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SA 831/836/841/846 Separation Systems

Installation System Reference


Printed Sep 2008
Book No. 1810949-02 V 8
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB Sep 2008.
Contents

1 Technical Data ........................................................................................................ 1


1.1 Demand Specification Water.......................................................................... 1
1.2 Demand Specifications Air ............................................................................. 1
1.3 System Data ....................................................................................................... 2

2 Drawings ...................................................................................................................... 4
2.1 Flow Chart ............................................................................................................ 4
2.2 Drawings ............................................................................................................... 5
2.2.1 SA 831/836 Separator Mounting Drawing, DIN........................................................ 5
2.2.2 SA 831/836 Separator Mounting Drawing with S R K, DIN ...................................... 6
2.2.3 SA 831/836 Separator Mounting Drawing, JIS ........................................................ 7
2.2.4 SA 831/836 Separator Mounting Drawing with S R K, JIS ....................................... 8
2.2.5 SA 831/836 Separator Basic Size Drawing ............................................................. 9
2.2.6 SA 831/836 Separator Foundation Drawing .......................................................... 10
2.2.7 SA 841/846 Separator Mounting Drawing, DIN...................................................... 11
2.2.8 SA 841/846 Separator Mounting Drawing with S R K, DIN .................................... 12
2.2.9 SA 841/846 Separator Mounting Drawing, JIS ...................................................... 13
2.2.10 SA 841/846 Separator Mounting Drawing with S R K, JIS .................................... 14
2.2.11 SA 841/846 Separator Basic Size Drawing ............................................................ 15
2.2.12 SA 841/846 Separator Foundation Drawing .......................................................... 16
2.2.13 Valve Block Oil, DN 25 Dimension Drawing ........................................................... 17
2.2.14 Valve Block Oil, DN 25 Assembly Drawing ........................................................... 18
2.2.15 Valve Block Water Assembly Drawing ................................................................... 19
2.2.16 Valve Block Air, Assembly Drawing ....................................................................... 20
2.2.17 Control Unit EPC 50 Dimension Drawing ............................................................... 21
2.2.18 Starter Dimension Drawing..................................................................................... 22
2.3 Electrical System Layout ............................................................................. 23
2.4 Electrical Diagrams ......................................................................................... 24
2.4.1 Cable List .............................................................................................................. 24
2.4.2 Interconnection Diagram, Starter ........................................................................... 27
2.4.3 Interconnection Diagram, Starter, cont. ................................................................. 28
2.4.4 Interconnection Diagram, Transmitters .................................................................. 29
2.4.5 Interconnection Diagram, Solenoid Valves ............................................................ 30
2.4.6 Interconnection Diagram, Solenoid Valves cont. ................................................... 31
2.4.7 Interconnection Diagram, Optional Equipment ...................................................... 32
2.4.8 Transformer Connection Diagram ......................................................................... 33
2.4.9 Circuit Diagram, Power Circuits ............................................................................. 34
2.4.10 Circuit Diagram, Separator Starter and Feed Pump ............................................. 35
2.4.11 Circuit Diagram, Remote Start Interlock (optional)................................................. 36
2.4.12 Circuit Diagram, ESD-relay and Trip Contacts (optional)....................................... 37

1810949-02
3 Remote Operation Systems......................................................................... 39

4 Specifications ....................................................................................................... 42
4.1 Cables ..................................................................................................................42
4.2 Cable Routing ....................................................................................................43
4.3 Oil, Water, Steam, and Condensate Piping ..............................................43
4.4 Ambient Temperature Limitation................................................................44
4.5 Sludge Removal Kit (Optional Equipment) .............................................45
4.6 Sludge Tank .......................................................................................................47
4.7 Sludge Piping .....................................................................................................49

5 Commissioning and Initial Start ............................................................... 52


5.1 Completion Check List ...................................................................................52
5.2 Initial Start-up ...................................................................................................54
5.2.1 Calculating Operating Pressure .............................................................................56

6 Shut-down and Storage .................................................................................. 57


6.1 Shut-down after Use........................................................................................57
6.2 Protection and Storage ..................................................................................58
6.3 Reassembly and Start up...............................................................................59

1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 1 TECHNICAL DATA

1 Technical Data
1.1 Demand Specification Water
Alfa Laval ref. 574487 rev. 1

Poor quality of the operating water may with time cause erosion, corrosion and/or
operating problems. The water shall be treated to meet certain demands.

1 Turbidity-free water, solids content <0,001% by volume.


Max. particle size 50 µm.
Deposits shall not be allowed to form in certain areas in the system.
2 Total hardness less than 180 mg CaCO3 per litre, which corresponds to 10 °dH or 12,5 °E. Hard
water may with time form deposits in the operating mechanism. The precipitation rate is
accelerated with increased operating temperature and low discharge frequency. These effects
become more severe the harder the water is.
3 Chloride content max. 100 ppm NaCl (equivalent to 60 mg Cl/l). Chloride ions contribute to
corrosion on surfaces in contact with the operating water.Corrosion is a process that is
accelerated by increased separating temperature, low pH, and high chloride ion concentration.
4 6,5 < pH < 9
Bicarbonate content (HCO3) min. 70mg HCO3 per litre, which corresponds to 3,2 °dKH.

NOTE

Alfa Laval accepts no liability for consequences


arising from unsatisfactorily purified operating
water supplied by the customer.

1.2 Demand Specifications Air


Specific requirements regarding the quality
of air NOTE
1 Pressure 500 – 700 kPa (5 – 7 bar). Electrical interconnections must be made by
qualified electricians.
2 Free from oil, and solid particles larger than Mechanical interconnections must be made by
0.01 mm. qualified mechanical technicians.

3 Dry, with dew point min. 10 °C below


ambient temperature.

