Alfa Laval MOPX 213TGT-20 Manual
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Alfa Laval MOPX 213TGT-20 Manual

Alfa Laval MOPX 213TGT-20 Manual

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Summary of Contents for Alfa Laval MOPX 213TGT-20

  • Page 1 Product No. 881039-04-02 Book No. 1270763-02 V2 ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...
  • Page 2 Telephone: +46 8 53 06 50 00 Telefax: +46 8 53 06 50 29 Printed in Sweden, 98-06 © Alfa Laval Separation AB 1998 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 Feed pump (MS) (option) Trouble-tracing 7.1 Mechanical functions 7.2 Separating functions, purification and clarification 7.3 Separating functions, purification only 7.4 Separating functions, clarification only 7.5 Vibration switch (option) Technical Reference 8.1 Technical data 8.2 Basic size drawing, without pump 8.3 Connection list, without pump...

  • Page 5: Service And Maintenance

    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 ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 7: Read This First

    15 and chapter ‘‘8 Technical Reference” on page 179. 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. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...
  • 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. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...
  • 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 ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 15: Separator Basics

    3 Separator Basics Contents 3.1 Basic principles of separation 3.2 Design and function 3.2.1 Overview 3.2.2 Mechanical power transmission 3.2.3 Brake 3.2.4 Feed inlet pump (option) 3.2.5 Paring disc pump 3.2.6 Sensors and indicators 3.2.7 Process main parts 3.3 Separating function 3.3.1 Purifier bowl 3.3.2...

  • Page 16: Basic Principles Of Separation

    3.1 Basic principles of separation 3 Separator Basics 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 Separator Basics 3.1 Basic principles of separation 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 3 Separator Basics Design and function 3.2.1 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 19: Mechanical Power Transmission

    3 Separator Basics 3.2 Design and function 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.

  • Page 20: Feed Inlet Pump (Option)

    3.2 Design and function 3 Separator Basics 3.2.4 Feed inlet pump (option) The separator can be equipped with a built-on feed inlet pump of gear type. The pump will be attached to and driven by the horizontal worm wheel shaft. Feed inlet pump of gear type (option) 3.2.5 Paring disc pump...
  • Page 21 3 Separator Basics 3.2 Design and function Revolution counter (2) A revolution counter, which should turn clockwise during operation, 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.

  • Page 22: Process Main Parts

    3.2 Design and function 3 Separator Basics 3.2.7 Process main parts Upper paring camber Gravity/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 23 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 pipe bend and the long inlet pipe (20) which extends into the middle of the bowl. •...
  • Page 24 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 water device.

  • Page 25: 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 level ring and gravity disc” on page 35.
  • Page 26 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 27: 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 larger hole diameter will move the interface towards the bowl periphery whereas a disc with smaller hole diameter will move the interface closer to the bowl...

  • Page 28: 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 pumped 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.

  • Page 29: 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 30 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 31: 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 32 3.4 Definitions 3 Separator Basics ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 33: Operating Instructions

    4 Operating Instructions Contents 4.1 Operating routine 4.1.1 Before first start 4.1.2 Selection of level ring and gravity disc 4.1.3 Ready for start 4.1.4 Start 4.1.5 Running 4.1.6 Normal stop 4.1.7 Safety stop ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 34: Operating Routine

    4.1 Operating routine 4 Operating Instructions Operating routine These 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 Before first start Technical demands for connections and logical limitations for the separator is described in the chapter ‘‘8 Technical Reference”...

  • Page 35: Selection Of Level Ring And Gravity Disc

    4 Operating Instructions 4.1 Operating routine 4.1.2 Selection of level ring and gravity disc The separator is delivered with two level rings and a set of gravity discs. How to replace a level ring and a gravity disc is described in ‘‘6.3 Bowl hood and disc stack (IS)” on page 108.
  • Page 36 4.1 Operating routine 4 Operating Instructions As an aid, use the nomogram on next page to find the correct gravity disc. It can be used when the density of the oil at a temperature of 15 °C is known. However, note that the nomogram is purely theoretical.
  • Page 37 4 Operating Instructions 4.1 Operating routine ρ Nomogram for MOPX 213 = Density of oil in kg/m at 15 °C = Throughput in m The presence of salt water may demand the use of a gravity disc with larger hole diameter than = Separating temperature in °C or °F indicated in the nomogram (the nomogram is based on the properties of fresh water).

  • Page 38: Ready For Start

    4.1 Operating routine 4 Operating Instructions 4.1.3 Ready for start To achieve the best separation result 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.

  • Page 39: Start

    4 Operating Instructions 4.1 Operating routine 4.1.4 Start 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, always check direction of rotation. If Check for correct direction of rotation incorrect, vital rotating parts could unscrew.

  • Page 40: Running

    4.1 Operating routine 4 Operating Instructions 4. 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.

  • Page 41: Normal Stop

    4 Operating Instructions 4.1 Operating routine 5. Adjust to desired throughput. 6. 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 ‘‘8.1 Technical data” on page 180.

