Alfa laval сепаратор мануал

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  Separator Manual High Speed Separator P 605 Specification No. 881099-06-04/0 Book No. 9010961-02, rev. 1…
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  Published By: Alfa Laval Tumba AB 11-2013 SE-147 80 Tumba, Sweden Telephone: +46 8 530 650 00 Telefax: +46 8 530 310 40 The original instructions are in English This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

• Page 3: Table Of Contents

  Contents Read this first Safety instructions Warning signs in text Environmental issues Requirements of personnel Remote start Basic principles of separation Introduction Separation by gravity Centrifugal separation Separating temperatures Separator basics Design and function 4.1.1 Application 4.1.2 Design 4.1.3 Outline of function 4.1.4 Separating function 4.1.5…

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  5.3.2 Erosion 5.3.3 Cracks 5.3.4 Discharge mechanism 5.3.5 Bowl hood and sliding bowl bottom 5.3.6 Spindle top cone and bowl body nave 5.3.7 Threads of inlet pipe, paring disc 5.3.8 Threads on bowl hood and bowl body 5.3.9 Priming of bowl parts 5.3.10 Disc stack pressure Check points at Major Service 5.4.1…
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  6.5.1 Dismantling/assembly Water tank Brake 6.7.1 Exploded view 6.7.2 Checking of friction element Frame feet 6.8.1 Mounting of new frame feet Technical Reference Product description Directives & Standards Technical Data Connection list Basic size drawing 7.5.1 Dimensions of connections Interface Description 7.6.1 Scope 7.6.2…
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  Operating Operating routine Clarifier Operation 8.2.1 Operating water interface Purifier Operation 8.3.1 Operating water interface 8.3.2 Selection of gravity disc 8.3.3 Gravity disc nomogram Before first Start Start after a service 8.5.1 Before normal start 8.5.2 Starting and running-up procedure 8.5.3 Separation 8.5.4…
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  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

  Alfa Laval separator If the separator has been delivered and installed by Alfa Laval as a part of a processing system, this manual should be viewed as part of the System Documentation. Study carefully all instructions in any System Documentation.

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  1 Read this first Fault finding Refer to this chapter if the separator functions abnormally. If the separator has been installed as a part of a processing system, always refer to the trouble-tracing instructions, in the System Documentation. Technical reference This chapter contains technical data concerning the separator and drawings.

• 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.

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  If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown. • Use the separator only for the purpose and m /h parameter range specified by Alfa Laval. kg/m r/min • Check that the gear/pulley ratio is correct for power frequency used.
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  2 Safety instructions Electrical hazard • Follow local regulations for electrical installation and earthing (grounding). • To avoid accidental start, switch off and lock power supply before starting any dismantling work. Crush hazards • Use correct lifting tools and follow lifting instructions.
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  2 Safety instructions Flying objects • Risk for accidental release of snap rings and springs when dismantling and assembly. Wear safety goggles. Health hazards • Risk for unhealthy dust when handling friction blocks/pads. Use a dust mask to make sure not to inhale any dust…

• Page 15: Warning Signs In Text

  2 Safety instructions Warning signs in 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 indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• Page 16: Environmental Issues

  2 Safety instructions Environmental issues Unpacking Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps. Wood and cardboard boxes can be reused, recycled or used for energy recovery. Plastics should be recycled or burnt at a licensed waste incineration plant.

• Page 17: Requirements Of Personnel

  2 Safety instructions Requirements of personnel Only skilled or instructed persons are allowed to operate the machine, e.g. operating and maintenance staff. • Skilled person: A person with technical knowledge or sufficient experience to enable him or her to perceive risks and to avoid hazards which electricity/mechanics can create.

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  2 Safety instructions…

• Page 19: Basic Principles Of Separation

  3 Basic principles of separation Introduction 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, • to separate and concentrate solid particles from a liquid.

• Page 20: Centrifugal Separation

  3.4 Separating temperatures 3 Basic principles of separation Centrifugal separation In a rapidly rotating bowl, the force of gravity is replaced by centrifugal force, which can be thousands of times greater. Separation and sedimentation is continuous and happens very quickly. The centrifugal force in the separator bowl can achieve in a few seconds what takes many hours in a tank under influence of gravity.

• Page 21: Separator Basics

  4 Separator basics Design and function 4.1.1 Application The separator is a high-speed centrifugal separator intended for marine and land applications. It is specifically designed for cleaning of mineral oils from water and solid particles (sludge). The cleaned oil is discharged continuously, while the sludge is discharged at intervals.

• Page 22: Design

  (type of liquid, rotational speed, temperature, density 7 Technical Reference on etc.) specified in chapter page 131 and in the Purchase Order documents. Consult your Alfa Laval representative before any changes outside these parameters are made. 4.1.2 Design The separator comprises a frame consisting of the frame lower part, the intermediate part and the frame top part with a frame hood.