1810949-02 1
1 TECHNICAL DATA SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

1.3 System Data


Media Fuel oil and lube oils for diesel engines
Feed density, max. 1010 kg/m³ at 15 °C
Viscosity, max. 55 cSt at 100 °C (700 cSt at 50 °C)
Pressure:
oil inlet Max. 200 kPa (2 bar) at separator inlet
oil outlet Max. delivery head 250 kPa (2.5 bar)
sludge outlet from separator open outlet
sludge outlet from sludge pump Max. 5 bar at 6 bar air pressure
Feed temperature 100 °C
Ambient temperature Min. +5 °C, max. +55 °C
Discharge volume 2.4 litre/discharge
Operating water pressure Min 200 kPa (2 bar), max. 800 kPa (8 bar)
Operating water temp. Min. +5 °C, max. +55 °C (unheated water)
Operating water consumption (without make-up water)
SA 831/836 3.7 litre/discharge
SA 841/846 5.3 litre/discharge
Make up water 1.1 litre/hour
Operating water flow from SV 10: 1.6 l/m
from SV 15: 11.0 l/m
from SV 16: 2.8 l/m
Air quality Instrument air
Air pressure Min. 500 kPa (5 bar), max. 700 kPa (7 bar)
Drain connection size 2x1” (internally threaded)
Mains supply voltage 3x230/400/440/480/575/690 V ± 10%
EPC supply voltage (from starter) 230 V /110V/115 V/100V ± 10%, max. fuse 10 A
Control voltage, operating 24 V AC
Power consumption, startup
SA 831/836 11 kW
SA 841/846 12 kW
Power consumption idling/max. capacity
SA 831/836 2.3 kW/5.4 kW
SA 841/846 3 kW/8.5 kW
Frequency 50 or 60 Hz ± max. 5%
Enclosure class Min. IP 54
Storage time before use (with bowl removed) max. 6 months
Storage temp. Min. +0 °C, max. +70 °C
Storage humidity Relative humidity (RH) 10% – 95 % Non Condensing

2 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 1 TECHNICAL DATA

Service intervals: Note! Regularly check connections. Tighten if necessary.


Separator Inspection every 4000 hours or 6 months operation
Overhaul every 12000 hours or 18 months operation
Note! Cleaning In Place (CIP) is recommended to avoid
manual internal cleaning of the bowl. The following intervals
are recommended: Prior to inspection and overhaul
HFO 1 – 2 months depending on oil quality
LO (Cross-head engines) 1 – 2 months depending on oil
quality and engine condition.
LO (Trunk engines) 1 month

Separation System Planned Maintenance Kits


Hours Period Separator Ancillary
Equipment
1000
2000
4000 6 months Inspection

12000 18 months Overhaul

24000 3 years Overhaul

As necessary Repair
(components)

With delivery Inspection


Tools

1810949-02 3
4
2 DRAWINGS

Ref. 568110 Rev. 2


Control unit
Drain

Starter
2.1 Flow Chart
2 Drawings

201 Oil inlet

206 Water for water seal and


displacement

209 Oil Recirculation to tank

220 Clean oil outlet

221 Water outlet

222 Sludge discharge outlet

1810949-02
371 Operating water

375 Opening/closing water

462 Drain
Lo-application Alt 501 Operating air

Alt 540 Ventilation

MCFR FC
Flow Control
Alt Optional Alfa Laval
Flow Control Sludge delivery
Tank
Block mounted

Not included in
Alfa Laval standard
delivery

Feed pump

Heating system
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

X0 19 2 11 B
The EPC-50 Control Unit must be If there is more than one separator system in the
postioned close to the separator. same installation, the EPC-50 Control Units and their
It must be possible to see the separator corresponding separators must be clearly marked
from the EPC-50 Control Unit position. 201 Oil inlet

206 Water for conditioning/displacement

209 Oil Recirculation to tank

Ref. 568078 Rev. 3


220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet


2.2 Drawings

Starter
371 Operating water – see chapt. 1

375 Opening water/closing water

501 Operating air. Instrument air,


pressure 500-700 kPa (5-7 bar).

709 Mains supply 3x230/400/440/480/


575/690 V

799 EPC 50 supply voltage, 230V, 110/


115V or 100V. AC

1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

Connections

A DIN Flange DN25-PN16-DIN2633


2.2.1 SA 831/836 Separator Mounting Drawing, DIN

Drain B DIN Flange DN50-PN16-DIN2543

C ISO G 1/8

D ISO G 1/2

F Flange DN25-PN16-DIN2633

Optional

* Internal flexible connection (enclosed


with delivery)
2 DRAWINGS

5
X0 19 2 12 C
6
The EPC-50 Control Unit must be If there is more than one separator system in the
201 Oil inlet
postioned close to the separator. same installation, the EPC-50 Control Units and their
It must be possible to see the separator corresponding separators must be clearly marked 206 Water for conditioning/displacement

from the EPC-50 Control Unit position. 209 Oil Recirculation to tank
2 DRAWINGS

220 Clean Oil outlet

221 Water outlet

Ref. 577914 Rev. 3


Starter 222 Sludge discharge outlet

371 Operating water – see chapt. 1

375 Opening water/closing water

501 Operating air. Instrument air,


pressure 500-700 kPa (5-7 bar).

540 Ventilation

709 Mains supply 3x230/400/440/480/


575/690 V

799 EPC 50 supply voltage, 230V, 110/


115V or 100V. AC

Drain

1810949-02
Connections

A For flange DN25-PN16-DIN2633

B DIN Flange DN25-PN16-DIN2543

C Air pipe connection ISO G 1/8

4 holes ∅ 12 for D Water pipe connection ISO G 1/2


foundation bolt G Ventilation pipe ∅ 48.3

Optional

* Internal flexible connection (enclosed


with delivery)
2.2.2 SA 831/836 Separator Mounting Drawing with S R K, DIN
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

X01 92 5 1B
The EPC-50 Control Unit must be If there is more than one separator system in the
postioned close to the separator. same installation, the EPC-50 Control Units and their
It must be possible to see the separator corresponding separators must be clearly marked
from the EPC-50 Control Unit position.
201 Oil inlet

206 Water for conditioning/displacement

Ref. 567986 Rev. 3


209 Oil Recirculation to tank

Starter 220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet

371 Operating water – see chapt. 1

375 Opening water/closing water

501 Operating air. Instrument air,


pressure 500-700 kPa (5-7 bar).

709 Mains supply 3x230/400/440/480/


575/690 V

799 EPC 50 supply voltage, 230V, 110/


115V or 100V. AC

1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

Connections
2.2.3 SA 831/836 Separator Mounting Drawing, JIS

A Welding connection ∅ 34.5


Drain
B Flange 50A-10K-JIS B2222

C ISO G 1/8

D ISO G 1/2

Optional

* Internal flexible connection (enclosed


with delivery)
2 DRAWINGS

7
X0 19 2 12 D
8
The EPC-50 Control Unit must be If there is more than one separator system in the
postioned close to the separator. same installation, the EPC-50 Control Units and their
It must be possible to see the separator corresponding separators must be clearly marked 201 Oil inlet
from the EPC-50 Control Unit position.
2 DRAWINGS

206 Water for conditioning/displacement

209 Oil Recirculation to tank

220 Clean Oil outlet

Ref. 577917 Rev. 3


Starter
221 Water outlet

222 Sludge discharge outlet

371 Operating water – see chapt. 1

375 Opening water/closing water

501 Operating air. Instrument air,


pressure 500-700 kPa (5-7 bar).