  • Page 42: Safety Stop

    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. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 43: 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 44 5 Service Instructions 5.5 Lifting instructions 5.6 Cleaning 5.6.1 External cleaning 5.6.2 Cleaning agents 5.6.3 Cleaning of bowl discs 5.6.4 CIP-system 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 5.8.2 Vibration switch (option)

  • Page 45: Periodic Maintenance

    5 Service Instructions 5.1 Periodic maintenance 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 46 5.1 Periodic maintenance 5 Service Instructions 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 47: Maintenance Procedure

    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.

  • Page 48: Service Kits

    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.

  • Page 49: Maintenance Logs

    5 Service Instructions 5.2 Maintenance Logs 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 50: Intermediate Service (Is)

    5.2 Maintenance Logs 5 Service Instructions 5.2.3 Intermediate Service (IS) Name of plant: Local identification: Separator: MOPX 213TGT-20 Manufacture No./Year: Total running hours: Product No: 881039-04-02 Date: Signature: Note: Renew all parts included in the Intermediate Service kit (IS). Main component and activity...
  • Page 51 5 Service Instructions 5.2 Maintenance Logs Main component and activity Part Page Notes Operating device Clean and check Operating paring disc – Renew O-rings – 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)

  • Page 52: Major Service (Ms)

    5.2 Maintenance Logs 5 Service Instructions 5.2.4 Major Service (MS) Name of plant: Local identification: Separator: MOPX 213TGT-20 Manufacture No./Year: Total running hours: Product No: 881039-04-02 Date: Signature: Note: Renew all parts included in the Intermediate Service kit (IS) and Major Service kit (MS).
  • Page 53 5 Service Instructions 5.2 Maintenance Logs Main component and activity Part Page Notes Operating device Clean and check Operating paring disc – Check Height position of operating paring disc Renew O-rings – Vertical driving device Clean and check Bowl spindle –...
  • Page 54 5.2 Maintenance Logs 5 Service Instructions Main component and activity Part Page Notes Feed pump (option) Clean and check Bushings, wear gaskets, flexible coupling, relief/safety valve and impeller shaft Renew Lipseal rings ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 55: 3-Year Service (3S)

    5 Service Instructions 5.2 Maintenance Logs 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).

  • Page 56: Check Points At Intermediate Service (Is)

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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 57: Bowl Spindle Cone And Bowl Body Nave

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 58 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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 59 5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 60: Cracks

    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 61: Disc Stack Pressure

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 62: Erosion

    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 63 5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 bowl body for the seal ring in the sliding bowl bottom.

  • Page 64: Guide Surfaces

    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 on surfaces (1 and 2).
  • Page 65 5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 66: Inlet Pipe And Oil Paring Disc

    Prime the repaired area with lubricating spray Molykote 321 R. Read the correct procedure under checkpoint. Apply Alfa Laval lubricating paste or Molykote 1000 Paste to the surface after priming. 5.3.8...

  • Page 67: Lock Ring; Wear And Damage

    213TGT-20), an Alfa Laval representative must be contacted immediately. (MAX 25 ) If the marks become illegible, an Alfa Laval representative should be contacted immediately The φ -mark on the lock ring must not pass the φ -mark to inspect thread wear and for determining the on the bowl body by more than 25°...
  • Page 68 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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 69: Operating Mechanism

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 70: Sliding Bowl Bottom

    5.3 Check points at Intermediate Service (IS) 5 Service Instructions Remove all the valve plugs. Tap in the new plugs. Correct height of plugs: 11,0 mm. Tap in new valve plugs 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.

  • Page 71: Springs For Operating Mechanism

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 72: Check Points At Major Service (Ms)

    5.4 Check points at Major Service (MS) 5 Service Instructions 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 73: Brake

    5 Service Instructions 5.4 Check points at Major Service (MS) 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 74 5.4 Check points at Major Service (MS) 5 Service Instructions 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). Cut view of ball bearing housing Top bearing springs In case of spring fracture, the complete set of...
  • Page 75 5 Service Instructions 5.4 Check points at Major Service (MS) 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. Max.

  • Page 76: Coupling Friction Pads

    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 10 minutes or the bowl lose speed during operation, the friction pads of the coupling may be worn or oily.

  • Page 77: Corrosion

    5 Service Instructions 5.4 Check points at Major Service (MS) Different friction blocks for different power supply frequencies If mounting new friction blocks, check that the blocks are correct for the power supply frequency. The measure B is different for 50 and 60 Hz separators.

  • Page 78: Flexible Plate In Coupling

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.11 Flexible 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: Measure the distance from the frame ring to the coupling disc of the separator.

  • Page 79: Guide Surfaces

    9. Finish the treatment by lubricating the contact Bowl body 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 80: Level Ring

    5.4 Check points at Major Service (MS) 5 Service Instructions 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 81 5 Service Instructions 5.4 Check points at Major Service (MS) 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 82: Lock Ring; Wear And Damage

    5.4 Check points at Major Service (MS) 5 Service Instructions 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 (1) should be checked if the bowl spindle has been removed or the bowl has been replaced.

