Alfa Laval MOPX 205 TGT-24 Manual
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Alfa Laval MOPX 205 TGT-24 Manual

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proyectos@fdm.com.pe
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Movil:959440045
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881034-01-08
1270366-02 V2
AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA
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S
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www.fdm.com.pe
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  • Page 1 Product No. 881034-01-08 proyectos@fdm.com.pe Book No. 1270366-02 V2 fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...
  • Page 2 Telephone: +46 8 53 06 50 00 Telefax: +46 8 53 06 50 29 Printed in Sweden, 96-10 © Alfa Laval Separation AB 1996 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.

  • Page 3: Table Of Contents

    Contents Read this first Safety Instructions Separator Basics 3.1 Basic principles of separation 3.2 Design and function 3.3 Separating function 3.4 Definitions Operating Instructions 4.1 Operating routine Service Instructions 5.1 Periodic maintenance 5.2 Maintenance Logs 5.3 Check points at Intermediate Service (IS) 5.4 Check points at Major Service (MS) 5.5 Lifting instructions 5.6 Cleaning...
  • Page 4 6.6 Vertical driving device (MS) 6.7 Horizontal driving device (MS) 6.8 Built-on oil feed pump Trouble-tracing 7.1 Mechanical function 7.2 Separation faults, purifier and clarifier 7.3 Separation faults, purifier 7.4 Separation faults, clarifier Technical Reference 8.1 Technical data 8.2 Connection list 8.3 Interface description 8.4 Water quality 8.5 Lubricants...
  • Page 5 Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents. In order to make the information clear only foreseeable conditions have been considered. No warnings are given, therefore, for situations arising from the unintended usage of the machine and its tools.
  • Page 6 proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...

  • Page 7: Read This First

    15 and chapter ‘‘8 Technical Reference” on page 169. 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.
  • Page 8 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.

  • Page 9: Safety Instructions

    • 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. proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA...
  • Page 10 2 Safety Instructions DANGER Disintegration hazards • Use the separator only for the purpose m /h and parameter range specified by Alfa Laval. kg/m • If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown. •...
  • Page 11 2 Safety Instructions 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.
  • Page 12 2 Safety Instructions 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. proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA –...
  • Page 13 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...
  • Page 14 2 Safety Instructions proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...

  • Page 15: Separator Basics

    3 Separator Basics Contents 3.1 Basic principles of separation 3.2 Design and function 3.2.1 Application 3.2.2 Overview 3.2.3 Mechanical power transmission 3.2.4 Sensors and indicators 3.2.5 Inlet pump (option) 3.2.6 Process main parts 3.3 Separating function 3.3.1 Purifier bowl 3.3.2 Clarifier bowl 3.3.3 Normal separation...

  • Page 16: Basic Principles Of Separation

    3 Separator Basics 3.1 Basic principles of separation 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, •...
  • Page 17 3.1 Basic principles of separation 3 Separator Basics 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.

  • Page 18: Design And Function

    3.2 Design and function Design and function 3.2.1 Application The MOPX 205 TGT-24 is a high-speed centrifugal separator intended for marine and land applications. It is specifically designed for cleaning of mineral oils from water and solid particles (sludge). The cleaned oil is discharged continuously, while the sludge is discharged at intervals.

  • Page 19: Overview

    3.2 Design and function 3 Separator Basics 3.2.2 Overview The separator comprises a processing part and a driving part. It is driven by an electric motor (10). Mechanically, the separator machine frame is composed of a bottom part, a top part and a frame hood.

  • Page 20: Mechanical Power Transmission

    3 Separator Basics 3.2 Design and function 3.2.3 Mechanical power transmission The main parts of the power transmission between motor and bowl are shown in the illustration. The friction coupling ensures a gentle start and acceleration and at the same time prevents overloading of the worm gear and motor.

  • Page 21: Sensors And Indicators

    3.2 Design and function 3 Separator Basics 3.2.4 Sensors and indicators Revolution counter (1) A revolution counter indicates the speed of the separator and is driven from the worm wheel shaft. The correct speed is needed to achieve the best separating results and for reasons of safety. The number of revolutions on the revolution counter for correct speed is shown in chapter ‘‘8 Technical Reference”...

  • Page 22: Inlet Pump (Option)

    3 Separator Basics 3.2 Design and function Back pressure gauge (4) Correct limits for the back pressure in the clean oil outlet can be found in chapter ‘‘8.2 Connection list” on page 172. Increasing back pressure in the clean oil outlet can be caused by: •...

  • Page 23: Process Main Parts

    3.2 Design and function 3 Separator Basics 3.2.6 Process main parts Water paring chamber Gravity disc or clarifier disc Small lock ring (with paring chamber cover) Oil paring chamber Level ring Distributor Top disc Bowl hood Bowl disc stack 10. Large lock ring 11.
  • Page 24 3 Separator Basics 3.2 Design and function Inlet and outlet device The inlet and outlet device consists of the following parts: • The inlet (201). This comprises the feed connection and the long inlet pipe (20) which extends into the middle of the bowl. •...
  • Page 25 3.2 Design and function 3 Separator Basics 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 (15) and an operating paring disc device.

  • Page 26: Separating Function

    3 Separator Basics 3.3 Separating function Separating function 3.3.1 Purifier bowl Characteristic parts The illustration shows characteristic parts of the purifier bowl: 1. The gravity disc, which should be chosen according to directions in chapter ‘‘4.1.2 Selection of gravity disc” on page 36. The gravity disc determines the interface position (see below) in a purifier bowl.
  • Page 27 3.3 Separating function 3 Separator Basics Correct interface position Wrong interface position - broken water seal Wrong interface position - bad separation Factors influencing the interface position: 1. Oil viscosity, density and throughput Oil with high density and/or high viscosity, as well as high throughput, will position the oil/water interface closer to the bowl periphery than for oil with low properties.

  • Page 28: Clarifier Bowl

    3 Separator Basics 3.3 Separating function 2. Gravity disc To compensate for the above factors the interface is adjusted to a correct position by altering the outlet for the water, i.e. exchanging the gravity disc. Changing to a gravity disc with a larger hole diameter will move the interface towards the bowl periphery whereas a disc with a smaller hole diameter will move the interface closer to the bowl...