540 Ventilation

709 Mains supply 3x230/400/440/480/


575/690 V

799 EPC 50 supply voltage, 230V, 110/


115V or 100V. AC

1810949-02
Drain

Connections

A Welding connection ∅ 34.5

B Flange 25A-10K-JIS B2222


4 holes ∅ 12 for
foundation bolt C Air pipe connection ISO G 1/8

D Water pipe connection ISO G 1/2

G Pipe ∅ 48.3

Optional

* Internal flexible connection (enclosed


2.2.4 SA 831/836 Separator Mounting Drawing with S R K, JIS

with delivery)
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

X0 19 25 2B
Maximum horizontal displacement
at the inlet/outlet connections
during operation ±5 mm

Ref. 561693 Rev. 5


Maximum vertical
displacement at the
sludge connection
during operation ±2 mm

Tightening torque 160 Nm

1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.2.5 SA 831/836 Separator Basic Size Drawing

∅28, depth 45 M10, depth 30


Connection house with connections 201, 220, and 221, turnable in ∅28, depth 45
60 ° steps all round. M10, depth 30
All connections to be installed non-loaded and flexible.

All dimensions are nominal. Reservation for individual deviations due


to tolerances.

∅22, depth 45
2 DRAWINGS

9
X 01 92 13 B
10
Min. lifting capacity required
when doing service: 300 kg
2 DRAWINGS

Ref. 561726 Rev. 1


Max. height of largest
component incl. lifting tool.

Service side.

1810949-02
Recommended free floor space for
unloading when doing service.
2.2.6 SA 831/836 Separator Foundation Drawing

No fixed installation within this area

Centre of gravity (complete machine)

Vertical force not exceeding 10 kN/foot


Foundation bolt

Horizontal force not exceeding 10 kN/foot


Installation acc. to stated
foundation forces
Total static load max. 4 kN
Centre of
separator bowl Centre of motor

8 holes for foundation bolts


SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

X0 19 2 14 G
The EPC-50 Control Unit must be
postioned close to the separator.
201 Oil inlet
It must be possible to see the separator
from the EPC-50 Control Unit position. 206 Water for conditioning/displacement

Ref. 568081 Rev. 4


209 Oil Recirculation to tank

220 Clean Oil outlet

221 Water outlet


Starter
222 Sludge discharge outlet

371 Operating water – see chapt. 1

375 Opening water/closing water

501 Operating air. Instrument air,


pressure 500-800 kPa (5-8 bar).

709 Mains supply 3x230/400/440/480/


575/690 V

799 EPC 50 supply voltage, 230V, 110/


115V or 100V. AC

213

1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

Connections

A For flange DN25-PN16-DIN2633


2.2.7 SA 841/846 Separator Mounting Drawing, DIN

Drain
B DIN Flange DN65-PN16-DIN2543

C ISO G 1/8

D ISO G 1/2

F Flange DN25-PN16-DIN2633

Optional

* Internal flexible connection (enclosed


with delivery)

If there is more than one separator system in the


same installation, the EPC-50 Control Units and their
corresponding separators must be clearly marked
2 DRAWINGS

11
X01 9 21 2E
12
The EPC-50 Control Unit must be If there is more than one separator system in
postioned close to the separator. the same installation, the EPC-50 Control Units 201 Oil inlet
It must be possible to see the separator and their corresponding separators must be
206 Water for conditioning/displacement
from the EPC-50 Control Unit position. clearly marked
209 Oil Recirculation to tank
2 DRAWINGS

220 Clean Oil outlet

Starter 221 Water outlet

Ref. 577918 Rev. 3


222 Sludge discharge outlet

371 Operating water – see chapt. 1

375 Opening water/closing water

501 Operating air. Instrument air,


pressure 500-700 kPa (5-7 bar).

540 Ventilation

709 Mains supply 3x230/400/440/480/


575/690 V

799 EPC 50 supply voltage, 230V, 110/


115V or 100V. AC

1810949-02
Drain Connections

A For flange DN25-PN16-DIN2633

B Flange DN25-PN16-DIN2543

C Air pipe connection ISO G 1/8

D Water pipe connection ISO G 1/2

G Pipe ∅ 48.3
4 holes ∅ 12 Optional
for foundation
x Internal flexible connection (enclosed
bolt with delivery)
2.2.8 SA 841/846 Separator Mounting Drawing with S R K, DIN
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

X0 19 25 3 B
The EPC-50 Control Unit must be
postioned close to the separator. 201 Oil inlet
It must be possible to see the separator
from the EPC-50 Control Unit position. 206 Water for conditioning/displacement

Ref. 568082 Rev. 4


209 Oil Recirculation to tank

Starter 220 Clean Oil outlet

221 Water outlet

222 Sludge discharge outlet

371 Operating water– see chapt. 1

375 Opening water/closing water

501 Operating air. Instrument air,


pressure 500-800 kPa (5-8 bar).

709 Mains supply 3x230/400/440/480/


575/690 V

799 EPC 50 supply voltage, 230V, 110/


115V or 100V. AC

213

1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

Connections
2.2.9 SA 841/846 Separator Mounting Drawing, JIS

A Welding connection ∅ 34.5


Drain
B Flange 65A-10K-JIS B2222

C ISO G 1/8

D ISO G 1/2

Optional

* Internal flexible connection (enclosed


with delivery)

If there is more than one separator system in the


same installation, the EPC-50 Control Units and their
corresponding separators must be clearly marked
2 DRAWINGS

13
X0 19 2 12 F
14
The EPC-50 Control Unit must be If there is more than one separator system
postioned close to the separator. in the same installation, the EPC-50
It must be possible to see the separator Control Units and their corresponding 201 Oil inlet
from the EPC-50 Control Unit position. separators must be clearly marked
206 Water for conditioning/displacement
2 DRAWINGS

209 Oil Recirculation to tank

Starter 220 Clean Oil outlet

Ref. 577919 Rev. 3


221 Water outlet

222 Sludge discharge outlet

371 Operating water – see chapt. 1

375 Opening water/closing water

501 Operating air. Instrument air,


pressure 500-700 kPa (5-7 bar).