  • Page 83: Operating Slide

    5 Service Instructions 5.4 Check points at Major Service (MS) 5.4.19 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.

  • Page 84: Springs For Operating Mechanism

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.22 Springs for operating mechanism Same as described in ‘‘5.3.14 Springs for operating mechanism” on page 71. 5.4.23 Worm; wear of groove Renew the worm if the wear in the groove (1) which receives the conveyor exceeds 3-4 mm.

  • Page 85: Worm Wheel Shaft; Radial Wobble

    Permissible radial wobble is maximum 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 86: Lifting Instructions

    5.5 Lifting instructions 5 Service Instructions Lifting instructions Attach three endless slings or cables to the lifting eyes (the screws must be tightened with spanner). Length of each sling must be min. 2 metres. NOTE Machine weight without frame hood and bowl is approx.

  • Page 87: 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 88 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 and lube oil separators Alfa Laval cleaning liquid for fuel oil separators has been developed for this purpose.
  • Page 89 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 90 5.6 Cleaning 5 Service Instructions 5.6.4 CIP-system Alfa Laval has developed a CIP (Cleaning-In- Place) system specifically designed for cleaning the bowl and with the inlet and outlets of lube and fuel oil separators without the need of dismantling. CIP Unit connected to separator ventas@fdm.com.pe...

  • Page 91: When Changing Oil

    5 Service Instructions 5.7 When changing oil 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 93.
  • Page 92 5.7 When changing oil 5 Service Instructions 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 93 5 Service Instructions 5.7 When changing oil 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 94 5.7 When changing oil 5 Service Instructions 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 ‘‘8.8 Lubricants” on page 196 must be well known.

  • Page 95: Vibration

    5 Service Instructions 5.8 Vibration 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 96 5.8 Vibration 5 Service Instructions 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.

  • Page 97: 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. Outer race A bearing that in appearance looks equivalent to...
  • Page 98 5.9 Common maintenance directions 5 Service Instructions 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.
  • Page 99 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 100 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 101. NOTE The bowl must not be left on the spindle during standstill for more than one week.

  • Page 101: 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 Feed pump (MS) (option) 6.2.1 Exploded view 6.8.1 Exploded view 6.2.2...

  • Page 102: Introduction

    6.1 Introduction 6 Dismantling/Assembly 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 103: References To Check Points

    6 Dismantling/Assembly 6.1 Introduction 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: 4 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 104: Inlet/Outlet, Frame Hood (Is)

    6.2 Inlet/outlet, frame hood (IS) 6 Dismantling/Assembly Inlet/outlet, frame hood (IS) 6.2.1 Exploded view O-ring Inlet pipe Support Pressure gauge Rectangular ring Support Rectangular ring Connecting housing Sight glass 10. Screw 11. Protecting washer 12. Height adjusting ring(s) 13. Frame hood 14.

  • Page 105: Dismantling

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

  • Page 106: Assembly

    6.2 Inlet/outlet, frame hood (IS) 6 Dismantling/Assembly 3. Remove the inlet and outlet piping supports and the connecting housing. Take care of the rectangular rings. 4. Remove the six screws for the frame hood and lift it off by using the two lifting eyes. 6.2.3 Assembly 1.
  • Page 107 6 Dismantling/Assembly 6.2 Inlet/outlet, frame hood (IS) 3. Lubricate the O-ring of the inlet pipe. Fit the inlet pipe and tighten it firmly. Left-hand thread! 4. Connect the displacement/liquid seal water hose. DANGER Disintegration hazards When power cables have been connected, always check direction of rotation, see ‘‘4.1.4 Start”...

  • Page 108: 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) 11. Seal ring O-ring 12. Top disc Upper paring disc (water) 13. Oil paring disc O-ring 14.

  • Page 109: Dismantling

    6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 6.3.2 Dismantling 1. Unscrew the paring chamber cover using the spanner. Left-hand thread! 2. Remove the upper paring disc, gasket and gravity/clarifier disc. 3. Apply the brake and unscrew the lock ring using the spanner.
  • Page 110 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 4. Fit eye bolts (M12) and remove the lock ring by a hoist. NOTE The lock ring must be kept lying horizontally or it may become distorted. Even slightest distortion could make it impossible to refit. 5.
  • Page 111 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 9. 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.
  • Page 112 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 11. 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.

  • Page 113: Assembly

    6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 6.3.3 Assembly 4 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 114 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 4 Check point ‘‘5.3.9 Level ring” on page 66. 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.
  • Page 115 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 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.
  • Page 116 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 11. Tighten until the assembly marks are at least in line. 4 Check point ‘‘5.3.5 Disc stack pressure” on page 61. NOTE The assembly marks must never pass each other more than 25° which corresponds to A=120 mm.

  • Page 117: 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 Cap nut Distributing cone O-ring Sliding bowl bottom Rectangular ring Screw Bowl body Nozzle, 3 mm Plug 10. O-ring 11. Valve plug 12.

