High level saz x74 |Lowoll pressure a XS2 | K8:4 lEmergency stop! —_—_ xsi |xe:4 | Vibrations* Saas — x93 {Heater taut 11 |x11:1-3.|High ottemperature? 11 /x11:1-8 |Low oi temperature? — [Output signals - x12 feotr starter Pepe Peery “ [Blocking vioation xst |x2a4 [Block a vi |x4:4 [Oil to separator ———_ — ave [xs |Tankerain — lm vio |x5:2 | Displ/Sealing water — = vis |x8:3 [Bow opening water bam ivie|x5:4 Bow closing water? - ae 1. Emargoncy stop (XS2) is normally connacted on terminal X84. eptonal bration ewitch (XS1) is installed, it wll be connected on terminal X84, Emorgoncy stop (XS2) wil ton bo eommectod on system power SUDA}. 2. Withoptional sensor TT1 italod P50 wil not star Ifthe fomperature i 100 low 0 too righ. 3. During PST iniormatinly 2 seconds every 15 minutes. 1810141-02 va 236 Additional Parameter Information MMPX Parameter List P54 Oil feed on during stabilizing period Oil admitted to separator bow! during a stabilizing period. If more than 30 seconds is needed for the purifier and 60 seconds for the clarifier it may indicate a malfunction. 6.3.2 Separation Sequence P60 Tank drain During P60 draining of the intermediate tank takes place. Conditions for activation of this function are selected by P26, P61 Time between sludge discharges The same as Pl (setting one parameter will set both to the same value). Bowl closing water is supplied for 2 seconds every 15 minutes. NB. In series operation the time sequence for the clarifier must be longer than for the purifier, in order to synchronize sludge discharges initiated from the purifier, 6.3.3 Sludge Discharge Sequence P70 Displacement water Filling of displacement water to the bow! eliminates the risk of oil loss at the next sludge discharge. If more than 40 seconds are required, this indicates a malfunction. N.B. If P2=C (clarifier mode), then P70 starts but the valve is not activated (i.e. no displacement water added). 22 P72 P78 NB. Sludge discharge Sludge discharge initiated by MV15 admitting water to the separator bowl. If more than 4 seconds are required, this indicates a malfunction, Sealing water Sealing water is used in the bowl to prevent oil from discharging through the water outlet in a purifier. The amount of sealing water in the bowl is balanced by the gravity disc. Insufficient volume of water will lead to a broken water seal. If broken water seal occurs during sludge discharge sequence the time setting can be increased, P78 should be set according to experience. If P2 = C (clarifier mode), then P78 starts but no conditioning water is added. 6.3.4 Stopping sequence P83 NB. Tank drain During P83 draining of the intermediate tank takes place. Displacement water. Oil feed off Before the separator is stopped displacement water is added to the bowl to displace the oil and ensure there is a minimum loss of oil. If P2 = C (clarifier mode), then P84 starts but no displacement water is added. Separator motor off The separator motor is automatically switched off. Restarting is blocked for 3 minutes. 1810141-02. Contents 1 Scope 1 2 Process Parameters 3 3 Installation Parameters . 5 4 Timer Sequence Parameters 7 5 Service Mode Parameters 90, 94, and 95 9 5.1 Countdown of Timers P50 - P89 9 5.2 Alarm Log 10 5.2.1 Examples of Logged Alarms 11 5.3 Timer function 13 6 Additional Parameter Information 15 6.1 Process Parameters 15 6.2 Installation Parameters 20 6.3 Timer Sequence Parameters 21 6.3.1 Starting Sequence 2 6.3.2 Separation Sequence 22 6.3.3 Sludge Discharge Sequence 22 6.3.4 Stopping sequence 22 7 Sequence Diagram 23 71 Purifier mode 23 7.2 Clarifier mode 24 saror4t-o2MMPxX Parameter List 6 Additional Parameter Information N.B. Ifa different type of heater is installed P40 Pal P43 181014102 6.3 (P37 = 0), only a start/stop signal is available from the EPC-41 control unit. If a steam heating system is connected to the EPC-4l and if the system i ‘equipped with an optional shut-off valve, and provided P37= 0 or 2, the valve is opened when the heater is started. P50 The valve is shut: P52 when the heater is stopped at high temperature alarm © at power failure * at EPC stand-by mode ‘Temperature reading