540 Ventilation

709 Mains supply 3x230/400/440/480/


575/690 V

799 EPC 50 supply voltage, 230V, 110/


115V or 100V. AC

1810949-02
Drain
Connections

A Welding connection ∅ 34.5

B Flange 25A-10K-JIS B2222

C Air pipe connection ISO G 1/8


4 holes ∅ 12
for foundation D Water pipe connection ISO G 1/2
bolt G Ventilation pipe ∅ 48.3

Optional

x Internal flexible connection (enclosed


with delivery)
2.2.10 SA 841/846 Separator Mounting Drawing with S R K, JIS
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

X0 1 92 54 B
Maximum horizontal displacement
at the inlet/outlet connections
during operation ±5 mm

Ref. 562557 Rev. 3


Maximum vertical
displacement at the
sludge connection
during operation ±2 mm

Tightening torque 160 Nm

1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.2.11 SA 841/846 Separator Basic Size Drawing

Connection house with connections 201, 220,


and 221, turnable in 60 ° steps all round.

All connections to be installed non-loaded and


flexible.

All dimensions are nominal. Reservation for


individual deviations due to tolerances.

M10, depth 30
∅28, depth 45

M10, depth 30

∅28, depth 45
∅22, depth 45
2 DRAWINGS

15
X 01 92 13 C
16
Min. lifting capacity required
2 DRAWINGS

when doing service: 300 kg

Ref. 562553 Rev. 2


Service side.
Max. height of largest
component incl. lifting tool.

1810949-02
Recommended free floor space for
unloading when doing service.

No fixed installation within this area

Centre of gravity (complete machine)


2.2.12 SA 841/846 Separator Foundation Drawing

Vertical force not exceeding 12 kN/foot


Foundation bolt
Horizontal force not exceeding 12 kN/foot

Total static load max. 4.5 kN


Installation acc. to stated
foundation forces
Total static load max. 4.5 kN
Centre of motor
Centre of
separator bowl

8 holes for foundation bolts


SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

X01 9 21 4H
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.2.13 Valve Block Oil, DN 25 Dimension Drawing

Weight circa 50 kg

X0 1 92 08 A

Ref. 568054 Rev. 0

1810949-02 17
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.2.14 Valve Block Oil, DN 25 Assembly Drawing

Cable 19
Connection kit

Water transducer

Connection
Valve

Pressure
* Angular coupling transmitter

Needle valve
Non-return valve
Nipple
Elbow *
Pressure
Connection gauge *
Pressure
transmitter

Needle valve Valve block

Temperature sensor Nipple


Needle valve

Shut-off valve *
Nipple
Pressure
Pneumatic transmitter
change-over valve
Connection
Non-return valve

Nipple *

Screw Washer Hexagon plug Elbow Silencer Flexible connection


*
X0 19 2 08 D

* To be sealed with locking liquid

Ref. 567802 Rev. 3

18 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.2.15 Valve Block Water Assembly Drawing

Flow valve for SV 10


Connection for solenoid valve
Flow valve for SV 15
Flow valve for SV 16

Quick coupling

Valve block
Non return
valve kit

Flexible connection

Flexible connection

X01 92 1 5A

Ref. 567940 Rev. 0

1810949-02 19
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.2.16 Valve Block Air, Assembly Drawing

Spade connection

Valve block

Flexible connection

X01 92 1 6A

Ref. 568048 Rev. 0

20 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.2.17 Control Unit EPC 50 Dimension Drawing

Operating panel

Separator interlock
indication (optional) Emergency stop,
separator

Sludge valve
interlock indication
(optional)
On-off, feed
pump

On-off,
PC connection separator

Plugged holes
for extra cable
glands

Technical Data

Ambient temperature Max. 55 °C

Protection class IP 65

Material in cabinet Sheet steel

Power supply 100,115, or 230 V AC 50/60 Hz

Operating voltage 24 v AC 50/60 Hz

Power consumption 70 VA (+200 VA for I/O)

Weight 19 kg

Optional
X0 23 36 9B

Ref. 568304 Rev. 5

1810949-02 21
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.2.18 Starter Dimension Drawing

X0 1 92 07 A

Ref. 568025 Rev. 1

22 1810949-02
Circuit board
SUM
Control unit –Vibration Alarm Remote
–Communication

Ref. 568029 Rev. 1


–Heater control OP unit
Remote
–Remote alarms
Temp. Al. Remote

Data Start/Stop

Comm.
System
Emergency

Starter
2.3 Electrical System Layout

1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

Heating system
See also 1765867 for
electric heater; 1765868
for steam heater
Mains supply

Feed pump SRK

Tank Sludge
pump Interconnection diagram 568030
Cable list 568031

Optional Alfa Laval


delivery

Functional blocks
2 DRAWINGS

23
X0 19 20 3 B
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.4 Electrical Diagrams

2.4.1 Cable List


No. Type Connection point Instruction Connection point Remarks
A B
Power cables (currents according to order)
1 MPRXCX 3x4 Mains supply Starter Fuse 20 A
1 MPRXCX 3x10 Mains supply Starter Fuse 35 A
1 MPRXCX 3x16 Mains supply Starter Fuse 50 A
1 MPRXCX 3x25 Mains supply Starter Fuse 63 A
1 MPRXCX 3x35 Mains supply Starter Fuse 80 A

2 MPRXCX 2x1.5 Starter EPC 50

3 MPRXCX 3x1.5 Starter Separator motor 2.5 – 6.3 A


3 MPRXCX 3x2.5 Starter Separator motor 6.3 – 16 A
3 MPRXCX 3x4 Starter Separator motor 16 – 20 A
3 MPRXCX 3x6 Starter Separator motor 20 – 25 A
3 MPRXCX 3x10 Starter Separator motor 25 – 32 A
3 MPRXCX 3x16 Starter Separator motor 32 – 45 A
3 MPRXCX 3x25 Starter Separator motor 45 – 63 A