  • Page 118: Dismantling

    6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 6.4.2 Dismantling 1. Unscrew and remove the cap nut. Hit with light blows on the inner part of the capnut wings with a drift and hammer. Left-hand thread! 2. Fit the lifting tool into the distributing cone and lift it out.
  • Page 119 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 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.
  • Page 120 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 8. Loosen the screws for the spring holder successively a little at a time. Remove the screws. 9. Remove the spring holder and the springs. 10. Fit two lifting eyes (M10) into the operating slide and lift it off from the bowl body.

  • Page 121: Assembly

    6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 11. Place the operating slide with the valve plugs facing upwards 12. Remove any thick deposits in the frame hood and clean all other parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning”...
  • Page 122 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 3. Lubricate the guide surfaces and O-ring of the spring holder. See chapter ‘‘8.8 Lubricants” on page 196. Fit the springs and support. 4. Lubricate and then tighten the three screws for the spring holder successively by hand a little at a time.
  • Page 123 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 7. 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. 8.
  • Page 124 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 12. 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. 13.

  • Page 125: Operating Water Device (Is)

    6 Dismantling/Assembly 6.5 Operating water device (IS) Operating water device (IS) 6.5.1 Exploded view Ring nut Operating paring disc O-ring Distributing ring Gasket Distributing cover Gasket Sleeve Height adjusting ring 10. Operating device Guide ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 126: Dismantling

    6.5 Operating water device (IS) 6 Dismantling/Assembly 6.5.2 Dismantling 1. Disconnect the water hoses to the operating water inlet device. 2. Loosen and pull out the device from the distributing cover. 3. Ease off the ring nut (1). 4. Lift out the paring disc assembly (2). 5.

  • Page 127: ''5.4.19 Operating Paring Disc; Height Position

    6 Dismantling/Assembly 6.5 Operating water device (IS) 4 Check point ‘‘5.4.19 Operating paring disc; height position” on page 83. Only at Major Service (MS). 5. Fit the operating water inlet device into the distributing cover. 6. Connect the water hoses to the device. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe...

  • Page 128: Vertical Driving Device (Ms)

    6.6 Vertical driving device (MS) 6 Dismantling/Assembly Vertical driving device (MS) 6.6.1 Exploded view ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...
  • Page 129 6 Dismantling/Assembly 6.6 Vertical driving device (MS) Screw Spring casing Protecting plate Buffer O-ring Spring Protecting collar Screw plug Screw Gasket Guard Bowl spindle Ball bearing Cover Worm Gasket Ball bearing O-ring Conveyor Stud bolt Washer Oil fan Ball bearing Lock ring Lock washer Ball bearing...

  • Page 130: 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. Unscrew the six screws and remove the hood and O-ring.
  • Page 131 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 4. Unscrew the six nuts and remove the cover and gasket. 5. Loosen (but do not remove) the six screw plugs for the buffers with a spanner and a hammer. 6. Unscrew the six screw plugs and remove the springs.
  • Page 132 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 8. Drain the oil from the worm gear housing. CAUTION Burn hazards Lubricating oil and various machine surfaces can be hot and cause burns. 9. Remove the brake cover and the revolution counter cap and their gaskets. 10.
  • Page 133 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 12. Fit the lifting tool onto the spindle and lift it out using the hoist. 13. Remove the gasket and O-ring which are remaining in the separator frame. 14. Unscrew - the oil fan (1) clockwise Left-hand thread! - the lock ring (2) counter-clockwise Right-hand thread!
  • Page 134 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 15. Remove the ball bearing housing and bearings by means of the puller. 16. Remove the buffer. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 135: Assembly

    6 Dismantling/Assembly 6.6 Vertical driving device (MS) 17. To strip the spindle, unscrew the round nut and remove the lock washer. Pull off the bearing together with the intermediate washer. Remove the driver which fits in the groove in the worm. 18.
  • Page 136 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 4 Check point ‘‘5.4.24 Worm wheel and worm; wear of teeth” on page 84. ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 91. 1. Heat and mount the two bearings for the worm.
  • Page 137 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 5. Fit the buffer in the spring casing and then thread on the casing to the spindle upon the bearing housing. 6. Screw the oil fan into the spring casing. Tighten the oil fan with the pin spanner. Left-hand thread! The oil fan will fix the bearing housing into the spring casing.
  • Page 138 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 8. Place the spring casing carefully to rest on the upper ballbearing on worm 4 Check point ‘‘5.4.5 Buffer springs and ball bearing housing” on page 74. 9. Place the axial buffer in the spring casing . ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe...
  • Page 139 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 10. Assemble the parts included in the bearing housing as shown in the illustration. If the bearings cannot be pushed in by hand, heat the ball bearing housing in oil. NOTE The angular contact ball bearing (1) must be fitted with the wide shoulder of the inner ball race facing upwards.
  • Page 140 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 12. Screw the oil fan into the spring casing. Tighten the oil fan with the pin spanner. Left-hand thread! The oil fan will fix the bearing housing into the spring casing. 13. Fit the buffers, springs and screw plugs into the bearing housing.
  • Page 141 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 15. Fit the lifting tool to the spindle and lift it by a hoist. 16. Carefully lower the spindle into the frame. Guide the bearings into the bottom sleeve. If they do not completely enter their seats, tap the spindle top with a tin hammer.
  • Page 142 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 18. Tighten the screw plugs. 19. Fit the guard and tighten the six screws. 20. Fit the protecting collar. Left-hand thread! 21. Fit the O-ring and protecting plate. Tighten the three screws for the protecting plate. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe...
  • Page 143 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 22. Fit the hood with O-ring and tighten the six screws. 23. Match the worm wheel with the teeth in the worm of the bowl spindle. Knock the taper pin into the worm wheel stop ring. 4 Check point ‘‘5.4.25 Worm wheel shaft;...

