hy: Alfa Laval FOPX 609 Separation System 1 Safety 2 System Description Operating Instructions Parameter List Alarms and Fault Finding System Reference Installation Instructions on oO on Fk w Separator Manual (inci. taut finding) Spare Parts Catalogue 9 Component Descriptions (inci. taut nding) 10 Optional Equipment CERN eee Printed Oct 1995 Product No. 1762764-07 Book No. -1817086-02 V1‘Atfa 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 oratefully appreciated. Copies of this publication can be ordered from your local Alfa Laval company. Published by: Alfa Laval Separation AB Marine & Power Oil Treatment Division ‘$- 147 80 Tumba ‘Sweden © Copyright Alta Laval Separation AB 1995.hy Alfa Laval Separation System Safety Printed Jul 1995 Book No. 1810158-02 V2 Alta Laval Marine & PowerContents 1 Safety Instructions 1.1 Warning Signs 1.2 Specific Factors re10188-02 v21. Safety Instructions 1.1 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. DANGER LN ‘Type of hazard This type of safety instruction indicates a situation which, if not avoided, could result in fatal injury, or fatal damage to health. A WARNING Type of hazard This type of safety instruction indicates a situation which, if not avoided, could result in disabling injury, or disabling damage to health. A CAUTION Type of hazard This type of safety instruction indicates a situation which, if not avoided, could result in light injury, or light damage to health. 181015802 v21 Safety Instructions Safety ‘The waming sign used when there is a risk to equipment. NOTE This type of safety instruction indicates a situation which, if not avoided, could result in damage to equipment, ‘The warning 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, sa1o1se-ce v2Safety 1 Safety Instructions 1.2 Specific Factors The centrifugal separator includes parts that rotate at high speed, generate high centrifugal forces, and take along 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 range 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. ‘© Use only Alfa Laval genuine spare parts and the special tools supplied. NOTE If safety instructions and installation instructions in this manual are not strictly followed, Alfa Laval can not bbe held responsible for any malfunction or injuries resulting. 1a10188-02 v21 Safety Instructions DANGER A\ Disintegration hazard Using the separation system outside limits specified by Alfa Laval could cause breakdown. 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. Do not enter the room after an emergency stop while the separator is still rotating. Do not start the separator after ant ‘emergency stop without first remedying the cause of the emergency. Afier an emergency stop the separator bowl must be manually cleaned before starting up again. Ifthe A7-10 (FOPX only) and A7-11 (LOPX only) alarm is not remedied there is a risk for breakdown. If the interval between sludge discharges is too long, there is a risk of heavy side breakdown. Satety ge sa1o1sec2 v2Safety 1 Safety Instructions DANGER i Disintegration hazard Operation in stand-by mode for a prolonged period of time may cause heavy side breakdown. If the separator is not assembled and connected properly it may lead to disintegration. Never discharge a vibrating separator. Vibration will increase if only part of solidified sludge is discharged. After an emergency stop the separator bow! must be manually cleaned before starting up again. Running a separator build for 50 Hz at higher frequency will result in overspeed and may cause disintegration. Entrapment hazard Do not begin maintenance work while the machine is still rotating. ‘Do not switch on without all covers and guards in place. Fire Hazard Excess of maximum idling time may cause fire, if a destillate with low flashpoint is used. 1810188-02 v21 Safety Instructions Safety jy WARNING Noise hazard Excessive noise can cause damage to hearing if no ear protection is used. Disintegration hazard Never reset an alarm without first finding and remedying the cause. Each new bunker requires reconsideration of the discharge time setting. Operating water shortage may result in sludge discharge failure and cause sludge accumulation and heavy imbalance. Entrapment hazard Do not switch on without all cover and guards in place. 181018802 v2Safety jy CAUTION Burn hazard Process pipes, lubrication vil and various machine surfaces can be hot and cause burns. Slip hazard Oil leakage may make the floor slippery and cause injuries. 1 Safety Instructions NOTE Be sure to study alll relevant documentation supplied and become familiar with the function and operation of the system and each particular unit, If safety instructions, installation specifications and additional installation information in this manual are not strictly followed, Alfa Laval ccan not be held responsible for any ‘malfunction or injuries resulting. 