Alfa Laval MOPX 310TGT-24 Manual
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Alfa Laval MOPX 310TGT-24 Manual

Alfa Laval MOPX 310TGT-24 Manual

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Product No.
881077-01-07
Book No.
1270376-02 V1
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Summary of Contents for Alfa Laval MOPX 310TGT-24

  • Page 1 Product No. 881077-01-07 Book No. 1270376-02 V1...
  • Page 3 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...

  • Page 5: 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 6 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 7 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 9: Read This First

    17 and chapter ‘‘8 Technical Reference” on page 185. 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 Manual. In this case, study carefully all the instructions in the System Manual.
  • Page 10 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 11: Safety Instructions

    Strictly follow the instructions for installation, operation and maintenance. • Ensure that personnel are competent and have sufficient knowledge of maintenance and operation, especially concerning emergency stopping procedures. • Use only Alfa Laval genuine spare parts and the special tools supplied.
  • Page 12 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 13 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 14 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.
  • Page 15 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 16 2 Safety Instructions...

  • Page 17: 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 18: 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 19 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 20: 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 21: 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 22: 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 23 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 24: 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 25 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 26 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 27: Separating Function

    3 Separator Basics 3.3 Separating function Separating function 3.3.1 Purifier bowl Characteristic parts The illustration shows the characteristic part of the purifier bowl, the gravity disc. The disc should be chosen according to directions in chapter ‘‘4.1.2 Selection of gravity disc” on page 37. The gravity disc determines the interface position in a purifier bowl (see below).
  • Page 28 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 29: 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 30: 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 31: 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 32 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 33: 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 34 3.4 Definitions 3 Separator Basics...

  • Page 35: 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 4.1.5 Running 4.1.6 Normal stop 4.1.7 Safety stop...

  • Page 36: 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 37: Selection Of Gravity Disc

    4 Operating Instructions 4.1 Operating routine 4.1.2 Selection of gravity disc The separator is delivered with a set of gravity discs. How to replace a gravity disc is described in ‘‘6.3 Bowl hood and disc stack (IS)” on page 112. Clarification When running the separator as a clarifier, select the gravity disc with the smallest hole diameter,...
  • Page 38 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 39 4 Operating Instructions 4.1 Operating routine How to use the nomogram ρ = Density of oil in kg/m Nomogram for MOPX 310 at 15 °C Q = Throughput in m The presence of salt water may demand the use of a gravity disc with larger hole diameter than T = Separating temperature in °C or °F indicated in the nomogram (the nomogram is based on the properties of fresh water).

  • Page 40: Ready For Start

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

  • Page 41: 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 42: 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. During start, the current reaches a peak and then drops slowly to a low and stable level, which is the normal current during operation.

  • Page 43: 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 186.

  • Page 44: Safety Stop

    Out-of-balance vibration can become worse if only part of the sediment is discharged. CAUTION Disintegration hazards After a safety stop the cause of the fault must be identified. If all parts have been checked and the cause remains unclear, contact Alfa Laval for advice.

  • Page 45: 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; height position 5.1.4 Service kits 5.4.4...
  • Page 46 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 47: 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 48 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 49: 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 50: 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 51: 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 52: Intermediate Service (Is)

    5.2 Maintenance Logs 5 Service Instructions 5.2.3 Intermediate Service (IS) Name of plant: Local identification: Separator: MOPX 310TGT-24 Manufacture No./Year: Total running hours: Product No: 881077-01-07 Date: Signature: Note: Renew all parts included in the Intermediate Service kit (IS). Main component and activity...
  • Page 53 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 54: Major Service (Ms)

    5.2 Maintenance Logs 5 Service Instructions 5.2.4 Major Service (MS) Name of plant: Local identification: Separator: MOPX 310TGT-24 Manufacture No./Year: Total running hours: Product No: 881077-01-07 Date: Signature: Note: Renew all parts included in the Intermediate Service kit (IS) and Major Service kit (MS).
  • Page 55 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 56 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...

  • Page 57: 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 58: 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 59: 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 60 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 61 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 62: 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 63: 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 64 5.3 Check points at Intermediate Service (IS) 5 Service Instructions Complementary check using the compressing tool With the large lock ring correctly tighten and the compressing tool mounted on the separator bowl, turn the switch to position 1 for compression. Compress the disc stack by pumping the lever arm until the oil pressure is released through the relief valve.