  • Page 144: Horizontal Driving Device (Ms)

    6.7 Horizontal driving device (MS) 6 Dismantling/Assembly Horizontal driving device (MS) 6.7.1 Exploded view ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...
  • Page 145 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) Screw Spring washer Round nut Lock washer Bearing shield Ball bearing Taper pin Stop ring Worm wheel 10. Ball bearing 11. Sealing ring 12. Sealing washer 13. O-ring 14. Worm-wheel shaft with coupling drum 15.

  • Page 146: 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 indicates if separator parts are rotating or not.
  • Page 147 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 3. Knock out the taper pin from the worm wheel stop ring. 4. 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.
  • Page 148 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly d. Remove the pump assembly and gasket. 5. Unscrew the four screws for the bearing shield and remove it. 6. Unscrew and remove the round nut and lock washer. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...
  • Page 149 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 7. Remove the ball bearing. 8. Remove the stop ring and worm wheel with ball bearing. 9. Pull off the ball bearing from the worm wheel. Use a washer as a support for the puller. 10.
  • Page 150 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 12. Remove the flexible plate and unscrew the six screws for the coupling disc and remove 13. Remove the worm wheel shaft with friction clutch pulley. 14. To dismantle the nave, unscrew the round nut with the pin spanner and remove the lock washer.

  • Page 151: Assembly

    6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 16. Remove the sealing washer using two screws with 1/4”-20 UNC threads. 17. Remove the sealing ring from the sealing washer. 18. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning”...
  • Page 152 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 4. Tighten the round nut with the pin spanner and secure it with the lock washer. 5. Fit the worm wheel shaft. 4 Check point ‘‘5.7.1 Worm wheel and worm; wear of teeth” on page 91.
  • Page 153 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) NOTE If any doubt how to mount roller bearings in a correct way, see the detailed description in chapter ‘‘5.9.1 Ball and roller bearings” on page 97. 7. Fit the worm wheel with the ball bearing and fit the stop ring.
  • Page 154 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 10. Tighten the round nut with the pin spanner and secure it with the lock washer. 11. Fit the bearing shield and tighten the four screws. 12. Fit the coupling disc with gasket and tighten the six screws.
  • Page 155 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 14. Fit the electric motor. DANGER Disintegration hazards When power cables have been connected, always check direction of rotation, see ‘‘4.1.4 Start” on page 39. If incorrect, vital rotating parts could unscrew causing disintegration of the machine.
  • Page 156 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly Separator with built-on pump a. Check that the key for the pump coupling half is fitted in the keyway in the worm wheel shaft. b. Fit the gasket and pump assembly. Be careful that the lipseal ring is not damaged by the shaft end and by the key in shaft.
  • Page 157 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 4 Check point ‘‘5.4.4 Brake” on page 73. 18. Fit the brake cover and revolution counter cap and their gaskets. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 158: Feed Pump (Ms) (Option)

    6.8 Feed pump (MS) (option) 6 Dismantling/Assembly Feed pump (MS) (option) 6.8.1 Exploded view ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...
  • Page 159 6 Dismantling/Assembly 6.8 Feed pump (MS) (option) Plate 20. Bearing Drive screw 21. Wear gasket Snap ring 22. Impeller Washer 23. Wear gasket Lipseal ring 24. Bearing O-ring 25. Pump housing Sleeve 26. O-ring 27. Valve cone Flexible coupling 28. Guide pole 9A.

  • Page 160: Dismantling

    6.8 Feed pump (MS) (option) 6 Dismantling/Assembly 6.8.2 Dismantling 1. Drain the oil from the worm gear housing. CAUTION Burn hazards Lubricating oil and various machine surfaces can be hot and cause burns. 2. Remove the pipe connections from the pump. 3.
  • Page 161 6 Dismantling/Assembly 6.8 Feed pump (MS) (option) 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 162: Cleaning And Inspection

    6.8 Feed pump (MS) (option) 6 Dismantling/Assembly 6.8.3 Cleaning and inspection 1. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6.2 Cleaning agents” on page 87. 2. Examine following parts: Bushings (2) Renew the bushings if they are scratched or there is a play between any impeller shaft and a bushing.

