Alfa laval сепаратор мануал

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A L F A L A V A L S E P A R A T I O N

FOPX 609TFD-24

Separator Manual

Product No. 881244-02-03

Book No. 1270843-02 V1

Alfa Laval Separation ABSeparator Manuals, dept. SKLS-147 80 Tumba, Sweden

Telephone: +46 8 53 06 50 00Telefax: +46 8 53 06 50 29

Printed in Sweden, 97-08

© Alfa Laval Separation AB 1997

This publication or any part thereof may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Separation AB.

Contents

1 Read this first 7

2 Safety Instructions 9

3 Separator Basics 15

3.1 Basic principles of separation 17

3.2 Design and function 19

3.3 Definitions 29

4 Operating Instructions 31

4.1 Operating routine 32

5 Service Instructions 37

5.1 Periodic maintenance 39

5.2 Maintenance Logs 43

5.3 Check points at Intermediate Service (IS) 50

5.4 Check points at Major Service (MS) 67

5.5 Lifting instructions 81

5.6 Cleaning 83

5.7 When changing oil 87

5.8 Vibration 91

5.9 Common maintenance directions 93

6 Dismantling/Assembly 97

6.1 Introduction 99

6.2 Inlet/outlet, frame hood (IS) 101

6.3 Bowl hood and disc stack (IS) 106

6.4 Bowl body and operating mechanism (IS) 120

6.5 Operating water device (IS) 131

6.6 Vertical driving device (MS) 140

6.7 Horizontal driving device (MS) 154

3

7 Trouble-tracing 167

7.1 FOPX mechanical functions 168

7.2 FOPX separating functions 172

7.3 Vibration switch (option) 175

8 Technical Reference 177

8.1 Technical data 179

8.2 Basic size drawing 181

8.3 Water quality 189

8.4 Lubricants 190

8.5 Drawings 199

8.6 Storage and installation 206

Index 217

4

ls and observe the ion, operation, .

ions can result in

clear only foreseeable conditions ings are given, therefore, for

ended usage of the machine and its

Study instruction manuawarnings before installatservice and maintenance

Not following the instructserious accidents.

In order to make the informationhave been considered. No warnsituations arising from the uninttools.

5

6

1 Read this first

This manual is designed for operators and service engineers working with the Alfa Laval separator FOPX 609TFD-24.

For information concerning the function of the separator, see chapter ‘‘3 Separator Basics” on page 15 and chapter ‘‘8 Technical Reference” on page 177.

If the separator has been delivered and installed by Alfa Laval as part of a processing system, this manual is a part of the system documentation. In this case, study carefully all the instructions in the system documentation.

In addition to this Separator Manual a Spare Parts Catalogue, SPC is supplied.

This Separator Manual consists of:

Safety Instructions

Pay special attention to the safety instructions for the separator. Not following the safety instructions can cause accidents resulting in damage to equipment and serious injury to personnel.

Separator Basics

Read this chapter if you are not familiar with this type of separator.

Operating Instructions

This chapter contains operating instructions for the separator only.

S0

0680

11

Separator Manual and Spare Parts Catalogue

7

1 Read this first

Service Instructions

This chapter gives instructions for daily checks, cleaning, oil changes, servicing and check points.

Dismantling / Assembly

This chapter contains step-by-step instructions for dismantling and assembly of the separator for service and repair.

Trouble-tracing

Refer to this chapter if the separator functions abnormally.

If the separator has been installed as part of a processing system always refer to the Trouble-tracing part of the system documentation first.

Technical Reference

This chapter contains technical data concerning the separator and drawings.

Index

This chapter contains an alphabetical list of subjects, with page references.

8

2 Safety Instructions

G00

1041

1

The centrifugal separator includes parts that rotate at high speed. This means that:

• Kinetic energy is high

• Great forces are generated

• Stopping time is long

Manufacturing tolerances are extremely fine. Rotating parts are carefully balanced to reduce undesired vibrations that can cause a breakdown. Material properties have been considered carefully during design to withstand stress and fatigue.

The separator is designed and supplied for a specific separation duty (type of liquid, rotational speed, temperature, density etc.) and must not be used for any other purpose.

Incorrect operation and maintenance can result in unbalance due to build-up of sediment, reduction of material strength, etc., that subsequently could lead to serious damage and/or injury.

The following basic safety instructions therefore apply:

• Use the separator only for the purpose and parameter range specified by Alfa Laval.

• Strictly follow the instructions for installation, operation and maintenance.

• Ensure that personnel are competent and have sufficient knowledge of maintenance and operation, especially concerning emergency stopping procedures.

• Use only Alfa Laval genuine spare parts and the special tools supplied.

9

2 Safety Instructions

kPam /h3

3o

C

rpmHz

kg/m

S00

513

11S

005

5611

DANGER

Disintegration hazards

• Use the separator only for the purpose and parameter range specified by Alfa Laval.

• If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown.

• When power cables are connected, always check direction of motor rotation. If incorrect, vital rotating parts could unscrew.

• Check that the gear ratio is correct for power frequency used. If incorrect, subsequent overspeed may result in a serious break down.

• Welding or heating of parts that rotate can seriously affect material strength.

• Wear on the large lock ring thread must not exceed safety limit. φ-mark on lock ring must not pass opposite φ-mark by more than specified distance.

• Inspect regularly for corrosion and erosion damage. Inspect frequently if process liquid is corrosive or erosive.

10

2 Safety Instructions

S0

0511

11S

005

1011

S0

0517

11S

005

1611

DANGER

Entrapment hazards

• Make sure that rotating parts have come to a complete standstill before starting any dismantling work.

• To avoid accidental start, switch off and lock power supply before starting any dismantling work.

• Assemble the machine completely before start. All covers and guards must be in place.

Electrical hazards

• Follow local regulations for electrical installation and earthing (grounding).

WARNING

Crush hazards

• Use correct lifting tools and follow lifting instructions.

• Do not work under a hanging load.

Noise hazards

• Use ear protection in noisy environments.

11

2 Safety Instructions

S00

554

11S

005

431

1

CAUTION

Burn hazards

• Lubrication oil and various machine surfaces can be hot and cause burns.

Cut hazards

• Sharp edges on separator discs and lock ring threads can cause cuts.

12

2 Safety Instructions

Warning signs in the text

Pay attention to the safety instructions in this manual. Below are definitions of the three grades of warning signs used in the text where there is a risk for injury to personnel.

DANGER

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.

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.

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.

NOTE

This type of instruction indicates a situation which, if not avoided, could result in damage to the equipment.

13

2 Safety Instructions

14

3 Separator Basics

Contents

3.1 Basic principles of separation 17

3.2 Design and function 19

3.2.1 Overview 19

3.2.2 Mechanical power transmission 20

3.2.3 Sensors and indicators 21

3.2.4 Process main parts 23

3.2.5 Separating function 26

3.2.6 Sludge discharge cycle 27

3.3 Definitions 29

15

16

3 Separator Basics 3.1 Basic principles of separation

G0

010

711

Sedimentation by gravity

G0

010

811

Sedimentation in a settling tank, with outlets making it possible to separate the lighter liquid parts from the heavier

G00

1091

1

The centrifugal solution

3.1 Basic principles of separation

The purpose of separation can be:

• to free a liquid of solid particles,

• to separate two mutually insoluble liquids with different densities while removing any solids presents at the same time,

• to separate and concentrate solid particles from a liquid.

Separation by gravity

A liquid mixture in a stationary bowl will clear slowly as the heavy particles in the liquid mixture sink to the bottom under the influence of gravity.

A lighter liquid rises while a heavier liquid and solids sink.

Continuous separation and sedimentation can be achieved in a settling tank having outlets arranged according to the difference in density of the liquids.

Heavier particles in the liquid mixture will settle and form a sediment layer on the tank bottom.

Centrifugal separation

In a rapidly rotating bowl, the force of gravity is replaced by centrifugal force, which can be thousands of times greater.

Separation and sedimentation is continuous and happens very quickly.

The centrifugal force in the separator bowl can achieve in a few seconds what takes many hours in a tank under influence of gravity.

17

3.1 Basic principles of separation 3 Separator Basics

G0

011

021

High viscosity (with low temperature)

G00

111

21

Low viscosity (with high temperature)

G00

112

21

High density (with low temperature)

G00

113

21

Low density (with high temperature)

Separating temperatures

For some types of process liquids (e.g. mineral oils) a high separating temperature will normally increase the separation capacity. The temperature influences oil viscosity and density and should be kept constant throughout the separation.

Viscosity

Low viscosity facilitates separation. Viscosity can be reduced by heating.

Density difference

The greater the density difference between the two liquids, the easier the separation. The density difference can be increased by heating.

18

3 Separator Basics 3.2 Design and function

G0

5803

11

1. Inlet and outlet device2. Bowl3. Vertical driving device with bowl spindle4. Horizontal driving device5. Worm gear6. Frame feet7. Friction coupling8. Elastic coupling9. Electric motor

201. Unseparated oil inlet206. Displacement/conditioning water inlet220. Clean oil outlet221. Water outlet222. Sludge discharge outlet372. Bowl opening water inlet376. Bowl closing and make-up water inlet

3.2 Design and function

3.2.1 Overview

The separator comprises a processing part and a driving part. It is driven by an electric motor (9).

Mechanically, the separator machine frame is composed of a bottom part, a top part and a frame hood. The motor is flanged to the frame as shown in the illustration. The frame feet (6) are vibration damping.

The bottom part of the separator contains the horizontal driving device (4), driving shaft with couplings (7, 8), a worm gear (5) and a vertical spindle (3).

The bottom part also contains an oil bath for the worm gear, a brake and a revolution counter.

The frame top part and the frame hood contain the processing parts of the separator, the inlet, outlets and piping (1).

The liquid is cleaned in the separator bowl (2). This is fitted on the upper part of the vertical spindle and rotates at high speed in the space formed by the frame top part and frame hood. The bowl also contains the discharge mechanism which empties the sludge from the bowl.

The main inlets and outlets are shown with connection numbers in the illustration. These numbers correspond with the numbers used in the connection list and the basic size drawing which can be found in chapter ‘‘8 Technical Reference” on page 177.

19

3.2 Design and function 3 Separator Basics

G02

4643

1

1. Bowl spindle2. Top bearing and spring casing3. Worm wheel4. Worm5. Friction coupling6. Worm wheel shaft

G0

246

321

Applying (1) and releasing (2) of brake

3.2.2 Mechanical power transmission

The main parts of the power transmission between motor and bowl are illustrated in the figure.

The friction coupling ensures a gentle start and acceleration and at the same time prevents overloading of the worm gear and motor.

The worm gear has a ratio which increases the bowl speed several times compared with the motor speed. For correct ratio see chapter ‘‘8.1 Technical data” on page 179.

To reduce bearing wear and the transmission of bowl vibrations to the frame and foundation, the top bearing of the bowl spindle is mounted in a spring casing.

The worm wheel runs in a lubricating oil bath. The bearings on the spindle and the worm wheel shaft are lubricated by the oil splash produced by the rotating worm wheel.

Brake

The separator is equipped with a brake to be used when stopping the separator. The use of the brake reduces the retardation time of the bowl and critical speeds will therefore be quickly passed.

The brake lining acts on the outside of the coupling pulley.

20

3 Separator Basics 3.2 Design and function

G0

5801

61

1. Revolution counter2. Sight glass3. Indicating pressure gauge4. Sight glass wiper5. Back pressure gauge6. Vibration switch (option)7. Cover interlocking switch (option)

G0

6032

11

Clean the sight glass by turning it around the scraper

3.2.3 Sensors and indicators

Revolution c ounter (1)

A revolution counter indicates the speed of the separator and is driven from the worm wheel shaft. The correct speed is essential to achieve the best separating results and for safety of operation. The number of revolutions on the revolution counter for correct speed is shown in chapter ‘‘8 Technical Reference” on page 177. Refer to name plate for speed particulars.

Sight glass (2)

The sight glass shows the oil level in the worm gear housing.

Indicating pressure gauge (3)

During normal operation, the indicating pressure gauge in the water outlet will indicate pressure of less than 1 bar. If the pressure increases and exceeds 1 bar, this indicates abnormal operating conditions for the separator caused by:

• increased back pressure in the clean oil outlet,

• clogged disc stack.

Sight glass wiper (4)

Cleaning of the sight glass for separated water has to be done frequently.

The advantages of the wiper are:

• it is not necessary to stop the separator in order to be able to clean the glass.

• Oil contents in the water can be checked at a glance.

• poor performance of the separator can be checked; i.e. no water separated out.

21

3.2 Design and function 3 Separator Basics

G05

484

21

Reset push button on vibration switch

Back pressure gauge (5)

Correct limits for the back pressure in the clean oil outlet can be found in chapter ‘‘8.2.2 Connection list” on page 183.

Increasing back pressure in the clean oil outlet can be caused by:

• restriction in the outlet piping, e.g. a buckled or bent pipe,

• increased throughput,

• increased viscosity, decreased separating temperature.

Vibration switch (6, option)

The vibration switch, properly adjusted, trips on a relative increase in vibration.

The vibration switch is sensitive to vibration in a direction perpendicular to its base. It contains a vibration detecting mechanism that actuates a snap-action switch when the selected level of vibration is exceeded. After the switch has tripped it must be reset manually by pressing the button on the switch.

Cover interlocking switch (7, option)

When provided, the cover interlocking switch should be connected to the starter equipment so that starting of the motor is prevented when the separator hood is not (completely) closed.

22

3 Separator Basics 3.2 Design and function

G05

802

11

Separator bowl, feed and discharge assembly, control paring disc and liquid flow.Non-rotating parts are indicated by black shading.

3.2.4 Process main parts

1. Upper paring camber2. Flow control disc3. Oil paring chamber4. Small lock ring (with paring chamber cover)5. Level ring6. Distributor7. Top disc8. Bowl hood9. Bowl disc stack10. Large lock ring11. Sludge port *12. Sludge space13. Bowl body14. Operating slide *15. Nozzle *16. Nozzle *17. Dosing ring *18. Sliding bowl bottom *19. Spring *20. Upper paring disc21. Oil paring disc22. Inlet pipe23. Distributing cone24. Bowl hood seal ring *25. Drain valve plug *26. Opening chamber *27. Closing chamber *28. Control paring disc *29. Spring support *

201. Unseparated oil inlet206. Displacement/conditioning water inlet220. Clean oil outlet221. Water outlet372. Opening water inlet *376. Closing and make-up water inlet *

*Parts effecting a sludge discharge

23

3.2 Design and function 3 Separator Basics

Inlet and outlet device

The inlet and outlet device consists of the following parts:

• The inlet (201). This comprises the pipe bend and the long inlet pipe (22) which extends into the middle of the bowl.

• The outlets (220, 221). These comprise the discharge cover and the paring discs (20, 21) which pump the separated oil and water out of the bowl. Each paring disc is located in a paring chamber (1, 3) in the top of the bowl.

The inlet and outlet device is held together by the inlet pipe threading which is fixed to the oil paring disc. O-rings and a seal ring seal the connections between the parts.

The outlet connection housing is fastened to the separator frame hood. Height adjusting rings determine the height position of the paring discs in the paring chambers.

Separator bowl

The separator bowl with its sludge discharge mechanism is built-up as follows:

The bowl body (13) and bowl hood (8) are held together by the large lock ring (10). Inside the bowl are the distributing cone (23), the distributor (6) and the disc stack (9). The disc stack is kept compressed by the hood. The sliding bowl bottom (18) forms an internal separate bottom in the bowl.

The bowl top is covered by the paring chamber cover (4). The space between this cover and the top disc (7) is the upper paring chamber with the upper paring disc which pumps the separated water out of the bowl. The oil paring chamber with its paring disc is located inside the upper part of the top disc. From this space the cleaned oil is pumped out of the bowl.

The sludge space (12) is the space between the sliding bowl bottom and the bowl hood in the bowl periphery. It is kept closed by the sliding bowl bottom which seals against a seal ring (24) in the bowl hood.

24

3 Separator Basics 3.2 Design and function

Sludge discharge mechanism

At intervals decided by the operator, the sliding bowl bottom drops to empty the bowl of sludge.

The sludge discharge mechanism, which controls the sliding bowl bottom, comprises an operating slide (14) and an operating water device. Passive parts are the dosing ring (17), nozzles (15, 16) and drain valve plugs (25). The operating water device on the underside of the bowl supplies opening (372) and closing/make-up (376) water to the discharge mechanism via the control paring disc (28).

25

3.2 Design and function 3 Separator Basics

G05

804

11

Separating principle

1. Water drain valve2. Upper paring disc3. Flow control disc4. Oil paring disc5. Level ring6. Inlet pipe7. Distributor8. Bowl disc stack9. Top disc10. Bowl hood11. Sludge port12. Sludge space

201. Unseparated oil inlet206. Displacement/conditioning water inlet220. Clean oil outlet221. Water outlet

3.2.5 Separating function

Unseparated oil is fed into the bowl through the inlet pipe (6) and is pumped via the distributor (7) towards the periphery of the bowl.

When the oil reaches slots in the base of the distributor, it will rise through the channels formed by the disc stack (8) where it is evenly distributed.

The oil is continuously cleaned as it travels towards the center of the bowl. When the cleaned oil leaves the disc stack it rises upwards, flows over the level ring (5) and enters the oil paring chamber. From the latter it is pumped by the oil paring disc (4) and leaves the bowl through outlet (220). Separated water, sludge and solid particles, which are heavier than the oil, are forced towards the periphery of the bowl and collected in the sludge space (12).

The space between bowl hood (10) and top disc (9) and also the upper paring chamber are filled with oil, which is distributed over the entire circumference via the groove in the top disc.

During normal operation, the outlet for the upper paring disc (2) is closed by the water drain valve (1).

26

3 Separator Basics 3.2 Design and function

3.2.6 Sludge discharge cycle

When the sludge space is filled up and water approaches the disc stack, some droplets of water start to escape with the cleaned oil. The small increase of the water content in the cleaned oil must be detected and initiate a short opening of the water drain valve or initiate a sludge discharge cycle.

The separator discharges a fixed volume of sludge and water. The discharge volume is approximately 70% of the space outside the disc stack, the so-called the sludge space. The contents of the discharge may contain some emulsified oil.

27

3.2 Design and function 3 Separator Basics

G05

8051

1

Separator bowl, feed and discharge assembly, control paring disc and liquid flow

1. Sludge port2. Operating slide *3. Nozzle *4. Nozzle *5. Dosing ring *6. Sliding bowl bottom *7. Spring *8. Closing water space9. Drain channel10. Drain valve plug11. Opening chamber *12. Closing chamber *

372. Opening water inlet *376. Closing and make-up water inlet *

* Parts effecting a sludge discharge

Closed bowl (normal operation)

The sliding bowl bottom (6) is pressed upwards by force of the closing water in the closing water space (8) under the sliding bowl bottom which is greater than the force of the process liquid above the sliding bowl bottom.

The operating slide (2) is pressed upwards by the springs (7) and the valve plugs (10) then cover the drain channels (9).

Bowl opens for discharge

The opening water (372), which is supplied into the space above the operating slide (2), overcomes the force from the springs (7) and the operating slide is pressed downwards. The drain channels (9) open and the closing water drains out through the nozzle (3). This allows the force on the underside of the sliding bowl bottom (6) to become lower than the force on the upper side. The sliding bowl bottom moves downwards and the bowl opens for a discharge through the sludge ports (1).