  • Page 29: Normal Separation

    3.3 Separating function 3 Separator Basics 3.3.3 Normal separation Unseparated oil is fed into the bowl through the inlet pipe (11) and is led via the distributor (4) and distributing cone (12) towards the periphery of the bowl. When the oil reaches slots of the distributor, it will rise through the channels formed by the disc stack (6) where it is evenly distributed into the disc stack.

  • Page 30: Sludge Discharge Cycle

    3 Separator Basics 3.3 Separating function 3.3.4 Sludge discharge cycle Sludge discharge interval The MOPX-separator is a total-discharge type separator which completely discharges sludge and water from the bowl. The appropriate time to be choosen between sludge discharges depends on local conditions because many factors influence accumulation and hardening of sludge between discharges.
  • Page 31 3.3 Separating function 3 Separator Basics Closed bowl (normal operation) The sliding bowl bottom (2) is pressed upwards by force of the closing water in the closing water space (6) under the sliding bowl bottom which is greater than the force of the process liquid above the sliding bowl bottom.

  • Page 32: Definitions

    3 Separator Basics 3.4 Definitions Definitions Back pressure Pressure in the separator outlet. Clarification Liquid/solids separation with the intention of separating particles, normally solids, from a liquid (oil) having a lower density than the particles. Clarifier disc An optional disc, which replaces the gravity disc in the separator bowl, in the case of clarifier operation.

  • Page 33: Operating Instructions

    4 Operating Instructions Contents 4.1 Operating routine 4.1.1 Before first start 4.1.2 Selection of gravity disc 4.1.3 Ready for start 4.1.4 Start and running-up 4.1.5 Running 4.1.6 Normal stop 4.1.7 Safety stop proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA –...

  • Page 34: Operating Routine

    4 Operating Instructions 4.1 Operating routine Operating routine These operating instructions are related only to the separator itself. If the separator is part of a system or module, also follow the instructions for the system. 4.1.1 Before first start Technical demands for connections and logical limitations for the separator are listed in chapter ‘‘8 Technical Reference”...
  • Page 35 4.1 Operating routine 4 Operating Instructions Clarification When the separator is run as a clarifier, select the gravity disc with the smallest hole diameter. See the Spare Parts Catalogue for actual diameters delivered. Purification The best separation results are obtained by using a gravity disc with as large a hole diameter as possible, which will not cause a broken water seal in the bowl or an emulsification in the water outlet.

  • Page 36: Ready For Start

    4 Operating Instructions 4.1 Operating routine 4.1.3 Ready for start To achieve the best separation results the bowl should be in a clean condition. 1. Check that the hinged bolts for the frame hood are fully tightened. 2. Check that all inlet and outlet connections have been correctly made and properly tightened.

  • Page 37: Start And Running-Up

    4.1 Operating routine 4 Operating Instructions 4.1.4 Start and running-up 1. Start the separator. 2. Check the direction of rotation of the bowl. The revolution counter should turn clockwise. DANGER Disintegration hazards When power cables have been connected, Check for correct direction of rotation always check direction of rotation.
  • Page 38 4 Operating Instructions 4.1 Operating routine 5. Check, if possible, the current consumption 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 idling value, which is slightly lower than the normal operating value.

  • Page 39: Running

    4.1 Operating routine 4 Operating Instructions 4.1.5 Running 1. Check that the feed has the correct flow and temperature. See chapter ‘‘8 Technical Reference” on page 169 for correct values. 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.

  • Page 40: Safety Stop

    Out-of-balance vibration can become worse! 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. proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV.

  • Page 41: Service Instructions

    5 Service Instructions Contents 5.1 Periodic maintenance 5.4 Check points at Major Service (MS) 5.1.1 Introduction 5.4.1 Bowl hood seal ring 5.1.2 Maintenance intervals 5.4.2 Bowl spindle cone and bowl body nave 5.1.3 Maintenance procedure 5.4.3 Bowl spindle; radial wobble 5.1.4 Service kits 5.4.4...
  • Page 42 5 Service Instructions 5.6 Cleaning 5.6.1 External cleaning 5.6.2 Cleaning agents 5.6.3 Cleaning of bowl discs 5.7 When changing oil 5.7.1 Worm wheel and worm; wear of teeth 5.7.2 Oil change procedure 5.8 Vibration 5.8.1 Vibration analysis 5.9 Common maintenance directions 5.9.1 Ball and roller bearings 5.9.2...

  • Page 43: Periodic Maintenance

    5.1 Periodic maintenance 5 Service Instructions 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. DANGER Disintegration hazards Separator parts that are either worn beyond their safe limits or incorrectly assembled may cause severe damage or fatal injury.
  • Page 44 5 Service Instructions 5.1 Periodic maintenance 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...
  • Page 45 5.1 Periodic maintenance 5 Service Instructions 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.
  • Page 46 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 spare parts may cause severe damage.

  • Page 47: Maintenance Logs

    5.2 Maintenance Logs 5 Service Instructions Maintenance Logs 5.2.1 Daily checks The following steps should be carried out daily. Main component and activity Part Page Notes Inlet and outlet Check for leakage Connecting housing – Separator bowl Check for vibration and noise Horizontal driving device Worm wheel shaft and gear casing Check for vibration and noise...
  • Page 48 5 Service Instructions 5.2 Maintenance Logs 5.2.3 Intermediate Service (IS) Name of plant: Local identification: Separator: MOPX 205 TGT-24 Manufacture No./Year: Total running hours: Product No: 881034-01-08 Date: Signature: Main component and activity Part Page Notes Inlet and outlet Clean and inspect...
  • Page 49 5.2 Maintenance Logs 5 Service Instructions Main component and activity Part Page Notes Horizontal driving device Worm wheel shaft and gear housing Check Worm wheel and worm Renew Oil in gear housing Electrical motor Lubrication (if nipples are fitted) See sign on motor –...
  • Page 50 5 Service Instructions 5.2 Maintenance Logs 5.2.4 Major Service (MS) Name of plant: Local identification: Separator: MOPX 205 TGT-24 Manufacture No./Year: Total running hours: Product No: 881034-01-08 Date: Signature: Main component and activity Part Page Notes Inlet and outlet Clean and inspect...
  • Page 51 5.2 Maintenance Logs 5 Service Instructions Main component and activity Part Page Notes Paring disc device Clean and check Operating paring disc – Check Height position of operating paring disc Vertical driving device Clean and check Bowl spindle – Buffer springs and ball bearing housing Radial wobble of bowl spindle Renew...
  • Page 52 5 Service Instructions 5.2 Maintenance Logs Main component and activity Part Page Notes Oil feed pump (if applicable) Cleaning and inspection Bushings, wear gaskets, flexible coupling, relief/safety valve and impeller shaft Lipseal rings Renew Note! Renew all parts included in the Intermediate Service kit (IS) and Major Service kit (MS) proyectos@fdm.com.pe fdmsac@gmail.com...
  • Page 53 5.2 Maintenance Logs 5 Service Instructions 5.2.5 3-year Service (3S) Renew the frame feet as described below. The 3- year service should be carried out in conjunction with a Major Service (MS). Frame feet, renewal 1. Disconnect pipes, hoses and cables connected to the separator.