• Page 23: Outline Of Function

  4 Separator basics 4.1 Design and function 4.1.3 Outline of function The separation process takes place in the rotating bowl. Unseparated oil is fed into the bowl through the inlet (201). The oil is cleaned in the bowl and leaves the separator through the outlet (220) via a paring chamber.

• Page 24: Separating Function

  4.1 Design and function 4 Separator basics 4.1.4 Separating function Liquid flow Separation takes place in the separator bowl to which unseparated oil is fed through the inlet pipe (201). The oil is led by the distributor (T) towards the periphery of the bowl. When the unseparated oil reaches the slots of the distributor, it will rise through the channels formed by the disc stack (G) where it is evenly…

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  4 Separator basics 4.1 Design and function Water seal in purification To prevent the oil from passing the outer edge of the top disc (I) and escaping through the water outlet (221), a water seal must be provided in the bowl. This is done by filling the bowl with water through the water inlet (206), before unseparated oil is supplied.

• Page 26: Sludge Discharge Function

  4.1 Design and function 4 Separator basics 4.1.5 Sludge discharge function Sludge is discharged through a number of ports (L) in the bowl wall. Between discharges these ports are covered by the sliding bowl bottom (M), which forms an internal bottom in the separating space of the bowl.

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  4 Separator basics 4.1 Design and function Bowl opening The key event to start a sludge discharge is the downward movement of the operating slide. This is accomplished by supply of opening water (372) to the discharge mechanism. Water is drained off through nozzles (Y) in the bowl body.

• Page 28: Power Transmission

  4.1 Design and function 4 Separator basics 4.1.6 Power transmission Bowl spindle In addition to its primary role in the power transmission system, the bowl spindle also serves as: • pump for the closing water • supply pipe for the closing water •…

• Page 29: Sensors And Indicators

  4 Separator basics 4.1 Design and function 4.1.7 Sensors and indicators Sight glass The sight glass shows the oil level in the oil sump. Vibration switch (option) The vibration switch, properly adjusted, trips on a relative increase in vibration. The vibration switch is sensitive to vibration in a direction perpendicular to its base.

• Page 30: Definitions

  4.2 Definitions 4 Separator basics Definitions Back pressure Pressure in the separator outlet. Clarification Liquid/solids separation with the intention of separating particles, normally solids, from a liquid 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 31: Service Instructions

  5 Service instructions Periodic maintenance 5.1.1 Introduction Periodic, preventive maintenance reduces the risk of unexpected stoppages and breakdowns. Maintenance logs are shown on the following pages in order to facilitate periodic maintenance. Disintegration hazards Separator parts that are worn beyond their safe limits or incorrectly assembled may cause severe damage or fatal injury.

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  5.1 Periodic maintenance 5 Service instructions IS — Intermediate Service consists of an overhaul of the separator bowl, inlet and outlet every 3 months or 2000 operating hours. Seals in bowl and gaskets in the inlet/outlet device and operating device are renewed. MS — Major Service consists of an overhaul of the complete separator every 12 months or 8000 operating hours.

• Page 33: Maintenance Procedure

  Service and Major Service The contents of the service kits are described in the Spare Parts Catalogue. 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…

• Page 34: Maintenance Logs

  5.2 Maintenance Logs 5 Service instructions Maintenance Logs 5.2.1 Daily checks The following steps should be carried out daily. Main component and activity Part Page Notes Inlet and outlet Check for leakage Connecting housing Separator bowl Check for vibration and noise Belt transmission Check for vibration and noise Oil sump…

• Page 35: Intermediate Service (Is)

  5 Service instructions 5.2 Maintenance Logs 5.2.3 Intermediate Service (IS) Name of plant: Local identification: Separator: Manufacture No./Year: Total running hours: Product No: Date: Signature: Renew all parts included in the Intermediate Service (IS) and do the following activities. Main component and activity Part Page Notes…

• Page 36: Major Service (Ms)

  5.2 Maintenance Logs 5 Service instructions 5.2.4 Major service (MS) Name of plant: Local identification: Separator: Manufacture No./Year: Total running hours: Product No: Date: Signature: Renew all parts included in the Intermediate service (IS) and Major Service (MS) and do the following activities.

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  5 Service instructions 5.2 Maintenance Logs Main component and activity Part Page Notes Vertical driving device Clean and inspect Oil mist fan Oil pump Water tank Pump sleeve Bowl spindle Ball bearing housing indentations Radial wobble of bowl spindle Check Oil sump Clean Oil sump…

• Page 38: Check Points At Intermediate Service

  Main bowl parts to check for corrosion Inspect regularly for corrosion damage. Inspect frequently if the process liquid is corrosive. 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.