Bowl closes after discharge

After some hundreds of a second the opening chamber (11) above the operating slide (2) has been filled by water leaving the closing water space (8). This water overflows through channels in the operating slide down to the closing chamber (12) between the operating slide and dosing ring (5). When this chamber has been filled, the hydraulic forces directed up- and downwards on the operating slide are equal and the springs (7) move the operating slide upwards.

The drain channels (9) are closed by the drain valve plugs (10) and the increasing force from the closing water (376) presses the sliding bowl bottom (6) upwards. The bowl closes and the sludge discharge cycle is complete.

Bowl closing water is supplied during the sludge discharge sequence and at intervals during the separation sequence to replace evaporated water.

Closing and opening water are supplied from the high pressure water system.

28

3 Separator Basics 3.3 Definitions

tor outlet.

n with the intention of separating ds, from a liquid (oil) having a lower les.

Expressed in kg/m3 at a specified at +15 °C.

for positioning the interface between outer edge of the top disc. This disc mode.

n the heavy phase (water) and the parator bowl.

bowl, inlet/outlet and operating water als in bowl inlet/outlet and operating

ete separator, including bottom part in an Intermediate Service, if any).

bearings in bottom part.

aration with the intention of xed and mutually insoluble liquid sities. Solids having a higher density removed at the same time. The il), which is the major part of the ed as far as possible.

a liquid.

the separator bowl.

uid to the separator per unit time. it/h.

st movement. Normally expressed in /s), at a specified temperature.

ce of the separator bowl to prevent m leaving the bowl through the heavy purifier mode.

3.3 DefinitionsBack pressure Pressure in the separa

Clarification Liquid/solids separatioparticles, normally solidensity than the partic

Counter pressure See Back pressure.

Density Mass per unit volume.temperature, normally

Gravity disc Disc in the bowl hood the disc stack and the is only used in purifier

Interface Boundary layer betweelight phase (oil) in a se

Intermediate Service (IS) Overhaul of separator device. Renewal of sewater device.

Major Service (MS) Overhaul of the compl(and activities includedRenewal of seals and

Purification Liquid/liquid/solids sepseparating two intermiphases of different denthan the liquids can belighter liquid phase (omixture, shall be purifi

Sediment (sludge) Solids separated from

Sludge discharge Ejection of sludge from

Throughput The feed of process liqExpressed in m3/h or l

Viscosity Fluid resistance againcentistoke (cSt = mm2

Water seal Water in the solids spathe light phase (oil) frophase (water) outlet, in

29

3.3 Definitions 3 Separator Basics

30

4 Operating Instructions

Contents

4.1 Operating routine 32

4.1.1 Ready for start 32

4.1.2 Start 33

4.1.3 Running 34

4.1.4 Normal stop 35

4.1.5 Safety stop 36

31

4.1 Operating routine 4 Operating Instructions

S0

0098

21

Check for leakages (not admitted)

G0

2620

11

Check the oil level

4.1 Operating routineThese operating instructions are related only to the separator itself. If the separator is a part of a system or module follow also the instructions for the system.

4.1.1 Ready for start

To achieve the best separation results the bowl should be in a clean condition.

1. Check that the bolts of the frame hood are fully tightened.

2. Check that all inlet and outlet connections have been correctly made and properly tightened.

3. Check that the oil level is exactly in the middle of the sight glass.

Fill if necessary. See chapter ‘‘8.4 Lubricants” on page 190, for a list of recommended oils.

CAUTION

Burn hazards

Make sure that hose connections and flange couplings are properly assembled and tightened.

Escaping hot liquid can cause burns.

NOTE

During running the oil level should be slightly below the middle of the sight glass.

Too much or too little oil may damage the bearings.

32

4 Operating Instructions 4.1 Operating routine

G05

2011

1

Release the brake

G0

246

211

Check for correct direction of rotation

S00

556

11

Check for vibration

4. Make sure that the brake is released.

4.1.2 Start

1. Start the separator.

2. Check the direction of rotation of the bowl. The revolution counter should turn clockwise.

3. Check the separator for vibration. Some vibration can occur for short periods during the starting cycle, when the separator passes through its critical speeds. This is normal and passes without danger. Try to learn the vibration characteristics of the critical speed pattern.

In the trouble-tracing chapter ‘‘7.1.1 Separator vibrates” on page 168, a number of causes are described that can create vibration.

DANGER

Disintegration hazards

When power cables have been connected, always check direction of rotation. If incorrect, vital rotating parts could unscrew.

DANGER

Disintegration hazards

When excessive vibration occurs, keep bowl filled and stop separator.

The cause of the vibration must be identified and rectified before the separator is restarted. Excessive vibration may be due to incorrect assembly or insufficient cleaning of the bowl.

33

4.1 Operating routine 4 Operating Instructions

S0

009

621

Current increases when the coupling engages…

S00

0963

1

… to decrease to a stable value when full speed has been reached

4. Check, if possible, the current drawn by of the motor starter to ensure that the separator has reached full speed.

At full speed the starter ammeter reading has decreased from a high starting value to a low steady value.

The time to reach full speed may not exceed the limit given in chapter ‘‘8.1 Technical data” on page 179.

5. When running normally, open the closing water valve (connection 376) for approximately 5 seconds to close the bowl.

4.1.3 Running

1. Check that the feed has the correct flow and temperature. See chapter ‘‘8 Technical Reference” on page 177 for correct values.

2. Adjust the oil outlet pressure to 1,5 bar.

3. Discharge by opening the valve for opening water (connection 372) until a discharge is heard. For max. and min. time for discharge intervals, see chapter ‘‘8 Technical Reference” on page 177.

4. For daily condition checks, see ‘‘5.2.1 Daily checks” on page 43.

DANGER

Disintegration hazards

Ensure that correct discharge intervals and cleaning procedures are used.

Unbalance due to improper washing out of solids may lead to contact between rotating and non-rotating parts.

34

4 Operating Instructions 4.1 Operating routine

G0

520

121

The final action, apply the brake

4.1.4 Normal stop

1. Carry out a sludge discharge before stopping the separator. Otherwise the bowl must be cleaned manually before the next start up.

The volume of the discharged sludge must be compensated for by additional feed.

2. After discharge, turn off the feed and stop the separator with the bowl filled with liquid.

3. Apply the brake.

35

4.1 Operating routine 4 Operating Instructions

S00

5111

1

The separator must not be dismantled until standstill

S0

0099

11

Push the safety stop if excessive vibration

4.1.5 Safety stop

1. If the separator begins to vibrate excessively during operation, stop it immediately by pushing the safety stop; the separator motor is switched off.

Keep the bowl filled during the run-down to minimize excessive vibration.

2. Evacuate the room. The separator may be hazardous when passing its critical speeds during the run-down.

DANGER

Entrapment hazards

Make sure that rotating parts have come to a complete standstill before starting any dismantling work. The revolution counter and the motor fan indicate if the separator parts are rotating or not.

DANGER

Disintegration hazards

Do not discharge a vibrating separator.

Out-of-balance vibration can become worse if only part of the sediment is discharged.

CAUTION

Disintegration hazards

After a safety stop the cause of the fault must be identified.

If all parts have been checked and the cause remains unclear, contact Alfa Laval for advice.

36

5 Service Instructions

Contents

5.1 Periodic maintenance 39

5.1.1 Introduction 39

5.1.2 Maintenance intervals 39

5.1.3 Maintenance procedure 41

5.1.4 Service kits 42

5.2 Maintenance Logs 43

5.2.1 Daily checks 43

5.2.2 Oil change 43

5.2.3 Intermediate Service (IS) 44

5.2.4 Major Service (MS) 46

5.2.5 3-year Service (3S) 49

5.3 Check points at Intermediate Service (IS) 50

5.3.1 Bowl hood seal ring 50

5.3.2 Bowl spindle cone and bowl bodynave 51

5.3.3 Corrosion 51

5.3.4 Cracks 54

5.3.5 Disc stack pressure 55

5.3.6 Dosing ring 57

5.3.7 Erosion 57

5.3.8 Guide surfaces 59

5.3.9 Inlet pipe and oil paring disc 61

5.3.10 Level ring 61

5.3.11 Lock ring; wear and damage 62

5.3.12 Operating mechanism 63

5.3.13 Operating slide 64

5.3.14 Sliding bowl bottom 64

5.3.15 Springs for operating mechanism 65

5.3.16 Worm wheel and worm; wear of teeth65

5.3.17 Cover interlocking switch (option) 66

5.3.18 Vibration switch (option) 66

5.4 Check points at Major Service (MS) 67

5.4.1 Bowl hood seal ring 67

5.4.2 Bowl spindle cone and bowl body nave 67

5.4.3 Bowl spindle; height position 67

5.4.4 Bowl spindle; radial wobble 68

5.4.5 Brake 68

5.4.6 Buffer springs and ball bearing housing 69

5.4.7 Coupling friction pads 71

5.4.8 Corrosion 72

5.4.9 Cracks 72

5.4.10 Disc stack pressure 72

5.4.11 Dosing ring 72

5.4.12 Erosion 72

5.4.13 Flexible plate in coupling 73

5.4.14 Guide surfaces 74

5.4.15 Inlet pipe and oil paring disc 74

5.4.16 Level ring 75

5.4.17 Lock ring; priming 75

5.4.18 Lock ring; wear and damage 77

5.4.19 Oil paring disc; height position 77

5.4.20 Operating mechanism 77

5.4.21 Operating paring disc; height position78

5.4.22 Operating slide 78

5.4.23 Sliding bowl bottom 78

5.4.24 Springs for operating mechanism 79

5.4.25 Worm; wear of groove 79

5.4.26 Worm wheel and worm; wear of teeth79

5.4.27 Worm wheel shaft; radial wobble 80

5.4.28 Cover interlocking switch (option) 80

5.4.29 Vibration switch (option) 80

37

5 Service Instructions

5.5 Lifting instructions 81

5.6 Cleaning 83

5.6.1 External cleaning 83

5.6.2 Cleaning agents 84

5.6.3 Cleaning of bowl discs 85

5.6.4 CIP-system 86

5.7 When changing oil 87

5.7.1 Worm wheel and worm; wear of teeth87

5.7.2 Oil change procedure 90

5.8 Vibration 91

5.8.1 Vibration analysis 91

5.8.2 Vibration switch (option) 92

5.9 Common maintenance directions 93

5.9.1 Ball and roller bearings 93

5.9.2 Before shutdowns 96

38

5 Service Instructions 5.1 Periodic maintenance

5.1 Periodic maintenance

5.1.1 Introduction

Periodic (preventive) maintenance reduces the risk of unexpected stoppages and breakdowns. Follow the maintenance logs on the following pages in order to facilitate the periodic maintenance.

5.1.2 Maintenance intervals

The following directions for periodic maintenance give a brief description of which parts to be cleaned, checked and renewed at different maintenance intervals.

The maintenance logs for each maintenance interval later in this chapter give detailed enumeration of the check points that must be done.

Daily checks consist of minor check points to carry out for detecting abnormal operating conditions.

Oil change

The oil change interval is every 1000-1500 hours or at least once every year if the total number of operating hours is less than 1000-1500 hours .

When using a group D oil, time of operation between oil changes can be extended from the normal 1000-1500 hours to 2000 hours .

DANGER

Disintegration hazards

Separator parts that are either worn beyond their safe limits or incorrectly assembled may cause severe damage or fatal injury.

39

5.1 Periodic maintenance 5 Service Instructions

e schedule

3rd year

MS

S IS IS IS

3S

Intermediate Service (IS)

Intermediate Service consists of an overhaul of the separator bowl, inlet/outlet and operating device every 3 months or 2000 operating hours . Seals in bowl and gaskets in inlet/outlet device are renewed.

Major Service (MS)

Major Service consists of an overhaul of the complete separator and includes an Intermediate Service every 12 months or 8000 operating hours . Seals and bearings in the bottom part are renewed.

3-year Service (3S)

3-year Service consists of renewing the frame feet. The feet get harder with increased use and age. Intermediate and Major services are also carried out.

2nd year

Oil change

Intermediate Service = IS

Major Service = MS

Periodic maintenanc

Installation 1st year

MS MS

IS IS IS IS IS IS IS IS I

3-year Service = 3S

40

5 Service Instructions 5.1 Periodic maintenance

5.1.3 Maintenance procedure

At each Intermediate and Major Service, take a copy of the maintenance log and use it for notations during the service.

An Intermediate and Major Service should be carried out in the following manner:

1. Dismantle the parts as mentioned in the maintenance log and described in chapter ‘‘6 Dismantling/Assembly” on page 97.

Place the separator parts on clean, soft surfaces such as pallets.

2. Inspect and clean the dismantled separator parts according to the maintenance log.

3. Fit all the parts delivered in the service kit while assembling the separator as described in chapter ‘‘6 Dismantling/Assembly” on page 97. The assembly instructions have references to check points which should be carried out before and during the assembly.

41

5.1 Periodic maintenance 5 Service Instructions

S0

021

021

Kits are available for Intermediate Service, Major Service and for servicing the frame feet

5.1.4 Service kits

Special service kits are available for Intermediate Service (IS) and Major Service (MS), as well as for servicing the frame feet (3S).

For other services the spare parts have to be ordered separately.

Note that the parts for IS are not included in the MS kit.

The contents of the service kits are described in the Spare Parts Catalogue.

NOTE

Always use Alfa Laval genuine parts as otherwise the warranty will become invalid.

Alfa Laval takes no responsibility for the safe operation of the equipment if non-genuine spare parts are used.

DANGER

Disintegration hazards

Use of imitation parts may cause severe damage.

42

5 Service Instructions 5.2 Maintenance Logs

5.2 Maintenance Logs

5.2.1 Daily checks

The following steps should be carried out daily.

5.2.2 Oil change

The oil change and check of worm gear should be carried out every 1000-1500a) hours of operation.

Note: In a new installation, or after replacement of gear, change the oil and clean the gear housing after 200 operating hours .

When the separator is running for short periods, the lubricating oil must be changed every 12 months even if the total number of operating hours is less than 1000-1500 hours (2000 h) .

a) When using a group D oil, time of operation between oil changes can be extended from the normal 1000-1500 hours to 2000 hours .

b) See chapter ‘‘8.4 Lubricants” on page 190 for further information.

1) See manufacturer’s instruction

Main component and activity Part Page Notes

Inlet and outlet

Check for leakage Connecting housing –

Separator bowl

Check for vibration and noise 91

Horizontal driving device

Worm wheel shaft and gear casing

Check for vibration and noise 91

Check Oil level in gear housing 32

Electrical motor

Check for heat, vibration and noise 1)

Main component and activity Part Page Notes

Horizontal driving device

Worm wheel shaft and gear housing

Check Worm wheel and worm 87

Renew Oilb) in gear housing 90

43

5.2 Maintenance Logs 5 Service Instructions

5.2.3 Intermediate Service (IS)

Name of plant: Local identification:

Separator: FOPX 609TFD-24 Manufacture No./Year:

Total running hours: Product No: 881244-02-03

Date: Signature:

Main component and activity Part Page Notes

Inlet and outlet

Clean and inspect Threads of inlet pipe 61

Connecting housing –

Separator bowl

Clean and check Upper paring disc –

Flow control disc –

Lock ring 62

Bowl hood 50

Top disc –

Oil paring disc 61

Level ring 61

Bowl discs 85

Distributor –

Distributing cone –

Sliding bowl bottom 64

Bowl body –

Bowl spindle cone and bowl body nave

51

Operating mechanism 57, 6364, 65

44

5 Service Instructions 5.2 Maintenance Logs

51

54

57

guide surface 60

pressure 55

d sealings —

paring disc –

—

el and worm 87

housing 90

n motor –

el on hood 203

f rotation arrow 204

ply frequency 179

witch 66

rlocking switch 66

Page Notes

Note: Renew all parts included in the Intermediate Service kit (IS).

Check Corrosion

Cracks

Erosion

Galling of

Disc stack

Renew O-rings an

Operating device

Clean and check Operating

Renew O-rings

Horizontal driving device

Worm wheel shaft and gear housing

Check Worm whe

Renew Oil in gear

Electrical motor

Lubrication (if nipples are fitted) See sign o

Signs and labels on separator

Check attachment and legibility Safety lab

Direction o

Power sup

Monitoring equipment (option)

Function check Vibration s

Cover inte

Main component and activity Part

45

5.2 Maintenance Logs 5 Service Instructions

5.2.4 Major Service (MS)

Name of plant: Local identification:

Separator: FOPX 609TFD-24 Manufacture No./Year:

Total running hours: Product No: 881244-02-03

Date: Signature:

Main component and activity Part Page Notes

Inlet and outlet

Clean and inspect Threads of inlet pipe 61

Connecting housing –

Separator bowl

Clean and check Upper paring disc –

Flow control disc –

Lock ring 75, 62

Bowl hood 50

Top disc –

Oil paring disc 61

Level ring 61

Bowl discs 85

Distributor –

Distributing cone –

Sliding bowl bottom 64

Bowl body –

Bowl spindle cone and bowl body nave

51

Operating mechanism 57, 6363, 65

46

5 Service Instructions 5.2 Maintenance Logs

51

54

57

guide surface 60

pressure 55

sition of oil paring 77

d sealings —

paring disc –

sition of operating c

77

—

dle –

roove in worm 79

ings and ball bearing 69

sition of bowl spindle 67

bble of bowl spindle 68

o-rings and sealings 140

arings and o-rings 140

el and worm 87

bble of worm wheel 80

of flexible plate 73

o-rings and sealings 154

housing 90

d brake shoe 68

Page Notes

Check Corrosion

Cracks

Erosion

Galling of

Disc stack

Height podisc

Renew O-rings an

Operating device

Clean and check Operating

Check Height poparing dis

Renew O-rings

Vertical driving device

Clean and check Bowl spin

Wear of g

Buffer sprhousing

Height po

Radial wo

Renew Bearings,

Renew Spindle be

Horizontal driving device

Worm wheel shaft and gear housing

Check Worm whe

Radial woshaft

Axial play

Renew Bearings,

Renew Oil in gear

Brake

Clean and check Spring an

Main component and activity Part

47

5.2 Maintenance Logs 5 Service Instructions

el coupling –

ds 71

n motor –

el on hood 203

f rotation arrow 204

ply frequency 179

witch 66

rlocking switch 66

Page Notes

Note: Renew all parts included in the Intermediate Service kit (IS) and Major Service kit (MS)

Friction coupling

Clean and check Worm whe

Renew (if necessary) Friction pa

Electrical motor

Lubrication (if nipples are fitted) See sign o

Signs and labels on separator

Check attachment and legibility Safety lab

Direction o

Power sup

Monitoring equipment (option)

Function check Vibration s

Cover inte

Main component and activity Part

48

5 Service Instructions 5.2 Maintenance Logs

G02

5891

1

1. Vibration damper, upper2. Vibration damper, lower3. Nut4. Lock nut

G02

5891

1

5.2.5 3-year Service (3S)

The 3-year service should be carried out in conjunction with a Major Service (MS). The extent of the 3-year service is the same as for a major service plus renewing of parts included in the 3-year Service kit (3S).

Frame feet, renewal

1. Disconnect pipes, hoses and cables connected to the separator.

2. Remove the nuts (3, 4).

3. Lift the separator.

4. Renew the vibration dampers (1, 2).

5. Lower the frame. Check that the bolts do not press against the edges of the holes.

6. Tighten the nut (3) to 20 Nm.

7. Hold the nut (3) firmly and secure with the lock nut (4).

8. Connect the previously disconnected pipes, hoses and cables.

NOTE

When lifting a separator it must always hang securely . See separate instruction in chapter ‘‘5.5 Lifting instructions” on page 81.