  • Page 65: 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 66 5.3 Check points at Intermediate Service (IS) 5 Service Instructions 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 67: 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 68 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 69: 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 70: Lock Ring; Wear And Damage

    If the original φ−mark on the lock ring passes the φ−mark on the bowl body by more than 25° (which corresponds to A=100 mm), an Alfa Laval representative must be contacted immediately. If the marks become illegible, an Alfa Laval...
  • Page 71 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 72: Operating Mechanism

    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 73: Sliding Bowl Bottom

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 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 74: Springs For Operating Mechanism

    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 75: Vibration Switch (Option)

    5 Service Instructions 5.3 Check points at Intermediate Service (IS) 5.3.17 Vibration switch (option) NOTE Before carrying out the function check described below, check that a safety stop will not cause serious interruption of the operation. Knock on the vibration switch cap a number of times within one second (the number is decided by the system parameter settings).

  • Page 76: 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 58. 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 77: Bowl Spindle; Radial Wobble

    5 Service Instructions 5.4 Check points at Major Service (MS) 5.4.4 Bowl spindle; radial wobble The bowl spindle wobble should be checked if the bowl spindle has been dismantled or if rough bowl running (vibration) occurs. NOTE Spindle wobble will cause rough bowl run. This leads to vibration and reduces lifetime of ball bearings.

  • Page 78: Buffer Springs And Ball Bearing Housing

    5.4 Check points at Major Service (MS) 5 Service Instructions If the friction pad is oily: • Clean the friction pad and the coupling drum with a suitable degreasing agent. • Roughen the friction surface of the friction pad with a coarse file. NOTE Identify the cause of oily friction pad.
  • Page 79 5 Service Instructions 5.4 Check points at Major Service (MS) Top bearing springs In case of spring fracture, the complete set of springs should be replaced, even if only one spring is broken. Ball bearing housing Radial buffer Buffer spring Screw plug Ball bearing housing Examine the contact surface for the buffers on the...

  • Page 80: Coupling Friction Pads

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.7 Coupling friction pads Worn or oily pads in the coupling will cause a long acceleration period. If the separator does not attain full speed within about 10 minutes or the bowl lose speed during operation, the friction pads of the coupling may be worn or oily.

  • Page 81: 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 A is different for 50 and 60 Hz separators 50 Hz: A = 20 mm...

  • Page 82: Flexible Plate In Coupling

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.12 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 83: Guide Surfaces

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

  • Page 84: Level Ring

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.15 Level ring Same as described in section ‘‘5.3.9 Level ring” on page 69. 5.4.16 Lock ring; priming The arrows indicate positions of threads, guide and contact surfaces to be primed. Recommended agents for priming procedure: •...
  • Page 85 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 86: Lock Ring; Wear And Damage

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.17 Lock ring; wear and damage Same as described in section ‘‘5.3.10 Lock ring; wear and damage” on page 70. 5.4.18 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 87: Operating Paring Disc; Height Position

    5 Service Instructions 5.4 Check points at Major Service (MS) 5.4.20 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 88: Springs For Operating Mechanism

    5.4 Check points at Major Service (MS) 5 Service Instructions 5.4.23 Springs for operating mechanism Same as described in ‘‘5.3.14 Springs for operating mechanism” on page 74. 5.4.24 Worm; wear of groove Renew the worm if the wear in the groove (1) which receives the conveyor exceeds 3-4 mm.

  • Page 89: 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 90: 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 91: 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 92 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 93: Cleaning Of Bowl Discs

    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 94: Cip-System

    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...

  • Page 95: 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. Examine the contact surfaces and compare the tooth profiles with the ‘‘...
  • Page 96 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 97 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 98: Oil Change Procedure

    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 202 must be well known.

  • Page 99: 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 100: Vibration Switch (Option)

    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 101: 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 102 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 103 5 Service Instructions 5.9 Common maintenance directions • When assembling ball bearings, the bearings must be heated in oil to max. 125 °C. NOTE Heat the bearing in a clean container. Use only clean oil with a flash point above 250 °C.