181015802 v2hy: FOPX Separation System System Description Printed Nov 1995 Book No. 1810235-02 V1 Alfa Laval Marine & PowerContents 24 22 34 3.2 3.3 34 35 3.6 Scope System Overview ‘System Layout Oil Flow The ALCAP FOPX Process The ALCAP Principle Low Water Content Medium Water Content High Water Content Extreme Water Content Definition of Terms 1810295021 Scope ‘This system description is valid for the following separation systems: FOPX 605 FOPX 609 FOPX 610 FOPX 611 FOPX 613 The FOPX separation systems are designed for cleaning of fuel oil for diesel engines in marine and power applications. ye10235.022 System Overview In the FOPX process, heated fuel oil is fed through the FOPX separator to clean the oil from solid particles and water. An FOPX system comprises: © AnFOPX separator. © Ancillary equipment including a control unit and a water transducer. © Optional equipment such as an oil feed pump and an oil heating system. Basically, the FOPX separator operates 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. ‘The control unit supervises the entire operation of the separation system and. performs monitoring, control and alarm functions. The process is automatically adapted to changed conditions such as changing water content of the unprocessed oil. 1210235022 System Overview 2.1 System Layout The basic FOPX system layout is illustrated by the following symbol diagram. The FOPX system ‘The inlet and outlet arrows indicate the following: ‘A Unprocessed oil inlet B_ Cleaned oil outlet to service tank C Oil returns to the settling tank FOPX System Description Water inlet Sludge outlet Water drain tem [ Symbot | Designation Function oO Displacement pump 1 Feeds unprocessed oil to the separator. va >| IV Heats unprocessed oil to separation temperature. @ ‘Temperature transmitier ‘Measures the oil temperature. 181023502FOPX System Description 2 System Overview them Designation Function Preumatically controlled | Leads the unprocessed ol to the separator or back 4 change over valve to the setting tank (recirculation), ‘Separator Cleans the oll by removing water and soi 6 particles. 6 ‘Shutottvaive ‘Drain valve. Opens when water should be arained from the separator bow. ‘Water transducer ‘Measures the changes of water content in the 7 separated oil. Flow indicator Displays the clean oll flow rate. High pressure switch ‘Senses high pressure in the oil outet. ° Low pressure switoh 1 ‘Senses low pressure in the oil outlet. Pressure gauge " Displays the pressure in the oil outlet lz] 1/R|@|@|@|@|@| Xp) ka|f Manualycontoled Regulates the clean ol back pressure % regulating valve 2 Non-return valve Stops reverse ol ow olencid valve block, water | Distibtes separator apaning and closing water, 14 condoning water, and displacement water. Conor unt Supenises the separator system, 15 1810295-002 System Overview FOPX System Description 2.2 Oil Flow ‘The unprocessed cil is fed through a heater by a positive displacement pump, operating at a constant flow. After 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 daily service tank. The oil can also be directed back to the settling tank. This is the case when the oil temperature is outside the preset range, during separator start and stop procedures, and during alarm conditions. 1810295023 The ALCAP FOPX Process ‘The terms used in this process description are explained in section “3.6 Definition of Terms” on page 16. 3.1 The ALCAP Principle During the separation process sludge and water accumulate at the periphery of the separator bowl. Sludge and water are discharged : at preset, time intervals or when needed, and &cessive water can also be drained from the separator bow! between discharge When the Bild up of separated water and sludge increases, water approaches the disc stack. Traces of water then start to escape with the cleaned oil. This small increase of water content is immediately detected by the water transducer, installed in the oil outlet. ‘The signal from the water transducer is continuously transmitted to the control unit, where a reference value is stored, The control unit continually compares tne transducer signal with the reference value. A deviation from the reference value will cause draining of water or a sludge discharge to keep the system at optimum separation efficiency. ya10296-023 The ALCAP FOPX Process FOPX System Description 3.2 Low Water Content When the fuel oil contains little or no water, sludge discharges are timer initiated. | o t ------4+ Transaucer signal, low water coment 8 Transducer signal E Maximum time between discharge sequences 1 Time F Displacement of oil A Trigger range G__ Addition of conditioning water B Trigger value H__ Addition of displacement water C Reference time 1 Storing of reference value D 2 ‘Minimum time between discharge sequences Sludge discharge The water transducer signal reflects the process cycle when the unprocessed oil contains little or no water. The minimum and maximum time between sludge discharges are set in the control unit as timer functions. 