49

5.3 Check points at Intermediate Service (IS) 5 Service Instructions

G0

2062

11

Max. permitted indentation of the seal ring is 1 mm

G0

2062

11G

0206

311

G02

0631

1

Removal of the seal ring

G0

206

411

Fitting of the seal ring

G0

206

411

5.3 Check points at Intermediate Service (IS)

5.3.1 Bowl hood seal ring

Poor sealing between the bowl hood seal ring and the sealing edge of the sliding bowl bottom will cause a leakage of process liquid from the bowl.

Renew the bowl hood seal ring at each Intermediate Service (IS).

Knock out the old ring by means of a pin inserted in the holes intended for this purpose.

Fit the new ring as follows:

Press the ring into the groove with a straight wooden board placed across the ring..

NOTE

If the new ring is too narrow, place it in hot water (70-80 °C) for about 5 minutes.

If it is too wide, it will shrink after drying at 80-90 °C for about 24 hours.

50

5 Service Instructions 5.3 Check points at Intermediate Service (IS)

G05

4791

1

Remove impact marks from the nave and cone

G05

4791

1G

0206

111

Main bowl parts to check for corrosion

G02

0611

1

5.3.2 Bowl spindle cone and bowl body nave

Impact marks on the spindle cone or in the bowl body nave may cause poor fit and out-of-balance vibrations.

The bowl spindle and the nave should also be checked if the bowl spindle has been dismantled or if the bowl runs roughly.

Corrosion may cause the bowl to stick firmly to the spindle cone and cause difficulties during the next dismantling.

• Remove any impact marks with a scraper and/or whetstone.

Rust can be removed by using a fine-grain emery cloth (e.g. No. 320).

Finish with polishing paper (e.g. No. 600).

5.3.3 Corrosion

Evidence of corrosion attack should be looked for and rectified each time the separator is dismantled. Main bowl parts such as the bowl body, bowl hood and lock ring must be inspected with particular care for corrosion damage.

NOTE

Always use a scraper with great care. The cone shape must not be deformed.

DANGER

Disintegration hazard

Inspect regularly for corrosion damage. Inspect frequently if the process liquid is corrosive.

51

5.3 Check points at Intermediate Service (IS) 5 Service Instructions

S00

2061

1S

0020

611

Example of chloride corrosion in stainless steel

Always contact your Alfa Laval representative if you suspect that the largest depth of the corrosion damage exceeds 1,0 mm or if cracks have been found. Do not continue to use the separator until it has been inspected and given clearance for operation by Alfa Laval.

Cracks or damage forming a line should be considered as being particularly hazardous.

Non-stainless steel and cast iron parts

Corrosion (rusting) can occur on unprotected surfaces of non-stainless steel and cast iron. Frame parts can corrode when exposed to an aggressive environment.

Stainless steel

Stainless steel parts corrode when in contact with either chlorides or acidic solutions. Acidic solutions cause general corrosion. The chloride corrosion is characterised by local damage such as pitting, grooves or cracks. The risk of chloride corrosion is higher if the surface is:

• Exposed to a stationary solution.

• In a crevice.

• Covered by deposits.

• Exposed to a solution that ofa low pH .

52

5 Service Instructions 5.3 Check points at Intermediate Service (IS)

S0

0205

11

Polish corrosion marks to prevent further damage

S0

0205

11

Corrosion damage caused by chlorides on stainless steel begins as small dark spots that can be difficult to detect.

1. Inspect closely for all types of damage by corrosion and record these observations carefully.

2. Polish dark-coloured spots and other corrosion marks with a fine grain emery cloth. This may prevent further damage.

Other metal parts

Separator parts made of materials other than steel, such as brass or other copper alloys, can also be damaged by corrosion when exposed to an aggressive environment. Possible corrosion damage can be in the form of pits and/or cracks.

DANGER

Disintegration hazard

Pits and spots forming a line may indicate cracks beneath the surface.

All forms of cracks are a potential danger and are totally unacceptable.

Renew the part if corrosion can be suspected of affecting its strength or function.

53

5.3 Check points at Intermediate Service (IS) 5 Service Instructions

5.3.4 Cracks

Cracks can initiate on the machine after a period of operation and propagate with time.

• Cracks often initiate in an area exposed to high cyclic material stresses. These are called fatigue cracks.

• Cracks can also initiate due to corrosion in an aggressive environment.

• Although very unlikely, cracks may also occur due to the low temperature embrittlement of certain materials.

The combination of an aggressive environment and cyclic stresses will speed-up the formation of cracks. Keeping the machine and its parts clean and free from deposits will help to prevent corrosion attacks.

It is particularly important to inspect for cracks in rotating parts and especially the pillars between the sludge ports in the bowl wall.

Always contact your Alfa Laval representative if you suspect that the largest depth of the damage exceeds 1,0 mm. Do not continue to use the separator until it has been inspected and cleared for operation by Alfa Laval.

DANGER

Disintegration hazard

All forms of cracks are potentially dangerous as they reduce the strength and functional ability of components.

Always replace a part if cracks are present.

54

5 Service Instructions 5.3 Check points at Intermediate Service (IS)

G0

544

411

1. Lock ring2. Bowl hood3. Bowl body4. Disc stack

G0

1358

11G

013

5811

φ-marks on bowl body and lock ring in line

5.3.5 Disc stack pressure

The lock ring (1) should press the bowl hood (2) firmly against the bowl body (3). The hood in turn should exert a pressure on the disc stack (4), clamping it in place.

Compress the disc stack by tightening the lock ring, see chapter ‘‘6.3.3 Assembly” on page 114.

Correct pressure is obtained when it is possible to tighten the lock ring so far by hand that theφ-mark on the lock ring is positioned 60° — 90° ahead of the mark on the bowl body.

To achieve this, add an appropriate number of discs to the top of the disc stack beneath the top disc.

Then advance the lock ring by giving the spanner handle some blows till the φ-marks are passed and the bowl is fully assembled.

If the φ-marks do not reach or pass each other, the reason could be an incorrectly assembled bowl or too many discs in the disc stack. Reassemble and check.

NOTE

Ensure that the disc stack pressure is sufficient to maintain bowl balance.

Insufficient pressure in the disc stack can cause vibration and reduce lifetime of ball bearings.

55

5.3 Check points at Intermediate Service (IS) 5 Service Instructions

G0

533

631

Measure of disc stack pressure with use of a compressing tool

G0

533

631

Complementary check using the compressing tool

With the large lock ring correctly tightened and the compressing tool mounted on the separator bowl, turn the lever to position 1 for compression.

Compress the disc stack by pumping the horizontal handle arm until the oil pressure is released through the relief valve.

Measure the height (H1) of the piston rod (see illustration) with the slide calliper depth gauge. Make a note of the reading obtained.

Release the pressure in the compressing tool by turning the lever to position 0. The piston rod will now move downwards slightly when the disc set is released inside the bowl.

Measure once again the height (H2) of the piston rod with the slide calliper and make a note of the reading obtained.

If the difference between H1 and H2 is less than 1,5 mm, the disc stack pressure is correct. If it exceeds 1,5 mm, the number of discs is insufficient. Add one or more discs and repeat the above procedure until the correct disc stack pressure is obtained.

NOTE

An insufficient number of discs will create an imbalance causing vibration.

56

5 Service Instructions 5.3 Check points at Intermediate Service (IS)

G05

370

21

1. Nozzles2. Surface inside the dosing ring3. Surface in contact with the operating slide

G05

370

21G

02

0522

1G

02

0522

1

Max. permitted erosion

5.3.6 Dosing ring

Clean the nozzles (1) with a soft iron wire and polish the surface (2) with steel wool.

Inspect the surface (3) in contact with the operating slide. Remove any marks with a whetstone or fine emery cloth (grain size 240).

5.3.7 Erosion

Erosion can occur when particles suspended in the process liquid flow along or strike against a surface. Erosion can become intensified locally by flows of higher velocity.

Always contact your Alfa Laval representative if the largest depth of any erosion damage exceeds 1,0 mm. Valuable information as to the nature of the damage can be recorded using photographs, plaster impressions or hammered-in lead.

Erosion is characterised by:

• Burnished traces on the material.

• Dents and pits having a granular and shiny surface.

DANGER

Disintegration hazard

Inspect regularly for erosion damage. Inspect frequently if the process liquid is erosive.

G0

8443

11

57

5.3 Check points at Intermediate Service (IS) 5 Service Instructions

G05

813

11

Surfaces particularly subjected to erosion

Surfaces particularly subjected to erosion are:

1. The upper paring disc.

2. The top disc.

3. The pillars between the sludge ports in the bowl wall.

4. The sealing edge of the sliding bowl bottom.

5. The underside of the distributor in the vicinity of the distribution holes and wings.

6. The surface of the sliding bowl bottom that faces the conical part of the distributor.

7. The sealing edge of the bowl body for the seal ring in the sliding bowl bottom.

Look carefully for any signs of erosion damage. Erosion damage can deepen rapidly and consequently weaken parts by reducing the thickness of the metal.

DANGER

Disintegration hazard

Erosion damage can weaken parts by reducing the thickness of the metal.

Pay special attention to the pillars between the sludge ports in the bowl wall.

Renew the part if erosion can be suspected of affecting its strength or function.

58

5 Service Instructions 5.3 Check points at Intermediate Service (IS)

1, 2 = Alfa Laval lubricating paste or Molykote 1000 Paste.

G0

378

231

Sliding bowl bottom

G03

7825

1

Bowl body

G03

7827

1

Operating slide

G0

378

261

Dosing ring

5.3.8 Guide surfaces

Check surfaces indicated (1and 2) for burrs or galling. Rectify when necessary.

Repair of galling on guide surfaces; see following pages. Before fitting the sliding bowl bottom, clean (do not degrease) the contact surfaces (1). Apply Alfa Laval lubricating paste or Molykote 1000 Paste with a well-cleaned brush on surfaces (1 and 2).

Lubricate the O-ring and the seal ring with silicone grease making sure they are not damaged and lie properly in their grooves.

NOTE

To avoid the risk of galling, the contact surfaces (1) should be primed with a slide lacquer at every Major Service (MS).

The slide-lacquered surfaces will be destroyed if the surfaces are degreased.

59

5.3 Check points at Intermediate Service (IS) 5 Service Instructions

G0

2055

11

Guide surface in the bowl body

G02

0561

1G

0205

711

Repair of galling on guide surfaces

Galling (friction marks) may appear on guide surfaces in the operating system, the bowl body and the sliding bowl bottom. Surfaces subject to repair are indicated by an arrow.

The example below describes the repair of the lower guide surface of the bowl body nave.

Recommended tools for correction of galling:- Emery cloth, 240 grade.- Small power drill- Degreasing agent.- Fibre brush, ∅ 25mm.- Fibre brush, ∅ 50 mm.- Very fine single-cut file.

1. Clean the surface thoroughly with a degreasing agent, i.e. white spirit. This is important.

2. If the galling is excessive, first use the fine single-cut file. The file should be used with caution so that the damage is not made worse.

Remove the high spots on the surface. Do not use rotating files or similar. Remove the high spots only — not the undamaged material.

60

5 Service Instructions 5.3 Check points at Intermediate Service (IS)

G02

0581

1G

020

5911

G0

581

411

G0

581

411

Check the threads of the inlet pipe and oil paring disc

G05

346

11

Check the level ring for burrs

3. An emery cloth of 240 grade should be used to smooth the edges and to remove any burnt-in foreign matter.

4. Finish off by polishing the damaged spot with the fibre brushes and brush wax. It is recommended that the whole area where galling may occur is polished. Polishing will help smooth the whole of the damaged area, even in the deepest parts.

Prime the repaired area with lubricating spray Molykote 321 R. Read the correct procedure under checkpoint ‘‘5.4.17 Lock ring; priming” on page 75. Apply Alfa Laval lubricating paste or Molykote 1000 Paste to the surface after priming.

5.3.9 Inlet pipe and oil paring disc

Damage to the threads and the top surface of level ring may cause the paring disc to scrape against the paring chamber cover even if the height has been adjusted correctly.

Screw the inlet pipe into the paring disc and check that the inlet pipe turns easily.

5.3.10 Level ring

Remove any burrs on the surface of the level ring with a file as the paring disc rests on that surface during the height position check.

61

5.3 Check points at Intermediate Service (IS) 5 Service Instructions

G05

352

11G

0535

211

1. Lock ring2. O-ring for the bowl hood

A

(MAX 25 )G

057

8131

The φ-mark on the lock ring must not pass the φ-mark on the bowl body by more than 25°

5.3.11 Lock ring; wear and damage

Excessive wear or impact marks on threads, guide and contact surfaces of the lock ring, bowl hood and bowl body may cause hazardous galling.

Check the thread condition by tightening the lock ring (1) after removing the disc stack and bowl hood O-ring (2) from the bowl.

In a new bowl the alignment marks on the lock ring and the bowl body are exactly opposite each other.

If thread wear is observed, mark the lock ring at the new position of the alignment mark on the bowl body by punching in a new mark.

If the original φ−mark on the lock ring passes the φ−mark on the bowl body by more than 25° (which corresponds to A=100 mm, an Alfa Laval representative must be contacted immediately.

If the marks become illegible, an Alfa Laval representative should be contacted immediately to inspect thread wear and for determining the position of new alignment marks.

DANGER

Disintegration hazards

Wear on large lock ring thread must not exceed safety limit. The φ-mark on lock ring must not pass opposite φ-mark by more than the specified distance.

62

5 Service Instructions 5.3 Check points at Intermediate Service (IS)

G05

3723

1

Clean and check thread, contact and guide surfaces of the lock ring

G05

4711

1

1. Bowl body2. Valve plug3. Operating slide4. Nozzles5. Dosing ring

Damage

The position of the threads, contact and guide surfaces are indicated by arrows in the illustration.

Clean the threads, contact and guide surfaces with a suitable degreasing agent.

Check for burrs and protrusions caused by impact. Watch your fingers for sharp edges.

If damage is established, rectify using a whetstone or fine emery cloth (recommended grain size 240).

If the damage is considerable, use a fine single-cut file, followed by a whetstone.

5.3.12 Operating mechanism

Dirt and lime deposits in the operating mechanism may cause poor discharge function or no function at all.

Clean and polish surfaces with steel wool if necessary.

Reasons for dirt or deposits:

• Hard or unclean operating water. Change water supply or install a water softener or a fine filter.

• Sludge has been sucked down into bowl casing and into the operating system. Check the installation and the venting system of both the sludge tank and bowl casing drain.

G0

844

311

63

5.3 Check points at Intermediate Service (IS) 5 Service Instructions

G05

368

11

1. Bowl body sealing surfaces in contact with the valve plugs

2. Operating slide guide surface in contact with the dosing ring

G0

536

911

Tap in new valve plugsG

03

7994

1

Min. height of the profile on sliding bowl bottom

5.3.13 Operating slide

Poor sealing between the valve plugs on the operating slide and bowl body may prevent complete closing of the bowl.

Examine the sealing surfaces (1) of the bowl body in contact with the valve plugs. Remove any marks and lime deposits with a very fine grain emery cloth.

Check the guiding surface (2) in contact with the dosing ring. Remove any marks with a whetstone (grain size 240).

Remove all the valve plugs. Tap in the new plugs.

Correct height of plugs: 13,8 mm .

5.3.14 Sliding bowl bottom

Poor sealing between the bowl hood seal ring and the sealing edge of the sliding bowl bottom will cause a leakage of process liquid from the bowl

Check the sealing edge of the sliding bowl bottom. If damaged either through corrosion or erosion or other means, it can be rectified by turning in a lathe. Maximum permissible reduction of the original profile height (2,0 mm) is 0,5 mm.

NOTE

Never reduce the height outside the sealing edge to reach the minimum profile height.

64

G02

075

11

Removal of the seal ring in sliding bowl bottom using compressed air

G0

5361

11

Check for defective or broken springs

If the seal ring for the sliding bowl bottom is to be renewed, turn the sliding bowl bottom upside down and inject compressed air through the hole on the underside. This will press the ring outwards far enough to be gripped easily.

5.3.15 Springs for operating mechanism

Defective or broken springs may prevent complete closing of the bowl.

Renew those springs which differ from other springs in regard to length or are defective in other respects.

5.3.16 Worm wheel and worm; wear of teeth

Described in ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87 in this chapter.

WARNING

Risk for eye injury

Wear safety goggles.

65

G0

5481

11

Measurements for operation range of the cover interlocking switch button

G0

548

411

Vibration switch

5.3.17 Cover interlocking switch (option)

When the button is pushed, check that the brown and blue wires are short-circuited and the two black wires are open circuit.

Check also the reverse when the button not pressed.

See the illustration for exact measurement when the button is operated.

Contact closed

Contact open

BK Black

BN Brown

BU Blue

GN-YW Green-Yellow

5.3.18 Vibration switch (option)

Knock on the vibration switch cap a number of times within one second (the number is decided by the system parameter settings). If the switch functions correctly, the separator will perform a safety stop.

How to adjust the setpoint is described in chapter ‘‘5.8.2 Vibration switch (option)” on page 92.

NOTEBefore carrying out the function check described below, check that a safety stop will not cause serious interruption of the operation.

66

G05

4011

1

Measurement of the bowl spindle height (A)

5.4 Check points at Major Service (MS)

5.4.1 Bowl hood seal ring

Described in ‘‘5.3.1 Bowl hood seal ring” on page 50.

5.4.2 Bowl spindle cone and bowl body nave

Described in ‘‘5.3.2 Bowl spindle cone and bowl body nave” on page 51.

5.4.3 Bowl spindle; height position

If the bowl spindle has been removed, its height position relative to the frame ring must be checked.

• Place a steel rule across the frame ring. Measure the distance between the spindle top and the underside of the steel rule with a depth gauge or rule.

• The distance (A) should be 24 ±1 mm .

• The height position is adjusted by adding or removing height adjusting rings inside the bottom bearing housing.

NOTEBefore starting adjustment, tap the spindle top a few times with a soft hammer to ensure that the bottom bearing of the spindle is properly seated in the bottom bearing housing.

67

G01

915

21

Measurement of the radial wobble

G01

3411

1

Brake lining is fastened with screws

5.4.4 Bowl spindle; radial wobble

The bowl spindle wobble should be checked if the bowl spindle has been dismantled or if rough bowl running (vibration) occurs.

Check the wobble before mounting the bowl.

Before measuring, make sure that the buffer plugs are properly tightened.

• Fit a dial indicator in a support and fasten it to the frame.

• Remove the brake cover to get access to the coupling drum. Use the coupling drum to revolve the spindle manually.

• Measure the wobble at the top of the tapered end of the spindle. Permissible radial wobble is maximum 0,04 mm .

• If wobble is too large, renew all the ball bearings on the spindle.

Measure wobble after assembly. If it is still excessive, the spindle is probably damaged and must be renewed

5.4.5 Brake

A worn or oily friction pad will lengthen the braking period.

If the friction pad is worn:

• Remove the screws and exchange the friction pad.

NOTE

Spindle wobble will cause rough bowl running. This leads to vibration and reduces lifetime of ball bearings.

NOTE

The screws are slotted at both ends.

68

G01

3421

1

Actions when the friction pad is oily

G01

343

11

1. Contact surface on the brake shoe for the spring2. Guide surface in the cap for the brake shoe3. Spring

G0

537

711

Sectional view of ball bearing housing

f the friction pad is oily:

• Clean the friction pad and the coupling drum with a suitable degreasing agent.

• Roughen the friction surface of the friction pad with a coarse file.

Checking of spring and brake shoe:

Rust on brake parts may cause the brake to jam.