  • Page 104: Before Shutdowns

    5.9 Common maintenance directions 5 Service Instructions Angular contact ball bearings Always fit single-row angular contact ball bearings with the wide shoulder of the inner race facing the axial load (upwards on a bowl spindle). The wide shoulder of the inner race must face the axial load 5.9.2 Before shutdowns...

  • Page 105: Dismantling/Assembly

    6 Dismantling/Assembly 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 Dismantling...

  • Page 106: 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 47. DANGER Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work.

  • Page 107: 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: Check point ‘‘5.3.5 Disc stack pressure” on page 63. In this example, look up check point Disc stack pressure in chapter 5 for further instructions.

  • Page 108: 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 109: 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 110: 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 111 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 ‘‘4.1.3 Ready for start”...

  • Page 112: 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. Bowl hood O-ring 12. O-ring Upper (water) paring disc 13. Seal ring O-ring 14. Top disc Sleeve with wings 15.

  • Page 113: Dismantling

    3. Apply the brake and unscrew the lock ring as described below. NOTE Use an Alfa Laval compressing tool (optional) to reduce shocks to bearings and thread wear minimized when unscrewing the large lock ring. Unscrewing lock ring without using a compressing tool a.
  • Page 114 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly Unscrewing lock ring with a compressing tool a. Fit the lifting tool on the bowl hood. b. Fit the compressing tool by screwing the pillar of the tool into the threads of the distributor using the lever.
  • Page 115 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) e. Release the pressure in the compressing tool and remove it from the lifting tool. 4. Remove the lock ring. NOTE The lock ring must be kept lying horizontally or it may become distorted. Even slightest distortion could make it impossible to refit.
  • Page 116 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly Separating bowl hood with a compressing tool a. Remove the lifting tool from the bowl hood. b. Fit the compressing tool by screwing the pole of the tool into the threads of the distributor using the lever.
  • Page 117 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 7. Remove the top disc. 8. Screw the inlet pipe into the paring disc located above the level ring inside the top disc. Left-hand thread! Place the top disc onto wooden blocks to act as protection for the top disc edge and for falling level ring.
  • Page 118 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly Fit the lifting tool into the distributor and lift the distributor with disc stack out of the bowl body using a hoist. 10. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning”...

  • Page 119: Assembly

    6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) 6.3.3 Assembly Check point ‘‘5.3.3 Corrosion” on page 59, ‘‘5.3.4 Cracks” on page 62, ‘‘5.3.6 Erosion” on page 65, ‘‘5.3.10 Lock ring; wear and damage” on page 1. Assemble the discs one by one on the distributor.
  • Page 120 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly Check point ‘‘5.3.9 Level ring” on page 69. 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 121 ‘‘5.4.16 Lock ring; priming” on page 84 (only when Major Service). Tighten the lock ring. NOTE Use an Alfa Laval compressing tool (optional) to reduce shocks to bearings and thread wear minimized when tightening the large lock ring Tightening of lock ring without using a compressing tool a.
  • Page 122 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly b. Tighten until the assembly marks are at least in line. Check point ‘‘5.3.5 Disc stack pressure” on page 63. NOTE The assembly marks must never pass each other more than 25° which corresponds to A=100 mm.
  • Page 123 6 Dismantling/Assembly 6.3 Bowl hood and disc stack (IS) d. Tighten the lock ring using the spanner for lock ring. Left-hand thread! e. Tighten until the assembly marks are in line. Check point ‘‘5.3.5 Disc stack pressure” on page 63. NOTE The assembly marks must never pass each other more than 25 °...
  • Page 124 6.3 Bowl hood and disc stack (IS) 6 Dismantling/Assembly 12. Fit and tighten the paring chamber cover using the spanner. Left-hand thread!

  • Page 125: 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 Nozzle, 2,5 mm Bowl body Plug 10. O-ring 11. Valve plug 12.