  • Page 54: Check Points At Intermediate Service (Is)

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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).
  • Page 55 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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.
  • Page 56 5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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.
  • Page 57 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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. Polish corrosion marks to prevent further damage DANGER Disintegration hazard...
  • Page 58 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.

  • Page 59: Lock Ring

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions 5.3.5 Disc stack pressure 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.
  • Page 60 Disintegration hazard Inspect regularly for erosion damage. Inspect frequently if the process liquid is erosive. 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.
  • Page 61 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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. Replace the part if erosion can be suspected of affecting its strength or function.
  • Page 62 Repair of galling on guide surfaces; see following pages. Before fitting the sliding bowl bottom, clean (do not degrease) the contact surfaces (1 and 2). Apply Alfa Laval lubricating paste or Molykote 1000 Paste with a well-cleaned brush Sliding bowl bottom on surfaces (1 and 2).
  • Page 63 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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.

  • Page 64: Level Ring

    Prime the repaired area with lubricating spray Molykote 321 R. Read the correct procedure under checkpoint ‘‘5.4.15 Lock ring; priming” on page 80. Apply Alfa Laval lubricating paste or Molykote 1000 Paste to the surface after priming. 5.3.8 Inlet pipe and oil paring disc...
  • Page 65 φ−mark on the bowl body by more than 25°, 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 The φ -mark on the lock ring must not pass the φ -mark position of new alignment marks.
  • Page 66 5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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.
  • Page 67 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 5.3.11 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: •...

  • Page 68: Sliding Bowl Bottom

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 5.3.13 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.
  • Page 69 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 5.3.14 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.

  • Page 70: Check Points At Major Service (Ms)

    5 Service Instructions 5.4 Check points at Major Service (MS) Check points at Major Service (MS) 5.4.1 Bowl hood seal ring Same as described in ‘‘5.3.1 Bowl hood seal ring” on page 56. 5.4.2 Bowl spindle cone and bowl body nave Same as described in ‘‘5.3.2 Bowl spindle cone and bowl body nave”...
  • Page 71 5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.4 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 The screws are slotted in both ends. Friction pad is fastened with screws If the friction pad is oily: •...
  • Page 72 5 Service Instructions 5.4 Check points at Major Service (MS) 5.4.5 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 run). Top bearing springs In case of spring fracture, the complete set of springs should be replaced, even if only one...
  • Page 73 5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.6 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 3 minutes or the bowl loses speed during operation, the friction pads of the coupling may be worn or oily.

  • Page 74: Corrosion

    5 Service Instructions 5.4 Check points at Major Service (MS) Different friction blocks for different power supply frequencies When mounting new friction blocks, check that the blocks are correct for the power supply frequency. The measure A is different for 50 and 60 Hz separators.
  • Page 75 5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.11 Elastic plate in coupling The axial play (1) of the flexible plate should be approximately 2 mm. Location of the axial play (1) in the flexible coupling Check the play as follows: Fit the elastic plate in its place in the coupling disc of the separator.
  • Page 76 5 Service Instructions 5.4 Check points at Major Service (MS) 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. Measure of distance for coupling on motor proyectos@fdm.com.pe fdmsac@gmail.com...
  • Page 77 Bowl body properly done. 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 excessive paste.
  • Page 78 5 Service Instructions 5.4 Check points at Major Service (MS) 5.4.14 Level ring Same as described in section ‘‘5.3.9 Level ring” on page 66. 5.4.15 Lock ring; priming The arrows indicate positions of threads, guide and contact surfaces to be primed. Recommended agents for priming procedure: •...
  • Page 79 5.4 Check points at Major Service (MS) 5 Service Instructions 3. Use a fibre brush to polish the slide lacquer into the surface. The black spray will look like well-polished leather when properly done. 4. Spray the lock ring a second time and let it dry for about 15 minutes.
  • Page 80 5 Service Instructions 5.4 Check points at Major Service (MS) 5.4.16 Lock ring; wear and damage Same as described in section ‘‘5.3.10 Lock ring; wear and damage” on page 67. 5.4.17 Oil paring disc; height position The height position of the oil paring disc should be checked if the bowl spindle has been removed or the bowl has been replaced.
  • Page 81 5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.19 Control paring disc device; height position Incorrect height position may cause the control paring disc to scrape against the distributing cover. If the bowl spindle has been removed, the height position of the operating paring disc device relative to the spindle top must be checked.
  • Page 82 Permissible radial wobble is max. 0,10 mm. If the wobble is larger, 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 replaced.

  • Page 83: Lifting Instructions

    5.5 Lifting instructions 5 Service Instructions Lifting instructions 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. Attach two endless slings or cables to the separator frame as illustrated.

  • Page 84: Cleaning

    5 Service Instructions 5.6 Cleaning 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.
  • Page 85 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 and lube oil Alfa Laval cleaning liquid for fuel oil separators separators has been developed for this purpose.
  • Page 86 5 Service Instructions 5.6 Cleaning 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.

  • Page 87: When Changing Oil

    5.7 When changing oil 5 Service Instructions When changing oil 5.7.1 Worm wheel and worm; wear of teeth To check at each oil change Check the teeth of both the worm wheel and worm for wear. See the ‘‘ Tooth appearance examples” on page 91.
  • Page 88 5 Service Instructions 5.7 When changing oil NOTE Presence of metal chips in the oil bath is an indication that the gear is wearing abnormally. 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.
  • Page 89 5.7 When changing oil 5 Service Instructions 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. Satisfactory teeth Worn teeth: Permissible wear is as a rule 1/3 of the thickness...
  • Page 90 5 Service Instructions 5.7 When changing oil 5.7.2 Oil change procedure 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 ‘‘8.5 Lubricants” on page 180 must be well known.