  • Page 163: Assembly

    6 Dismantling/Assembly 6.8 Feed pump (MS) (option) 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 description in the “Cleaning and inspection”-section above.
  • Page 164 6.8 Feed pump (MS) (option) 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 165 6 Dismantling/Assembly 6.8 Feed pump (MS) (option) 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 166 6.8 Feed pump (MS) (option) 6 Dismantling/Assembly ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 167: Trouble-Tracing

    7 Trouble-tracing Contents 7.1 Mechanical functions 7.5 Vibration switch (option) 7.1.1 Separator vibrates 7.5.1 Vibration switch does not reset 7.1.2 Smell 7.5.2 Impossible to adjust setpoint setting to obtain tripping 7.1.3 Noise 7.5.3 Vibration switch does not reset 7.1.4 Speed too low 7.1.5 Starting power too high 7.1.6...

  • Page 168: Mechanical Functions

    7.1 Mechanical functions 7 Trouble-tracing Mechanical functions 7.1.1 Separator vibrates NOTE Some vibration is normal during the starting and stopping sequences when the separator passes through its critical 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.
  • Page 169 7 Trouble-tracing 7.1 Mechanical functions 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 7.1.3 Noise Cause...
  • Page 170 7.1 Mechanical functions 7 Trouble-tracing 7.1.5 Starting power too high Cause Corrective actions Page Incorrect friction blocks (50 Hz blocks for 60 Hz power supply) DANGER Stop immediately and change the friction blocks to suit the power supply frequency Wrong direction of rotation Change electrical phase connections to the –...
  • Page 171 7 Trouble-tracing 7.1 Mechanical functions 7.1.8 Retardation time too long Cause Corrective actions Page Brake friction pad is worn or oily Renew or clean friction pad 7.1.9 Water in worm gear housing Cause Corrective actions Page Bowl casing drain obstructed Clean the casing and the drains properly.

  • Page 172: Separating Functions, Purification And Clarification

    7.2 Separating functions, purification and clarification 7 Trouble-tracing Separating functions, purification and clarification 7.2.1 Liquid flows through the bowl casing drain and/or sludge outlet Cause Corrective actions Page Sludge discharge or water draining in None (normal) – progress The water line is obstructed or the water Check water pressure/flow: –...
  • Page 173 7 Trouble-tracing 7.2 Separating functions, purification and clarification 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 –...

  • Page 174: Separating Functions, Purification Only

    7.2 Separating functions, purification only 7 Trouble-tracing 7.2.4 Unsatisfactory sludge discharge Cause Corrective actions Page Valve plugs in the operating slide too high Renew with correct valve plugs Sludge deposits in the operating system Check and clean the operating system 117, 125 7.2.5 High pressure in oil outlet...
  • Page 175 7 Trouble-tracing 7.2 Separating functions, purification only 7.3.2 Outgoing water contains oil Cause Corrective actions Page Gravity disc hole too large Use a disc with smaller hole The water line is obstructed or the water Check water pressure/flow: – pressure/flow is too low Closing water pressure, 22-32 kPa Closing water flow, min.
  • Page 176 7.2 Separating functions, purification only 7 Trouble-tracing 7.3.3 Oil discharges through water outlet (broken water seal) Cause Corrective actions Page Gravity disc hole too large Use a disc with smaller hole Incorrect separation temperature Adjust – Throughput too high Adjust –...

  • Page 177: Separating Functions, Clarification Only

    7 Trouble-tracing 7.4 Separating functions, clarification only Separating functions, clarification only 7.4.1 Unsatisfactory separation result Cause Corrective actions Page Incorrect separation temperature Adjust – Throughput too high Adjust – Feed oil contains water 1. Check preceeding purifier when operating in series –...

  • Page 178: Vibration Switch (Option)

    Cause Corrective actions Page Dirt or iron chips on magnets Clean magnets – Leaf spring broken Return to Alfa Laval for repair – Reset coil open Check for continuity and proper coil – resistance 7.5.2 Impossible to adjust setpoint setting to obtain...

  • Page 179: Technical Reference

    8 Technical Reference Contents 8.1 Technical data 8.9 Other drawings 8.9.1 Foundations 8.2 Basic size drawing, without pump 8.9.2 Electric motor, 15 kW 8.9.3 Electric motor, 16 kW 8.2.1 Separator excl. connections 8.9.4 Machine plates and safety labels 8.2.2 Dimensions of connections 8.9.5 Vibration sensor (option) 8.9.6...

  • Page 180: Technical Data

    8.1 Technical data 8 Technical Reference Technical data Alfa Laval ref. 556195/0 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 181 8 Technical Reference 8.1 Technical data Discharge interval, min./max. 1/240 minutes Bowl volume litres Starting time minutes Stopping time with brake minutes Max. running time without flow; - empty bowl minutes - filled bowl minutes Sound power level – Bel(A) ISO 3744, 4,5 m Sound pressure level dB(A) ISO 3744, 4,5 m Vibration level, separator in use, max.
  • Page 182 8.1 Technical data 8 Technical Reference Oil inlet pump, built-on (option) Capacity 50 Hz 60 Hz Pump No. (lit/h) (lit/h) 538721-87 2 420 2 900 538721-84 3 630 4 350 538721-85 4 350 5 220 538721-83 5 760 6 920 538721-81 8 540 10 250...