  • Page 126: 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 a hoist.
  • Page 127 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 4. Unscrew the three screws in the bottom of the bowl body. 5. Fit the lifting tool into the bowl body bottom with the three screws. 6. Release the bowl body from the spindle by using the lifting tool as a puller.
  • Page 128 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 8. Thread a strap through two sludge ports and turn the bowl body upside down using a hoist. WARNING Crush hazards Support the bowl body when turning to prevent it from rolling. Loosen the screws for the spring holder successively a little at a time.

  • Page 129: Assembly

    6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 11. Fit two lifting eyes (½”-13 UNC) into the operating slide and lift it off from the bowl body. 12. Place the operating slide with the valve plugs facing upwards 13. Remove any thick deposits in the frame hood and clean all other parts thoroughly in a suitable cleaning agent.
  • Page 130 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 2. Fit the operating slide onto the bowl body. Check that the guide pin in the bowl body enters the hole in the operating slide. 3. Lubricate the guide surfaces and O-ring of the spring holder.
  • Page 131 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 6. Turn the bowl body using a hoist to its up- right position with a strap threaded through two sludge ports. WARNING Crush hazards Support bowl body when turning to prevent it from rolling.
  • Page 132 6.4 Bowl body and operating mechanism (IS) 6 Dismantling/Assembly 10. Lubricate the guide surfaces of the bowl body and sliding bowl bottom with lubricating paste. See chapter ‘‘8.8 Lubricants” on page 202. 11. Fit the lifting tool to the sliding bowl bottom and lift it into the bowl body using a hoist.
  • Page 133 6 Dismantling/Assembly 6.4 Bowl body and operating mechanism (IS) 14. Screw on the cap nut and tighten firmly. Left-hand thread!

  • Page 134: Operating Water Device (Is)

    6.5 Operating water device (IS) 6 Dismantling/Assembly 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...

  • Page 135: Dismantling

    6 Dismantling/Assembly 6.5 Operating water device (IS) 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 136 6.5 Operating water device (IS) 6 Dismantling/Assembly Check point ‘‘5.4.20 Operating paring disc; height position” on page 87. Only at Major Service (MS). 5. Fit the operating water inlet device into the distributing cover. 6. Connect the water hoses to the device. 372.
  • Page 137 6 Dismantling/Assembly 6.5 Operating water device (IS)

  • Page 138: Vertical Driving Device (Ms)

    6.6 Vertical driving device (MS) 6 Dismantling/Assembly Vertical driving device (MS) 6.6.1 Exploded view...
  • Page 139 6 Dismantling/Assembly 6.6 Vertical driving device (MS) Protecting plate O-ring Protecting collar Guard O-ring Ball bearing housing Spring casing Gasket Oil fan 10. Ball bearing 11. Screw 12. Screw 13. Screw 14. Spring washer 15. Buffer 16. Spring 17. Buffer plug 18.

  • Page 140: 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 141 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 4. Loosen (but do not remove) the six screw plugs for the buffers with a spanner and a hammer. 5. Unscrew the six screw plugs and remove the springs. Move the spindle top a few turns in a circle while pressing outwards.
  • Page 142 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 8. Prize out the ball bearing housing from the spring casing with a screw driver. Remove the spring casing and gasket. 10. Drain the oil from the worm gear housing. CAUTION Burn hazards Lubricating oil and various machine surfaces can be hot and cause burns.
  • Page 143 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 13. Push the worm wheel to one side before removing the spindle. If worm wheel is stuck use a piece of wood to loosen it. 14. Fit the lifting tool onto the spindle and lift out using the hoist.
  • Page 144 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 19. Drive off the top ball bearing from the sleeve spindle with the driving-off sleeve. Use a wooden plank or similar as a soft base for the spindle top. 20. Lift out the axial bottom ball bearing and the washer beneath using the lifting pin.