71 MPRXCX 2x1.5 Starter Separator motor

4 MPRXCX 3x1.5 Starter Feed pump 0.4 – 6.3 A


4 MPRXCX 3x2.5 Starter Feed pump 6.3 – 16 A

72 MPRXCX 2x1.5 Starter Feed pump

Ref. 568031 Rev. 1

24 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

No. Type Connection point Instruction Connection point Remarks


A B
Signal cables
11 RFE–HF 1x2x0.75 EPC 50 SV1
12 RFE–HF 1x2x0.75 EPC 50 SV4
13 RFE–HF 1x2x0.75 EPC 50 SV5
14 RFE–HF 1x2x0.75 EPC 50 SV10
15 RFE–HF 1x2x0.75 EPC 50 SV15
16 RFE–HF 1x2x0.75 EPC 50 SV16
17 RFE–HF 1x2x0.75 EPC 50 SSC PT1
18 RFE–HF 1x2x0.75 EPC 50 SSC PT4
2)
19 PUR-cable 4x0.34 EPC 50 SSC + EMC MT
20 RFE–HF 4x2x0.50 EPC 50 SSC + EMC ST, (YT, SS)
21 RFE–HF 1x2x0.75 EPC 50 SSC PT5
22 RFE–HF 1x2x0.75 EPC 50 SUM Alarm
23 RFE–HF 4x2x0.75 EPC 50 SSC TT1/TT2

50 RFE–HF 4x2x0.75 EPC 50 Starter


51 RFE–HF 4x2x0.75 EPC 50 Starter
52 RFE–HF 1x4x0.75 EPC 50 Starter

Options (as ordered)


31 RFE–HF 1x4x0.75 EPC 50 SSC + EMC Rem. OP unit
32 RFE–HF 1x4x0.75 EPC 50 Rem. Temp. al.
33 MPRXCX 5x1.5 EPC 50 Rem. Start/Stop
34 RFE–HF 1x4x0.75 EPC 50 SSC + EMC Comm. module
35 RFE–HF 1x4x0.75 Starter GS, Valve switch
36 RFE–HF 1x2x0.75 EPC 50 LS, Sludge Level
37 RFE–HF 1x2x0.75 EPC 50 SV6, Sol. Valve For pneumatic
sludge pump
1)
38 MPRXCX 4x1.5 EPC 50 Syst. Emergency

40 RFE–HF 4x2x0.75 EPC 50 Power unit


45 RFE–HF 1x2x0.75 Starter Power unit

41 RFE–HF 1x4x0.75 EPC 50 Steam reg. valve


44 RFE–HF 1x2x0.75 EPC 50 Shut-off valve
1)
This cable cannot be longer than 25 m to avoid voltage drop.
2)
Cable with moulded connector included in Alfa Laval delivery.
Ref. 568031 Rev.1

1810949-02 25
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

Other equivalent and approved cables may be


used.
Cable areas are calculated with correction
factor 0.7.
Cables used are Shipboard Cables, designed
according to IEC 92-3.
Flame retardant according to IEC 332-3/A.
Halogen-free according to IEC 754-1
Code designations for cables obtainable
through cable producers Helkama, Finland,
and Acatel, France.
Where SSC is indicated it should be a Signal
Shielded Cable with the shield properly
connected to earth as shown in the electrical
drawings.
For other connections, an armoured cable may
be used provided the armour is connected to
earth, as shown in the electrical drawings, and
gives sufficient EMI protection. Copper wire
armouring is normally used.

26 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.4.2 Interconnection Diagram, Starter

Mains suppy
3x230,400, 440, 480, 575 or 690 V AC
Select correct voltage on transformer T8

Separator motor

Space heater 230 VAC


Separator motor
optional

Contactor response, separator


Potential free contacts, max. 250 V 0.5 A

STARTER
Feed pump motor
optional

Space heater 230 VAC


Separator motor
optional
Contactor response, separator
Potential free contacts, max. 250 V 0.5 A
sheet 2
ESD-relay option,

Systems emergency stop


(Control voltage off)

Power supply to EPC 50 (Sheet 5)


230 V AC, 50/60 Hz
X0 1 92 02 A

Ref. 568030 Sheet 1, Rev. 4

1810949-02 27
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.4.3 Interconnection Diagram, Starter, cont.

* = Replaces jumper in terminals


** = Internal connections

To EPC 50 (sheet 5)

To EPC 50 (sheet 5)

Separator emergency stop


(optional, external)

STARTER
Sludge valve interlock switch
optional

Remote stop
Feed pump
Remote start

Feed pump interlock

Heater interlock
Potential free contact, max. 250 V 0.5 A
(Feed pump running = contact closed)
Tripped motor circuit breakers (optional)
Potential free NC contacts, max. 250 V 0.5 A

Emergency Shut Down (ESD) signal (optional)

Emergency Shut Down (ESD) feedback

To EPC 50 (sheet 3)
X0 1 92 02 G

Ref. 568030 Sheet 2, Rev. 4

28 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.4.4 Interconnection Diagram, Transmitters

MT
Water transducer

connections
Internal
* Termination
jumper. Only at
sattbus end units.

Remote OP unit
* Termination
jumper. Only at
sattbus end units.

Temp. sensor,
2xPT 100
TT 1 (Alarm)

Optional
Heater board
TT 2 (Control)

CONTROL UNIT EPC 50


PT1

PT4

PT5

Speed sensor
(Cable included in Blue Brown
separator delivery) Brown Blue
Sheet 5

Speed transmitter
on separator
Alt. wiring when using junction box

Vibration transmitter
Internal connections

(Optional

Separator interlock
switch
optional

From starter (sheet 2)

LS Note!
Level Switch
Sludge Tank
X01 9 20 2J

(Optional)

Ref. 568030 Sheet 3, Rev. 4

1810949-02 29
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.4.5 Interconnection Diagram, Solenoid Valves

to S1
connection
internal
Preset
Signal to alarm panel.
Pot. free contact, opens at alarm
Max. 50 V AC/DC, 1.0 A

SV6
Solenoid Valve for
control of
Pneumatic Sludge
Pump
(Optional)

SV1
Oil feed

CONTROL UNIT EPC 50


SV4
Oil outlet

SV5
Water outlet

SV10
Water seal

SV15
Opening water

SV16
Closing water
Internal connections

X0 19 20 2I

Ref. 568030 Sheet 4, Rev. 4

30 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.4.6 Interconnection Diagram, Solenoid Valves cont.

24 V phase
Systems emergency stop
(Control voltage off)

24 V neutral

CONTROL UNIT EPC 50


From starter (sheet 2)
Jumper at 110/115 V AC
Jumper at 100 V AC

voltages
Connections for alternative

Jumper at 230 V AC

From starter (sheet 2)

From starter (sheet 2)

* Replaces jumper in terminals


X0 1 92 02 E

Sheet 6

Ref. 568030 Sheet 5, Rev. 4

1810949-02 31
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.4.7 Interconnection Diagram, Optional Equipment

VIBR. BOARD

CONTROL UNIT EPC 50


For steam heater see 1765868
For elecrtric heater see 1765867

HEATER BOARD
Remote alarm indication
High temp. indication
Low temp. indication
Pot. free contacts
Max. 50 V AC/DC, 1.0 A
Contact closes at alarm.