  • Page 91: Vibration

    5.8 Vibration 5 Service Instructions 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.

  • Page 92: Common Maintenance Directions

    The bearings used for the bowl spindle are special to withstand the speed, vibration, temperature and load characteristics of high- speed separators. Only Alfa Laval genuine spare parts should be used. 1. Outer race A bearing that in appearance looks equivalent to 2.
  • Page 93 5.9 Common maintenance directions 5 Service Instructions NOTE Do not hit with a hammer directly on the bearing. 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.
  • Page 94 5 Service Instructions 5.9 Common maintenance directions • 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. −...
  • Page 95 5.9 Common maintenance directions 5 Service Instructions 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 NOTE The bowl must not be left on the spindle during standstill for more than one week.
  • Page 96 5 Service Instructions 5.9 Common maintenance directions proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...

  • Page 97: Dismantling/Assembly

    6 Dismantling/Assembly Contents 6.1 Introduction 6.7 Horizontal driving device (MS) 6.1.1 General directions 6.7.1 Exploded view 6.1.2 References to check points 6.7.2 Dismantling 6.1.3 Tools 6.7.3 Assembly 6.2 Inlet/outlet, frame hood (IS) 6.8 Built-on oil feed pump 6.2.1 Exploded views 6.8.1 Exploded view 6.2.2...

  • Page 98: Introduction

    6 Dismantling/Assembly 6.1 Introduction 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 45. DANGER Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work.

  • Page 99: References To Check Points

    6.1 Introduction 6 Dismantling/Assembly 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 ‘‘5.3.5 Disc stack pressure” on page 61. In this example, look up check point Disc stack pressure in chapter 5 for further instructions.

  • Page 100: Inlet/Outlet, Frame Hood (Is)

    6 Dismantling/Assembly 6.2 Inlet/outlet, frame hood (IS) Inlet/outlet, frame hood (IS) 6.2.1 Exploded views O-ring Inlet pipe O-ring Support Connecting housing (with sight glass and pressure gauge) Protecting washer Height adjusting ring Frame hood Screw 10. Washer 11. Screw proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe...

  • Page 101: Dismantling

    6.2 Inlet/outlet, frame hood (IS) 6 Dismantling/Assembly 6.2.2 Dismantling 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 indicate if separator parts are rotating or not.

  • Page 102: Assembly

    6 Dismantling/Assembly 6.2 Inlet/outlet, frame hood (IS) 6.2.3 Assembly 1. Put the frame hood in place and clamp it with the hinged bolts. 2. Lubricate the sealing rings for the inlet/outlet device with silicone grease. Renew the sealing rings at each Intermediate Service (IS).

  • Page 103: Bowl Hood And Disc Stack (Is)

    6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly Bowl hood and disc stack (IS) 6.3.1 Exploded view Paring chamber cover (small lock ring) 10. Bowl hood with seal ring O-ring 11. Top disc Upper paring disc 12. Oil paring disc Guide sleeve with gasket 13.

  • Page 104: Dismantling

    6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 6.3.2 Dismantling 1. Unscrew the small lock ring (paring chamber cover) by using the special spanner. Left-hand thread! 2. Remove the lock ring, paring disc, guide sleeve, gasket and gravity disc. 3.
  • Page 105 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 4. Fit the lifting tool on the bowl hood. 5. 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. 6.
  • Page 106 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 9. Remove the top disc. 10. Screw the inlet pipe into the oil 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.

  • Page 107: Assembly

    6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 6.3.3 Assembly Check point ‘‘5.3.3 Corrosion” on page 57, ‘‘5.3.4 Cracks” on page 60, ‘‘5.3.6 Erosion” on page 62, ‘‘5.3.10 Lock ring; wear and damage” on page 1. Assemble the discs one by one on the distributor.
  • Page 108 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 3. Check that the guide pin in the distributing cone (in line with guide lug B) fits into the recess on the underside of the distributor. The recess is in line with the disc guide rib (A).
  • Page 109 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly Check point ‘‘5.3.1 Bowl hood seal ring” on page 56. 6. Fit the lifting tool to the bowl hood and lift it using hoist. Check that the seal rings of the bowl hood are properly fitted and lubricated.
  • Page 110 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 8. Remove the lifting tool. 9. Lubricate the lock ring threads, contact and guide surfaces with lubricating paste. Check point ‘‘5.4.15 Lock ring; priming” on page 80 (only at Major Service). 10.
  • Page 111 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 12. Assemble the upper paring disc and the guide sleeve to the small lock ring (paring chamber cover). Then fit the gravity disc and the lock ring assembly to the bowl hood. Check point ‘‘5.3.8 Inlet pipe and oil paring disc”...

  • Page 112: Bowl Body And Operating Mechanism (Is)

    6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 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. Screw 7. Bowl body 8. Nozzle 9.

  • Page 113: Dismantling

    6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 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 hoist.
  • Page 114 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 5. Fit the lifting tool onto the bowl body bottom. If necessary, unscrew the central screw. Release the bowl body from the spindle by using the lifting tool as a puller. Turn the eye of the central screw of the lifting tool until the bowl body comes loose from the spindle taper.
  • Page 115 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 9. Remove the spring support and the springs. 10. Remove the operating slide and place it with the valve plugs facing upwards. 11. Remove any thick deposits in the frame hood and clean all other parts thoroughly in a suitable cleaning agent.

  • Page 116: Assembly

    6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 6.4.3 Assembly Check point ‘‘5.3.3 Corrosion” on page 57, ‘‘5.3.4 Cracks” on page 60, ‘‘5.3.6 Erosion” on page 62, ‘‘5.3.7 Guide surfaces” on page 64 (IS), ‘‘5.4.12 Guide surfaces” on page 79 (MS), ‘‘5.3.11 Operating mechanism”...
  • Page 117 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 5. Wipe off the spindle top and nave bore in the bowl body. Apply a drop of oil to the tapered end of the spindle, smear it over the surface and wipe it off with a clean cloth. Check point ‘‘5.3.2 Bowl spindle cone and bowl body nave”...
  • Page 118 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 11. Fit the distributing cone onto the sliding bowl bottom. Check that the guide pins on the underside of the distributing cone enter the recesses in the sliding bowl bottom. 12. Screw on the cap nut and tighten firmly. Left-hand thread! proyectos@fdm.com.pe fdmsac@gmail.com...

