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Summary of Contents for Alfa Laval MBPX507
- Page 1 Alfa Laval Separation System MBPX507 Installation and Operating Lit. Code 200008463-1-EN-GB Manual No. 9662152079 instructions BRITISH ENGLISH...
- Page 2 © Alfa Laval 2023-03 This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval AB (publ) or any of its affiliates (jointly “Alfa Laval”). 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’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..........10 MBPX507 System description................. 11 2 Installation, Maintenance and Lifting Instructions ......15 Unpacking and Initial Inspection of the Separator...........15 Lifting instructions....................18... - Page 4 6.2.5 Current log....................46 6.2.6 Trend......................47 6.2.7 I/O status....................48 7 Alarm Management ....................49 Alarm management....................49 8 Ordering Spare parts ................... 51 Spare parts......................51 Alfa Laval Service....................51 9 Installation and Setup information .............. 53 VFD Parameters......................53 Speed converter settings..................55 Passwords.......................56...
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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 Siemens 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.
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Page 10: General Description Of Alfa Laval Separation System
• Avoid placing hands into valve orifice pinch points. 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 control panel and starter panel. -
Page 11: Mbpx507 System Description
Introduction and General Information 1 1.4 MBPX507 System description Separator The separator is a solids‑discharging high speed separator, for clarification. Sediment ejection (discharge) takes place through sludge ports in the bowl periphery while the separator is in full operation. The separator is equipped with an operating water module. The operating liquid (inlet 375) closes and opens the bowl in the separator. - 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 a feed pump (P201– There is also two product outlets (220.1, 220.2). The solids outlet from the cyclone (222.1) is equipped with a solids pump.
- Page 13 Introduction and General Information 1 The flushing water is used at solids discharge to clean the outside of the bowl, the inside of the bowl cover, the cyclone and the solids channel. Electrical and Control system The system consists of the control panel with the pneumatic unit and a variable frequency drive (VFD) for the separator.
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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 Installation, Maintenance and Lifting Instructions 2 Lifting procedure • Always check with an Alfa Laval representative that the installation is properly planned. • A clear area around the equipment is required for servicing. • A lifting device of sufficient capacity that can be positioned exactly over the centre of the bowl spindle is needed to remove the bowl assembly.
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Page 20: 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 21: Electrical Installation And Maintenance
Installation, Maintenance and Lifting Instructions 2 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 22: 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 23: Installation Of Auxiliary Equipment
Installation, Maintenance and Lifting Instructions 2 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 24 This page is intentionally left blank.
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Page 25: 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 condition should be fulfilled: • Before first start, check direction of rotation according to instructions in the Service & maintenance manual. The bowl should rotate clockwise seen from above. -
Page 26: 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 27: 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 28: Start
4 Description of operating conditions 4.3 START When the START function is selected on the operator panel. STARTING is indicated. The separator motor begins to run and the bowl begins rotating and accelerating. Product is not fed to the separator and the centrifugate outlet is open. Purified water and cooling liquid are supplied to the separator and cooling return liquid starts. -
Page 29: Production
Description of operating conditions 4 4.5 PRODUCTION PRODUCTION means that the separator is running at full selected speed (set in parameter (P144)). Product is fed to the separator from product line (201.1), the centrifugate leaves through the centrifugate outlet (220.1). The feed can be controlled by the feed control valve (FCV220.1) or the feed pump (P201–1). -
Page 30: Stop
4 Description of operating conditions 4.7 STOP STOP means that the separator motor is turned off and the bowl speed decreases. Nothing is fed to the separator and FCV201-1 is closed. A stop discharge sequence is initiated (see Sub seq. Stop Discharge in the SDS) and water is added during a period of time followed by a number of discharges, in order to clean out the bowl from solids material. -
Page 31: 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. -
Page 32: Start
5 Operating routine 5.2 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 33: Standby
Operating routine 5 5.3 STANDBY In STANDBY mode the separator is running at full selected speed without liquid feed. This is known as STANDBY DRY. Select Discharge on the operator panel. NOTE Overheating hazard Overheating hazard The system should not be left in STANDBY DRY for too long time. Change over to PRODUCTION as soon as possible. -
Page 34: Production
5 Operating routine 5.4 PRODUCTION PRODUCTION can be selected from STANDBY. Select PRODUCTION on the operator panel. The separator is fed with product from the feed inlet line (201.1) To initiate a discharge manually select DISCHARGE on the control panel. The accumulated solids in the bowl periphery are discharged automatically at certain intervals. -
Page 35: Cip (Cleaning In Place)
Operating routine 5 5.5 CIP (Cleaning in place) CIP can be selected from STANDBY. 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 36: Stop
5 Operating routine 5.6 Stop STOP can be selected from START and STANDBY DRY. Select STOP on the operator panel. The display indicates STOP. The separator motor will be deactivated and the separator will slow until stopped. A discharge cycle is activated. When the separator bowl has come to a complete stop, the system switches automatically to STAND STILL after 0 rpm has been detected for >30 sec. -
Page 37: Emergency Stop
Operating routine 5 5.7 Emergency Stop EMERGENCY STOP can be activated from any operation mode (except STANDSTILL and SAFETY STOP). Press the EMERGENCY STOP button on the control panel. Power to all motors is cut, and all other equipment is controlled as in STOP. The alarm (A42) “Emergency stop activated”... - Page 38 This page is intentionally left blank.
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Page 39: 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 Control panel The control cabinet contains Siemens PLC, CPU, communication processor, circuit breakers, signal converters, and interface relay. The control panel door consists of: Siemens TP1500 Comfort hmi -S01... -
Page 40: Operator Interface & Function Description
Select the Process tab at the of the screen to access the Process screen. The process screen provides a visual overview of the unit, with actual input and output values. The top header of the screen contains: • Alfa Laval logo • Current operation mode • System language (flag) • Time •... - Page 41 The Control system and Function description 6 The middle part of the screen contains: • The actual condition of the process as a flow chart • Speed, current, and vibration of the separator and instrument air pressure • Valve status •...
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Page 42: Parameters
6 The Control system and Function description 6.2.2 Parameters To view the Parameters screen, select the Parameters tab in the second row of the screen. 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. -
Page 43: Discharge Logic
The Control system and Function description 6 6.2.3 Discharge Logic To view the Discharge Logic screen, select the Dch. Logic tab in the second row of the screen. This screen is used to view the discharge time interval (CIP and PRODUCTION) and chosen discharge logic (only PRODUCTION). - Page 44 6 The Control system and Function description The turbidity system with sensor in the centrifugate outlet is used for discharge initiation in PRODUCTION. For complete information about the turbidity monitor equipment, please consult the equipment manual. If “Time + Turbidity” is selected, a controller function for the turbidity monitoring system is displayed.
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Page 45: System Information
The Control system and Function description 6 6.2.4 System Information To view the System Information screen, select the System tab in the second row of the screen. The system screen displays system information such as PLC program number, version and date. The running hours, accumulated volume, and discharge counter are displayed and there are buttons to clear their values. -
Page 46: Current Log
6 The Control system and Function description 6.2.5 Current log To view the Current Log screen, select the Current Log tab in the second row of the screen. This screen indicates the ten last current peaks during a discharge cycle. The size of current increase after the latest discharge can be inspected. -
Page 47: Trend
The Control system and Function description 6 6.2.6 Trend To view the Trend screen, select the Trend tab in the second row of the screen. On the Trend screen, and on certain screens where the Show Trend button is available and clicked, diagrams like this will be displayed: Select the trend which is to be displayed, by selecting it in the drop down menu, located right underneath the System tab. -
Page 48: I/O Status
6 The Control system and Function description 6.2.7 I/O status To view the I/O Status screen, select the I/O tab in the second row of the screen. On the I/O screen it is possible to see the status of all digital input and output out, as well as analog input and output addresses in the system (refer to the I/O-list in the technical documentation). -
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 management 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 the customer). - Page 50 7 Alarm Management Select ALARM LIST to display a list containing the alarms still active. 200008463-1-EN-GB...
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Page 51: Ordering Spare Parts
8.2 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). - Page 52 This page is intentionally left blank.
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Page 53: Installation And Setup Information
9 Installation and Setup information 9.1 VFD Parameters Separator VFD ABB ACS 880 Default value Number Parameter name Used value Notes from ABB 10.24 RO1 SOURCE READY RUN Other[6.18.07[STO–1]] 10.27 RO2 SOURCE RUNNING RUNNING Relay contact must be 10.30 RO3 source Fault(-1) SUPERVISION connected NO... - Page 54 9 Installation and Setup information Default value Number Parameter name Used value Notes from ABB 99.07 MOTOR NOM VOLTAGE 99.08 MOTOR NOM FREQ 99.09 MOTOR NOM SPEED 3551 99.10 MOTOR NOM POWER 99.11 Cos fii 0,89 Other settings: Jumper J1-> mA DIP switch J6->...
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Page 55: Speed Converter Settings
Installation and Setup information 9 9.2 Speed converter settings Parameter Adjusted value Unit Input Line monitor LB – OFF SC – OFF Smoothing filter Debounce filter Start-up override Factor 2 pulses/unit Output (Iout) Current output 4-20mA Error status Min value (Down) Start value 0 rpm End value... -
Page 56: Passwords
9 Installation and Setup information 9.3 Passwords User Password admin system 2760 process For a full overview of user access levels, refer to the Login New section of the SDS. 200008463-1-EN-GB...
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