Remote operation
Remote mode selected
I/O-EXPANSION BOARD

(output 24 V AC)
Sep. status indication
(output 24 V AC)
Separation Start/Stop
Note
Jumper X71:1 to X71:3 to
avoid false alarm when not Start
used. Stop
COMM. BOARD

Data communication
Bus GND
Line A
Line B
Shield
X0 1 92 02 F

Ref. 568030 Sheet 6, Rev. 4

32 1810949-02
Main switch

Line filter
Line phase

Ref. 31830-6337-0 Rev. 2


Line neutral

To I/O
board (Alarm)

Yellow/green
Protective earth

Brown

Brown Red
Black Brown
Black
Black
2.4.8 Transformer Connection Diagram

White
Blue

1810949-02
To I/O Blue
board Green
Green
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

Red Yellow

Red

Red

Red

Red
Red
2 DRAWINGS

33
X0 1 89 21 A
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.4.9 Circuit Diagram, Power Circuits

Mains supply

Separator

Space heater
(optional)

Feed pump
(optional)

Space heater
(optional)

Cont.
X0 1 92 04 A

Ref. 568028 Sheet 1, Rev. 0

34 1810949-02
Ref. 568028 Sheet 2, Rev. 0
EMERGENCY STOP

START SEPARATOR
CONTACTOR,
SEPARATOR
(Optional)
SLUDGE
VALVE
INTERLOCK
AUTO SWITCH
MAN (Optional)
OP PILOT LAMP,
SEPARATOR
AUTO MODE

(Remote indication)

SLUDGE VALVE INDICATION


SEPARATOR FEEDBACK Optional

1810949-02
PILOT LAMP, FEED
PUMP
FEED PUMP FEEDBACK
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

CONTACTOR, FEED
PUMP
START FEED PUMP
2.4.10 Circuit Diagram, Separator Starter and Feed Pump

(Remote indication)
2 DRAWINGS

35
X0 1 92 04 B
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

2.4.11 Circuit Diagram, Remote Start Interlock (optional)

Separator interlock
indication
Aux. relay

Aux. relay
Separator Interlock

(Optional)
Switch

Vibration
Board

X0 1 92 04 C

Ref. 568028 Sheet 3, Rev. 0

36 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 2 DRAWINGS

2.4.12 Circuit Diagram, ESD-relay and Trip Contacts (optional)

Trip contact kit


(optional)
ESD relay kit
(optional)

X0 1 92 04 D

Ref. 568028 Sheet 4, Rev. 0

1810949-02 37
2 DRAWINGS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

38 1810949-02
SA 831/836 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 3 REMOTE OPERATION SYSTEMS

3 Remote Operation Systems

ING
WARN
!

Disintegration hazard
If the system is operated from a position from
which the separator is not visible, a Remote
Operation System must be installed, including
vibration sensor and frame cover interlock switch.

Connection to steering system via


PROFIBUS or MODBUS fieldbus systems.
PROFIBUS or MODBUS communication
protocol can be used to connect an EPC 50
Control Unit to a central steering system. The
EPC 50 Control Unit uses a PROFIBUS DP or
MODBUS RTU. Every node, or EPC 50 Control
Unit, on the bus has a unique address, and can
use 200 bytes for data exchange. An interface
board is needed to connect an EPC 50 Control
Unit to the respective fieldbus system. This is
mounted on the I/O card.
Remote fieldbus connection for EPC 50 Control
Unit is for use in those cases where the user
wants access to data and operation information
from the control cabinet, and supervision and/
or remote control from his own steering
system.

1810949-02 39
3 REMOTE OPERATION SYSTEMS SA 831/836 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

Alternative PROFIBUS MODBUS


User interface To be arranged by To be arranged by
customer. customer.

Cable Cable for PROFIBUS Cable for MODBUS


aquired and installed aquired and installed
by customer. by customer.
Manual Hardware and software Hardware and software
instructions exist. instructions exist.
Board Part no. 31830-6559-1 Part no. 31830-6558-1

40 1810949-02
SA 831/836 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 3 REMOTE OPERATION SYSTEMS

1810949-02 41
4 SPECIFICATIONS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

4 Specifications
4.1 Cables

Cable Identification
All cables are to be marked to simplify
identification and fault finding.

Specifications
The following specifications apply to cables
connected to and from Alfa Laval equipment.
Follow the instructions given in the cable list.
Examples of cable types that can be used:
• Steel armoured cable.

G 0 32 22 4A
• Copper armoured cable with a separate earth
core.

G 0 32 2 44 A
• Steel armoured and shielded signal cable;
pair twisted or parallel.

G 03 22 14 A

• Shielded signal cable; pair twisted or parallel.


G 03 22 3 4A

42 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS

4.2 Cable Routing


Recommendations
Power cables carry the power supply to motors,
heaters, etc.
Any distance between signal and power cables

S00 28 9 1A
reduces electrical noise transfer.
Examples of recommended routing of various
cable types.
Power Signal
• Power cables and signal cables routed on a Cables Cable
cable rack should be separated.
• Sattbus cables should be routed away from

G 03 22 7 3A
power cables.
If the space is limited, cables can be routed in
tubes.

4.3 Oil, Water, Steam, and Condensate Piping


For piping to and from Alfa Laval equipment,
see the specifications below.

Specifications
• The correct pipe size must be used in the oil
system.
• The number of bends in the oil pipes must
be minimized.
• The suction height must be as low as
possible.
• The oil feed pump must be of positive
displacement type.
• The pump must be positioned close to the
oil tank.
• The heater must be installed close to the
separation system to maintain correct feed
oil temperature.
• The recirculation line should be connected
either directly to the settling tank (HFO) or to
the oil outlet line from the separator (LO).
• The oil outlet line from the separator must be
connected to the system tank for lube oil, or
the service tank for fuel oil.

1810949-02 43
4 SPECIFICATIONS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

4.4 Ambient Temperature Limitation


Specification
Leading classification societies state in their
regulations for engine room equipment that the
maximum ambient temperature permissible is
+55 ° C. To meet this regulation, it is essential
that electrical and electronic components have
good ventilation, and temperature control.