  • Page 119: Paring Disc Device For Operating Water (Is)

    6.5 Paring disc device for operating water (IS) 6 Dismantling/Assembly Paring disc device for operating water (IS) 6.5.1 Exploded view Ring nut Control paring disc O-ring O-ring Distributing ring Gasket Screw Washer Screen 10. Rectangular ring 11. Distributing cover 12. Gasket 13.
  • Page 120 6 Dismantling/Assembly 6.5 Paring disc device for operating water (IS) 6.5.2 Dismantling 1. Remove the operating device 2. Remove the screen 3. Ease off the ring nut. Remove the distributing cover together with the paring disc device. 4. Dismantle the parts in the sequence appearing from the exploded view.
  • Page 121 6.5 Paring disc device for operating water (IS) 6 Dismantling/Assembly 6.5.3 Assembly 1. Assemble the parts to the distributing cover in the sequence appearing from the exploded view. Ensure the parts are placed in positions defined by guides. 2. Fit the distributing cover with the paring disc assembly and the height adjusting ring (see arrow).
  • Page 122 6 Dismantling/Assembly 6.5 Paring disc device for operating water (IS) 5. Fit the operating device. proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...

  • Page 123: Vertical Driving Device (Ms)

    6.6 Vertical driving device (MS) 6 Dismantling/Assembly Vertical driving device (MS) 6.6.1 Exploded view proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...
  • Page 124 6 Dismantling/Assembly 6.6 Vertical driving device (MS) Screw Protecting plate Screw Protecting guard O-ring Protecting collar Screw Spring washer Spring casing Deflector Ball bearing Ball bearing housing Axial buffer 13A. Split pin 13B. Wear ring 13C. Spring 13D. Spring support Buffer Screw plug Spring...

  • Page 125: Dismantling

    6.6 Vertical driving device (MS) 6 Dismantling/Assembly 6.6.2 Dismantling 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. 1. Drain the oil from the worm gear housing. CAUTION Burn hazards The lubricating oil and various machine...
  • Page 126 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 5. Unscrew the screws of the spring casing. 6. Remove the bearing shield/built-on pump: Separator with no built-on pump a. Remove the bearing shield and gasket. Separator with built-on pump a. Remove the pipe connections from the pump.
  • Page 127 6.6 Vertical driving device (MS) 6 Dismantling/Assembly d. Remove the pump assembly and gasket. 7. Remove the revolution counter (1). Apply the brake (2). 8. Remove the round nut and lock washer at the worm wheel shaft. 9. Remove the ball bearing and worm wheel fitted on the shaft.
  • Page 128 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 10. Lift out the bowl spindle by using the special lifting tool. 11. 50 Hz separator: Remove the axial buffer from the frame. 60 Hz separator: The buffer can be removed from the spindle after the worm has been knocked off, see following text.
  • Page 129 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 15. Knock off the worm by using a hammer and a soft drift. 16. 60 Hz separator: Remove the axial buffer. 17. Remove the screw plugs, springs and buffers. Then remove the spring casing. 18.

  • Page 130: Assembly

    6 Dismantling/Assembly 6.6 Vertical driving device (MS) 6.6.3 Assembly When mounting ball bearings on the spindle as described below, the bearings must be heated in oil to max 125 °C. WARNING Burn hazards Use protective gloves when handling the heated bearings. NOTE If any doubt how to mount roller bearings in a correct way, see the detailed description in...
  • Page 131 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 6. For 50 Hz separators, fit the axial buffer in the frame. 7. Carefully lower the spindle into the frame. Guide the bearing into the bottom bushing. If it does not completely enter its seat, tap the spindle top with a tin hammer.
  • Page 132 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 9. Tighten the buffer plugs. 10. Screw the protecting collar onto the spindle. Left-hand thread! Fit its O-ring, guard and protecting plate. 11. Fit the worm wheel with ball bearing onto the shaft. Match the worm wheel with the teeth on the worm of the bowl spindle.
  • Page 133 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 13. Fit the revolution counter. 14. Fit the bearing shield/built-on pump: Separator with no built-on pump a. Fit the gasket and bearing shield. The parts can be fitted only in one position because of the asymmetrical positioned screw holes.
  • Page 134 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 15. Pour oil into worm gear housing. The oil level should be slightly above the middle of the sight glass. For correct oil volume, see chapter ‘‘8.1 Technical data” on page 170. For recommended oil brands, see chapter ‘‘8.5.3 Recommended oil brands”...

  • Page 135: Horizontal Driving Device (Ms)

    6.7 Horizontal driving device (MS) 6 Dismantling/Assembly Horizontal driving device (MS) 6.7.1 Exploded view proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...
  • Page 136 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 1. Screw 2. Coupling nave 3. Coupling disc 4. Elastic plate 5. Coupling disc 6. Friction block 7. Friction pad 8. O-ring 9. Round nut 10. Lock washer 11. Ball bearing 12. Spacing ring 13.

  • Page 137: Dismantling

    6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 6.7.2 Dismantling 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 indicate if separator parts are rotating or not.
  • Page 138 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) Separator with built-on pump a. Remove the pump assembly. See the dismantling instructions for the vertical driving device on page 129 for a detailed description. 3. Remove the revolution counter (1). Apply the brake (2). 4.
  • Page 139 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 6. Pull off the ball bearing from the worm wheel. Use a washer as a support for the puller. 7. Remove: − the electric motor (1) − the elastic plate (2) − the friction blocks (3). If disconnecting the motor cables, note the positions of cables in the terminal box to reconnect correctly (for correct direction of...
  • Page 140 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 9. Dismantle the nave in the following way: − remove the screws (1) and then the coupling disc (2) − unscrew the round nut (3) and remove the lock washer − put the coupling disc in place (4) again and pull off the nave with a 3/8”...

  • Page 141: Assembly

    6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 11. Remove the seal ring by using a drift. 12. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning” on page 86. 6.7.3 Assembly 1. Lubricate the O-ring on the sealing washer periphery and the sealing ring with silicone grease.
  • Page 142 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 5. Fit the worm wheel shaft. NOTE Before fitting the worm wheel, mount the bowl spindle into the separator frame if removed. Check point ‘‘5.4.23 Worm wheel and worm; wear of teeth” on page 83. 6.
  • Page 143 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 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 133. 7.
  • Page 144 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 11. Pour oil into worm gear housing. The oil level should be slightly above the middle of the sight glass. For correct oil volume, see chapter ‘‘8.1 Technical data” on page 170. For recommended oil brands, see chapter ‘‘8.5.3 Recommended oil brands”...