• Remove any rust from the surface (1) of the brake shoe and the corresponding guide surface in the cap (2).

• Rub in Molykote Paste on the surfaces.

• Rennewplace the spring (3) if it has become weak. This is indicated by chattering of the spring when the brake is in released position.

• Oil the spring when assembling.

5.4.6 Buffer springs and ball bearing housing

Weakened or broken buffer springs or defective contact surfaces for the buffers on the ball bearing housing may give rise to separator vibration (rough bowl running).

NOTE

Identify the cause of oily friction pad. If oil is leaking from the gear housing, renew the sealing ring between the two parts.

69

G0

5378

11

1. Ball bearing housing2. Radial buffer3. Buffer spring4. Screw plug

G0

2836

11

Max. permitted indentations made by radial buffers

Top bearing springs

In case of spring failure, the complete set of springs should be renewed, even if only one spring is affected.

Ball bearing housing

Examine the contact surface for the buffers on the ball bearing housing. In case of defects (indentations deeper than 0,5 mm ), renew the housing as well as buffers and springs.

70

G06

3021

1

Location of coupling friction blocks

G0

6303

11

A friction block is fixed with screw, spring washer and holding bracket

G06

304

11

Unscrew the holding bracket screws to remove the friction blocks

G0

630

511

Three screws fix the friction pad to the friction block

5.4.7 Coupling friction pads

Worn or oily pads in the coupling will cause a long acceleration period.

If the separator does not attain full speed within about 10 minutes or if the bowl loses speed during operation, the friction pads of the coupling may be worn or oily.

Check the pads. If the pads are oily:

• Clean the pads and the inside of the coupling drum with a suitable degreasing agent. Roughen the friction surfaces of the pads with a coarse file.

If the pads are worn:

• Remove the screws and renew the pads.

How to renew friction pads without dismantling horizontal driving device:

• Remove the brake cap.

• Undo the screws of the holding brackets.

• Remove the holding brackets and friction blocks.

• Remove the screws and renew the pads.

NOTE

The screws are slotted at both ends.

Renew all pads even if only one is worn.

71

A

G0

603

011

Dimension A is different for 50 and 60 Hz installations

Different friction blocks for different power supply frequencies

If fitting new friction blocks, check that the blocks are correct for the power supply frequency. The dimension A is different for 50 and 60 Hz separators.

50 Hz: A = 20 mm

60 Hz: A = 5,5 mm

The thickness does not include the friction pad.

5.4.8 Corrosion

Described in ‘‘5.3.3 Corrosion” on page 51.

5.4.9 Cracks

Described in ‘‘5.3.4 Cracks” on page 54.

5.4.10 Disc stack pressure

Described in ‘‘5.3.5 Disc stack pressure” on page 55.

5.4.11 Dosing ring

Described in ‘‘5.3.6 Dosing ring” on page 57.

5.4.12 Erosion

Described in ‘‘5.3.7 Erosion” on page 57.

72

G0

5382

21

Location of the axial play (1) in the flexible coupling

G0

5383

21

Measurement of distance for coupling in separator

G0

538

411

Measurement of distance for coupling on motor

5.4.13 Flexible plate in coupling

The axial play (1) of the flexible plate should be approximately 2 mm.

Check the play as follows:

Measure the distance from the frame ring to the coupling disc of the separator.

Measure the distance from the motor coupling disc to the motor flange.

X mm — Y mm = 2 mm .

If required, adjust the position of the motor coupling disc.

73

G0

378

231

Sliding bowl bottom

G0

3782

41

Bowl body

At major service

Alfa Laval lubricating paste or Molykote 1000 Paste

Slide lacquer(Molykote D 321R) Paste

5.4.14 Guide surfaces

Check surfaces indicated (1) for burrs or galling. Rectify when necessary.

Repair of galling on guiding surfaces, see ‘‘5.3.8 Guide surfaces” on page 59.

Treat the guide surfaces with slide lacquer in the following way:

1. Mask the nave hole of the bowl body. Slide lacquer must not enter this hole.

2. Carefully degrease the contact surfaces (1) between the sliding bowl bottom and bowl body. Dry the surfaces well.

3. Apply slide lacquer Molykote D321R with a well cleaned brush. Protect the surfaces which should not be treated.

4. Air-cure the treated surfaces for 15 minutes.

5. Use a smooth fibre brush to polish to an even, homogeneous contact film.

6. Apply slide lacquer a second time.

7. Air-cure the lacquer for a further 15 minutes.

8. Polish the film to a shiny surface. The film should look like well-polished leather when properly finished.

9. Finish the treatment by lubricating the contact surfaces (A) with Alfa Laval lubricating paste or Molykote 1000 Paste. Use a well-cleaned brush. Rub it into the surface, do not leave any excess paste.

10. Lubricate the O-ring and the seal ring with silicone grease and check that they rest properly in their grooves.

5.4.15 Inlet pipe and oil paring disc

Described in ‘‘5.3.9 Inlet pipe and oil paring disc” on page 61.

74

G05

812

11

Threads, guide and contact surfaces to be primed

G02

069

11G

020

701

1

5.4.16 Level ring

Described in section ‘‘5.3.10 Level ring” on page 61.

5.4.17 Lock ring; priming

The arrows indicate positions of threads, guide and contact surfaces to be primed.

Recommended agents for priming procedure:

• Degreasing agent

• Lubricating spray Molykote 321 R

• Small power drill

• 2 fibre brushes

1. Clean the lock ring thoroughly with a degreasing agent and wipe it off.

2. Spray the threads, guide and contact surfaces with slide lacquer Molykote 321 R. Let the lacquer air-cure for about 15 minutes.

75

G0

2073

11G

020

721

1G

0207

311

3. Use a fibre brush to polish the slide lacquer into the surface. The black spray will look like well-polished leather when properly finished.

4. Spray the lock ring a second time and let it dry for about 15 minutes.

5. Polish the slide lacquer to a black shiny surface which will now last about a year.

Proceed in the same way with the threads of the bowl body and with the guide surfaces of the bowl hood and bowl body.

76

G0

5818

11

Measurement of distance A

5.4.18 Lock ring; wear and damage

Described in section ‘‘5.3.11 Lock ring; wear and damage” on page 62.

5.4.19 Oil paring disc; height position

The height position of the oil paring disc (1) should be checked if the bowl spindle has been removed or the bowl has been replaced.

• Assemble the bowl without small lock ring, flow control disc and upper paring disc.

• Tighten the large lock ring until the bowl hood is in close contact with the bowl body.

• Put the frame hood in place and tighten it to the frame ring.

• Measure the distance A according to the figure. The distance should be 65 ±0,5 mm.

• Adjust the distance by adding or removing height adjusting rings (2).

With inlet and outlet parts mounted:

• Revolve the worm wheel shaft by hand. If it turns heavily or if a scraping noise occurs, incorrect height adjustment or wrong fitting of the inlet pipe may be the cause.

5.4.20 Operating mechanism

Described in section ‘‘5.3.12 Operating mechanism” on page 63.

77

G05

815

11

Templet supported on the spindle top

G05

816

11

Templet supported on the operating paring disc

G05

8172

1

The height position can be adjusted with height adjusting rings (1)

5.4.21 Operating paring disc; height position

If the bowl spindle has been removed or the bowl has been replaced, the height position of the operating device relative to the bowl spindle top must be checked.

• The operating paring disc device should be assembled and fitted.

• Support the templet on the spindle top with the measurement indication 177,3 facing the spindle.

• There should be a small gap between the lower end of the templet and the upper side of the paring disc, otherwise the paring disc position is too high.

• Turn the templet so that the measurement indication on the other side (178,3) faces the spindle and the templet lower end supports on the paring disc.

• There should be a small gap between the templet tongue and the spindle top, otherwise the paring disc position is too low.

• The height position is adjusted by adding or by removing height adjusting rings (1) under the distributing cover.

• After adjustment rotate the spindle. If a scraping noise is occurs, re-adjust.

5.4.22 Operating slide

Described in section ‘‘5.3.13 Operating slide” on page 64.

5.4.23 Sliding bowl bottom

Described in section ‘‘5.3.14 Sliding bowl bottom” on page 64.

78

G05

3792

1

Measurement of wear in groove (1)

5.4.24 Springs for operating mechanism

Described in ‘‘5.3.15 Springs for operating mechanism” on page 65.

5.4.25 Worm; wear of groove

Renew the worm if the wear in the groove (1) which receives the conveyor exceeds 3-4 mm .

If renewing the worm, it is recommended to renew also the worm wheel, see ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87

5.4.26 Worm wheel and worm; wear of teeth

Described in section ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87.

79

G0

2461

31

Measurement of the radial wobble

5.4.27 Worm wheel shaft; radial wobble

Excessive wobble on the worm wheel shaft may cause vibration and noise.

Clamp a dial indicator in a magnetic support and fasten it to the surface for the worm wheel guard. Turn the worm wheel shaft by hand.

Permissible radial wobble is maximum 0,10 mm .

If the wobble is greater, the worm wheel shaft must be removed from the frame for closer examination. Get in touch with your Alfa Laval representative as the worm wheel shaft may need to be renewed.

5.4.28 Cover interlocking switch (option)

Described in ‘‘5.3.17 Cover interlocking switch (option)” on page 66.

5.4.29 Vibration switch (option)

Described in ‘‘5.3.18 Vibration switch (option)” on page 66.

80

G05

4451

1

Lift the separator with the frame hood and bowl removed

5.5 Lifting instructionsAttach three endless slings or cables to the lifting eyes (the screws must be tightened with spanner).

The circumferense of each sling must be min. 2 metres.

Do not lift the separator unless the frame hood and bowl have been removed.

NOTE

Machine weight without frame hood and bowl is approx. 850 kg .

WARNING

Crush hazards

Use only the three special lifting eyes (M16) for lifting the machine. They are to be screwed into the special threaded holes normally covered by the frame hood.

Other holes are not dimensioned for lifting the machine.

A falling separator can cause accidents resulting in serious injury to persons and damage to equipment.

81

G05

4461

1

The lock ring must be properly tightened when lifting the bowl

When lifting the bowl, use the special lifting tool fastened on the bowl hood.

NOTE

Check that the lock ring is properly tightened.

The height of the lock ring above the bowl body must not exceed 12 mm , see illustration.

Weight to lift is approx. 300 kg .

When lifting the bowl out of the separator frame, the cap nut fixing the bowl to the bowl spindle and the screws fixing the bowl body to the operating water device must first be removed.

82

G0

5451

21

Never wash down a separator with a direct water stream or playing a water jet on the motor

G05

4513

1

Use a sponge or cloth and a brush when cleaning

5.6 Cleaning

5.6.1 External cleaning

The external cleaning of the frame and motor should be restricted to brushing, sponging or wiping while the motor is running or is still hot.

Never wash down a separator with a direct water stream. Totally enclosed motors can be damaged by direct hosing to the same extent as open motors and even more than those, because:

• Many operators believe that these motors are sealed, and normally they are not.

• A water jet played on these motors will produce an internal vacuum, which will suck the water between the metal-to-metal contact surfaces into the windings, and this water cannot escape.

• Water directed on a hot motor may cause condensation resulting in short-circuiting and internal corrosion.

Be careful even when the motor is equipped with a protecting hood. Never play a water jet on the ventilation grill of the hood.

83

S0

0085

11

Alfa Laval cleaning liquid for lube and fuel oil separators

5.6.2 Cleaning agents

When using chemical cleaning agents, make sure you follow the general rules and suppliers’ recommendations regarding ventilation, protection of personnel, etc.

For separator bowl, inlet and outlet

A chemical cleaning agent must dissolve the deposits quickly without attacking the material of the separator parts.

• Fuel oil sludge mainly consists of complex organic substances such as asphaltenes. The most important property of a cleaning liquid for the removal of fuel oil sludge is the ability to dissolve these asphaltenes.

Alfa Laval cleaning liquid for fuel oil separators has been developed for this purpose. The liquid is water soluble, non-flammable and does not cause corrosion of brass and steel. It is also gentle to rubber and nylon gaskets in the separator bowl.

Before use, dilute the liquid with water to a concentration of 3-5%. Recommended cleaning temperature is 50-70 °C.

For operating mechanism

Use 10% acetic acid solution to dissolve lime deposits. The acid should be heated to 80 °C.

CAUTION

Skin irrit ation hazard

Read the instructions on the label of the plastic container before using the cleaning liquid.

Always wear safety goggles, gloves and protective clothing as the liquid is alkaline and dangerous to skin and eyes.

84

G00

6583

1

Put the discs one by one into the cleaning agent

G0

0658

41

Clean the discs with a soft brush

For parts of the driving devices

Use white spirit, cleaning-grade kerosene or diesel oil.

Oiling (protect surfaces against corrosion)

Protect cleaned carbon steel parts against corrosion by oiling. Separator parts that are not assembled after cleaning must be wiped and coated with a thin layer of clean oil and protected from dust and dirt.

5.6.3 Cleaning of bowl discs

Handle the bowl discs carefully so as to avoid damage to the surfaces during cleaning.

1. Remove the bowl discs from the distributor and lay them down, one by one , in the cleaning agent.

2. Let the discs remain in the cleaning agent until the deposits have been dissolved. This will normally take between two and four hours.

3. Finally clean the discs with a soft brush.

NOTE

Mechanical cleaning is likely to scratch the disc surfaces causing deposits to form quicker and adhere more firmly.

A gentle chemical cleaning is therefore preferable to mechanical cleaning.

85

G0

0390

31

CIP unit connected to separator

5.6.4 CIP-system

Alfa Laval has developed a CIP (Cleaning-In-Place) system specifically designed for cleaning the bowl and without the need of dismantling.

86

G0

205

311

1 Worm2 Worm wheel

G0

205

411

Check the gear ratio (number of teeth) when replacing the gear

5.7 When changing oil

5.7.1 Worm wheel and worm; wear of teeth

Check at each oil change.

Check the teeth of both the worm wheel and worm for wear.

See the ‘‘ Tooth appearance examples” on page 89. Examine the contact surfaces and compare the tooth profiles. The gear may operate satisfactorily even when worn to some degree.

• Replace both worm wheel and worm at the same time, even if only one of them is worn.

• To avoid damaging the teeth when lifting the bowl spindle: push the worm wheel to one side first.

Position the spindle in correct place before fitting the worm wheel.

When replacing the gear, always make sure that the new worm wheel and worm have the same number of teeth as the old ones. See chapter ‘‘8.1 Technical data” on page 179 for correct number of teeth.

DANGER

Disintegration hazards

Check that gear ratio is correct for power frequency used. If incorrect, subsequent overspeed may result in a serious breakdown.

87

Important!

When using mineral-type oil in the worm gear housing, the presence of black deposits on the spindle parts is an indication that the oil base has deteriorated seriously or that some of the oil additives have precipitated. If pitting is found on the worm gear, the cause could be that the additives are not suitable for this purpose.

In all these cases it is imperative to change to a high-temperature oil.

For further information, see chapter ‘‘8.4 Lubricants” on page 190.

NOTE

Presence of metal chips in the oil bath is an indication that the gear is wearing abnormally.

88

G05

3871

1

Satisfactory teeth

G05

388

11

Worn teeth

G0

5389

11

Spalling

G05

390

11

Pitting

Tooth appearance examples

Satisfactory teeth:

Uniform wear of contact surfaces. Surfaces are smooth.

Good contact surfaces will form on the teeth when the gear is subjected to only moderate load during its running-in period.

Worn teeth:

Permissible wear is as a rule 1/3 of the thickness of the upper part of a tooth, provided that

• the wear is uniform over the whole of the flank of a tooth

• and all teeth are worn in the same way.

Spalling :

Small bits of the teeth have broken off, so-called spalling. This is generally caused by excessive load or improper lubrication. Damage of this type may not necessitate immediate replacement, but careful checking at short intervals is of imperative importance.

Pitting:

Small cavities in the teeth, so-called pitting, can occur through excessive load or improper lubrication. Damage of this type need not necessitate immediate replacement, but careful check at short intervals is of imperative importance.

89

G0

134

411

1. Oil filling plug2. Sight glass3. Oil drain plug

G00

359

21

Burn hazards: The drained oil may be hot

G02

6201

1

The oil level must not be above the middle of the sight glass

5.7.2 Oil change procedure

1. Place a collecting tray under the drain hole, remove the drain plug and drain off the oil.

2. Fill new oil in the worm gear housing. The oil level should be exactly in the middle of the sight glass:

Oil volume: approx. 12 litres.

For oil brands see ‘‘8.4.3 Recommended oil brands” on page 193.

NOTE

Before adding or renewing lubricating oil in the worm gear housing, the information concerning different oil groups, handling of oils, oil change intervals etc. given in chapter ‘‘8.4 Lubricants” on page 190 must be well known.

CAUTION

Burn hazards

Lubricating oil and various machine surfaces can be sufficiently hot to cause burns.

NOTE

During operation the oil level must be slightly below the middle of the sight glass.

If the oil level is too high, the life of the rolling bearings will be reduced due to high temperature.

90

G0

5828

11

Measuring points for vibration analysis

5.8 Vibration

5.8.1 Vibration analysis

Excessive vibration or noise indicates that something is incorrect. Stop the separator and identify the cause.

Use vibration analysis instrument to periodically check and record the level of vibration. See the illustration where to take measurements.

NOTE

The level of vibration should not exceed 11,2 mm/s at full speed.

DANGER

Disintegration hazards

If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown.

The cause of the vibration must be identified and corrected before the separator is restarted. Excessive vibration can be due to incorrect assembly or poor cleaning of the bowl.

91

G0

546

521

Setpoint adjustment1. Adjusting screw2. PointerA. Direction of increased set point

(admit higher vibration)

5.8.2 Vibration switch (option)

Adjustment of setpoint

The vibration switch is adjusted with the separator in operation. The cover must be removed to gain access to the setpoint adjusting screw (1).

1. Back-off the setpoint adjusting screw counter-clockwise (A) two or three turns. Press the reset button. If the armature does not remain in the reset position, turn the adjusting screw another turn or two until the armature stays in position when the reset button is pressed.

2. Now turn the adjusting screw slowly clockwise until the armature rocks. Mark this position with a line immediately in front-of the adjusting screw pointer (2).

3. Back-off the adjusting screw counter-clockwise a three-quarter turn. Press the reset button. If the armature now rocks, turn the adjusting screw counter-clockwise another quarter turn and so on until the armature remains in the reset position.

4. Refit the cap and fasten with the screws.

NOTEFurther adjustment may become necessary if alarm occurs due to vibration from surrounding equipment.

92

G05

873

21

1. Outer race2. Ball/roller3. Inner race4. Cage

G05

874

11

For bearings where no driving-off sleeve is included in the tool kit, use a puller when removing bearings

5.9 Common maintenance directions

5.9.1 Ball and roller bearings

Special-design bearings for the bowl spindle

The bearings used for the bowl spindle are specified to withstand the speed, vibration, temperature and load characteristics of high-speed separators.

Only Alfa Laval genuine spare parts should be used.

A bearing appears equivalent to the genuine may differ considerably in various respects: inside clearances, design and tolerances of the cage and races as well as material and heat treatment.

Dismantling

For bearings where no driving-off sleeve is included in the tool kit, remove the bearing from its seat by using a puller. If possible, let the puller engage the inner ring, then remove the bearing with a steady force until the bearing bore completely clears the entire length of the cylindrical seat.

The puller should be accurately centred during dismantling; otherwise, it is easy to damage the seating.

NOTE

Using an incorrect bearing can cause a serious breakdown with damage to equipment as a result.

Do not re-fit a used bearing. Always replace it with a new.