Degrees Celsius (°C) or Fahrenheit (°F) temperature readings available. PS, P6 and P7 have to be set according to °C or °F, Max. start time for heater Sets the maximum allowed start time for the heater. Minimum temperature limit (P6) must be reached within this, time, P53, Extra alarm function Extra alarm functions can be connected. By setting P43 to | the oil feed to the separator will be stopped when the extra alarm occur. NB. N.B, 1810141-02 Timer Sequence Parameters 6.3.1 Starting Sequence Sludge discharge To ensure that the bowl is always emptied at start (e.g. after power failure). Bowl closing water For proper closing of the separator bowl during start-up sequence. If more than 60 seconds is required, it may indicate a malfunction. Sealing water Sealing water is used in the bowl to prevent oil from discharging through the water outlet in a purifier, The amount of sealing water in the bowl is balanced by the gravity disc. ‘During the starting sequence, sufficient water must be admitted to the empty bow! to establish an adequate water seal. Insufficient water will lead toa broken water seal. If a broken water seal occurs during the starting sequence the time setting can be increased. P53 should be set according to experience. Before increasing the sealing water, make sure that the appropriate gravity disc is fitted to the separator bowl. This function is blocked in the clarifier mode (P2 = C, and P51 =“---"). 216 Additional Parameter Information MMPX Parameter List PIS 6.2 P20 P26 P23 HFO / DO selection of oil type P34 To prevent false alarm (A7-10) when cleaning diesel oil the type of oil must be specified. Once P5, P6 and P7 are set for HFO or DO they automatically follow the selection of P15. If P15 = “HFO” and PS is set > 0 then PS for DO is automatically reset to 50 °C (120 °F). If P15 = “do” then P53 =P70 = 0. See PS for the relationship between P5, P35 P6, P7 and PIS. Installation Parameters Separator type When P20=2.1 the specific functions for the MMPX are automatically set. Tank drain action = Drain valve or optional pump activated after discharge. For timing see timer P60. P36 1 = Drain valve or optional pump activated when level indicating switch, LSI 4, is activated. For timing see timer P60. EPC-41 address If the separator works as a single unit P37 the EPC-41 address is always 1. ‘When using more than one separator in the same system (parallel or series) each interconnected EPC-41 control unit must be identified. The EPC-41 address shows the order in which the control units ate linked. See also P3 for the relationship between the parameters, Alarm delay time Activation of most alarm functions can be delayed up to 30 seconds, except for © emergency / vibration alarm high temperature alarm, which have a fixed delay time of 2 seconds. If operating two separators in series, P34 for the clarifier separator must be 3 seconds longer. Low temperature alarm delay after MV1 change over ‘When the oil feed change over valve changes position the flow rate and thus the oil temperature may be influenced, By delaying the temperature alarm, a false alarm is avoided as the oil temperature has time to stabilize. P35 should be set according to plant application, If delay time above 120 seconds is necessary, check the heating system and the installation layout. Remote control Remote control can be applied in form of: ¢ extemal switches ¢ external computers Heater type ‘The EPC-41 control unit is designed for control of: * Heatpac EHS-62 (P37 =1) ¢ Heater with heating media control valve (P37=2) 1910141-02 1 Scope This parameter list is valid for the MMPX separation systems, including the EPC-41 control unit with PROM: 31830-6213-1. 1810141-021 Scope MMPX Parameter List MMPX Parameter List 6 Additional Parameter Information How to set P8 and P9: If the temperature varies with regularly repeated oscillation, setting of the proportional band and integral time is necessary. © Increasing the value of parameter P8 (proportional band width) will resuit in a slower and more stable control action * Increasing the value of parameter P9 (integral time) also results in slower response from the EPC-41. We recommend that you follow these guidelines: 1, Set P9 = 10 minutes. 