  • Page 145: Assembly

    6 Dismantling/Assembly 6.6 Vertical driving device (MS) 6.6.3 Assembly 1. Fit the bottom sleeve with mounted parts (rings and sleeve) into the bottom bearing housing. Use the lifting pin. Check that one ball is fitted both on top and bottom of the bottom sleeve. 2.
  • Page 146 6.6 Vertical driving device (MS) 6 Dismantling/Assembly Check point ‘‘5.4.24 Worm; wear of groove” on page 88. 4. Heat the two ball bearings and fit them on the worm. 5. Fit the stop sleeve (1) and the worm (2) on the spindle.
  • Page 147 6 Dismantling/Assembly 6.6 Vertical driving device (MS) Carefully lower the spindle into the frame and guide the spindle into the right position in the bottom bearing housing so the ball bearings enter their seats. If the ball bearings do not completely enter their seats, tap the spindle top gently with a tin hammer.
  • Page 148 6.6 Vertical driving device (MS) 6 Dismantling/Assembly 13. Tighten the six screw plugs. 14. Fit the guard with O-ring and tighten the six screws. 15. Fit the protecting collar with O-ring and protecting plate. NOTE Check that the protecting collar is in the bottom position before tightening the protecting plate.
  • Page 149 6 Dismantling/Assembly 6.6 Vertical driving device (MS) 16. Fit the hood with O-ring and tighten the six screws. Check point ‘‘5.4.3 Bowl spindle; height position” on page 17. Match the worm wheel with the teeth in the worm of the bowl spindle. Knock the taper pin into the worm wheel stop ring.

  • Page 150: Horizontal Driving Device (Ms)

    6.7 Horizontal driving device (MS) 6 Dismantling/Assembly Horizontal driving device (MS) 6.7.1 Exploded view...
  • Page 151 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) Ball bearing Screw Spring washer Round nut Lock washer Bearing shield Spring washer Oil shield 10. Taper pin 11. Stop ring 12. Worm wheel 13. Ball bearing 14. Sealing ring 15. Sealing washer 16.

  • Page 152: 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 153 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 154 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly d. Remove the pump assembly and gasket. 5. Unscrew the two nuts holding the oil shield. The shield can not be removed from the housing before the bearing shield is moved. 6. Unscrew the four screws for the bearing shield and remove it together with the oil shield.
  • Page 155 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 8. Remove the ball bearing. Remove the stop ring and worm wheel with ball bearing. 10. Pull off the ball bearing from the worm wheel. Use a washer as a support for the puller. 11.
  • Page 156 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 13. Remove the flexible plate and unscrew the six screws for the coupling disc and remove 14. Remove the worm wheel shaft with friction clutch pulley. 15. To dismantle the nave, unscrew the round nut with the pin spanner and remove the lock washer.

  • Page 157: Assembly

    6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 17. Remove the sealing washer using two screws with 1/4”-20 UNC threads. 18. Remove the sealing ring from the sealing washer. 19. Remove deposits and clean all parts thoroughly in a suitable cleaning agent. See chapter ‘‘5.6 Cleaning”...
  • Page 158 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. Check point ‘‘5.4.25 Worm wheel and worm; wear of teeth” on page 88. 6.
  • Page 159 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 101. 7. Fit the worm wheel with the ball bearing and fit the stop ring.
  • Page 160 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 together with the oil shield. Tighten the four screws for the bearing shield.
  • Page 161 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 13. Fit the coupling disc with gasket and tighten the six screws. If necessary, use the driving- on sleeve. 14. Fit the flexible plate. Check point ‘‘5.4.12 Flexible plate in coupling” on page 82. 15.
  • Page 162 6.7 Horizontal driving device (MS) 6 Dismantling/Assembly 17. 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. Separator with built-on pump a.
  • Page 163 6 Dismantling/Assembly 6.7 Horizontal driving device (MS) 18. Pour oil into worm gear housing. The oil level should be exactly in the middle of the sight glass. Oil volume: Approx. 12 litres. For recommended oil brands, see chapter ‘‘8.8 Lubricants” on page 202. Check point ‘‘5.4.5 Brake”...

  • Page 164: Feed Pump (Ms) (Option)

    6.8 Feed pump (MS) (option) 6 Dismantling/Assembly Feed pump (MS) (option) 6.8.1 Exploded view...
  • Page 165 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 166: 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 167 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 168: 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 91. 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 169: 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 170 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 171 6 Dismantling/Assembly 6.8 Feed pump (MS) (option) 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 172 6.8 Feed pump (MS) (option) 6 Dismantling/Assembly...

  • Page 173: 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 174: 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 175 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 176 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 177 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 178: 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 179 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 180 7.2 Separating functions, purification and clarification 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 125, 134 7.2.5 High pressure in oil outlet...