NOTE

Do not strike with a hammer directly on the bearing.

93

G0

5875

11

Clean and oil the bearing seating before assembly

G0

5876

11

The bearing must not be in direct contact with the container

Cleaning and inspection

Check shaft (spindle) end and/or bearing seat in the housing for damage indicating that the bearing has rotated on the shaft (spindle) and/or in the housing respectively. Replace the damaged part(s), if the faults cannot be remedied by polishing.

Assembly

• Leave new bearings in original wrapping until ready to fit. The anti-rust agent protecting a new bearing should not be removed before use.

• Use the greatest cleanliness when handling the bearings.

• To facilitate assembly and also reduce the risk of damage, first clean and then lightly oil the bearing seating on shaft (spindle) or alternatively in housing, with a thin oil.

• When assembling ball bearings, the bearings must be heated in oil to max. 125 °C .

NOTE

Heat the bearing in a clean container.

Use only clean oil with a flash point above 250 °C.

The bearing must be well covered by the oil and not be in direct contact with the sides or the bottom of the container. Place the bearing on some kind of support or suspended in the oil bath.

94

G0

5877

11Use a driving-on sleeve for bearings that are not heated

S0

116

521

The wide shoulder of the inner race must face the axial load

• There are several basic rules for assembling cylindrical bore bearings:

— Never directly strike a bearing’s rings, cage or rolling elements while assembling. A ring may crack or metal fragments break off.

— Never apply pressure to one ring in order to assemble the other.

— Use an ordinary hammer. Hammers with soft metal heads are unsuitable as fragments of the metal may break off and enter the bearing.

— Make sure the bearing is assembled at a right angle to the shaft (spindle).

• If necessary use a driving-on sleeve that abuts the ring which is to be assembled with an interference fit, otherwise there is a risk that the rolling elements and raceways may be damaged and premature failure may follow.

Angular contact ball bearings

Always fit single-row angular contact ball bearings with the wide shoulder of the inner race facing the axial load (upwards on a bowl spindle).

WARNING

Burn hazards

Use protective gloves when handling the heated bearings.

95

5.9.2 Before shutdowns

Before the separator is shut-down for a period of time, the following must be carried out:

• Remove the bowl, according to instructions in chapter ‘‘6 Dismantling/Assembly” on page 97.

• Protect cleaned carbon steel parts against corrosion by oiling. Separator parts that are not assembled after cleaning must be wiped and protected against dust and dirt.

• If the separator has been shut-down for more than 3 months but less than 12 months, an Intermediate Service (IS) has to be made. If the shut-down period has been longer than 12 months, a Major Service (MS) should be carried out.

NOTE

The bowl must not be left on the spindle during standstill for more than one week.

Vibration in foundations can be transmitted to the bowl and produce one-sided loading of the bearings. The resultant indentations in the ball bearing races can cause premature bearing failure.

96

6 Dismantling/Assembly

Contents

6.1 Introduction 99

6.1.1 General directions 99

6.1.2 References to check points 100

6.1.3 Tools 100

6.2 Inlet/outlet, frame hood (IS) 101

6.2.1 Exploded view 101

6.2.2 Dismantling 102

6.2.3 Assembly 104

6.3 Bowl hood and disc stack (IS) 106

6.3.1 Exploded view 106

6.3.2 Dismantling 107

6.3.3 Assembly 114

6.4 Bowl body and operating mechanism (IS) 120

6.4.1 Exploded view 120

6.4.2 Dismantling 121

6.4.3 Assembly 126

6.5 Operating water device (IS) 131

6.5.1 Exploded view 131

6.5.2 Dismantling 133

6.5.3 Assembly 136

6.6 Vertical driving device (MS) 140

6.6.1 Exploded view 140

6.6.2 Dismantling 143

6.6.3 Assembly 148

6.7 Horizontal driving device (MS) 154

6.7.1 Exploded view 154

6.7.2 Dismantling 156

6.7.3 Assembly 161

G0

5803

21

97

98

G02

462

21

The revolution counter indicates if the separator still is rotating

6.1 Introduction

6.1.1 General directions

The separator must be dismantled regularly for cleaning and inspection.

The recommended intervals are stated in chapter ‘‘5.1.2 Maintenance intervals” on page 39.

The frame hood and heavy bowl parts must be lifted by a hoist. Position the hoist directly above the bowl centre. Use an endless sling and a lifting hook with catch.

These parts must be handled carefully.

Do not place parts directly on the floor, but on a clean rubber mat, fibreboard or a suitable pallet.

DANGER

Entrapment hazard

Make sure that rotating parts have come to a complete standstill before starting any dismantling work.

The revolution counter and the motor fan indicate if separator parts are rotating or not.

NOTE

Never interchange bowl parts

To prevent mixing of parts, e.g. in an installation comprising several machines of the same type, the major bowl parts carry the machine manufacturing number or its last three digits.

99

6.1.2 References to check points

In the text you will find references to the Check Point instructions in chapter 5. The references appear in the text as in the following example:

✔ Check point‘‘5.4.10 Disc stack pressure” on page 72.

In this example, look up check point Disc stack pressure in chapter 5 for further instructions.

6.1.3 Tools

Special tools from the tool box must be used for dismantling and assembly. The special tools are specified in the Spare Parts Catalogue and are shown as illustrations together with the dismantling/assembly instructions.

NOTEWhen lifting parts without weight specifications, always use lifting straps with the capacity of at least 500 kg.

100

G05

865

11

6.2 Inlet/outlet, frame hood (IS)

6.2.1 Exploded view

1. Plug

2. O-ring

3. Support

4. Square-sectioned ring

5. Inlet pipe

6. Support

7. Connecting housing

8. O-ring

9. Frame hood

101

G02

462

21S

005

1011

G0

5866

51

6.2.2 Dismantling

The frame hood and the heavy bowl parts must be lifted by means of a hoist. Position the hoist exactly above the bowl centre. Use an endless sling and a lifting hook with catch.

The parts must be handled carefully. Don’t place parts directly on the floor, but on a clean rubber mat, fibreboard or a suitable pallet.

1. Loosen the clamp screw and lower the clamping stirrup. Remove the plug.

2. Undo the coupling nuts of inlet and outlet piping at the pipe support. Swing aside the feed pipe.

DANGER

Entrapment hazards

1. Make sure that rotating parts have come to a complete standstill before starting any dismantling work.

The revolution counter and the motor fan indicates if separator parts are rotating or not.

2. To avoid accidental start, switch off and lock power supply before starting any dismantling work.

102

G0

5867

51

G0

5868

41

3. Unscrew the inlet pipe using the special pin spanner.

Left-hand thread!

4. Remove the inlet pipe.

5. Swing aside the oil outlet pipe. Loosen the coupling nut of the connection housing.

S0

0662

11

103

G05

869

11G

05

8676

1

6. Remove the connection housing.

7. Remove the six screws holding the frame hood at lift it off.

6.2.3 Assembly

1. Put the frame hood in place and tighten it with the six screws.

2. Fit the connection housing. Note its angular position on the upper paring disc.

3. Connect the water outlet pipe and oil outlet pipe. Do not tighten the coupling nuts yet.

4. Fit the inlet pipe.

5. Tighten the inlet pipe properly using the special pin spanner.

Left-hand thread!

6. Fit the square-sectioned ring on the inlet pipe.

S00

662

11

104

G0

5866

61

7. Fit the feed pipe and plug and tighten the clamp screw properly.

8. Tighten the coupling nuts of inlet and outlet piping at the pipe support.

DANGER

Disintegration hazards

When power cables have been connected, always check direction of rotation. If incorrect, vital rotating parts could unscrew causing disintegration of the machine.

105

106

sc

G0

5895

11

6.3 Bowl hood and disc stack (IS)

6.3.1 Exploded view

1. Paring chamber cover (small lock ring)2. O-ring3. O-ring4. Upper paring disc5. O-ring6. Gasket7. Flow control disc8. Lock ring9. O-ring

10. Bowl hood11. O-ring12. Seal ring13. Top disc14. Oil paring di15. Level ring16. O-ring17. Bowl disc18. Wing insert19. Distributor

G0

531

011

G0

531

121

G05

334

31

6.3.2 Dismantling

1. Unscrew the paring chamber cover using the spanner.

Left-hand thread!

2. Remove the upper paring disc, gasket and flow control disc.

3. Apply the brake and unscrew the lock ring as described below.

Unscrewing lock ring without using a compressing tool

a. Unscrew the lock ring using the spanner.

Left-hand thread!

NOTE

Use an Alfa Laval compressing tool (optional) to reduce shocks to bearings and keep thread wear minimized when unscrewing the large lock ring.

S0

0647

11S

0066

911

107

G0

5312

21

G0

531

311

G05

3362

1G

053

1421

Unscrewing lock ring by using a compressing tool

a. Fit the lifting tool on the bowl hood.

b. Fit the compressing tool by screwing the pillar of the tool into the threads of the distributor using the horizontal handle.

The control lever on the compressing tool should be in position 0.

c. Turn the control lever to position 1 for compression.

Compress the disc stack by pumping the horizontal handle until the oil pressure is released through the relief valve.

d. Unscrew the large lock ring by using the spanner.

Left-hand thread!

S0

0676

11S

0067

811

S0

066

911

108

G05

313

11G

053

1221

e. Release the pressure in the compressing tool and remove it from the lifting tool.

4. Remove the lock ring.

5. Separate the bowl hood from the bowl body as described below before lifting off the bowl hood.

Separating bowl hood without using a compressing tool

a. Fit the lifting tool on the bowl hood.

NOTE

The lock ring must be kept lying horizontally or it may become distorted. Even the slightest distortion could make it impossible to refit.

S0

0676

11

109

G0

543

721

b. Screw the spindle plate into the lifting tool. Unscrew the spindle a few turns if the plate is not in contact with the lifting tool.

c. Screw home the spindle until the bowl hood loosens from the bowl body.

d. Remove the spindle plate from the lifting tool.

S0

064

511

110

G05

439

11G

054

401

1G

053

9971

Separating bowl hood by using a compressing tool

a. Remove the lifting tool from the bowl hood.

b. Fit the compressing tool by screwing the pole of the tool into the threads of the distributor using the horizontal handle.

The control lever on the compressing tool should be in position 0.

c. c.Fit the lifting tool on the bowl hood.

d. Turn the control lever to position 2 for expansion.

Separate the bowl hood from the bowl body by pumping the horizontal handle.

e. Remove the lifting tool and the compressing tool. Then refit the lifting tool.

6. Lift off the bowl hood using a hoist. Be careful not to scratch the bowl hood seal ring.

CAUTION

Crush hazards

If the top disc is stuck into the bowl hood, remove it now before it accidentally falls out.

111

G0

5317

91

G05

896

41

7. Remove the top disc.

8. Screw the inlet pipe into the paring disc located above the level ring inside the top disc.

Left-hand thread!

Place the top disc onto wooden blocks to act as protection for the top disc edge and for falling level ring. Place a piece of wood between the tin hammer and the inlet pipe and then force out the level ring and the paring disc carefully from the top disc.

112

G0

5319

21

9. Fit the lifting tool into the distributor and lift the distributor with disc stack out of the bowl body using a hoist.

10. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning” on page 83.

S00

649

11

113

G06

0311

1G

053

192

1

6.3.3 Assembly

✔ Check point‘‘5.3.3 Corrosion” on page 51,‘‘5.3.4 Cracks” on page 54,‘‘5.3.7 Erosion” on page 57,‘‘5.3.11 Lock ring; wear and damage” on page 62.

1. Assemble the discs one by one on the distributor. The distributor has one guide rib for the correct positioning of the discs.

For correct number of discs above and below the wing insert when the machine was new, see the Spare Parts Catalogue.

The number of bowl discs above the wing insert may be increased to adjust the disc stack pressure.

2. Fit the lifting tool to the distributor and lift the distributor with disc stack into the sliding bowl bottom using a hoist.

Check that the guide pins in the distributing cone fit into the recesses on the underside of the distributor.

CAUTION

Cut hazard

Sharp edges on the separator discs may cause cuts.

S0

0649

11

114

G0

5321

51G

0531

7A1

G05

3997

1

✔ Check point‘‘5.3.10 Level ring” on page 61.

3. Fit the oil paring disc and level ring with the O-ring into the top disc.

Make sure that the paring disc is positioned in the right direction.

4. Fit the top disc onto the distributor. The drilled assembly mark on the top disc must face the guide lug on the bowl body.

✔ Check point‘‘5.3.1 Bowl hood seal ring” on page 50.

5. Fit the lifting tool to the bowl hood and lift it using a hoist. Check that the O-ring and the seal ring of the bowl hood are properly fitted and lubricated.

Lower the bowl hood straight down onto the disc stack, otherwise it may get stuck. Be careful not to scratch the bowl hood seal ring.

In set of tools without compressing tool.

In set of tools with compressing tool.

For correct position of bowl hood, see next illustration.

S0

0654

11S

006

7611

115

G05

356

21G

0581

211

G05

334

41

6. Check that the guide recess on the bowl hood enters the guide lug in the bowl body.

7. Remove the lifting tool.

8. Lubricate the lock ring threads, contact and guide surfaces with lubricating paste.

✔ Check point‘‘5.4.17 Lock ring; priming” on page 75 (only when Major Service).

9. Tighten the lock ring.

Tightening of lock ring without using a compressing tool

a. Tighten the lock ring using the spanner for lock ring.

Left-hand thread!

NOTE

Use an Alfa Laval compressing tool (optional) to reduce shocks to bearings and keep thread wear minimized when unscrewing the large lock ring.

S0

066

911

116

A

(MAX 25 )

G05

7813

1G

053

1221

G05

3131

1G

053

3621

b. Tighten until the assembly marks are at least in line.

✔ Check point‘‘5.3.5 Disc stack pressure” on page 55.

Tightening of lock ring using a compressing tool

a. Fit the lifting tool onto the bowl hood.

b. Fit the compressing tool by screwing the pole of the tool into the threads of the distributor by the horizontal handle.

The control lever on the compressing tool, should be in position 0.

c. Turn the control lever to position 1 for compression.

Compress the disc stack by pumping with the horizontal handle until the oil pressure is released through the relief valve.

NOTEThe assembly marks must never pass each other more than 25° which corresponds to A=100 mm.

S00

6761

1S

006

7811

117

G05

3143

1

A

(MAX 25 )

G0

578

131

G0

531

121

d. Tighten the lock ring using the spanner for lock ring.

Left-hand thread!

e. Tighten until the assembly marks areat least in line.

✔ Check point‘‘5.3.5 Disc stack pressure” on page 55.

f. Release the pressure in the compressing tool by turning the control lever to position 0 and then remove the compressing and lifting tools.

10. Check that the small holes in the flow control disc and upper paring disc are not clogged.

Fit the flow control disc , gasket and the upper paring disc.

✔ Check point‘‘5.3.9 Inlet pipe and oil paring disc” on page 61.

NOTEThe assembly marks must never pass each other more than 25° which corresponds to A=100 mm.

S0

066

911

118

G0

5310

21

11. Fit and tighten the paring chamber cover by using the spanner.

Left-hand thread!

S00

647

11

119

G0

546

221

6.4 Bowl body and operating mechanism (IS)

6.4.1 Exploded view

1. Cap nut

2. Distributing cone

3. O-ring

4. Sliding bowl bottom

5. Rectangular ring

6. Cylindrical pin

7. Bowl body

8. Guide lug

9. O-ring

10. Cylindrical pin

11. O-ring

12. Valve plug

13. Operating slide

14. Spring

15. Spring support

16. Screw

17. Dosing ring

18. Nozzle *)

19. Screw

*) Secured with Loctite 242

120

G0

5897

11G

053

272

1G

053

3211

6.4.2 Dismantling

1. Unscrew and remove the cap nut.

Left-hand thread!

2. Fit the lifting tool into the distributing cone and lift it out.

3. Fit the lifting tool onto the sliding bowl bottom and lift it out by a hoist.

S00

6701

1S

006

491

1S

006

481

1

121

G05

3281

1G

053

2911

G05

333

11

4. Unscrew the three screws in the bottom of the bowl body.

5. Fit the lifting tool into the bowl body bottom with the three screws.

Release the bowl body from the spindle by using the lifting tool as a puller. Turn the handle at top of the lifting tool until the bowl body comes loose from the spindle taper. Turn the handle two more turns in order to avoid damaging the paring disc device.

6. Lift out the bowl body using a hoist.

S0

0646

11

122

G05

3591

1G

053

601

1G

053

6111

7. Thread a strap through two sludge ports and turn the bowl body upside down using a hoist.

8. Loosen the screws for the spring support successively a little at a time. Remove the screws.

9. Remove the spring support and the springs.

WARNING

Crush hazards

Support the bowl body when turning to prevent it from rolling.

123

G0

5362

11G

0536

311

10. Unscrew the screws for the dosing ring.

11. Dismantle the dosing ring from the bowl body with the special puller.

Proceed in the following way:

a. Screw the nuts against the heads of the screws.

b. Place the puller on the operating slide and screw the screws into the dosing ring.

c. Force off the dosing ring by tightening the nuts crosswise. Remove the puller when the dosing ring is loose.

S00

660

11

124

G0

536

411

G05

3651

1

12. Fit two lifting eyes (M10) or two screws from the puller into the dosing ring and lift it off from the bowl body.

13. Fit two lifting eyes (M10) or two screws from the puller into the operating slide and lift it off from the bowl body.

125

G0

5366

11G

0536

511

14. Place the operating slide with the valve plugs facing upwards.

15. Remove any thick deposits in the bowl hood and clean all other parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning” on page 83.

6.4.3 Assembly

✔ Check point‘‘5.3.3 Corrosion” on page 51,‘‘5.3.4 Cracks” on page 54,‘‘5.3.6 Dosing ring” on page 57,‘‘5.3.7 Erosion” on page 57,‘‘5.3.8 Guide surfaces” on page 59,‘‘5.3.12 Operating mechanism” on page 63, ‘‘5.3.13 Operating slide” on page 64,‘‘5.3.14 Sliding bowl bottom” on page 64,‘‘5.3.15 Springs for operating mechanism” on page 65.

1. Lubricate the guide surfaces of the bowl body, operating slide and dosing ring with lubricating paste. See chapter ‘‘8.4 Lubricants” on page 190.

2. Fit the operating slide onto the bowl body.

Check that the guide pin in the bowl body enters the hole in the operating slide.

126

G0

536

411

G0

5449

11

3. Fit the dosing ring.

Check that the guide pin in the bowl body enters the hole in the dosing ring.

4. Apply only a thin film of lubricating paste on the screws for the dosing ring.

Tighten the dosing ring screws to a torque of 20 Nm. The screws should first be tightened diametrically, then tightened symmetrically around the bowl.

If torque is too low, there is a risk that the bolts will loosen by themselves when the separator is in operation. If torque is too high, the dosing ring as well as the bolts will be deformed. This may lead to sticking of the operating slide which moves inside the dosing ring.

NOTEIf there is too much lubrication paste applied, the surplus will collect between the operating slide and bowl body with risk of malfunction.

127

G0

544

821

G05

226

11G

053

591

1

5. Lubricate the guide surfaces of the spring support. See chapter ‘‘8.4 Lubricants” on page 190.

Fit springs and support.

6. Tighten the three screws for the spring support successively by hand a little at a time.

Finally tighten the screws to a torque of 25 Nm.

7. Wipe off the spindle top and nave bore in the bowl body. Lubricate the tapered end of the spindle and wipe it off with a clean cloth.

✔ Check point‘‘5.3.2 Bowl spindle cone and bowl body nave” on page 51.