2, Decrease P-band (P8) band in steps until the process reaches the point where it starts to oscillate with a constant amplitude. Test the stability after each step by introducing a step-change of load or set point, 3. When you have discovered the Constant amplitude point where the process oscillates with a constant amplitude note the following figures: ‘A= The value of P-band (P8). B= The time for one full period in seconds. 4. Calculation of optimal parameter B settings, P-band T-time P8=22xA PI=0.8xB ‘The settings above give a rather good result but may be adjusted according to individual characteristics in different loops 2 1810141-02 1810141-02 196 Additional Parameter Information MMPX Parameter List P4 PS P6 18 Sludge discharge signals from purifier to clarifier The number of sludge discharges initiated by the first separator (purifier) before a discharge signal is sent to the second separator to start its sludge discharge sequence. P4 should be set in the purifier controller. High temperature alarm PS should be set sufficiently above the temperature set point P7. 5~10°C (10-20 °F) higher than P7 is recommended. If PS = 0 (monitoring temperature sensor (Pt 100) not connected) then P6 = P7 =“---". PS, P6 and P7 can be set both for heavy fue] oil (HFO) and for diesel oil (DO), see P15. If both oils are to be used, the following must be done: 1, Set P5, P6 and P7 for “HFO" (P15 is factory set to “HFO"). 2. Change P15 to “do”. 3. Go back to PS and set PS, P6é and P7 for DO. If only diesel oil is to be used for the installation, the following must be done: 1. Set PS greater than 0, 2, Change P15 to “do”. 3. Go back to P5 and set P5, P6 and P7 for DO. Low temperature alarm Should be set sufficiently below the temperature set point P7. 5-10°C (10-20 °F) lower than P7 is recommended. P8 ‘Temperature set point To be set according to plant application. See also PS and P6. P-band (Proportional band) If P37 = 0 then PS a If P37 = | or 2 then P8 is automatically preset to 40%. L-time (Integral time) IfP37 = 0 then P9=*- --", If P37=1 or 2 then P9 is automatically preset to 1.2 minutes, 1810141-02 2 Process Parameters ‘The EPC-41 control unit controls the separa- tion process, It can be programmed for differ- ent separation systems and different condi- tions within the system, by setting parameters. ‘The process parameters can be easily adjusted, as often as required, to meet changes in the operating conditions, e.g. oil temperature, alarm points, time between sludge discharges. Each separator has its own EPC-41 control unit. Up to three separation systems can be interconnected via cables between their con- trol units. The separators can work in parallel or series operation. Only two separators can work in series; the third must work in parallel oract as a stand-by. The first separator in series should always be defined as a purifier and the second as a clarifier. NOTE P2 is factory set to P (purifier). If you change it to C (clarifier) you get all the factory settings for a clarifier, which is shown in columa “Factory set value, Clarifier” in the tables. Q WARNING Disintegration hazard If the time between sludge discharges is set too long, sludge accumulation and bowl imbalance may occur. 1810141-022 Process Parameters MMPX Parameter List Factory set value | Plant Parameter Description or unit Range set Purifier | Clarifier! yaiue Pit | Max. time between | Minutes 0-999 30 30 sludge discharges | P1 = P61 Changing of P1 automatically changes P61. P2' | Purifier/Clarifier mode | P = Purifier Porc P © = Clarifier P3! | Series configuration 0 = No separator in series 0, 12, 13, 23 9 0 12 = The 1st and the 2nd sepa- rator work in series 19 = The 1st and the Ord separa tor work in series 23 = The 2nd and the 3rd sepa- rator work in series Pa? | Sludge discharge sig-| 1 = Every purifier discharge 14 eee ee nal from puriier to. | 2 = Every 2nd purifier aaritier discharge 3 = Every 3rd purifier discharge| 4 = Every 4th purifier cischarge| IPS = 0 then P4 = Ps! | High temperature | °C or °F 0-115°Cor | 0 ° alarm 0-255 °F P6' | Lowtemperature | °C or *F 0-115 °Cor |---| --- alarm 0-255 °F P7' | Temperature set point| °C or °F o-110°%Cor | --- | - 0-240 °F pet | P-band % 10-500 = Pe! | |-time Minutes 0.1 -10.0 P10 to By” Not used pete eee P15! | HFO/ DO selection of | HFO = Heavy Fuel Oil HFO or do | HFO | HFO type of oll do = diesel oi For lubricating oil select HFO P16to Big | Not used sf 1. For more information, see"Additional Parameter Information” on page 16. 