  • Page 181: Separating Functions, Purification Only

    7 Trouble-tracing 7.3 Separating functions, purification only Separating functions, purification only 7.3.1 Unsatisfactory separation result Cause Corrective actions Page Gravity disc hole too small Use a disc with larger hole Incorrect separation temperature Adjust – Throughput too high Adjust – Disc stack is clogged Clean disc stack Sludge space in bowl is filled...
  • Page 182 7.3 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 183: 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 184: 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 185: Technical Reference

    8 Technical Reference Contents 8.1 Technical data 8.9 Other drawings 8.9.1 Foundations 8.2 Basic size drawing, 8.9.2 Electric motor (land application) without pump 8.9.3 Electric motor (marine application) 210 8.2.1 Separator excl. connections 8.9.4 Electric motor (Brazil) 8.2.2 Dimensions of connections 8.9.5 Machine plates and safety labels 8.9.6...

  • Page 186: Technical Data

    8.1 Technical data 8 Technical Reference Technical data Alfa Laval ref. 556195 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 187 8 Technical Reference 8.1 Technical data Lubricating oils, by-pass treatment, optimum • R & O type: Maximum oil flow (lit/h) Crosshead diesel 6 800 • Detergent: Maximum oil flow (lit/h) Crosshead diesel 5 800 Trunk piston diesel 4 300 • Steam turbine: Maximum oil flow (lit/h) At 55 °C...
  • Page 188 8.1 Technical data 8 Technical Reference Weight of separator 1 060 (without motor) Weight of bowl The materials in contact with process fluid (excluding seals and O-rings) are brass, bronze and stainless steel. Cast iron frame. Intended for both land and marine applications. Oil inlet pump, built-on (option) Capacity 50 Hz...

  • Page 189: 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. 557236 Maximum horizontal displacement at the Maximum vertical displacement at the in/outlet connections during operation sludge connection during operation ±15 mm.

  • Page 190: Dimensions Of Connections

    8.2 Basic size drawing, without pump 8 Technical Reference 8.2.2 Dimensions of connections Alfa Laval ref. 557236 Data for connections, see chapter ‘‘8.3 Connection list, without pump” on page 191. All connections to be installed non-loaded and flexible.

  • Page 191: Connection List, Without Pump

    8 Technical Reference 8.3 Connection list, without pump Connection list, without pump Alfa Laval ref. 557297 rev. 1 Connection No. Description Requirements/limits Inlet for product - Allowed temperature Min. 0 °C, max. 100 °C Inlet to liquid seal and displacement liquid, water...
  • Page 192 8.3 Connection list, without pump 8 Technical Reference Connection No. Description Requirements/limits Drain of frame top part, lower See connection No. 377 (common outlet) Motor for separator - Allowed frequency variation ± 5% (momentarily 10% during a period of maximum 5 seconds) Vibration sensor (delivered as option) See ‘‘8.6 Interface description”...

  • Page 193: 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. 557266 Maximum horizontal displacement at the Maximum vertical displacement at the in/outlet connections during operation sludge connection during operation ±15 mm.

  • Page 194: Dimensions Of Connections

    8.4 Basic size drawing, with pump 8 Technical Reference 8.4.2 Dimensions of connections Alfa Laval ref. 557266 Data for connections, see chapter ‘‘8.5 Connection list, with pump” on page 195. All connections to be installed non-loaded and flexible.

  • Page 195: Connection List, With Pump

    8 Technical Reference 8.5 Connection list, with pump Connection list, with pump Alfa Laval ref. 557312, rev. 1 Connection No. Description Requirements/limits 201.1 Inlet for product to pump - Allowed temperature Min. 0 °C, max. 100 °C 201.2 Outlet for process liquid from pump 201.3...
  • Page 196 8.5 Connection list, with 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 - Allowed frequency variation ±...

  • Page 197: 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 198: 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 199 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 200: Function Graph And Running Limitations

    8.6 Interface description 8 Technical Reference 8.6.4 Function graph and running limitations A. Stand still Starting mode Running mode Stop mode Safety stop mode...