44 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS

4.5 Sludge Removal Kit (Optional Equipment)


If you have a Sludge Removal Kit, this must be
connected to a ventilation pipe.

NOTE

The sludge removal pump must be set to the correct


speed – circa 60 strokes/min, otherwise the lifetime
of the diaphragm, valve balls, and air motor will be
severely shortened.

ING
WARN
!

Health Risk
Oil mist and vaporized oil constituents from hot oily
sludge may be dangerous to health and must not be
inhaled.

A pipe or hose must be drawn from the flange to


the nearest oil tank ventilation pipe.
The pipe /hose must have the same diameter as
the flange opening.
The pipe/hose must be as straight as possible,
with a steady upward incline.
The connection to the oil tank ventilation pipe
must point upwards as shown.

NOTE Oil tank ventilation


pipe

For HFO separation, it is not recommended to make


the connection to the separator room ventilation SA system
system.
For LO separation, connection to the separator room
ventilation system should be made only if the
separator room ventilation is adequate. Use the
optional connection hose (part no. 568023-80, -81, or
~ 5 mm
-82) for this purpose. This hose is designed to entrap
P 00 00 63 A

oil drops in the vent hose, and lead the oil back to the
Sludge Removal Kit tank.

1810949-02 45
4 SPECIFICATIONS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

NOTE

Impurities gather in the Sludge Removal Kit tank.


Regularly check the tank and level switch. See
instructions below.

Proceed as follows:
• From the Control Panel, run the sludge pump
manually for a few seconds.
• Undo the four screws at the top of the sludge
tank and remove the sludge pump.
• If necessary, clean the level switch and the
inside of the tank using diesel oil.
• Check the seals and gaskets, and change if
necessary.
• Loosen the hose clip and check the inside of
the ventilation hose. Clean if necessary.
To avoid breakdown of the Sludge Removal
system, the sludge pump must be regularly
overhauled as follows using spare parts kit
1766702-81.
• Replace the diaphragms and the O-rings with
those delivered in the spare parts kit.
• Perform a 4000 hour Inspection Service.
For Service and Overhaul intervals, see ‘‘1.3
System Data” on page 2.

46 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS

4.6 Sludge Tank


• Sludge tank volume per separation system Ventilation pipe
should cover approximately up to 2 days
storage at a discharge interval of 2 hours (for
discharge volumes see technical data). Sludge pipe
connection

• A manhole should be installed for inspection


and cleaning.
• The tank should be fitted with a sounding
pipe. Min. height
Sludge outlet 400 mm
• The tank floor, or most of it, should have a pump connection

slope (B) of minimum 15°.

G 00 4 27 3A
Min. slope 15°
• The sludge outlet pump connection should be
positioned in the lowest part of the tank.
• A high level alarm switch, connected to the
sludge pump, should be installed.
• A heating coil should be used to keep the
Bowl casing drain Manhole Water drain High level
sludge warm and fluid while being pumped connection connection alarm
switch
out.
• Tank ventilation must follow the classification
rules for evacuation of gases. Heating
coil
• There should be a ventilation pipe to fresh air.
• The ventilation pipe should be straight. If this

G 00 42 7 0A
is not possible, any bends must be gradual.
• The ventilation pipe must not extend below the
tank top.
• A sludge tank with partition walls must have
ventilation pipes in all compartments, or
cutouts in the upper edge, to allow vapours to
travel through the tank.

1810949-02 47
4 SPECIFICATIONS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

The number of ventilation pipes, and their


minimum dimension, depend on the size and
number of separators connected to the same
tank. See table below.

Type 1 system 2 systems

SA 811, SA 816 1 x ∅50mm 1 x ∅50mm

SA 821, SA 826 1 x ∅75mm 1 x ∅75mm


SA 831, SA 836
SA 841, SA 846

SA 851, SA 856 1 x ∅100mm 1 x ∅100mm


SA 861, SA 866

SA 871, SA 876 1 x ∅100mm 1 x ∅125mm


SA 881, SA 886

The separation system generates almost no air


during operation. At any discharge, the
maximum volume of air produced is the same as
the bowl volume (see technical data).

48 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS

4.7 Sludge Piping

Specification
• The sludge pipe from the separator to the
sludge tank should be vertical.
If a vertical pipe is not possible, the deviation (A)
from the vertical line must not exceed 30°.

G 0 04 40 1A
• The sludge pipe must not extend below the
tank top.

NOTE

An extended sludge pipe will obstruct ventilation and


create back pressure that could cause separator
problems.

G 00 43 16 A

1810949-02 49
4 SPECIFICATIONS SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

If more than one separator is connected to the


same sludge tank, a butterfly valve should be
installed in each sludge pipe.

NOTE

If a butterfly valve is not used, the bowl and the


operating system may be affected.

• If a butterfly valve is used, it should be


equipped with an interlocking switch
(connected to the separator starter) to prevent
the separator from being started when the
valve is not fully open.

G 0 0 44 11 A

50 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 4 SPECIFICATIONS

1810949-02 51
5 COMMISSIONING AND INITIAL START SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

5 Commissioning and Initial Start


5.1 Completion Check List
It is essential before starting up the separation
system that all units are in good operating
condition and that all pipelines and control
equipment are properly connected to assure
correct operation.
Use this check list as a guide for completing the
system installation:

ING
WARN
!

Breakdown hazard
Check that the power frequency is in agreement with
the machine plate. If incorrect, resulting overspeed
may cause breakdown.

1 Check that transport seals are removed from


all pipes.
2 Use flushing filters to prevent pipe work debris
from being pumped into the separation
system.

NOTE

The flushing filters must be removed after initial


flushing.

3 Check that all separators are in proper


working condition. Follow the manufacturer’s
instructions.
4 Make sure that separators are lubricated in
accordance with instructions.

NOTE

Make sure that the spindle bearings are prelubricated

5 Separators are delivered without oil in the oil


sump. For information on oil filling and oil type,
see the Service Manual booklet.

52 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 5 COMMISSIONING AND INITIAL START

NOTE

Too much, or too little oil may result in damage to


separator bearings.
Neglecting an oil change may result in damage to
separator bearings.

6 Power on.
7 With the mode selector switch in the CIP
postion, check that the separator rotation M AN
direction corresponds with the arrow on the
frame by doing a quick start/stop (1–2 CIP
CIP
seconds.) and looking at the motor fan
rotation.

G 0 46 60 6 A
ON
CAUTI
!

If power cables have been installed incorrectly, the


separator will rotate in reverse, and vital rotating
parts can unscrew.