  • Page 145: Built-On Oil Feed Pump

    6.8 Built-on oil feed pump 6 Dismantling/Assembly Built-on oil feed pump 6.8.1 Exploded view proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...
  • Page 146 6 Dismantling/Assembly 6.8 Built-on oil feed pump Plate 20. Bearing Drive screw 21. Wear gasket Snap ring 22. Impeller Washer 23. Wear gasket Seal ring 24. Bearing O-ring 25. Pump housing Sleeve 26. O-ring 27. Valve cone Flexible coupling 28. Guide pole 9A.
  • Page 147 6.8 Built-on oil feed pump 6 Dismantling/Assembly 6.8.2 Dismantling The oil feed pump should be dismantled for inspection of parts with respect to wear and cavitation damage. 1. Drain the oil from the worm gear housing. CAUTION Burn hazards Lubricating oil and various machine surfaces can be hot and cause burns.
  • Page 148 6 Dismantling/Assembly 6.8 Built-on oil feed pump 6. Undo the four screws holding the pump shield and remove the shield. 7. Insert two screws (3/8”-16 UNC) into the centre hole of the impeller shafts. Use the screws as a handle to withdraw the impellers. 8.
  • Page 149 6.8 Built-on oil feed pump 6 Dismantling/Assembly 6.8.3 Cleaning and inspection 1. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning” on page 86. 2. Examine following parts: Bushings (2) Renew the bushings if they are scratched or if there is a play between any impeller shaft and a bushing.
  • Page 150 6 Dismantling/Assembly 6.8 Built-on oil feed pump Lipseal rings (4) Renew the lipseal rings at MS-service. Note: Turn the rings the right way round, see pos. A in the illustration. 6.8.4 Assembly 1. Check that the lipseal rings are correctly mounted, see above.
  • Page 151 6.8 Built-on oil feed pump 6 Dismantling/Assembly 5. Refit the impellers. Check that the hole for the tubular pin is exactly opposite the corresponding hole in the coupling. 6. Drive in the tubular spring pin. 7. Check the axial play with a liner (B). The total axial play (A) must be 0,1 - 0,3 mm.
  • Page 152 6 Dismantling/Assembly 6.8 Built-on oil feed pump 9. Fit the pump shield. (Four screws, four washers and four nuts.) 10. Check that the clearance on each side of the coupling flexible element is 2 mm. Tighten the stop screw in the coupling half nearest the separator frame with a hexagon wrench.

  • Page 153: Trouble-Tracing

    7 Trouble-tracing Contents 7.1 Mechanical function 7.1.1 Separator vibrates 7.1.2 Smell Trouble-tracing 7.1.3 Noise 7.1.4 Speed too low 7.1.5 Speed too high First study Trouble-tracing in 7.1.6 Starting power too low system 7.1.7 Starting power too high documentation 7.1.8 Starting time too long (if applicable).

  • Page 154: Mechanical Function

    7 Trouble-tracing 7.1 Mechanical function Mechanical function 7.1.1 Separator vibrates NOTE Some vibration is normal during the starting and stopping sequences when the separator passes through its critical speeds. 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.

  • Page 155: Smell

    7.1 Mechanical function 7 Trouble-tracing 7.1.2 Smell Cause Corrective actions Page Normal occurrence during start while the None – friction blocks are slipping Brake is applied Release the brake – Oil level in gear housing too low Check oil level and add oil if necessary Bearing is overheated Renew all bearings 126, 138...

  • Page 156: Speed Too High

    In the event of overspeed, examine the bowl for possible deformation. The separator must not be started before the effects of the fault have been corrected. Contact your Alfa Laval representative. Frequency of power supply (50/60 Hz) Check – 7.1.6...

  • Page 157: Starting Power Too High

    7.1 Mechanical function 7 Trouble-tracing 7.1.7 Starting power too high Cause Corrective actions Page Incorrect gear transmission (50 Hz gear DANGER running on 60 Hz power supply) After immediate stop, install correct 89, 126, transmission Incorrect friction blocks (50 Hz coupling DANGER for 60 Hz power supply) After immediate stop change the friction...

  • Page 158: Retardation Time Too Long

    7 Trouble-tracing 7.1 Mechanical function 7.1.9 Retardation time too long Cause Corrective actions Page Brake friction pad is worn or oily Renew or clean brake friction pad 7.1.10 Water in worm gear housing Cause Corrective actions Page Bowl casing drain obstructed Clean worm gear housing and change oil Leakage at top bearing...

  • Page 159: Separation Faults, Purifier And Clarifier

    7.2 Separation faults, purifier and clarifier 7 Trouble-tracing Separation faults, purifier and clarifier 7.2.1 Liquid flows through the bowl casing drain and/or sludge outlet Cause Corrective actions Page Sludge discharge in progress None (normal) – Strainer in operating water line is clogged Clean the strainer and check pressure/flow: or pressure is too low Discharge liquid (opening): 200-600 kPa...

  • Page 160: Bowl Opens Accidentally During Operation

    7 Trouble-tracing 7.2 Separation faults, purifier and clarifier 7.2.2 Bowl opens accidentally during operation Cause Corrective actions Page Strainer in the operating water supply is Clean the strainer clogged No water in the operating water system Check the operating water system and make sure the valve(s) are open Water connections to the separator are Correct...
  • Page 161 7.2 Separation faults, purifier and clarifier 7 Trouble-tracing 7.2.4 Unsatisfactory sludge discharge Cause Corrective actions Page Water pressure too low Check the opening water pressure Water flow too low Check the opening water flow Valve plugs in operating slide too high Fit correct valve plugs Sludge deposits in the operating system Check and clean the operating system...

  • Page 162: Separation Faults, Purifier

    7 Trouble-tracing 7.3 Separation faults, purifier Separation faults, purifier 7.3.1 Unsatisfactory separation result Cause Corrective actions Page Gravity disc hole is too small Use a gravity disc with a larger hole Incorrect separation temperature Adjust – Throughput too high Adjust –...
  • Page 163 7.3 Separation faults, purifier 7 Trouble-tracing 7.3.3 Oil discharges through water outlet = Broken water seal Cause Corrective actions Page Gravity disc hole is too large Use a gravity disc with a smaller hole Incorrect separation temperature Adjust – Throughput too high Adjust Valves in clean oil outlet line closed Check...