8 1e10296-02FOPX System Description Process Cycle 1 Conditioning water is added to the separator bowl. The conditioning water softens the sludge in order to accomplish a good discharge. A new reference value is stored by the control unit. ‘When the maximum time between sludge discharges has elapsed, displacement water is added to the separator bowl. The displacement water eliminates the risk of oil Luss at the following sludge discharge. ‘The interface between oil and water moves toward but never into the disc stack, This means that there is no risk of water contaminated oil leaving the separator, ‘When the interface between oil and water approaches the disc stack, the transducer signal reaches the tigger value. A sludge discharge is initiated. After the sludge discharge a new process cycle stars with the adding of conditioning water. A new reference value is then stored. s810205-.02 3 The ALCAP FOPX Process8 The ALCAP FOPX Process FOPX System Description 3.3 Medium Water Content When the water content is medium, the transducer signal will reach the trigger value after the minimum time between discharge sequences but before the maximum time. j- (1 _____& ny L i 1 ‘Medium water content s Transducer signal D__ Minimum time between discharge sequences t Time E Maximum time between discharge sequences A Trigger range F Addition of conditioning water B Trigger value 1 Storing of reference value C Reference time 2 Sludge discharge Process Cycle 1. After the sludge discharge a new cycle starts with the adding of conditioning water, 2. Anew reference value is stored. 10 1810296.02FOPX System Description 3 The ALCAP FOPX Process 3. Separated water will fill out the sludge space of the bow! before the maximum time between discharge sequences has elapsed. 4, Water escaping with the cleaned oil is immediately detected by the water insducer, and a sludge discharge is initiated. No displacement water is added in this case. The next process cycle starts with addition of conditioning water and storing of a new reference value. 1910236-02 "3 The ALCAP FOPX Process FOPX System Description 3.4 High Water Content ‘When the water content is high, the transducer signal will reach the trigger value before the minimum time between sludge discharges. s High water content s Transducer signal E Maximum time between discharge sequences t Time ‘A Trigger range 1 Storing of reference value B Trigger value 2 Drain valve opens at trigger value C Reference time 3. Drain valve closes D_— Minimum time between discharge sequences 4 Sludge discharge Process Cycle 1. The transducer signal reaches the trigger value before the minimum time between discharges has elapsed. 2, ‘The water drain valve opens to decrease the amount of water in the separator bowl 12 1810295-02FOPX System Description 3 The ALCAP FOPX Process 3. When the transducer signal has decreased to the trigger range, the drain valve stays ‘open another 20 seconds. 4, Step 1-3 may be repeated for each trigger value before the minimum time between discharge sequences. 5. When this minimum time has elapsed, the next trigger value will not open the drain valve but initiate a sludge discharge. No displacement water is added. The next process cycle starts with storing of a new reference value. In this case no conditioning water is added. se10295.02 133 The ALCAP FOPX Process FOPX System Description 3.5 Extreme Water Content If the water content of the unprocessed oil is extremely high, opening the drain valve may not be enough to reduce the amount of water in the separator bowl. S Extremely high water content = Transducer signal 1D. Minimum time hetween discharge sequences t Time E Drain valve open, transducer signal remains high A. Trigger range 1 Storing of reference value B Trigger value 2 Drain valve opens at trigger value C Reference time 3 Sludge discharge Process Cycle 1. The transducer signal reaches the trigger value before the minimum time between discharge sequences has elapsed. 2. The drain valve opens. 3. If the transducer signal is not decreased to the trigger value within 2 minutes, a sludge discharge is initiated. No displacement water is added. 14 1810236-02FOPX System Description 3 The ALCAP FOPX Process 4. The next process cycle starts with the storing of a new reference value. No conditioning water is added. 5, If the next trigger value is reached before the minimum time between discharge sequences, a sludge discharge is immediately initiated. The process cycle is not affected. Alarm Should the water content stay extremely high for two consecutive process cycles, an alarm is activated. 1910206-02 153. The ALCAP FOPX Process FOPX System Description 3.6 Definition of Terms ‘Transducer signal Reference value Reference time interval (Parameter value) ‘Trigger range (Parameter value) ‘Trigger value Maximum time hetween sludge discharge sequences (Parameter value) Minimum time between sludge discharge sequences (Parameter value) Conditioning water Displacement water 16 The analog signal from the water transducer. The transducer signal is monitored by the control unit to detect minor changes of water content in the outlet oil. ‘The lowest achievable transducer value for the oil that is being processed. The reference value is determined during the reference time interval and stored in the control unit. The time period after each sludge discharge, after which the actual transducer signal is stored as a reference value. ‘The allowed deviation of the water transducer signal, compared with the reference value. ‘The trigger range lower limit is the reference value, and the range is normally set to 0.2% of the reference value. ‘Trigger range upper limit. When the transducer signal reaches the trigger value, water must be discharged from the separator. ‘When this time has elapsed after a sludge discharge, the next discharge is initiated. ‘When this time has elapsed after a sludge discharge, the next discharge may be initiated by the transducer signal. Water, added to the separator bowl to soften the sludge. ‘Water, added to the separator bowl to displace the oil and ensure there is no loss of oil at sludge discharge. 