  • Page 183: Basic Size Drawing, Without Pump

    8 Technical Reference 8.2 Basic size drawing, without pump Basic size drawing, without pump 8.2.1 Separator excl. connections Alfa Laval ref. 558588 Maximum horizontal Maximum vertical Tigthening torque 20 Nm. displacement at the in/outlet displacement at the sludge Locked with lock nut.

  • Page 184: Dimensions Of Connections

    8.2 Basic size drawing, without pump 8 Technical Reference 8.2.2 Dimensions of connections Alfa Laval ref. 558588 Data for connections, see chapter ‘‘8.3 Connection list, without pump” on page 185. All connections to be installed non-loaded and flexible. Connections 201 and 220 are turnable 360°.

  • Page 185: Connection List, Without Pump

    8 Technical Reference 8.3 Connection list, without pump Connection list, without pump Alfa Laval ref. 557637 rev. 3 Connection No. Description Requirements/limits Inlet for product − Allowed temperature Min. 0 °C, max. 100 °C Inlet to liquid seal and displacement liquid, water Fresh water −...
  • Page 186 8.3 Connection list, without pump 8 Technical Reference Connection No. Description Requirements/limits Outlet for operating liquid (discharge and make-up liquid) (463) Drain of frame top part, upper Drain of frame top part, lower See connection No. 377 (common outlet) Motor for separator −...

  • Page 187: Basic Size Drawing, With Pump

    8 Technical Reference 8.4 Basic size drawing, with pump Basic size drawing, with pump 8.4.1 Separator excl. connections Alfa Laval ref. 559740/0 Maximum horizontal Maximum vertical Tigthening torque 20 Nm. displacement at the in/outlet displacement at the sludge Locked with lock nut.

  • Page 188: Dimensions Of Connections

    8.4 Basic size drawing, with pump 8 Technical Reference 8.4.2 Dimensions of connections Alfa Laval ref. 558585 Data for connections, see chapter ‘‘8.5 Connection list, with pump” on page 189. All connections to be installed non-loaded and flexible. Connections 201.3 and 220 are turnable 360°.

  • Page 189: Connection List, With Pump

    8 Technical Reference 8.5 Connection list, with pump Connection list, with pump Alfa Laval ref. 557155, rev. 4 Connection No. Description Requirements/limits 201.1 Inlet for product − Allowed temperature Min. 0 °C, max. 100 °C 201.2 Outlet for process liquid from pump 201.3...
  • Page 190 8.5 Connection list, with pump 8 Technical Reference Connection No. Description Requirements/limits 372 + 376 Discharge and make-up liquid − Consumption 2,4 litres/discharge Outlet for operating liquid (discharge and make-up liquid) (463) Drain of frame top part, upper Drain of frame top part, lower See connection No.

  • Page 191: Interface Description

    8 Technical Reference 8.6 Interface description Interface description Alfa Laval ref. 557138, rev. 3 8.6.1 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 192: Component Description And Signal Processing

    8.6 Interface description 8 Technical Reference 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. •...
  • Page 193 8 Technical Reference 8.6 Interface description Cover interlocking switch 760 (option) The cover of the separator can be equipped with an interlocking switch as option. When the cover is closed the interlocking circuit in the control system is closed and the separator could be started.

  • Page 194: Function Graph And Running Limitations

    8.6 Interface description 8 Technical Reference 8.6.4 Function graph and running limitations Stand still Starting mode Running mode Stop mode Safety stop mode ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 195: Water Quality

    For test methods, contact any Alfa Laval representative. If these demands cannot be met, the water should be pretreated according to Alfa Laval's recommendations. Alfa Laval accepts no liability for consequences arising from unsatisfactorily purified water supplied by the customer. ventas@fdm.com.pe fdmsac@gmail.com...

  • Page 196: 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 197 8 Technical Reference 8.8 Lubricants 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 198: Recommended Lubricating Oils

    Alfa Laval ref. 553219-15 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 ‘‘8.8.3 Recommended oil...

  • Page 199: Recommended Oil Brands

    8 Technical Reference 8.8 Lubricants 8.8.3 Recommended oil brands Alfa Laval lubricating oil group A/320 Alfa Laval ref. 553218-11 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) >95 Manufacturer Designation Alfa Laval 546099-80 20 litres 546099-81 4 litres...
  • Page 200 8.8 Lubricants 8 Technical Reference Alfa Laval lubricating oil group D/220 Alfa Laval ref. 553218-08 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) >130 Manufacturer Designation Alfa Laval 542690-80 20 litres 542690-81 4 litres 542690-82 208 litres 542690-83...
  • Page 201 8 Technical Reference 8.8 Lubricants Alfa Laval lubricating oil group D/320 Alfa Laval ref. 553218-06 Viscosity grade VG (ISO 3448/3104) Viscosity index VI (ISO 2909) >130 Manufacturer Designation Alfa Laval 542690 Separation AB - blue Castrol Alpha Syn T 320...