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  5 Service instructions 5.3 Check points at Intermediate Service Stainless steel Stainless steel parts corrode when in contact with either chlorides or acidic solutions. Acidic solutions cause general corrosion. The chloride corrosion is characterized by local damage such as pitting, grooves or cracks. The risk of chloride corrosion is higher if the surface is: Example of chloride corrosion in stainless steel •…

• Page 40: 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 or if the surface of the sliding bowl bottom shows any sign of damage.

• Page 41: Cracks

  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 42: Discharge Mechanism

  5.3 Check points at Intermediate Service 5 Service instructions 5.3.4 Discharge mechanism Dirt and lime deposits in the sludge discharge mechanism can cause discharge malfunction or no discharge. • Thoroughly clean and inspect the parts. Pay special attention to important surfaces (1, 2, 3 and 4).

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  5 Service instructions 5.3 Check points at Intermediate Service Fit a new bowl hood seal ring at each Intermediate Service (IS) if the old ring is damaged or indented more than 0,5 mm. Fit a new ring as follows: Press the ring into the groove with a straight board (1”…
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  5.3 Check points at Intermediate Service 5 Service instructions Check the sealing edge (a) of the sliding bowl bottom. If damaged through corrosion or erosion or in other ways it can be rectified by turning in a lathe. Minimum permissible height of sealing edge: 4,5 mm.

• Page 45: Spindle Top Cone And Bowl Body Nave

  5 Service instructions 5.3 Check points at Intermediate Service 5.3.6 Spindle top cone and bowl body nave Impact marks on the spindle cone or in the bowl body nave may cause the separator to vibrate while running. Corrosion may cause the bowl to stick firmly to the spindle cone and cause difficulties during the next dismantling.

• Page 46: Threads On Bowl Hood And Bowl Body

  When the bowl is new the alignment marks on the bowl hood and the bowl body should be aligned. If not, contact an Alfa Laval representative. G0071311 Wear…

• Page 47: Priming Of Bowl Parts

  5 Service instructions 5.3 Check points at Intermediate Service Damage The position of threads, contact and guide surfaces are indicated by arrows in the illustration. Examine for burrs and protrusions caused by impact. Clean the threads, contact and guide surfaces with a suitable degreasing agent.

• Page 48: Disc Stack Pressure

  5.3 Check points at Intermediate Service 5 Service instructions 5.3.10 Disc stack pressure The bowl hood exerts a pressure on the disc stack clamping it in place. Insufficient pressure in the disc stack may affect the bowl balance, which in turn will cause abnormal vibration of the separator and shorten the life of ball bearings.

• Page 49: Check Points At Major Service

  5 Service instructions 5.4 Check points at Major Service Check points at Major Service 5.4.1 Paring disc height adjustment The height of the paring disc above the frame hood must be measured if the bowl spindle has been dismantled or if the bowl has been replaced with a new one.

• Page 50: Radial Wobble Of Bowl Spindle

  Use the flat belt to turn the spindle. 3. Permissible radial wobble: max. 0,04 mm. If the spindle wobble is more than the maximum permitted value, contact Alfa Laval representatives. 4. Finally fit the water tank to the frame bottom part.

• Page 51: 3-Year Service

  5 Service instructions 5.5 3-year service 3-year service Exchange of frame feet 6.8.1 Mounting of new frame feet on page 129. Friction coupling Exchange of ball bearings, see 6.3 Friction coupling on page 114. Frame intermediate part Replace O-ring and gasket, see 6.2.2 Bowl spindle and frame — assembly on page 105.

• Page 52: Lifting Instructions

  5.6 Lifting instructions 5 Service instructions Lifting instructions Remove the inlet/outlet housings, the frame hood and the bowl according to the instructions 6.1.1 Inlet/outlet and bowl — dismantling on page Make sure to remove the cap nut fixing the bowl to the bowl spindle.

• Page 53: Cleaning

  5 Service instructions 5.7 Cleaning Cleaning External cleaning The external cleaning of 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 54: Cleaning Agents

  Alfa Laval cleaning liquid for lube oil and fuel oil separators. Skin irritation hazard Read the instructions on the label of the container before using the chemical cleaning agent.

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  5 Service instructions 5.7 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 56: Cleaning Of Bowl Discs

  5.7 Cleaning 5 Service instructions 5.7.2 Cleaning of bowl discs Handle the bowl discs carefully to avoid damage to the surfaces during cleaning. Cut hazard Sharp edges on the separator discs may cause cuts. Mechanical cleaning is likely to scratch the disc surfaces causing deposits to form quicker and adhere more firmly.

• Page 57: Oil Change

  5 Service instructions 5.8 Oil change Oil change 5.8.1 Oil change procedure Before adding or renewing lubricating oil in the oil sump, the information concerning different oil groups, handling of oils, oil change intervals etc. given in 5.9 Lubricants on page 59 chapter must be well known.

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  5.8 Oil change 5 Service instructions Fill the oil sump in the frame housing with new oil. The oil level should be slightly above middle of the sight glass. Information on volume see 7.3 Technical Data on page 133. Push in the oil filling device. G0069211…

• Page 59: Lubricants

  5 Service instructions 5.9 Lubricants Lubricants 5.9.1 Lubrication chart, general Alfa Laval ref. 553216-01 Rev. 8 Lubricating points Type of lubricant Interval The oil bath. Lubricating oil as specified in Oil Change: Bowl spindle ball bearings are 5.9.3 Recommended lubricating 1.

• Page 60: Recommended Lubricants

  Lubricant recommendation for hygienic and non-hygienic applications Alfa Laval ref. 553217 01 Rev. 13 Lubricants with a Alfa Laval part number are approved and recommended for use. The data in the below tables is based on supplier information in regards to lubrication properties.

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  5 Service instructions 5.9 Lubricants Paste for assembly of metallic parts, hygienic applications (NSF registered H1 is preferred) Part no Remark Quantity Designation Manufacturer Molykote D paste Dow Corning 537086-07 50 g Molykote P-1900 Dow Corning NSF Registered H1 (22 Jan 2004) Molykote TP 42 Dow Corning…
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  5.9 Lubricants 5 Service instructions Silicone grease/oil for rubber rings, hygienic and non-hygienic applications Part no Remark Quantity Designation Manufacturer No-Tox Food Grade Bel-Ray NSF Registered H1 (16 Silicone grease December 2011) Tested according to Dow Corning 360 Dow Corning Medical Fluid and complies with all National Formulary…
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  5 Service instructions 5.9 Lubricants Always follow the lubrication recommendations of the bearing manufacturer. Grease for ball and roller bearings in electric motors Part no Quantity Designation Manufacturer Remark Energrease LS2 Energrease LS-EP2 Energrease MP-MG2 APS 2 Castrol Spheerol EPL 2 Castrol Multifak EP2 Chevron…

• Page 64: Recommended Lubricating Oils

  Type of frame: D/D and P/P with motor < 7,5 Two different groups of lubricating oils are approved. They are designated as Alfa Laval lubricating oil groups A and D. The numerical value after the letter states the viscosity grade.

• Page 65: Recommended Oil Brands

  5 Service instructions 5.9 Lubricants 5.9.4 Recommended oil brands Alfa Laval ref. 553218-04 Rev. 6 Paraffinic mineral lubricating oil category (ISO-L-) HM 150 . Viscosity grade (ISO 3448/3104) VG 150. The oil shall follow the requirements in one of the standards below.

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  5.9 Lubricants 5 Service instructions Paraffinic mineral lubricating oil category HM 150 for hygienic applications. Conform to U.S. Food and Drug Administration (FDA) requirements of lubricants with incidental food contact, Title CFR 21 178.3570, 178.3620 and/or those generally regarded as safe (US 21 CFR 182).

• Page 67: Recommended Oil Brands

  The following are lists of recommended oil brands. Trade names and designations might vary from country to country. Please contact your local oil supplier for more information. Brands with Alfa Laval article number are approved and recommended for use. Alfa Laval lubrication oil group D Manufacturer…

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  5.9 Lubricants 5 Service instructions Synthetic lubricating oil, category PAO (ISO-L-) CKE 220 for hygienic applications. Conform to U.S. Food and Drug Administration (FDA) requirements of lubricants with incidental food contact, Title CRF 21 178.3570, 178.3620 and/or those generally regarded as safe (US 21 CRF 182).

• Page 69: Vibration

  5 Service instructions 5.10 Vibration 5.10 Vibration 5.10.1 Vibration analysis A separator normally vibrates and produces a different sound when passing through its critical speeds during run-up and run-down. It also vibrates and sounds to some extent when running. It is good practice to be acquainted with these normal conditions.

• Page 70: Vibration Switch (Optional)

  5.10 Vibration 5 Service instructions 5.10.2 Vibration switch (optional) 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). Back-off the setpoint adjusting screw counter-clockwise (A) two or three turns.

• Page 71: General 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. A bearing that in appearance looks equivalent G0587321 to the correct may be considerably different in 1.

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  5.11 General directions 5 Service instructions Assembly • Leave new bearings in original wrapping until ready to fit. The anti-rust agent protecting a new bearing should not be removed before use. • Use the greatest cleanliness when handling the bearings. To facilitate assembly and also reduce the risk of damage, first clean and then lightly smear the bearing seating on shaft (spindle) or…

• Page 73: Before Shut-Downs

  5 Service instructions 5.11 General directions 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). G0587211 The wide shoulder of the inner race must face the axial load.

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  5.11 General directions 5 Service instructions…

• