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Summary of Contents for Alfa Laval MBPX810H
- Page 1 Alfa Laval Separation System MBPX810H Installation and Operating Lit. Code 200006740-2-EN-GB Manual No. 9662058516 instructions BRITISH ENGLISH...
- Page 2 © Alfa Laval Corporate AB 2022-06 This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose.
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Page 3: Table Of Contents
1 Introduction and General Information ............5 Scope of this book.....................5 Safety Instructions.....................6 General description of Alfa Laval Separation System..........11 MBPX810 System description................. 11 2 Installation, Maintenance and Lifting Instructions ......15 Unpacking and Initial Inspection of the Separator...........15 Lifting instructions....................18... - Page 4 6.13 Bowl speed control....................47 6.14 Discharge performance and Bowl closing supervision..........48 7 Alarm Management ....................49 Alarm acknowledgement..................49 Alarm activation diagram..................50 8 Installation and Setup information .............. 51 Passwords.......................51 VFD Parameters......................51 9 Ordering Spare parts ................... 53 Spare parts......................53 Alfa Laval Service....................53...
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Page 5: Introduction And General Information
1 Introduction and General Information 1.1 Scope of this book The Installation and Operating instructions given in this manual are designed for the Alfa Laval separation system with valve arrangement and Allen Bradley PLC automation. In this manual you will find: •... -
Page 6: Safety Instructions
Alfa Laval will not be responsible for any breakdown of the equipment caused by the owner’s failure to follow the instructions given in this documentation. This documen- tation describes the authorized way to use the separator system. - Page 7 Repairs: unscheduled break-down of a component, often causing the system to stop. Damaged components shall be replaced or repaired. • Stock of recommended spare parts: Alfa Laval recommends keeping a stock of spare parts facilitating preventive maintenance and reducing the system down time in case of unplanned bread downs.
- Page 8 Safety Stop • 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. Vibration • If the separator begins to vibrate excessively during operation, stop it immediately by pushing the emergency stop button and evacuate the room.
- Page 9 Introduction and General Information 1 Hazards Hazardous Area • Cleaning, maintenance and repair work may be done only at nonexplosive atmos- phere. • The separator may be hazardous when passing its critical speeds during the run- down. • For reasons of safety, only tools made of non-sparking material may be used when performing work in hazardous area.
- Page 10 1 Introduction and General Information Corrosion Hazard • Always handle cleaning liquids, lye and acid with great care and in accordance with separate instructions for those fluids. • When using chemical cleaning agents and lubricants, make sure you follow the general rules and suppliers recommendation regarding ventilation, personnel pro- tection etc.
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Page 11: General Description Of Alfa Laval Separation System
Introduction and General Information 1 1.3 General description of Alfa Laval Separation System The separation system is designed for clarification purposes in biotech applications. It is a system with product and utility line, valve arrangement, and automation with starter panel and control panel. - Page 12 1 Introduction and General Information Process/service liquid module The process liquid components are used for flow control through the separator. There is an inlet for process liquid (201.1) and an inlet for buffer liquid (206). There is also a product outlet (220.1) which alternatively can be open to drain (460a).
- Page 13 Introduction and General Information 1 he pneumatic equipment distributes instrument air (502) to the pneumatic valves and for pressurizing purposes.. The control equipment controls and supervises the entire system and gives alarms and actions if anything goes wrong. The supervision includes the following: •...
- Page 14 1 Introduction and General Information 200006740-2-EN-GB...
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Page 15: Installation, Maintenance And Lifting Instructions
2 Installation, Maintenance and Lifting Instructions NOTE For installation and maintenance of the separator, refer to the instructions in the separator documentation. NOTE For installation and maintenance of equipment, refer to the supplier documentation provided in section 4 and 5 of the turnover package. 2.1 Unpacking and Initial Inspection of the Separator THIS WAY UP Position: Near left hand upper corner... - Page 16 • If during the inspection of the delivered components there are found damaged or missing items, it shall be reported to Alfa Laval immediately after the delivery has taken place. • Alfa Laval can instruct how to repair possible damages or how to replace missing items.
- Page 17 Installation, Maintenance and Lifting Instructions 2 Storage Before storing a separator that has been in operation, make sure to drain any parts containing water, such as Operating water module (if any), Operating water system and Cooling jackets. Upon arrival to the store, check all components and keep them: •...
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Page 18: Lifting Instructions
2.2 Lifting instructions NOTE Always refer to the layout drawing and lifting drawing for overall dimensions, weight and connection points (as per scope of supply from Alfa Laval). NOTE When lifting a separator, always follow the instructions from the separator’s installation manual. -
Page 19: Mechanical Installation And Maintenance
2.3 Mechanical installation and maintenance The separation system should be placed in such a way that suitable space for maintenance and repair is obtained. Always contact local Alfa Laval representative for a guidance on the installation details. Mechanical installation work should always be performed by authorized personnel and according to local legislation. -
Page 20: Electrical Installation And Maintenance
2 Installation, Maintenance and Lifting Instructions 2.4 Electrical installation and maintenance Always refer to the electrical drawings provided with the system before carrying out electrical installation. Electrical installation work must always be performed by authorized electricians and personnel, and should be done according to local legislation. The dimensions of the control cabinet and cables can be found in the electrical drawing for the system. -
Page 21: Cleaning
Clean all parts of the remains of product and contamination. Do not scratch or damage parts during cleaning. Use only Alfa Laval recommended CIP liquids. The plant operator is responsible for selecting the cleaning material and performing the procedure. -
Page 22: Installation Of Auxiliary Equipment
2 Installation, Maintenance and Lifting Instructions 2.6 Installation of Auxiliary Equipment Below are the general check points of installation of auxiliary equipment such as valve modules and electric/pneumatic units. • Fasten valve modules such as process liquid module or service liquid unit with bolts of high strength material to the foundation. -
Page 23: Start-Up And Commissioning
3 Start-Up and Commissioning 3.1 Before Start-Up and Commissioning Before commissioning or start-up of the system can be initiated, the following two conditions should be fulfilled: • OWMC service to be done before separator commissioning according to instructions in the “Service & maintenance manual” of separator. •... -
Page 24: Completion And Start-Up
3 Start-Up and Commissioning 3.2 Completion and Start-Up • For general start-up of the module please refer to the “Operation Instructions” of the documentation and check below points: • Check that all pipe connections have been made according to the supplied drawings and documentation. -
Page 25: Description Of Operating Conditions
4 Description of operating conditions 4.1 MAIN SEQUENCE The software has been specially developed to operate the system to always provide the best possible performance, flexibility and a safe operation. The control program has many features and the main operating modes and options are described below. -
Page 26: Start
4 Description of operating conditions 4.4 START The power to separator motor is ON and separator motor begins to run when the START function is selected on the operator panel. STARTING is indicated. The bowl is rotating and accelerating. Nothing is fed to the separator, the centrifugate outlet is open. Purified water, cooling liquid are supplied to the separator and cooling return liquid starts. -
Page 27: Cip (Cleaning In Place)
Description of operating conditions 4 It is possible to change a whole set of essential data for a PRODUCTION run in one step using a RECIPE. Each recipe contains values for parameters RPn00 to RPn17. 4.7 CIP (Cleaning in place) CIP means that the separator is running at full selected speed. - Page 28 4 Description of operating conditions NOTE If the system has been in SAFETY STOP mode before the emergency stop button is pushed, the system will remain in SAFETY STOP after the button is reset. 200006740-2-EN-GB...
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Page 29: Operating Routine
5 Operating routine NOTE Make sure that the separator is assembled correctly. Always consult the Installation manual of the separator. NOTE Make sure that all electrical and liquid connections are made correctly according to the electrical drawing and the connection list, and that all couplings are tightened. NOTE Make sure that the separator control system is activated. -
Page 30: System Drain
5 Operating routine 5.2 SYSTEM DRAIN SYSTEM DRAIN can be selected in STAND STILL. Make sure that all liquid supplies to the system are closed. Select SYSTEM DRAIN on operator panel. Most automatic valves will be open, and the separator motor starts once up to a certain speed set point. -
Page 31: Start
Operating routine 5 5.3 START START can be selected from STAND STILL or STOP. Make sure that cooling liquid and purified water is available. Check that no alarm override functions are activated. If necessary, sterilize the separator. Select START on the operator panel. The system indicates STARTING and the power to the separator motor is on and it begins to run. -
Page 32: Standby
5 Operating routine 5.4 STANDBY There are two sub modes of the STANDBY mode: STANDBY WET (with water feed) and STANDBY DRY (without liquid feed). In STANDBY WET automatic discharges are possible. In both sub modes it is possible to initiate a solids discharge manually: Select Discharge on the operator panel. -
Page 33: Production
Operating routine 5 5.5 PRODUCTION PRODUCTION can be selected from STANDBY DRY or STANDBY WET. The feed could be controlled by FCV220–1 (RPn10=0) or feed pump P201–1 (RPn10=1). Select PRODUCTION on the operator panel. The separator is fed with product from the feed inlet line (201.1) The accumulated solids in the bowl periphery is discharged at certain intervals. -
Page 34: Cip (Cleaning In Place)
5 Operating routine 5.6 CIP (Cleaning in place) CIP can be selected from STANDBY DRY or STANDBY WET. Select CIP on the operator panel. CIP is indicated on the display. The discharge interval to the next discharge is counted down. The separator is fed with cleaning liquid from the feed inlet line (201.1). -
Page 35: The Control System And Function Description
6 The Control system and Function description In the following section the operator interface and the control and supervision functions of the system are described. 6.1 Starter panel The starting equipment includes the electrical power supply/distributor for the separator and the components of the control system. The starter panel door consists of: •... -
Page 36: Control Panel
6 The Control system and Function description 6.2 Control panel The control cabinet contains Allen Bradley PLC, CPU, communication processor, circuit breakers, signal converters, and interface relay. The control panel door consists of: • Allen Bradley Panel view plus 7 •... -
Page 37: Operator Interface And Function Description
The Control system and Function description 6 6.3 Operator interface and function description NOTE To be able to use all functions of the operator interface the operator has to log in on the right authority level. Read more about different authority levels in the Log In section of the SDS. -
Page 38: Process Screen
6 The Control system and Function description 6.4 Process screen The top header of the screen contains: • Alfa Laval logo • Current operation mode • Time • Manual mode on/off The second row contains: • Functionality to change or select HMI screen according to the Operating interface diagram. -
Page 39: Parameters
The Control system and Function description 6 6.5 Parameters Parameter settings gives functionality to set different set points within minimum and maximum allowed values for each parameter. The process parameters shows all process parameters including unit, minimum and maximum values. The system parameters shows all system parameters including unit, minimum and maximum values Some of the parameter settings are system specific and should not be... -
Page 40: Recipe
6 The Control system and Function description 6.6 Recipe In PRODUCTION and CIP it is possible to load recipes. A recipe is a set of pre-adjusted parameters for bowl speed, discharge interval and flush pattern during discharge etc. The number of the selected recipe is displayed together with the mode indication. - Page 41 The Control system and Function description 6 6.7 I/O On the I/O screen it is possible see the status of all digital in/out and analog in/out addresses in the system (refer to the I/O-list in the technical documentation). 200006740-2-EN-GB...
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Page 42: Discharge Logic
6 The Control system and Function description 6.8 Discharge logic This screen is used to set the discharge time interval and volume discharge set point. In operation modes with discharge initiation by time, only the field with discharge interval time is displayed. The discharge time intervals are set by P120, RPn00 and RCn00. -
Page 43: System
The Control system and Function description 6 6.9 System The system screen displays system information such as PLC program number, version and date. On system access level it is possible to define or change new users and the passwords on the different levels. 200006740-2-EN-GB... -
Page 44: Current Log
6 The Control system and Function description 6.10 Current log This screen indicates the ten last current peaks during a discharge cycle. The size of current increase after the latest discharge can be inspected. By selecting Show Trend, a current trend diagram for the current log can be displayed. -
Page 45: Trend
The Control system and Function description 6 6.11 Trend On the Trend screen, and on certain screens the where the Show Trend button is available and clicked, diagrams like the following will be displayed: Diagrams can be displayed for: • Vibration / Speed trend (only real time date, no logging) •... -
Page 46: Flow Control
6 The Control system and Function description 6.12 Flow control The feed flow rate measured on FIT201-1 is controlled via valve FCV220–1, or by feed pump P201-1. Selection of flow control between the feed control valve or the feed pump, can be done in the production recipe setup. Feed flow rate can be regulated by changing set point on FIT201-1 on the separator process screen. -
Page 47: Bowl Speed Control
The Control system and Function description 6 6.13 Bowl speed control NOTE For detailed information about the speed control, please refer to the Speed control section in the SDS. The control system uses the parameter for the bowl speed to be reached (see below for different operation modes) to calculate a control value which is transmitted to the VFD. -
Page 48: Discharge Performance And Bowl Closing Supervision
6 The Control system and Function description 6.14 Discharge performance and Bowl closing supervision A current monitor for supervision of the discharge performance and that the bowl is not leaking is included in the control equipment. The power consumption characteristics of the separator motor changes when sediment is discharged from the bowl periphery. -
Page 49: Alarm Management
7 Alarm Management The separator and the auxiliary equipment are supervised by the control system. If one of the system components does not function as assigned, an alarm is given and in some cases action is required. 7.1 Alarm acknowledgement New alarm You are alerted to the new alarm by the alarm lamp flashing on the control panel, and an optical or acoustical signal (if connected, normally supplied by... -
Page 50: Alarm Activation Diagram
7 Alarm Management Alarm history Alarm history screen displays the latest 100 alarms. Selecting the Alarm tab gives access to the alarm history list. 7.2 Alarm activation diagram How to read the Alarm activation diagram The Alarm activation diagram in the SDS of technical documentation lists all supervised functions in the system and gives an explanation of the different alarm codes used. -
Page 51: Installation And Setup Information
8 Installation and Setup information 8.1 Passwords User Password admin system 2760 process 8.2 VFD Parameters Separator VFD ACS880 Default value Number Parameter name Used value Notes from ABB Relay contact must be 10.24 RO1 SOURCE READY RUN Other[6.18.07[STO-1]] connected NO 10.27 RO2 SOURCE RUNNING... - Page 52 8 Installation and Setup information Default value Number Parameter name Used value Notes from ABB 35.11 Temp source 1 Disabled 35.12 Temp 1 fault limit Disabled 43.06 Brake chopper enabled Disabled 46.01 Speed scaling 1500 1728 95.01 Supply voltage 380-415 97.03 Slip gain 99.04...
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Page 53: Ordering Spare Parts
9.2 Alfa Laval Service Alfa Laval is represented in all major ports of the world. Do not hesitate to contact your local Alfa Laval representative with any questions, problems or requirement of spare parts for Alfa Laval equipment. When asking for assistance, always state installation reference and year (see name plate on electrical panels).
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