  • Page 201: 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 202: 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 203 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 204: 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 205: 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 206 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...
  • Page 207 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 208: 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 209 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 210: Other Drawings

    8.9 Other drawings 8 Technical Reference Other drawings 8.9.1 Foundations Alfa Laval ref. 557258 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 211: Electric Motor (Land Application)

    8 Technical Reference 8.9 Other drawings 8.9.2 Electric motor (land application) Alfa Laval ref. 539827 Note! This motor is for land application only A = Four holes Manufacturer Not fixed Standards IEC 72-2, 34-1, CENEL/2B Size 160M Poles Degree of protection...

  • Page 212: Electric Motor (Marine Application)

    8.9 Other drawings 8 Technical Reference 8.9.3 Electric motor (marine application) Alfa Laval ref. 552813 Manufacturer ABB Motors Manuf. drawing MK20-92S Standards IEC 34-1, IEC 72 Size 160M Type MBT 160M Weight 72 kg Poles Insulation class Bearings DE 6209-Z/C3 – NDE 6209-Z/C3 Method of cooling IC 41 (IEC 34-6) Spec.
  • Page 213 8 Technical Reference 8.9 Other drawings Article No Output Speed Freq Voltage Current Pow.fac Therm Note cos ϕ °C 552813-01 1445 200 D 0,85 552813-02 1445 220 D 0,85 552813-03 1445 380 D 0,85 552813-04 1445 415 D 0,85 552813-05 1445 440 D 0,85...

  • Page 214: Electric Motor (Brazil)

    8.9 Other drawings 8 Technical Reference 8.9.4 Electric motor (Brazil) Alfa Laval ref. 552943 Note! This motor is for local use in Brazil only Manufacturer WEG, Brazil Poles Manuf. drawing 003.10/03 1990 Insulation class Standards IEC 34-1, IEC 72 Bearings DE 6308-Z –...

  • Page 215: Machine Plates And Safety Labels

    8 Technical Reference 8.9 Other drawings 8.9.5 Machine plates and safety labels Alfa Laval ref. 554651 1. Machine plate Separator MOPX 310TGT-24 Manufacturing serial No / Year XXXX Product No 881077-01-07 Machine top part 557303-01 Bowl 544721-07 Machine bottom part...
  • Page 216 8.9 Other drawings 8 Technical Reference 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 217: Vibration Sensor (Option)

    8 Technical Reference 8.9 Other drawings 8.9.6 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 218: Storage And Installation

    8.10 Storage and installation 8 Technical Reference 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 219 8 Technical Reference 8.10 Storage and installation 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 220: Planning Of Installation

    8.10 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 chapter ‘‘5.5 Lifting instructions”...
  • Page 221 8 Technical Reference 8.10 Storage and installation 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 222: Foundations

    8.10 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 223 8 Technical Reference 8.10 Storage and installation • 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 224 8.10 Storage and installation 8 Technical Reference...
  • Page 225 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 227 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 229: Index

    Index Disc stack pressure Erosion Assembly External cleaning Bowl body and operating mechanism Flexible plate in coupling Bowl hood and disc stack Guide surfaces Feed pump Inlet pipe and oil paring disc General directions Level ring Horizontal driving device Lifting instructions Inlet/outlet, frame hood Lock ring - priming Operating water device...
  • Page 230 Cracks Gear Number of teeth Daily checks Wear of teeth Density of feed Gravity disc Disc Selection Disc stack pressure Guide surfaces Dismantling Intermediate Service Bowl body and operating mechanism Major Service Bowl hood and disc stack Repair of galling Feed pump General directions Horizontal driving device...
  • Page 231 Oil change Maintenance, general information Ready for start Ball and roller bearings Retardation time too long Before shutdowns Revolution counter Cleaning Function Lifting instructions Number of revolutions Maintenance intervals Running-up procedure Maintenance procedure Oil change procedure Service kits Vibration analysis Safety Instructions Major service Safety stop...
  • Page 232 Technical data Throughput Capacity Definition Transport Trouble tracing - mechanical functions Noise Retardation time too long Separator vibrates Smell Speed too low Starting power too high Starting power too low Starting time too long Water in worm gear housing Trouble tracing - purification faults Broken water seal Outgoing water contains oil Unsatisfactory separation result...

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