8. Turn the bowl body using a hoist to its up-right position with a strap threaded through two sludge ports.

WARNING

Crush hazards

Support bowl body when turning to prevent it from rolling.

128

G05

333

11G

05

3281

1G

0533

211

G05

3571

1

9. Fit the lifting tool into the bowl body bottom with the three screws.

Turn the handle at the top of the lifting tool so that the central screw is home.

10. Lower the bowl body using a hoist until the central screw rests on the spindle top. Then screw up the central screw so that the bowl body sinks down onto the spindle.

Remove the tool.

11. Rotate the bowl body and align it so that the three screw holes in the bowl body bottom are exactly above the three holes in the distributing ring.

Tighten the three screws firmly.

12. Lubricate the guide surfaces of the bowl body and sliding bowl bottom with lubricating paste. See chapter ‘‘8.4 Lubricants” on page 190.

13. Fit the lifting tool to the sliding bowl bottom and lift it into the bowl body using a hoist.

For correct position of the sliding bowl bottom, see below.

14. Bring the assembly mark on the sliding bowl bottom in line with the guide lug on the bowl body to ensure that the sliding bowl bottom enters into the correct position.

S0

064

611

S0

064

811

129

G0

5327

21G

058

9721

15. Fit the distributing cone onto the sliding bowl bottom.

Check that the guide pins on the underside of the distributing cone enter the recess in the sliding bowl bottom.

16. Tighten the cap nut firmly.

Left-hand thread!

130

G0

587

911

6.5 Operating water device (IS)

6.5.1 Exploded view

1. O-ring

2. Distributing ring

3. Operating paring disc

4. O-ring

5. Cover

6. Gasket

7. Distributing cover

8. Height adjusting ring

131

132

G0

131

721

G0

5880

11

6.5.2 Dismantling

1. Slacken the screws of the paring disc with a hexagon wrench and unscrew with a suitable screw driver.

2. Lift out the paring disc device.

133

G05

4831

1G

058

8111

3. Loosen and pull out the operating water inlet pipes.

4. Loosen the screws and lift out the distributing cover.

134

G0

5882

11G

058

921

1

5. To dismantle the paring disc device turn it upside down and remove the screws.

6. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. Pay special attention to the channels. See chapter ‘‘5.6 Cleaning” on page 83.

7. Check the parts for damage and corrosion.

135

G0

5881

11G

054

8321

6.5.3 Assembly

1. Put the distributing cover in place. Do not tighten the screws (this will make it easier to fit the operating water inlet tubes).

2. Fit the operating water inlet pipes into the distributing cover and connect the water hoses.

136

G0

5893

11G

060

1911

3. Fasten the distributing cover.

4. Assemble the paring disc device. Do not forget the gasket on its underside.

137

G05

894

21G

058

801

1

5. Align the three holes (1) in the paring disc with the three holes (2) in the distributing cover.

6. Fit the paring disc device in its place.

138

G0

1317

21

7. Tighten the screws of the paring disc.

✔ Check point‘‘5.4.21 Operating paring disc; height position” on page 78. Only at Major Service (MS).

139

G0

546

421

6.6 Vertical driving device (MS)

6.6.1 Exploded view

140

1. Protecting plate

2. O-ring

3. Protecting collar

4. Guard

5. O-ring

6. Ball bearing housing

7. Spring casing

8. Gasket

9. Oil fan

10. Ball bearing

11. Screw

12. Screw

13. Screw

14. Spring washer

15. Buffer

16. Spring

17. Buffer plug

18. Bowl spindle

19. Stop sleeve

20. Ball bearing

21. Worm

22. Ball bearing

23. Conveyor

24. Ball bearing

25. Spacing washer

26. Ball bearing

27. Washer

28. Ball

29. Support ring

30. Height adjusting ring

31. Spacing sleeve

32. Bottom sleeve

33. Slotted pin

34. Ball

35. Bottom bearing housing

36. Washer

37. Screw

38. Gasket

141

142

G01

391

31G

013

203

1G

0132

141

6.6.2 Dismantling

1. Unscrew the six screws and remove the hood and O-ring.

2. Unscrew the three screws and remove the protecting plate, O-ring and protecting collar.

3. Unscrew the six screws and remove the guard and O-ring.

NOTE

Clean the space in the bowl casing thoroughly before starting to dismantle the bowl spindle to prevent contaminations falling down into the oil gear housing.

143

G01

322

31G

053

672

1G

0522

421

G0

1324

21

4. Loosen (but do not remove) the six screw plugs for the buffers with a spanner and a hammer.

5. Unscrew the six screw plugs and remove the springs. Move the spindle top a few turns in a circle while pressing outwards. This will disengage buffers from the ball bearing housing.

6. Remove the six buffers from the spring casing.

7. Unscrew the six screws holding the spring casing.

144

G05

4501

1G

0035

921

G0

1279

11G

05

2451

1

8. Prize out the ball bearing housing from the spring casing with a screw driver.

9. Remove the spring casing and gasket.

10. Drain the oil from the worm gear housing.

11. Remove the brake cover and revolution counter cap and their gaskets.

12. Knock out the taper pin from the worm wheel stop ring.

CAUTION

Burn hazards

Lubricating oil and various machine surfaces can be hot and cause burns.

145

G0

1281

11G

052

481

1G

054

5321

G0

1284

21

13. Push the worm wheel to one side before removing the spindle. If worm wheel is stuck use a piece of wood to loosen it.

14. Fit the lifting tool onto the spindle and lift out using the a hoist.

15. Pull off the ball bearing (1) together with the spacing washer (2) and upper ball race (3) for the axial bottom ball bearing.

16. Remove the conveyor (4) for worm.

17. Remove the oil fan (5).

18. Remove the worm and stop sleeve from the spindle. Pull off ball bearings from the worm. Use a washer (a) as a support for the puller.

S00

668

11

146

G05

3751

1G

013

664

1G

0136

631

G01

365

31

19. Drive off the top ball bearing from the sleeve spindle with the driving-off sleeve. Use a wooden plank or similar as a soft base for the spindle top.

20. Lift out the axial bottom ball bearing and the washer beneath using the lifting pin.

21. Lift out the bottom sleeve using the lifting pin.

22. Knock out the slotted pin (1) from the spacing sleeve (2) and remove it. Unscrew support plug (3) using two screws (4) with threads 1/4”-20 UNC to make height adjusting ring (5) accessible.

23. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning” on page 83.

S00

666

11S

0066

711

147

G0

546

611

G01

3664

1G

0545

411

6.6.3 Assembly

1. Fit the bottom sleeve with mounted parts (rings and sleeve) into the bottom bearing housing. Use the lifting pin.

Check that one ball is fitted both on top and bottom of the bottom sleeve.

2. Fit the washer and the ball bearing onto the bottom sleeve.

When mounting ball bearings on the spindle and worm as described below, the bearings must be heated in oil to max. 125 °C .

3. Heat the ball bearing and fit it on the spindle.

WARNING

Burn hazards

Use protective gloves when handling the heated bearings.

NOTE

If in doubt how to mount roller bearings correctly, see the detailed description in chapter ‘‘5.9.1 Ball and roller bearings” on page 93.

S0

066

711

148

G0

6020

11G

054

5221

G0

545

321

G05

248

11

✔ Check point‘‘5.4.25 Worm; wear of groove” on page 79.‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87.

4. Heat the two ball bearings and fit them on the worm.

5. Fit the stop sleeve (1) and the worm (2) on the spindle.

6. Fit the ball bearing (1) on the spindle. Then fit the spacing washer (2) and upper ball race (3) for the axial bottom bearing. The ball race must be heated.

7. Fit the conveyor (4) and the oil fan (5).

8. Fit the lifting tool to the spindle and lift it using a hoist.

S0

066

811

149

G0

1333

11G

052

492

1G

013

242

1G

05

2242

1

9. Carefully lower the spindle into the frame and guide the spindle into the correct position in the bottom bearing housing so the ball bearings enter their seats. If the ball bearings do not completely enter their seats, tap the spindle top gently with a soft hammer.

✔ Check point‘‘5.4.6 Buffer springs and ball bearing housing” on page 69.

10. Fit the spring casing with gasket and ball bearing housing. Position the flat surfaces of the ball bearing housing in front of the buffer holes in the spring casing.

11. Tighten the six screws for the spring casing.

12. Fit the buffers, springs and screw plugs.

150

G0

1334

31G

013

2141

G0

1320

31

13. Tighten the six screw plugs.

14. Fit the guard with O-ring and tighten the six screws.

15. Fit the protecting collar with O-ring and protecting plate.

Tighten the three screws for the protecting plate.

NOTE

Check that the protecting collar is in the bottom position before tightening the protecting plate.

151

G01

3913

1G

0524

521

G05

380

21G

02

6201

1

16. Fit the hood with O-ring and tighten the six screws.

✔ Check point‘‘5.4.3 Bowl spindle; height position” on page 67.

17. Match the worm wheel with the teeth in the worm of the bowl spindle. Knock the taper pin into the worm wheel stop ring.

✔ Check points‘‘5.4.27 Worm wheel shaft; radial wobble” on page 80. ‘‘5.4.4 Bowl spindle; radial wobble” on page 68.

18. Fit the protecting cover with gasket.

19. Pour oil into worm gear housing. The oil level should be exactly in the middle of the sight glass.

For correct oil volume and recommended oil brands, see chapter ‘‘8.4 Lubricants” on page 190.

152

G05

373

11

✔ Check point‘‘5.4.5 Brake” on page 68.

20. Fit the brake cover and revolution counter cap and their gaskets.

153

G0

5912

21

6.7 Horizontal driving device (MS)

6.7.1 Exploded view

154

g drum

1. Ball bearing

2. Screw

3. Spring washer

4. Round nut

5. Lock washer

6. Bearing shield

7. Spring washer

8. Nut

9. Oil shield

10. Taper pin

11. Stop ring

12. Worm wheel

13. Ball bearing

14. Sealing ring

15. Sealing washer

16. O-ring

17. Worm-wheel shaft with couplin

18. Nave

19. Friction block

20. Friction pad

21. Holding bracket

22. Ball bearing

23. Spacing sleeve

24. Ball bearing

25. Lock washer

26. Round nut

27. Gasket

28. Coupling disc

29. Elastic plate

155

G0

246

221

S00

5101

1G

0035

921

G0

127

911

6.7.2 Dismantling

The parts must be handled carefully. Don’t place parts directly on the floor, but on a clean rubber mat, fibreboard or a suitable pallet.

If the bowl spindle has been removed according to earlier description, points 1-5 below are already done. Proceed with point 6.

1. Drain the oil from the worm gear housing.

2. Remove the brake cover and revolution counter cap and their gaskets.

DANGER

Entrapment hazards

1. Make sure that rotating parts have come to a complete standstill before starting any dismantling work.

The revolution counter and the motor fan indicates if separator parts are rotating or not.

2. To avoid accidental start, switch off and lock power supply before starting any dismantling work.

CAUTION

Burn hazards

Lubricating oil and various machine surfaces can be hot and cause burns.

156

G05

245

11G

053

802

1G

060

2911

G05

2552

1

3. Knock out the taper pin from the worm wheel stop ring.

4. Remove the protecting cover with gasket.

5. Unscrew the two nuts holding the oil shield. The shield can not be removed from the housing before the bearing shield is moved.

6. Unscrew the four screws for the bearing shield and remove it together with the oil shield.

157

G0

525

421

G0

5223

11G

05

2221

1G

0547

611

7. Unscrew and remove the round nut and lock washer.

8. Remove the ball bearing.

9. Remove the stop ring and worm wheel with ball bearing.

10. Pull off the ball bearing from the worm wheel. Use a washer as a support for the puller.

S0

066

411

158

G05

2463

1G

052

4711

G0

522

111

11. Disconnect the motor cables. Note the positions of cables in the terminal box to re-connect correctly (for correct direction of rotation).

12. Remove the electric motor using a hoist.

13. Remove the flexible plate and unscrew the six screws for the coupling disc and remove it.

14. Remove the worm wheel shaft with friction clutch pulley.

159

G05

2202

1G

052

502

1G

052

292

1G

052

5111

15. To dismantle the nave, unscrew the round nut with the pin spanner and remove the lock washer.

16. Pull off the nave with the puller and remove the friction blocks.

17. Remove the sealing washer using two screws with 1/4”-20 UNC threads.

18. Remove the sealing ring from the sealing washer.

19. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning” on page 83.

S0

066

411

S0

0655

11

160

G0

5229

21G

02

8373

1G

05

2201

1G

052

2111

6.7.3 Assembly

1. Lubricate the O-ring on the sealing washer periphery and the sealing ring with silicone grease. Fit the sealing washer in frame and check that the sealing ring is fitted in the correct direction, as illustrated.

✔ Check point‘‘5.4.7 Coupling friction pads” on page 71.

2. Fit the friction blocks (3) with pads (2) on the nave and lock them with holding brackets (4).

Lubricate the ball bearings.

For recommended luricants, see chapter ‘‘8.4 Lubricants” on page 190.

3. Fit the ball bearings (1) and spacing sleeve (5) with the driving on sleeve tool to force the ball bearings into their correct positions.

4. Tighten the round nut with the pin spanner and secure it with the lock washer.

5. Fit the worm wheel shaft.

S00

6631

1S

006

6411

161

G05

4771

1G

052

221

1

✔ Check point‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87.‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 87.

6. Heat the ball bearing and fit it on the worm wheel.

When mounting the ball bearings on the worm wheel and shaft, the bearings must be heated in oil to max. 125 °C .

7. Fit the worm wheel with the ball bearing and fit the stop ring.

WARNING

Burn hazards

Use protective gloves when handling the heated bearings.

NOTE

If any doubt how to mount roller bearings correctly, see the detailed description in chapter ‘‘5.9.1 Ball and roller bearings” on page 93.

162

G05

223

11G

052

4421

G0

5254

21

8. Fit the ball bearing.

9. Knock the ball bearing into its seat with the driving-on sleeve tool.

10. Tighten the round nut with the pin spanner and secure it with the lock washer.

S00

663

11S

0066

411

163

G05

2551

1G

060

2911

G0

524

711

11. Fit the bearing shield together with the oil shield. Tighten the four screws for the bearing shield.

12. Tighten the two nuts holding the oil shield in the bearing shield.

13. Fit the coupling disc with gasket and tighten the six screws. If necessary, use the driving-on sleeve.

14. Fit the flexible plate.

✔ Check point‘‘5.4.13 Flexible plate in coupling” on page 73.

164

G05

2463

1G

052

452

1G

053

802

1

15. Fit the electric motor.

The remaining description in this section implies that the bowl spindle is mounted in the frame. If not, proceed with the assembly instruction for the vertical driving device in chapter ‘‘6.6.3 Assembly” on page 148.

16. Match the worm wheel with the teeth in the worm of the bowl spindle. Knock the taper pin into the worm wheel stop ring.

✔ Check point‘‘5.4.27 Worm wheel shaft; radial wobble” on page 80.

17. Fit the protecting cover with gasket.

DANGER

Disintegration hazards

When power cables have been connected and the separator is completely assembled see‘‘4.1.1 Ready for start” on page 32, always check direction of rotation. If incorrect, vital rotating parts could unscrew causing disintegration of the machine.

165

G02

6201

1G

0537

311

18. Pour oil into worm gear housing. The oil level should be exactly in the middle of the sight glass.

For correct oil volume and recommended oil brands see chapter ‘‘8.4 Lubricants” on page 190.

✔ Check point‘‘5.4.5 Brake” on page 68.

19. Fit the brake cover and revolution counter cap and their gaskets.

166

7 Trouble-tracing

Contents

7.1 FOPX mechanical functions 168

7.1.1 Separator vibrates 168

7.1.2 Smell 169

7.1.3 Noise 169

7.1.4 Speed too low 169

7.1.5 Starting power too high 170

7.1.6 Starting power too low 170

7.1.7 Starting time too long 170

7.1.8 Retardation time too long 170

7.1.9 Water in worm gear housing 171

7.2 FOPX separating functions 172

7.2.1 Liquid flows through the bowl casing drain and/or sludge outlet 172

7.2.2 Bowl opens accidentally during operation 173

7.2.3 Bowl fails to open for sludge discharge 173

7.2.4 Unsatisfactory sludge discharge 174

7.2.5 Unsatisfactory separation 174

7.2.6 High pressure in oil outlet 174

7.3 Vibration switch (option) 175

7.3.1 Vibration switch does not reset 175

7.3.2 Impossible to adjust setpoint to obtain tripping 175

7.3.3 Vibration switch does not reset 175

167

topping sequences when the separator

and keep bowl filled with liquid during

corrected before the separator is restarted. mbly or poor cleaning of the bowl.

tive actions Page

tle the separator and check the bly and cleaning

114

tle and clean the separator bowl 107

e separator, measure, and if ary, adjust the height(s)

67, 77

the bowl spindle 68

all bearings 140, 154

all rubber cushions 49

all springs 140

7.1 FOPX mechanical functions

7.1.1 Separator vibrates

NOTE

Some vibration is normal during the starting and spasses through its critical speeds.

DANGER

Disintegration hazards

When excessive vibration occurs, stop separatorrundown.

The cause of the vibration must be identified and Excessive vibration may be due to incorrect asse

Cause Correc

Bowl out of balance due to:- poor cleaning- incorrect assembly- incorrect disc stack compression- bowl assembled with parts from other separators

Dismanassem

Uneven sludge deposits in the sludge space

Disman

Height adjustment of the oil paring disc or bowl spindle is incorrect

Stop thnecess

Bowl spindle bent (max 0,04 mm) Renew

Bearing is damaged or worn Renew

Vibration damping rubber cushions are worn out

Renew

Spindle top bearing spring is broken Renew

168

tive actions Page

–

e the brake –

oil level and add oil if necessary 32

tive actions Page

oil level and add oil if necessary 32

e separator, measure and adjust ght(s)

67, 77

worm wheel and worm 87

all bearings 140, 154

the play 73

tive actions Page

e the brake –

or renew friction pads 71

tle the bowl and check 106

the motor –

all bearings 140, 154

nd change the gear transmission the power supply frequency

87, 140, 154

e the friction blocks to suit the supply frequency

71

7.1.2 Smell

7.1.3 Noise

7.1.4 Speed too low

Cause Correc

Normal occurrence during start while the friction blocks are slipping

None

Brake is applied Releas

Oil level in gear housing is too low Check

Cause Correc

Oil level in gear housing is too low Check

Height adjustment of the oil paring disc or bowl spindle is incorrect

Stop ththe hei

Worm wheel and worm are worn Renew

Bearing is damaged or worn Renew

Incorrect play between coupling pulley and elastic plate

Adjust

Cause Correc

Brake is applied Releas

Coupling pads are oily or worn Clean

Bowl is not closed or leaking Disman

Motor failure Repair

Bearing is damaged Renew

Incorrect gear transmission (60 Hz gear for 50 Hz power supply)

Stop ato suit

Incorrect coupling friction blocks (60 Hz blocks for 50 Hz power supply)

Changpower

169

tive actions Page

DANGER

mediately and change the friction to suit the power supply frequency

71

e electrical phase connections to the –

e the brake –

tive actions Page

mediately and change the friction to suit the power supply frequency

71

or renew friction pads 71

the motor –

tive actions Page

e the brake. –

or clean friction pads 71

heck and adjust the height 71, 78

the motor –

all bearings 140, 154

tive actions Page

or clean brake friction pad 68

7.1.5 Starting power too high

7.1.6 Starting power too low

7.1.7 Starting time too long

7.1.8 Retardation time too long

Cause Correc

Incorrect friction blocks (50 Hz blocks for 60 Hz power supply)

Stop imblocks

Wrong direction of rotation Changmotor

Brake is applied Releas

Cause Correc

Incorrect friction blocks (60 Hz blocks for 50 Hz power supply)

Stop imblocks

Friction pads are oily or worn Clean

Motor failure Repair

Cause Correc

Brake is applied. Releas

Friction pads are oily or worn Renew

Height position of oil paring disc or operating device is incorrect

Stop, c

Motor failure Repair

Bearing is damaged or worn Renew

Cause Correc

Brake friction pad is worn or oily Renew

170

tive actions Page

the casing and the drains properly. ains have connection Nos. 462 and the Basic size drawing.he reason for obstruction.worm gear housing and change oil.