  • Page 202: Recommended Lubricants

    8.8 Lubricants 8 Technical Reference 8.8.4 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 203 8 Technical Reference 8.8 Lubricants Greases for ball and roller bearings Alfa Laval ref. 554900-01 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 204: Other Drawings

    8.9 Other drawings 8 Technical Reference Other drawings 8.9.1 Foundations Alfa Laval ref. 557660 Min. lifting capacity 1000 kg Recommended free floor space for unloading Recommended speed for lifting: when doing service Low speed 0,5-1,5 m/min. Min. access area for overhead hoist.

  • Page 205: Electric Motor, 15 Kw

    8 Technical Reference 8.9 Other drawings 8.9.2 Electric motor, 15 kW Alfa Laval ref. 540467 A = Four holes This motor is attended only for land application. Manufacturer Not fixed Standards IEC 72 Size 160L Poles Degree of protection IP44...

  • Page 206: Electric Motor, 16 Kw

    8.9 Other drawings 8 Technical Reference 8.9.3 Electric motor, 16 kW Alfa Laval ref. 552814 A. 4 x Pg 29. Max cable diameter 29 mm Manufacturer ABB Motors Manufacturers drawing MK20-92S Standards IEC 34-1, IEC 72 Size 160L Type MBT 160L...
  • Page 207 8 Technical Reference 8.9 Other drawings Article No Output Speed Freq Voltage Current Pow.fac Therm Note cos ϕ °C 552814-01 1445 200 D 0,86 552814-02 1445 220 D 0,86 552814-03 1445 380 D 0,86 552814-04 1445 415 D 0,86 552814-05 1445 440 D 0,86...

  • Page 208: Machine Plates And Safety Labels

    8.9 Other drawings 8 Technical Reference 8.9.4 Machine plates and safety labels Alfa Laval ref. 554651 1. Machine plate Separator MOPX 213TGT-20 Manufacturing serial No./ Year XXXX Product No. 881039-04-02 Machine top part 557766-02 Bowl 540399-84 Machine bottom part 540225-17/18 (50/60 Hz, without pump) 540225-42/43 (50/60 Hz, with pump) Max.
  • Page 209 8 Technical Reference 8.9 Other drawings 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.

  • Page 210: Vibration Sensor (Option)

    8.9 Other drawings 8 Technical Reference 8.9.5 Vibration sensor (option) Alfa Laval ref. 557311 rev. 1 Type: Mechanical velocity Switch rating, voltage: Max. 460 V AC Reset coil: 24 V DC, 48 V DC, 117 V AC 60 Hz Interconnection diagram...

  • Page 211: Storage And Installation

    8 Technical Reference 8.10 Storage and installation 8.10 Storage and installation 8.10.1 Introduction Most of the installation 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, connection lists and interface description, can be found previous in this chapter.
  • Page 212 8.10 Storage and installation 8 Technical Reference 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.

  • Page 213: 8.10.3 Planning Of Installation

    8 Technical Reference 8.10 Storage and 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”...
  • Page 214 8.10 Storage and installation 8 Technical Reference 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.

  • Page 215: Foundations

    8 Technical Reference 8.10 Storage and installation 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 216 8.10 Storage and installation 8 Technical Reference • 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.
  • Page 217 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 218 ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...
  • Page 219 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 220 ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045...

  • Page 221: Index

    Index Cover interlocking switch Cracks Assembly Disc stack pressure Bowl body and operating mechanism Erosion Bowl hood and disc stack External cleaning Feed pump Flexible plate in coupling General directions Guide surfaces Horizontal driving device Inlet pipe and oil paring disc Inlet/outlet, frame hood Level ring Operating water device...
  • Page 222 Cover interlocking switch (option) Design and function Gear Drawing Number of teeth Cracks Wear of teeth Gravity disc Selection Daily checks Guide surfaces Density of feed Intermediate Service Disc Major Service Disc stack pressure Repair of galling Dismantling Bowl body and operating mechanism Bowl hood and disc stack Horizontal driving device Feed pump...
  • Page 223 Maintenance logs Purification 3-year Service (3S) Broken water seal Daily checks Definition Intermediate Service (IS) Outgoing water contains oil Major Service (MS) Start procedure Oil change Unsatisfactory separation result Maintenance, general information Purifier bowl Ball and roller bearings Gravity disc Before shutdowns Cleaning Lifting instructions...
  • Page 224 Start Check points Warning signs Clarification start procedure Water Purification start procedure Water quality specifications Starting power too high Water in worm gear housing Starting power too low Weight Starting time Worm gear Starting time too long Function and description Stopping procedure Number of teeth Stopping time...

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