  • Page 164: Separation Faults, Clarifier

    7 Trouble-tracing 7.4 Separation faults, clarifier Separation faults, clarifier 7.4.1 Unsatisfactory separation result Cause Corrective actions Page Feed oil contains water b. Reduce time between discharges – c. Assemble and operate the separator as a purifier Incorrect separation temperature Adjust –...

  • Page 165: Technical Reference

    8 Technical Reference Contents 8.1 Technical data 8.6.10 Cover interlocking switch 8.7 Storage and installation 8.2 Connection list 8.7.1 Storage and transport of goods 8.2.1 Separator without pump 8.7.2 Planning of installation 8.2.2 Separator with built-on pump 8.7.3 Foundations 8.3 Interface description 8.3.1 General 8.3.2...

  • Page 166: Technical Data

    8 Technical Reference 8.1 Technical data Technical data Alfa Laval ref. 557602, 557614 NOTE The separator is a component operating in an integrated system including a monitoring system. If the technical data in the system description does not agree with the technical data in this instruction manual, the data in the system description is the valid one.
  • Page 167 8.1 Technical data 8 Technical Reference Motor power rating Power consumption, max. kW (at starting up) Power consumption, idling Power consumption, at max. capacity Discharge volume litres fixed discharge volume Discharge interval, min. minute Discharge interval, max. minutes Bowl volume litres Starting time 2 - 2,5...

  • Page 168: Connection List

    8 Technical Reference 8.2 Connection list Connection list 8.2.1 Separator without pump Alfa Laval ref. 557950 Connection No. Description Requirements/limits Inlet for product - Allowed temperature Min. 0 °C, max. 100 °C Inlet for liquid seal or displacement Fresh water...

  • Page 169: Cover Interlocking Switch

    Cover interlocking switch See ‘‘8.3 Interface description’’ and ‘‘8.6.10 Cover interlocking switch” on page 201. 8.2.2 Separator with built-on pump Alfa Laval ref. 557951 Connection No. Description Requirements/limits 201.1 Inlet for process liquid, to pump 201.2 Outlet for process liquid, from pump 201.3...

  • Page 170: Connection List

    8 Technical Reference 8.2 Connection list Connection No. Description Requirements/limits Inlet for discharge liquid - Pressure Min. 200 kPa Max. 600 kPa - Consumption per discharge 6 litres - Quality requirements See ‘‘8.4 Water quality” on page 179 Inlet for make-up liquid - Pressure Min.

  • Page 171: Interface Description

    8.3 Interface description 8 Technical Reference Interface description Alfa Laval ref. 557697rev. 2 8.3.1 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.

  • Page 172: Component Description And Signal Processing

    8 Technical Reference 8.3 Interface description • 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. •...
  • Page 173 8.3 Interface description 8 Technical Reference 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. proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045...

  • Page 174: Function Graph And Running Limitations

    8 Technical Reference 8.3 Interface description 8.3.4 Function graph and running limitations A. Stand still B. Starting mode C. Running mode D. Stop mode E. Safety stop mode proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA –...

  • Page 175: Water Quality

    For test methods, contact an Alfa Laval representative. If these demands cannot be met, the water should be pre-treated in accordance with Alfa Laval’s recommendations. Alfa Laval accepts no liability for consequences arising from unsatisfactory purified operating water supplied by the customer. Suspended particles Content of suspend substances: Less than 0,001 percentage of volume.

  • Page 176: Lubricants

    The bearings are packed with grease and sealed and need no extra lubrication Electric motor (if nipples are fitted) Follow manufacturer’s instructions. Alfa Laval Lubricating Oil Groups: • Group A oil: a high quality gear oil on paraffin base with stable AW (anti wear) additives.
  • Page 177 8.5 Lubricants 8 Technical Reference 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.
  • Page 178 Alfa Laval ref. 553219-03 Three different groups of lubricating oils are approved for this separator. They are designated as Alfa Laval lubricating oil groups A, B and D. The numerical value after the letter states the viscosity grade. The corresponding commercial oil brands are listed in chapter ‘‘8.5.3 Recommended oil brands”...
  • Page 179 8.5 Lubricants 8 Technical Reference 8.5.3 Recommended oil brands Alfa Laval lubricating oil group A/220 Alfa Laval ref. 553218-01 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) > 92 Manufacturer Designation Castrol Alpha ZN 220 Esso Standard Oil/...
  • Page 180 8 Technical Reference 8.5 Lubricants Alfa Laval lubricating oil group B/220 Alfa Laval ref. 553218-02 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) > 92 Manufacturer Designation Bel Ray 100/06-220 Energol GR-XP 220 Castrol Alpha SP 220 Chevron...
  • Page 181 8.5 Lubricants 8 Technical Reference Alfa Laval lubricating oil group D/220 Alfa Laval ref. 553218-03 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) > 135 Manufacturer Designation Alfa Laval 542690-80 20 litres 542690-81 4 litres 542690-82 208 litres...
  • Page 182 8 Technical Reference 8.5 Lubricants 8.5.4 Recommended lubricants Pastes and bonded coatings for non-food applications Alfa Laval ref. 553217-01 Manufacturer Designation Alfa Laval No. Application Gleitmolybdän Gleitmo 805 K or 805 K varnish 901 Gleitmo Paste G rapid 537086-04 Dow Corning...
  • Page 183 8.5 Lubricants 8 Technical Reference Greases for ball and roller bearings Alfa Laval ref. 553217-01 Manufacturer Designation Alfa Laval No. Energrease MMEP2 Energrease LS2 Castrol Spheerol SW2 EP Spheerol EPL2 Chevron Duralith grease EP2 Exxon Beacon EP2 Mobil Mobilith SHC 460...
  • Page 184 8 Technical Reference 8.5 Lubricants proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...