8 Check the pump function and direction.


9 If a Sludge Removal Kit is used, check that the
sludge pump speed is set to circa
60 strokes/min.If necessary, adjust the
throttling valve (positioned after solenoid valve
SV 6).

1810949-02 53
5 COMMISSIONING AND INITIAL START SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

5.2 Initial Start-up


Use this check list for initial system start up:
1 Check that there is oil in the feed oil tank.
2 Check water and air supply. See ‘‘System
Data” on page 2.
3 Check power supplies to the control unit and
that the voltage is in accordance with data in
‘‘System Data” on page 2.
4 Check all parameter settings in the control
unit. See Installation Parameters in the
Parameter List booklet.
5 Check the separator.

NOTE

6 Always lubricate the bearings before start-up.

NOTE

The Control Unit is supplied with standard


configuration parameters. You may have to make
some changes to suit your installation.

7 Start the separation system as described in


the Operating Instructions booklet.
8 Start up step by step, checking that the
machine and units function properly.
9 Establish system pressures.
The delivery height pressure is the pressure in
the oil pipe work down stream from the
separation system, due to the pipe bends and
the height (head) to the cleaned oil tank. If the
cleaned oil tank is below the separation
system the delivery height pressure may be
very low. The oil paring disc pressure will have
to be greater than the delivery height pressure
for any oil to flow.
Proceed as follows:
• Ensure the valves in the oil system are in the
correct positions.
• The oil should be at separation temperature.
Cont.

54 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 5 COMMISSIONING AND INITIAL START

• The adjustment screw for the water paring


tube should be in the outer position. The
paring tube should be able to move freely.
• Ensure that V5 is closed.
• Fully open the back pressure regulating valve
RV4.
• The shut off valve V4 should be open.
• Open SV15 for 3 seconds to prime the
operating slide.
• Open SV16 for 15 seconds to close the bowl.
• Open SV10 for 1 minute to put water into the
bowl.
• Feed oil to the separator at the normal flow
rate by opening SV1.
• Note the pressure in the oil outlet PT4, both on
the pressure gauge and in the EPC50 display.
This pressure is P min.
• Gradually close the back pressure regulating
valve RV4. The pressure on PT4 will increase.
The water pressure (PT5) decreases slightly
as the paring tube moves inwards. The water
pressure will suddenly drop when oil passes
from the oil paring chamber to the water
paring chamber. Note the pressure of PT4
both on the pressure gauge and in the EPC50
display. This pressure is P max.
• Open RV4.
• Stop the oil feed to the separator and note the
pressure in the oil outlet. This is the delivery
height pressure P del.
• Stop the heater.
• Stop the separator.
• Stop the feed pump when the heater has
cooled.

1810949-02 55
5 COMMISSIONING AND INITIAL START SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

5.2.1 Calculating Operating Pressure


• Calculate the normal back pressure level
during operation as follows:

Pmin + Pmax
= Pnormal
2

• Calculate the value for low pressure alarm


setting (Pr 11) as follows:

Pmin + Pnormal
= Plow press.
2

• Calculate the value for high pressure alarm


setting (Pr 10) as follows:

Pnormal + Pmax
= Phigh press.
2

Adjust the back pressure to Pnormal


Set Pr 11 to give alarm at pressure decreasing
below the Plow press. value.
Set Pr 10 to give alarm at pressure increasing
above the Phigh press. value.

56 1810949-02
SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 6 SHUT-DOWN AND STORAGE

6 Shut-down and Storage


Storage before Installation
If the separation system is stored before
installation, the following safeguards must be
taken:

Storage period 1 – 6 months > 6 months See


Action
Protect from dust, dirt, x x This chapter
water, etc.
Protect with anti-rust x x This chapter
oil
Inspection x x On commissioning

Overhaul x On commissioning

6.1 Shut-down after Use


If the separation system is going to be shut down
for a period of time, the following safeguards
must be taken:

Shut-down 1 – 6 months 6 – 18 > 18 See


period months months
(stand-by)
Action
Remove bowl x x x Dismantling and
Assembly in the
Service Manual
Protect from dust, dirt, x x x This chapter
water, etc.
Protect with anti-rust x x x This chapter
oil
Inspection x x x On new start-up

Overhaul x On new start-up

1810949-02 57
6 SHUT-DOWN AND STORAGE SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

6.2 Protection and Storage


All system equipment, both the separator and
the ancillary equipment, must be stored indoors
at 5 – 55°C, if not delivered in water-resistant
box for outdoor storage.
If there is a risk for condensation of water, the
equipment must be protected by ventilation and
heating above dew point.
The following protection products are
recommended:
• Anti-rust oil (Dinitrol 112 or equivalent) with
long lasting effective treatment for external
surfaces. The oil should prevent corrosion
attacks and give a waxy surface.
• Anti-rust oil (Dinitrol 40 or equivalent) thin and
lubricating for inside protection. It gives a
lubricating transparent oil film.
• Solvent, e.g. white spirit, to remove the anti-
rust oil after the shut-down.
• Moist remover to be packed together with
separator equipment.
• If the storage time exceeds 12 months, the
equipment must be inspected every 6 months
and, if necessary, the protection be renewed.

Rubber Parts
• Gaskets, O-rings and other rubber parts
should not be stored for more than two years.
After this time, they should be replaced.

Separator
Dismantle the separator bowl and take out the
O-rings. Clean the bowl with oil and reassemble
without the O-rings. Place in a plastic bag with
silica dessicant bags and seal the plastic bag.
Grease the spindle.

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SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE 6 SHUT-DOWN AND STORAGE

Valves, Pipes and Similar Equipment


• Components such as valves need to be
cleaned with solvent and treated with anti-rust
oil (type 112).
• Water pipes should be drained and treated
with anti-rust oil (type 112).
• Articles made of rubber or plastics (e.g. seals)
must not be treated with anti-rust oil.

6.3 Reassembly and


Start up
• Clean away the anti-rust oil with white spirit.
• Remove all silica gel bags.
• Pre-lubricate the separator spindle bearings
• If stored for 6 months or longer, perform an
inspection service (including change of oil in
the separator sump).
• Follow all relevant instructions in the Service
Manual and Operating Instructions.

NOTE

Always lubricate the separator bearings before start-


up.

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6 SHUT-DOWN AND STORAGE SA 831/836/841/846 SEPARATION SYSTEMS INSTALLATION SYSTEM REFERENCE

60 1810949-02

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