4 1810181-02 MMPX Parameter List P3 Series configuration Up to three EPC-41 control units can be linked together. Only two of the three connected separators can work in series. The first separator in series should always be defined as a purifier and the second separator as a clarifier. ‘The relationship between the parameters P2, P3 and P23 is shown in the following table. ‘The Ist linked control unit must always have the power on (the separator does not need to be operating) when the 2nd and the 3rd separators are operating in series, 6 Additional Parameter Information Type of operation | First linked control unit] Second linked control unit] Third linked control unit Single operation: P2 = P (Purifier) = a PS = 0 (No separator in series) P2a= 1 (Single unit) Parallel operation: | P2 = P P2=P P3=0 P3=0 P23= 1 (Istlinked | P23= 2 (2nd linked control P23= 3 (Grd linked control control unit unit) unit) ‘Series operation Pas? Pe = 6 (Clarif P2=P stand 2nd separator:| P3= 12(1and2in | P3 = 12 P3=0 series) Page 2 P23. 3 Pade 1 This separator works as a stand-by unit: i.e. in parallel operation or not used. Series operation a= P P=? P= 0 4st and 3rd separator: | P3 = 18 (1 and 3 in P3= 13 series) Page 2 P2a= 3 Pea. This separator works as a stand-by unit Series operation P2=P P2=P P2- 0 2nd and 31d separator:| P3 = 0 P3 = 23 (2 and 3in series) | P3 = 23 P23= 1 P2322 P23= 3 This separator works as stand-by unit. 1810141-02 176 Additional Parameter Information MMPxX Parameter List 3 Installation Parameters "Type of oi! Initial discharge | Time to first bow! inspection] Distilate (1.5 - 6 cSt /40 °O) ‘hours 1 week Marine Diesel Oil (max. 13 St / 40 °C} 2 hours 1 week Intermediate / Heavy Fuel Oil 0.5 hour 2 days 1 Het NOTE Lubricating oil cleaning The interval between discharges must EPC-41 parameter P21 is factory set be shortened if the separator has been to 50 Hz, If connected to a 60 Hz out of service for 24 hours or longer supply an alarm will occur. Set P21 to while the diesel engine has been 60 Hz. and press the reset button, The running. alarm will disappear. In order to have a reasonable starting — — point the table below shows ‘The installation parameters must be set before recommended initial discharge the initial start-up and before process para~ intervals and operating time to first meters are set. The parameters rarely need to inspection, be adjusted again, Main lubricating oll system 7 NOTE Initial discharge Time to first bow! inspection| for trunk piston engines Recommended interval 1 hour 1 week for cross head engines Stuffing box oil 5 minutes After one batch Recommended interval 0.5 hour 2 days P2— Purifier/clarifier mode ‘The MMPX separator can be defined as a clarifier or as a purifier. It can operate as a single separator or in parallel or series. This is defined by the parameters P2, P3 and P23, See P3 for the relationship between these parameters. If a separator operates in series when the mode is changed the parameter P3 has to be changed accordingly. 16 Alfa Laval can not be held responsible for injuries and damage caused by use of parameter values not recommended by Alfa Laval Factory set value] Plant Parameter Description or unit Range Purter | curt | P20 _| Separator type 1.2= MMPX ra-21 | 12 12 | 12 | P21 | Power frequency Hz 50 or 60 50 50 Check that the frequency is cor- rect, see label on the separator. P22__| Not used on 231 | EPC-41 address 41 = Single unit or the ‘st linked 1-8 1 1 control unit 2 = The 2nd linked control unit = The 3rd linked control unit 4-8= Not used Up to 3 control units can be linked together, Peg For remote communication with 48 48 P25 Profibus protocol 2 2 1et014t-02 1810141-02