1910235-02hy: ‘Alfa Laval FOPX Separation System Operating Instructions Printed Oct 1995 Book No. 1810016-02 V3 Alta Laval Marine & PowerContents 24 22 23 24 25 26 Scope Operating Start up Check List Start up Operating Check List Stop Emergency Stop After Emergency Stop 181001602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.1 Scope These operating instructions are valid for the following separation systems: FOPX 605 FOPX 609 FOPX 610 FOPX 611 FOPX 613 ‘The FOPX separation system is designed for cleaning of fuel oil for marine and power diesel engines. 1810016022 Operating 2.1 Start up Check List Separator 1. Check that the separator is correctly assembled and connected to power of correct voltage and frequency. A If the separator is not assembled and connected properly it may lead to disintegration. DANGER Disintegration hazard 2. Check the oil sump level: it should be no more than half way up the sight glass and not less than 1/4 of the sight glass. —— NOTE Too much or too little oil can damage the separator bearings. 3. Release the brake. Starter 4, Power on, s810016-02 FOPX series shown above. The FOPX 611 has a different pipe arrangement on top of the separator.2 Operating FOPX Operating instructions Control Unit 5. Check that the mode selector switch points to L (local), 6. Power on. ‘The display reads “OFF”. 7. Close the door. 8. Check the direction of rotation of the bow! by doing a quick start/stop. The revolution ‘counter must rotate clockwise. N DANGER Disintegration hazard If power cables have been connected, always check the rotation direction. If the separator rotates in reverse vital rotating parts could unscrew. Air Valve Block 9. Check that there is correct air supply by reading the pressure gauge situated on the valve block; see “System Reference”. Plant set value: min. re10016-02FOPX Operating Instructions 2.2 Startup 1, Start the oil feed pump from the pump, starter. 2. Switch on the heater from the control unit. If the heater is not connected to the control unit it must be switched on independently. 4, Listen and observe. Vibration may occur during start up, when passing critical speeds. az This is normal and should pass without | danger. If vibration increases, or continues at full E speed, press the emergency stop button. The cause of vibration must be determined and corrected before starting again! See “Separator Manual”, chapter “Technical Reference”. A\ DANGER Disintegration hazard Excessive vibration may cause breakdown, 1810016-02 52 Operating 5, Ensure that the separator is at full speed. At full speed the starter ammeter reading has decreased from a high starting value to allow steady value; the idling value (slightly lower than the normal operating value). 6. Check 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. 7. Wait until the oil feed temperature is correct: + Heavy fuel mode 98 °C + Diesel oil mode 40 °C For the further information about separation temperatures see the “Technical Data” in the “System Reference”. 8. Start the feed to the system from the control unit. When the temperature is correct the operation LED is lit (green). FOPX Operating Instructions = 2 2 Gal = oS 1810016-02FOPX Operating instructions 2 Operating 2.3 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 components are in good condition and function correctly. 2. Change the oil in the separator oil sump. Clean the oil sump before filling with new oil. For further information see the “Separator Manual”. The level should be no more than half way up 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. The level should be no more than half way up the sight glass, see fig.1. —— NOTE | ‘Too much or too little oil can damage | the separator bearings. | Check that the starter ammeter reading is the AY normal low and steady value. u i 1610016-02 72 Operating FOPX Operating Instructions 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 trigger value is shown on the left, and 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. 4, the water transducer value. NB. 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 trigger value, and time to next sludge discharge. 1, How to interpret the displayed figures as hours: (000 999 = actual value in hours 1,00 — 9.99 = 1000 - 9990 hours 10,0 99.9 = 10000 — 99900 hours 100, 999, = 100000 - 999000 hours — 1810016-02FOPX 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: If excessive vibration occurs press the emergency stop button and evacuate the room. A DANGER Disintegration hazard Never discharge a vibrating separa- tor. Vibration will increase if only part of solidified sludge is discharged. Check all connections for leakage. p CAUTION Slip hazard Oil leakage may make the floor slippery and cause injuries. 191001602 2 Operating