87

seal ring and change oil. 140, 90

worm gear housing and oil.

90

7.1.9 Water in worm gear housing

Cause Correc

Bowl casing drain is obstructed. Clean The dr463 onSolve tClean

Leakage at the top bearing. Renew

Condensation. Clean change

171

tive actions Page

normal) –

the strainer and check water re/flow: water pressure, 20-30 kPa water flow

–

the operating water device 131

the O-rings 106

the paring chamber cover 106

the seal ring 106

hen sealing edge of the sliding bowl or renew it

64

all valve plugs 64

ction ‘‘7.1.4 Speed too low” on page this chapter

–

7.2 FOPX separating functions

7.2.1 Liquid flows through the bowl casing drain and/or sludge outlet

Cause Correc

Sludge discharge or water draining in progress

None (

Strainer in operating water line is clogged or water pressure/flow is too low

Clean pressuClosingClosing

Channels in operating water device are clogged

Clean

O-rings at the flow control disc are defective

Renew

Paring chamber cover (small lock ring) is defective

Renew

Seal ring in the bowl hood defective. Renew

Sealing edge of the sliding bowl bottom is defective

Smootbottom

Valve plugs are defective Renew

Bowl speed is too low See se169 in

172

tive actions Page

the strainer –

the operating water system and ure the valve(s) are open

–

–

the nozzle. Carry out an Intermediate (IS)

57

the square-sectioned ring. Carry out rmediate Service (IS)

64

all plugs. Carry out an Intermediate (IS)

64

the leak –

tive actions Page

the strainer –

the seal rings 131

the opening water flow; 18 l/min –

the tightening torque 127

the nozzle. Carry out an Intermediate (IS)

57

the seal ring. Carry out an ediate Service (IS)

120

7.2.2 Bowl opens accidentally during operation

7.2.3 Bowl fails to open for sludge discharge

Cause Correc

Strainer in the operating water supply is clogged

Clean

No water in the operating water system Checkmake s

Water connections to the separator are incorrectly fitted

Rectify

Upper nozzle in the dosing ring is clogged

Clean Service

Square-sectioned ring in sliding bowl bottom is defective

Renewan Inte

Valve plugs are defective RenewService

Supply valve for opening water is leaking Rectify

Cause Correc

Strainer in the operating water supply is clogged

Clean

Seal rings in operating water device are defectiv

Renew

Operating water flow is too low Check

Dosing ring too firmly tightened Check

Lower nozzle in the dosing ring is clogged

Clean Service

Seal ring in the operating slide is defective

RenewInterm

173

tive actions Page

the tightening torque 127

with correct valve plugs 64

and clean the operating system 120, 131

tive actions Page

–

–

disc stack 85

and reduce the time between sludge rges

85

e the motor and power transmission g the gear ratio

87, 154

tive actions Page

–

he valve(s) –

disc stack 85

7.2.4 Unsatisfactory sludge discharge

7.2.5 Unsatisfactory separation

7.2.6 High pressure in oil outlet

Cause Correc

Dosing ring is too firmly tightened Check

Valve plugs in the operating slide too are high

Renew

Sludge deposits in the operating system Check

Cause Correc

Incorrect separation temperature Adjust

Throughput is too high Adjust

Disc stack is clogged Clean

Sludge space in bowl is filled Clean discha

Bowl speed is too low Examinincludin

Cause Correc

Throughput is too high Adjust

Valve(s) in the oil outlet line is closed Open t

Bowl disc stack is clogged Clean

174

tive actions Page

magnets –

to Alfa Laval for repair –

for continuity and proper coil nce

–

tive actions Page

st the air gap with the stop pin screw –

tive actions Page

and verify by manually moving the re to the latched (tripped) position ten for an audible click. Verify contact orming a continuity check

–

that the switch plunger is just free of ature when in the set (un-tripped)

n

–

7.3 Vibration switch (option)

7.3.1 Vibration switch does not reset

7.3.2 Impossible to adjust setpoint to obtain tripping

7.3.3 Vibration switch does not reset

Cause Correc

Dirt or iron particles on magnets Clean

Leaf spring is broken Return

Reset coil is open Checkresista

Cause Correc

Incorrect air gap between hold-down magnet (lower) and armature in switch

Readju

Cause Correc

Defective switch Renewarmatuand lisby perf

Incorrect position Checkthe armpositio

175

176

8 Technical Reference

Contents

8.1 Technical data 179

8.2 Basic size drawing 181

8.2.1 Dimensions of connections 182

8.2.2 Connection list 183

8.2.3 Interface description 185

8.2.4 General 185

8.2.5 Definitions 185

8.2.6 Component description and signal processing 186

8.2.7 Function graph and runninglimitations 188

8.3 Water quality 189

8.4 Lubricants 190

8.4.1 Lubrication chart, general 190

8.4.2 Recommended lubricating oils 192

8.4.3 Recommended oil brands 193

8.4.4 Recommended lubricants 196

8.5 Drawings 199

8.5.1 Foundations 199

8.5.2 Electric motor 200

8.5.3 Machine plates and safety labels 203

8.5.4 Vibration sensor (option) 205

8.5.5 Cover interlocking switch (option) 205

8.6 Storage and installation 206

8.6.1 Introduction 206

8.6.2 Storage and transport of goods 206

8.6.3 Planning of installation 208

8.6.4 Foundation 211

177

178

grated system including a monitoring tion do not agree with the technical data escription shall apply.

02-03

09TFD-24

ous clarification of heavy fuel oil. for both land and marine applications.

h point of the fuel oil to be separated must be °C.

100

kg/m3

kg/m3

litres/h

°C

5 °C The min. temperature is dependent of the used oil type. See ‘‘8.4.2 Recommended lubricating oils” on page 192.

148 r/min, 50/60 Hz

800 r/min, 50/60 Hz

mmmm

mm

. 12 litres

8.1 Technical dataAlfa Laval ref. 555051

NOTE

The separator is a component operating in an intesystem. If the technical data in the system descripin this instruction manual, the data in the system d

Product number

Separator type

Application

881244-

FOPX 6

ContinuIntended

The flasmin. 60

Density of operating water, max.

Density of sediment/feed, max.

Hydraulic capacity, max.

1 000

1 350/1

16 000

Feed temperature, min./max. 0/100

Ambient temperature, min./max. 5-15/5

Bowl speed, max. 5175/5

Motor shaft speed, max. 1500/1

Gear ratio, 50 Hz 3,45:1

Gear ratio, 60 Hz 2,86:1

No. of teeth;- on worm, 50 Hz- on worm, 60 Hz- on worm wheel, 50 Hz- on worm wheel, 60 Hz

20216960

Friction blocks for coupling, thickness- 50 Hz- 60 Hz

205,5

Valve plugs, height 13,8

Lubricating volume approx

179

kW, 50/60 Hz

kW (at starting up)

kW (idling/at max. capacity)

litres fixed discharge volume

minutes

litres

litres

minutes

minutes

minutesminutes

Bel(A) ISO 3744, 4,5 m3/h

dB(A) ISO 3744, 4,5 m3/h

mm/s (RMS)

kg

kg

kg

g seals and O-rings) are brass, bronze and

Motor power rating 12/14

Power consumption, max. 16

Power consumption, normal 4,5/9

Discharge volume, nominal 3,4

Discharge interval, min./max. 1/240

Bowl volume 13

Sediment space 6

Starting time 3-4

Stopping time with brake, min./max. 4-7

Max. running time without flow;- empty bowl- filled bowl

180180

Sound power level –

Sound pressure level 84

Vibration level, separator in use, max. 11,2

Weight of separator(without frame hood and bowl)

850

Weight of bowl 244

Weight of motor 72

The materials in contact with process fluid (excludinstainless steel. Cast iron frame.

180

Maximum horizontal displacement at the in/outlet connections during operation ± 15 mm.

R01

041

11

8.2 Basic size drawingAlfa Laval ref. 554900 rev. 2

A. Maximum vertical displacement at the sludge connection during operation ± 10 mm.

B.

181

onnections to be installed non-loaded flexible.

G0

6179

51

8.2.1 Dimensions of connectionsAlfa Laval ref. 554900 rev. 2

Data for connections, see chapter ‘‘8.2.2 Connection list” on page 183.

All cand

182

Requirements/limits

Min. 0 °C, max. 100 °C

ent liquid, water. Fresh water

2,8 litre/minute

200/600 kPa

0 — 220 kPa.

The outlet after the separator should be installed in such a way that you can not fill the frame top part with sludge. (Guidance of sludge pump or open outlet)

See demand in chapter ‘‘8.3 Water quality” on page 189

18 litres/minute

3 seconds/discharge

200/600 kPa

See demand in chapter ‘‘8.3 Water quality” on page 189

22/32 kPa

1,4 litres/discharge

8.2.2 Connection listAlfa Laval ref. 554904 rev. 3

Connection No. Description

201 Inlet for product

− Allowed temperature

206 Inlet to liquid seal or displacem

− Instantaneous flow

− Pressure (Min./Max.)

220 Outlet for light phase (oil).

− Counter pressure.

221 Outlet for heavy phase (water).

222 Outlet for solid phase.

372 Inlet of discharge liquid.

− Instantaneous flow

− Time

− Pressure (Min./Max.)

376 Inlet for make-up liquid.

− Pressure (Min./Max.)

372 + 376 Discharge and make-up liquid

− Consumption

183

arge and make-up

minal frequency. ± 5% (momentarily 10% during a period of maximum 5 seconds).

ption). See ‘‘8.2.3 Interface description’’.

Mechanical switch

t range 0 to 4,5 g from 0 to 300 Hz

load max. 5 A12 V DC2 A24 V DC1 A48 V DC0,5 A120 V DC7 A460 V AC50/60 Hz

y max. 14 W 48 V DC

ered as option). See ‘‘8.2.3 Interface description’’

Mechanical switch

load max. 3 A 500 V

Requirements/limits

377 Outlet for operating liquid (dischliquid)

(463) Drain of frame top part, upper.

462 Drain of frame top part, lower

701 Motor for separator.

− Max. deviation from no

753 Vibration sensor (delivered as oMechanical switch.

− Type

− Vibration measuremen

− Switch rating, resistive

− Reset coil power suppl

760 Cover interlocking switch (deliv

− Type

− Switch rating, resistive

Connection No. Description

184

8.2.3 Interface descriptionAlfa Laval ref. 557138 rev. 3

8.2.4 General

In addition to the Connection List this document describes limitations and conditions for safe control, monitoring and reliable operation.

At the end of the document a function graph and running limitations are found.

8.2.5 Definitions

Ready for start means:

• The machine is assembled correctly.

• All connections are installed according to Connection List, Interconnection Diagram and Interface Description.

Start means:

• The power to the separator is on.

• The acceleration is supervised to ensure that a certain speed has been reached within a certain time. See technical data.

The start procedure continues until full speed has been reached and a stabilization period has passed (about 1 minute).

Normal stop means:

• Stopping of the machine at any time with brake applied.

• The bowl must be kept filled.

185

Safety stop means:

The machine must be stopped in the quickest and safest way due to vibrations or process reasons.

Comply to following conditions:

• The bowl must be kept filled.

• Sludge ejection must not be made.

• The machine must not be restarted before the reason for the safety stop has been investigated and action has been taken.

In case of emergency condition in the plant, the machine must be stopped in a way that is described in EN 418.

8.2.6 Component description and signal processing

Separator motor 701

The separator is equipped with a 3-phase DOL-started (direct on line) motor. The separator can also be started by a Y/D starter, but then the time in Y-position must be maximized to 5 seconds.

Vibration sensor 753 (option)

The vibration sensor is an acceleration sensitive instrument with a mechanical switch. It gives an open contact when the unbalance exceeds the preset value.

Signal processing

If to high vibration occur the machine must be stopped with automatic Safety Stop.

Cover interlocking switch 760 (option)

The cover of the separator is equipped with an interlocking switch.

When the cover is closed the interlocking circuit in the control system is closed and the separator could be started.

186

Signal Processing

The circuit is closed when the frame hood of the separator is closed.

The interlocking switch should be connected so that starting of the motor is prevented when the separator hood is not closed.

Discharge signal processing

The control system shall contain a memory function for registration of the number of initiated discharges.

At indication of the absence of a discharge, the operator or the control system must initiate a new discharge. At indication of the absence of two consecutive sludge discharges, an alarm must be given and action must be taken.

187

G0

543

211

8.2.7 Function graph and running limitations

A

B

C

D

E

A. Stand stillB. Starting modeC. Running modeD. Stop modeE. Safety stop mode

188

nctions: Discharge-flushing.

, corrosion and/or re be treated to meet

rtance.

volume.

areas in the

(corresponds to ature accelerates the

60mg Cl/l).

arator surfaces in pindle. Corrosion is a ting temperature, low ide concentration

n; this is accelerated n content.

tive.

e pretreated

ing from er.

8.3 Water qualityAlfa Laval ref. 553406 rev.3

Specific requirements regarding the quality of water

Water is used in the separator for several different fumechanisms, liquid seals, as cooling media and for

Bad quality of the water can with time cause erosionoperating problems in the separator and must therefocertain demands.

The following requirements are of fundamental impo

1.1 Turbidity-free water, solids content < 0,001% of

Deposits must not be allowed to form in certainseparator.

1.2 Max particle size 50 m.

2. Total hardness ≤ 180 mg CaCo3 per litre.

Chalk deposits can build-up if the water is hard 10 °dH or 12,5 °E). Increased operating temperchalk built-ups.

3. Chloride content ≤ 100 ppm NaCl (equivalent to

Chloride ions contribute to corrosion on the sepcontact with the operating water, including the sprocess that is accelerated by increased separapH, and high chloride ion concentration. A chlorabove 60 mg/l is not recommended.

4. pH > 6

Increasing acidity (lower pH) increases corrosioby increased temperatures and high chloride io

For test methods, contact any Alfa Laval representa

If these demands cannot be met, the water should baccording to Alfa Laval’s recommendations.

Alfa Laval accepts no liability for consequences arisunsatisfactorily purified water supplied by the custom

189

Lubricants

Lubricating oil as specified in ‘‘8.4.2 Recommended lubricating oils” on page 192

Lubricating oil (only a few drops for rust protection)

Lubricating oil

Pastes as specified in ‘‘8.4.4 Recommended lubricants” on page 196

If not specified otherwise, follow the supplier’s recommendation about method of application

Grease as specified in ‘‘8.4.4 Recommended lubricants” on page 196

The bearings are packed with grease and sealed and need no extra lubrication

Follow manufacturer’s instructions

8.4 Lubricants

8.4.1 Lubrication chart, generalAlfa Laval ref. 553216-01 rev. 5

Alfa Laval Lubricating Oil Groups:

• Group A oil: a high quality gear oil on paraffin base with stable AW (anti wear) additives.

• Group B oil: a high quality gear oil on paraffin base with stable EP (extreme pressure) additives.

• Group D oil: a synthetic base oil with additives stable at high operating temperatures.

Do not mix different oil brands or oils from different oil groups.

Always use clean vessels when handling lubricating oil.

Lubricating points

Bowl spindle ball bearings and buffers are lubricated by oil mist

Bowl spindle taper

Buffers of bowl spindle

Bowl:

Sliding contact surfaces and pressure loaded surfaces such as lock rings, threads of lock rings, bowl hood, and cap nut

Rubber seal rings

Friction coupling ball bearings

Electric motor (if nipples are fitted)

190

Great attention must be paid not to contaminate the lubricating oil. Of particular importance is to avoid mixing of different types of oil. Even a few drops of motor oil mixed into a synthetic oil may result in severe foaming.

Any presence of black deposits in a mineral type oil is an indication that the oil base has deteriorated seriously or that some of the oil additives have precipitated. Always investigate why black deposits occur.

If it is necessary to change from one group of oil brand to another it is recommended to do this in connection with an overhaul of the separator. Clean the gear housing and the spindle parts thoroughly and remove all deposits before filling the new oil.

It is of utmost importance to use the lubricants recommended in our documentation. This does not exclude, however, the use of other brands, provided they have equivalently high quality properties as the brands recommended. The use of oil brands and other lubricants than recommended, is done on the exclusive responsibility of the user or oil supplier.

Applying, handling and storing of lubricants

Always be sure to follow lubricants manufacturer’s instructions.

NOTEAlways clean and dry parts (also tools) before lubricants are applied.

NOTE

Check the oil level before start. Top up when necessary. Oil volume see ‘‘4.1.1 Ready for start” on page 32.

191

oil Time in operation Oil change interval

1 000 — 1 500 h

2 000 h

2 000 h

8.4.2 Recommended lubricating oils

Alfa Laval ref. 553219-15 rev. 0

Two different groups of lubricating oils are approved for this separator.

They are designated as Alfa Laval lubricating oil groups A and D.

The numerical value after the letter states the viscosity grade.

The corresponding commercial oil brands are found in chapter ‘‘8.4.3 Recommended oil brands” on page 193.

Note:

• In a new installation or after change of gear transmission, change oil after 200 operating hours.

• When the separator is operated for short periods, lubricating oil must be changed every 12 months even if the total number of operating hours is less than stated in the recommendations above.

• Check and prelubricate spindle bearings on separators which have been out of service for 6 months or longer.

• In seasonal operation: change oil before every operating period.

Ambient temperature °C Alfa Laval lubricating group

between +15 and +60 A/320

between -10 and +60

between ±0 and +60

D/220

D/320

192

20 litres4 litres

208 litres1 litre

20

8.4.3 Recommended oil brands

Alfa Laval lubricating oil group A/320

Alfa Laval ref. 553218-11

Viscosity grade VG (ISO 3448/3104) 320

Viscosity index VI (ISO 2909) >95

Manufacturer Designation

Alfa Laval 546099-80546099-81546099-82546099-83

BP Bartran 320

Castrol Alpha ZN 320

Esso Standard Oil/Svenska Statoil/Exxon

Nuto 320Teresso 320Terrestic 320

Lubmarine/Beijer(ELF Brand designation according to ELF)

Polytelis 320

Mobil DTE Oil AAGencirc TQ 320

Q8/Kuwait (Gulf) Harmony AW 320

Shell Tellus C 320Vitrea 320Tellus 320

Texaco/Caltex Regal R&O 320Paper Machine HD 3

193

20 litres4 litres

208 litres1 litres

resso SHP 220

Alfa Laval lubricating oil group D/220

Alfa Laval ref. 553218-08 rev. 0

Viscosity grade VG (ISO 3448/3104) 220

Viscosity index VI (ISO 2909) > 130

Manufacturer Designation

Alfa Laval 542690-80542690-81542690-82542690-83

BP Enersyn HTX 220

Castrol Alpha Syn T 220

Chevron Ultragear 220

Esso/Exxon/Statoil Terrestic SHP 220, Te

Lubmarine/ELF Epona SA 220

Mobile (Engen) SHC 630

Q8/Kuwait /Gulf Schumann 220

Shell Paolina 220

194

Alfa Laval lubricating oil group D/320

Alfa Laval ref. 553218-06

( ) = available in a few countries

* These oils must be used when the frame temperature is about 80 °C.

If you can’t measure the temperature: about 80 °C is reached when you can touch the lower frame surface for a short time only.

Viscosity grade VG (ISO 3448/3104) 320

Viscosity index VI (ISO 2909) >130

Manufacturer Designation

Alfa LavalSeparation AB

542690- blue

Castrol Alpha Syn T 320

Lubmarine/Beijer(ELF Brand designation according to ELF)

Epona SA 320

Optimol Ölwerke Optigear HT 320

Q8/Kuwait Schumann 320

Chevron Ultragear 320

Esso/EXXON/Standard Oil/Svenska Statoil

Terrestic SHP 320

Mobil SHC 632

Shell (Delima HT 320)*(Paolina 320)

195

Alfa Laval No. Application

537086-04All pressure loaded surfaces

0 537086-02535586-01535586-02

Alfa Laval No.

539474-02539474-03

8.4.4 Recommended lubricants

Pastes and bonded coatings for non-food applicationsAlfa Laval ref. 553217-01 rev. 2

Silicone grease

Manufacturer Designation

Gleitmolybdän Gleitmo 805 K or805 K varnish 901Gleitmo Paste G rapid

Dow Corning Molykote paste 100spray D321 Rvarnish D321 R

Rocol Antiscuffing paste (ASP)

Klueber Wolfracoat C paste

Russian Standard VNII NP 232

Gost 14068-90

Manufacturer Designation

Dow Corning Molykote 111 compound100 g

25 g

Gleitmolybdän Silicone paste 750

Wacker Silicone Paste P(vacuum paste)

196

Alfa Laval No.

Greases for ball and roller bearingsAlfa Laval ref. 553217-01 rev.2

Manufacturer Designation

BP Energrease MMEP2Energrease LS2

Castrol Spheerol SW2 EPSpheerol EPL2

Chevron Duralith grease EP2

Exxon Beacon EP2

Mobil Mobilith SHC 460Mobilux EP2

Gulf Gulflex MP2

Q8 Rembrandt EP2

Shell Cailithia EP Grease T2Alvania EP Grease 2 or R.A

SKF LGEP2 or LGMT2

Texaco Multifak AF B2Multifak premium 2,3

Russian Standard Fiol 2M, Litol 24TU 38.201.188

197

198

Recommended free floor space for unloading when doing service

Min. access area for overhead hoist (no fixed piping within this area)

Center of gravity(without motor)

Vertical force not exceeding 20 kN/foot

Horizontal force not exceeding 20 kN/foot

G05

8581

1

8.5 Drawings

8.5.1 FoundationsAlfa Laval ref. 554895

A Min. lifting capacity 1000 kgB Max. height of largest

component incl. lifting toolC Center of separator bowlD 4 holes Ø 17 for anchorageE Service sideF Tightening torque 20 Nm

Locked with lock nutG M16 Minimum property class 8.8

199

G05

878

21

8.5.2 Electric motorAlfa Laval ref. 552813 rev. 2

Manufacturer ABB Motors

Manuf. drawing 3GZV 1000 007-4

Standards IEC 34-series, 72,79 and 85

Size 160M

Type M2AA 160M-4

Weight 62 kg

Poles 4

Insulation class F

Bearings DE 6209-2Z/C3 – NDE 6209-2Z/C3

Method of cooling IC 41 (IEC 34-6)

Spec. Totally enclosed three-phase motor for marine service 3)

Type of mounting Degree of protection

IM 1001

IM 3001

IM 3011

IM 3031

IP 55

IP 55

IP 55

A. 4xPg29, max. cable diameter 29 mm

200

w.fac os ϕ

|st / | 1) Therm 2)

°CNote

0,85 5,6

0,85 5,6

0,85 5,6

0,85 5,6

0,85 5,6

0,85 5,6

0,85 5,6 D-serD-par

0,85 5,6 D-serD-par

0,85 5,6 CSA- plated

0,85 5,6

0,85 5,6

0,85 5.6

0,85 5,6

1) lst /l = starting current /rated current at directon line starting.

2) Thermistors tripping temperature if applicable

3) The motors can be designed to fulfill requirements of following Classification Societies:

Lloyds Register of shipping (LRS) (Essential Service)Det Norske Veritas (DnV) (Essential Service)Germanischer Lloyd (GL) (Essential Service)Bureau Veritas (BV) (Essential Service)American Bureau of shipping (ABS) (Essential Service)Registro Italiano Navale (RINA) (Essential Service)USSR Register of Shipping (RSU) (Essential Service)Japanese ClassificationSociety (NKK) (Essential Service)

Required classification society must always be specified when ordering. Factory test certificate to be enclosed at the delivery.Rated output (kW) valid for temp-rise max. 90 °C.

Article No OutputkW

Speed RPM

FreqHz

Voltage V

CurrentA

Poc

552813-01 11,5 1445 50 200 D 44,5

552813-02 11,5 1445 50 220 D 40,5

552813-03 11,5 1445 50 380 D 23,5

552813-04 11,5 1445 50 415 D 21,5

552813-05 11,5 1445 50 440 D 20,5

552813-06 11,5 1445 50 500 D 18,9

552813-07 13 1745 60 220 D440 D

4723,5

552813-08 13 1745 60 230 D460 D

4522,5

552813-09 13 1745 60 575 D 18

552813-10 11,513

14451745

5060

380 D440 D

23,523,5

522813-111 11,5 1440 50 690Y400D

12,922,5

552813-12 13 1740 60 460D 22,5

552813-13 13 1740 60 460D 21,5

201

s 4

lation class 3

rings DE 6308-Z – NDE 6207-Z

hod of cooling IC 41 (IEC 34-6)

c. Totally enclosed fan cooled induction motor

Pow.fac cos ϕ

|st / | 1) Therm 2)

°CNote

0,86 8,2

G0

541

021

Alfa Laval ref. 552943

Manufacturer WEG, Brazil Pole

Manuf. drawing 003.10/03 1990 Insu

Standards IEC 34-1, IEC 72 Bea

Size IEC 132 M Met

Type WEG132 M Spe

Weight 68 kg

Article No. Output kW

Speed RPM

FreqHz

Voltage V

CurrentA

552943-01 11 1750 60 380 D 23

1) lst /l = starting current /rated current at direct on line starting.2) Thermistors tripping temp.

Type of mounting Degree of protection

IM 1001

IM 3001

IM 3011

IM 3031

IP 54

Note! This motor is for local use in Brazil only

202

FOPX 609TFD-24

ar XXXX

881244-02-03

561012-01

554048-05

540225-09/10 (50/60 Hz)

5175 r.p.m.(50 Hz), 5148 r.p.m. (60 Hz)

←

1500 r.p.m. (50 Hz), 1800 r.p.m. (60 Hz)

50/60 Hz

12 kW (50 Hz), 14 kW (60 Hz)

1100 kg/m3

1300 kg/m3

uid 1000 kg/m3

ax. 0/100 °C

FOPX 609TFD-24

G0

5443

11

8.5.3 Machine plates and safety labels

Alfa Laval ref. 554651

1. Machine plate

Separator

Manufacturing serial No / Ye

Product No

Machine top part

Bowl

Machine bottom part

Max. speed (bowl)

Direction of rotation (bowl)

Speed motor shaft

El. current frequency

Recommended motor power

Max. density of feed

Max. density of sediment

Max. density of operating liq

Process temperature min./m

Separator

S00

6141

1

203

S0

061

521

S0

0632

11

50Hz

60Hz

S0

063

111

3. Safety label

Text on label:

DANGER

Read the instruction manuals before installation, operation and maintenance. Consider inspection intervals.

Failure to strictly follow instructions can lead to fatal injury.

If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown.

Out of balance vibration will become worse if bowl is not full.

Separator must stop rotating before any dismantling work is started.

4. Name plate

6. Arrow

Indicating direction of rotation of horizontal driving device.

8. Power supply frequency

204

G0

5473

21

Interconnection diagram1-2 Reset coil3 No4 Common5 NC6-8 Heater

R Reset button

G0

5472

11

Interconnection diagram

8.5.4 Vibration sensor (option)Alfa Laval ref. 536498-80

For other technical information see chapter ‘‘8.2.2 Connection list” on page 183 and ‘‘8.2.3 Interface description” on page 185.

8.5.5 Cover interlocking switch (option)

For other technical information see chapter‘‘8.2.2 Connection list” on page 183 and‘‘8.2.3 Interface description” on page 185.

Type: Mechanical velocity

Switch rating, voltage: Max. 460 V AC

Reset coil: 24 V DC, 48 V DC,117 V AC 60 Hz

Switch rating

AC (VA) DC (W)

12 V 75 7

24 V 200 7

48 V 280 9

127 V 500 13

230 V 550 –

BKBNBUGNYW

BlackBrownBlueGreenYellow

205

8.6 Storage and installation

8.6.1 Introduction

Most of the instructions are specifications, which are compulsory requirements.

These specifications are sometimes completed with non-compulsory recommendations, which could improve the installation quality.

Additional installation information, such as drawings and component installation instructions, can be found previous in this chapter.

8.6.2 Storage and transport of goods

Storage

Specification

Upon arrival to the store, check all components and keep them:

1. Well stored and protected from mechanical damage and theft.

2. Dry and protected from rain and humidity.

3. Organized in the store for ease of access during installation.

A separator can be delivered with different types of protection:

206

G04

020

51

Fixed on a pallet

G04

0206

1

In a wooden box which is not water tight

G0

402

071

In a special water-resistant box for outdoor storage

A separator can be delivered with different types of protection:

• Fixed on a pallet.

The separator must be stored in a storage room well protected from mechanical damage and theft and also dry and protected from rain and humidity.

• In a wooden box which is not water tight.

The separator must be stored dry and protected from rain and humidity.

• In a special water-resistant box for outdoor storage.

The separator and its parts have been treated with an anti-corrosion agent. Once the box has been opened, store dry and protected from rain and humidity.

The packaging for outdoor storage is to special order only.

207

G00

206

11

Check the drawings when planning the installation

Transport

Specification

• During transport of the separator, the frame hood and bowl must always be removed from the machine.

• When lifting a separator it must always be hung securely . See chapter ‘‘5.5 Lifting instructions” on page 81.

• During erection, all inlets and outlets to separators and accessories must be covered to be protected from dirt and dust.

8.6.3 Planning of installation

Introduction

The space required for one or more separators can be calculated by consulting the drawings in the chapters ‘‘8.2 Basic size drawing” on page 181, ‘‘8.5.1 Foundations” on page 199 and instructions for ancillary equipment, electrical and electronic equipment and cables.

WARNING

Crush hazards

Use correct lifting tools and follow lifting instructions.

208

G0

0207

21

Suitable space must be obtained for the maintenance work

Important measurements

Important measurements are the minimum lifting height for lifting tackle, shortest distance between driving motor and wall, free passage for dismantling and assembly, maintenance and operation.

Plan your installation with sufficient room for the controls and operation so that instruments are easily visible. Valves and controls must be within convenient reach. Pay attention to space requirements for maintenance work, work benches, dismantled machine parts or for a service trolley.

Space for separator

The separator shall be placed in such a way that suitable space for maintenance and repair is obtained.

Specification

• See chapter ‘‘8.5.1 Foundations” on page 199 for the service space required with the separator installed.

Recommendation

• The spanner for the large lock ring should have sufficient space to make a complete turn without touching any of the ancillary equipment surrounding the separator.

Lifting height for transport of bowl

Specification

• A minimum height is required to lift the bowl, bowl parts and the bowl spindle, see chapter ‘‘8.5.1 Foundations” on page 199.

Recommendation

• When two or more separators are installed, the lifting height may have to be increased to enable parts from one separator to be lifted and moved over an adjoining assembled separator.

209

G00

3592

1

Place the separator in such a way that makes the oil change easy

Space for oil changing

Specification

The plug for gearbox oil draining must not be blocked by floor plate arrangement, etc.

Recommendation

• It should be possible to place a portable collecting tray under the gearbox drain plug for changing oil.

210

G0

5478

11

F = ForwardA = Aft

G0

2589

11

1. Vibration damper, upper2. Vibration damper, lower3. Nut4. Lock nut

8.6.4 Foundation

Specification

• The separator should be installed at floor level, see chapter ‘‘8.5.1 Foundations” on page 199.

• When a separator is installed on a ship, the separator should be installed in such a way that the centre line of the electric motor is parallel with the centre line of the ship. The electric motor should preferably be pointing aft.

• The separator must be installed on a strong and rigid foundation to reduce the influence of vibrations from adjacent machinery.

• The foundation should be provided with a cofferdam.

• Fit the separator frame on the foundation as follows:

— Place the separator frame without cushions in position.

— Check that the bolts do not press against the edges of the holes, otherwise the elasticity of the mounting of the separator frame will be impeded.

— Fit height adjusting washers required.

— Check that the separator frame is horizontal and that all feet rest on the foundation.

— Lift the separator frame, fit the vibration dampers (1, 2), lower and check that the bolts do not press against the edges of the holes.

— Tighten nut (3) with 20 Nm. Hold firmly and secure with the lock nut (4). Repeat for the other frame feet.

NOTE

When lifting a separator it must always be hung securely . See chapter ‘‘5.5 Lifting instructions” on page 81..

211

212

e manuals as possible. Should you have any ual, please note them down and send them to g it by fax, or you could mail it, or hand it over

SKL, S-147 80 Tumba, Sweden.

Company:

City:

Book No.: 1270843-02 V1

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Reader’s Comment Form

Dear reader,

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Date:

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215

216

Index

A

AssemblyBowl body and operating mechanism 126Bowl hood and disc stack 114General directions 99Horizontal driving device 161Inlet/outlet, frame hood 104Operating water device 136Tools (special) 100Vertical driving device 148

B

BearingsMaintenance directions 93Replacement on bowl spindle 140Replacement on horizontal driving device 154

Bowl 50Assembly 114, 126Dismantling 107, 121

Bowl discsCleaning 85Disc stack pressure 55

Bowl spindleAssembly 148Dismantling 143

BrakeDesign and function 19Renewing of brake lining 68

C

Centrifugal separation 17Check points

Ball and roller bearings 93Before shutdowns 96Bowl hood seal ring 50Bowl spindle — height position 67Bowl spindle — radial wobble 68Bowl spindle cone and bowl body nave 67Brake lining 68Buffer springs and ball bearing housing 69Cleaning agents 84Cleaning of bowl discs 85Corrosion 51Coupling friction pads 71Cover interlocking switch 66Cracks 54

Disc stack pressure 72Dosing ring 57Erosion 57External cleaning 83Flexible plate in coupling 73Guide surfaces 59, 74Inlet pipe and oil paring disc 61Level ring 61Lifting instructions 81Lock ring — priming 75Lock ring — wear and damage 77Oil change procedure 90Oil paring disc — height position 77Operating mechanism 63Operating paring disc — height position 78Operating slide 64Repair of galling 60Sliding bowl bottom 64Springs for operating mechanism 65Vibration analysis 91Vibration switch — adjustment of set point 92Vibration switch — function check 66Worm — wear of groove 79Worm wheel and worm — wear of teeth 87Worm wheel shaft — radial wobble 80

ClarifierDefinition 29Description 26

CleaningCIP-system 86Cleaning agents 84Cleaning of bowl discs 85External cleaning 83

Connection list 183Connections

Description 185Dimensions 182

Corrosion 51Coupling

Function 20Renewing of friction elements 71

Cover interlocking switch (option)Design and function 21Drawing 205

Cracks 54

217

D

Daily checks 43Density of feed 179Disc 55Disc stack pressure 55Dismantling

Bowl body and operating mechanism 121Bowl hood and disc stack 107General directions 99Horizontal driving device 156Inlet/outlet, frame hood 102Operating water device 133Tools 100Vertical driving device 148

DrawingsCover interlocking switch (option) 205Dimensions of connections 182Electric motor 200Foundations 199Machine plates and safety labels 203Vibration sensor (option) 205

E

Electric motorDrawings 202See Motor 200

Emergency stop. See Safety stopErosion 57Exploded views

Bowl body and operating mechanism 120Bowl hood and disc stack 106Horizontal driving device 154Inlet/outlet, frame hood 101Operating water device 131Vertical driving device 140

F

FoundationsDrawing 199Installation 211

Frame feetInstallation 211Replacement 49

Friction couplingFunction 20

G

GearNumber of teeth 179Wear of teeth 87

Guide surfacesIntermediate Service 59Major Service 74Repair of galling 60

H

Horizontal driving deviceAssembly 161Dismantling 156

I

Installation 208Interface

Definition 29Description 27

Interface description 185Intermediate service 39, 44

L

Lifting instructions 81Lock ring

Priming 75Wear and damage 62

LubricantsLubrication chart, general, oil groups 190Oil change interval 192Oil change procedure 90Oil level 90Recommended greases 197Recommended lubricating oils 192Recommended oil brands 193Recommended pastes and bonded coatings 196Volume of lubricating oil 180

M

Machine plates and safety labels 203Main parts 19Maintenance intervals 40Maintenance logs

3-year Service (3S) 49Daily checks 43Intermediate Service (IS) 44Major Service (MS) 46Oil change 43

Maintenance, general informationBall and roller bearings 93Before shutdowns 96Cleaning 83Lifting instructions 81Maintenance intervals 39Maintenance procedure 41Oil change procedure 90Service kits 42Vibration analysis 91

Major service 39, 46Materials 179

218

Metal surfacesCleaning and cleaning agents 83, 84Corrosion 51Cracks 54Erosion 57

MotorCleaning 83Coupling 73Drawing 200Power consumption 179

N

Noise 179

O

Oil. See LubricationOperation 32

P

Power consumption 179Power transmission 20Process capacity 179Purification

Definition 29

R

Ready for start 32Revolution counter

Design and function 21Number of revolutions 179

S

Safety Instructions 9Separation

Basic principles 17Process main parts 23Separating function trouble tracing 172Separation temperatures 18

SeparatorBasic size drawing 181Brake 20Connection list 183Foundations 199Installation planning 208Interface description 185Lifting instructions 81Main parts 23Mechanical power transmission 20Normal stop 35Overview 19

Ready for start 32Running 34Safety stop 36Sensors and indicators 21Separating function 26Sludge discharge cycle 27Start 33Storage and transportation 206Technical data 179

Service instructions. See Check pointsService kits 42Shutdown 96Start 33Stopping procedure 35Storage 206

T

Technical data 179Throughput

Capacity 179Definition 29

Transport 206Trouble tracing — mechanical functions

Noise 169Retardation time too long 170Separator vibrates 168Smell 169Speed too low 169Starting power too high 170Starting power too low 170Starting time too long 170Water in worm gear housing 171

Trouble tracing — separating functionsBowl fails to open 173Bowl opens accidentally 173Unsatisfactory separation result 174

Trouble tracing — vibration switchImpossible to adjust setpoint to obtain tripping 175Vibration switch does not reset 175

V

Vertical driving deviceDismantling 143

VibrationDuring start 33Trouble tracing 168Vibration analysis 91

Vibration switch (option)Adjustment of setpoint 92Description and signal processing 186Drawing 205Function check 66Trouble tracing 175

219

W

Warning signs 13Weight 179Worm gear

Function and description 20Number of teeth 179Wear of teeth 87

220

• Contents

• Table of Contents

• Bookmarks

Summary of Contents for Alfa Laval A MRPX 614HGV-14C