  • Page 185: Drawings

    8.6 Drawings 8 Technical Reference Drawings 8.6.1 Basic size drawing, separator with built-on pump Alfa Laval ref. 557889 Maximum horizontal Maximum vertical Tigthening torque 20 Nm. displacement at the in/outlet displacement at the solid Secured with lock nut connections during phase connection during operation: ±20 mm...
  • Page 186 8 Technical Reference 8.6 Drawings 8.6.2 Dimensions of connections, separator with built-on pump Alfa Laval ref. 557889 Data for connections, see chapter ‘‘8.2 Connection list” on page 172. All connections to be installed non-loaded and flexible. Connections 201.3 and 220 are turnable.
  • Page 187 8.6 Drawings 8 Technical Reference 8.6.3 Basic size drawing, separator without pump Alfa Laval ref. 557600 Maximum horizontal Maximum vertical Tigthening torque 20 Nm. displacement at the in/outlet displacement at the solid Secured with lock nut connections during phase connection during operation: ±20 mm...
  • Page 188 8 Technical Reference 8.6 Drawings 8.6.4 Dimensions of connections, separator without pump Alfa Laval ref. 557600 Data for connections, see chapter ‘‘8.2 Connection list” on page 172. All connections to be installed non-loaded and flexible. Connections 201 and 220 are turnable.
  • Page 189 8.6 Drawings 8 Technical Reference proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...
  • Page 190 8 Technical Reference 8.6 Drawings 8.6.5 Foundations Alfa Laval ref. 557856 Min. lifting capacity required when Recommended free floor space for unloading doing service: 100 kg when doing service Recommended speed for lifting: No fixed installations within this area. Low speed 0,5-1,5 m/min.
  • Page 191 8.6 Drawings 8 Technical Reference 8.6.6 Gravity disc nomogram ρ = Oil density, kg/m Gravity disc hole diameter, φ mm at 15 °C Oil temperature in °C or °F Q = Throughput, m proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA –...
  • Page 192 8 Technical Reference 8.6 Drawings The nomogram is based on the properties of fresh water. The presence of salt water in the oil may demand a gravity disc with a larger hole than indicated in the nomograms. Example I in nomogram Reference in graph: _________ Oil density 988 kg/m...
  • Page 193 8.6 Drawings 8 Technical Reference 8.6.7 Electric motor Alfa Laval ref. 552810 A. Max. cable diameter is 21 mm Manufacturer ABB Motors Manufacturers drawing MK20-92S Standards IEC 34-1, IEC 72 Size 112 M Type MBT 112M Weight 31 kg Poles...
  • Page 194 8 Technical Reference 8.6 Drawings Article No Output Speed Freq Voltage Current Pow.fac Therm Note cos ϕ °C 552810-01 1425 200 D 0,83 552810-02 1425 220 D 0,83 552810-03 1425 380 D 0,83 552810-04 1425 415 D 0,83 552810-05 1425 440 D 0,83 552810-06...
  • Page 195 8.6 Drawings 8 Technical Reference 8.6.8 Electric motor Alfa Laval ref. 540196 A: 4 holes, diam. 14 mm Only for applications on shore. Standards IEC 34-1, IEC 72 Size 112 M/F215 acc. to IEC72 Poles Method of cooling Specification Totally enclosed three-phase...
  • Page 196 8 Technical Reference 8.6 Drawings Article No Power Freq Voltage Note 540196-10 220 VD 540196-11 380 VD 540196-12 440 VD 540196-13 575 VD 540196-18 200 VD 540196-19 220 VD 540196-20 380 VD 540196-21 415 VD 540196-22 500 VD 540196-23 660 VD 540196-24 200 VD According to the rules of CSA...
  • Page 197 8.6 Drawings 8 Technical Reference 8.6.9 Machine plates and safety labels Alfa Laval ref. 557410, 557602, 557614 1. Machine plate Separator MOPX 205 TGT-24 Manufacturing serial No. / Year XXXX Product No. 881034-01-08 Machine top part 540216-87 Bowl 540148-83 Machine bottom part (without pump)
  • Page 198 Indicating direction of rotation of horizontal driving device. 8. Power supply frequency 8.6.10 Cover interlocking switch Alfa Laval ref. 557950, 557951, 557237 Switch rating, voltage: Max. 500 V current: Max. 3 A For other technical information see chapter ‘‘8.3 Interface description” on page 175.

  • Page 199: Storage And Installation

    8.7 Storage and installation 8 Technical Reference Storage and installation 8.7.1 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.
  • Page 200 8 Technical Reference 8.7 Storage and installation A separator can be delivered with different types of protection: • Fixed on a pallet. The separator must be stored in a dry storage room, protected from rain and humidity. It must be well protected from mechanical damage and theft.
  • Page 201 8.7 Storage and installation 8 Technical Reference 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 details in chapter ‘‘5.5 Lifting instructions”...
  • Page 202 8 Technical Reference 8.7 Storage and installation 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.
  • Page 203 8.7 Storage and installation 8 Technical Reference 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.
  • Page 204 8 Technical Reference 8.7 Storage and installation 8.7.3 Foundations NOTE When lifting a separator it must always be hung securely. See chapter ‘‘5.5 Lifting instructions” on page 85. Specification • The separator can either be installed at floor level or on a platform, see chapter ‘‘8.6.5 Foundations”...
  • Page 205 You can do this by copying this page and sending it by fax, or you could mail it, or hand it over to your local Alfa Laval representative. Alfa Laval Separation AB, Separator Manuals, dept. SKL, S-147 80 Tumba, Sweden. Fax: +46 8 53065029.
  • Page 206 proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...
  • Page 207 If you wish to order extra copies of this manual, please copy this page and give it to your local Alfa Laval representative, who will advise you of current prices. Your local Alfa Laval representative will also be able to help you with information regarding any other manuals.
  • Page 208 proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...

  • Page 209: Index

    Index Guide surfaces Inlet pipe and oil paring disc Application Level ring Assembly Lifting instructions Bowl body and operating mechanism Lock ring - priming Bowl hood and disc stack Lock ring - wear and damage General directions Oil change procedure Horizontal driving device Oil paring disc - height position Inlet/outlet, frame hood...
  • Page 210 Operating water device Tools Installation Vertical driving device Interface Drawings Definition Basic size drawing Description Cover interlocking switch (option) Interface description Dimensions of connections Intermediate service Electric motor Foundations Machine plates and safety labels Lifting instructions Lock ring Priming Electric motor Wear and damage Drawings.
  • Page 211 Motor Running Cleaning Safety stop Coupling Sensors and indicators Drawing Sludge discharge cycle Power consumption Start Storage and transportation Technical data Service instructions. See Check points Noise Service kits Shutdown Speed Speed too high Oil. See Lubrication Start Operation Stopping procedure Storage Power consumption Power transmission...
  • Page 212 Warning signs Water Water quality specifications Weight Worm gear Function and description Number of teeth Wear of teeth proyectos@fdm.com.pe fdmsac@gmail.com Movil:959440045 www.fdm.com.pe AV. NÉSTOR GAMBETA MZ. C LOTE 10 – COOPERATIVA – VENTANILLA – CALLAO...

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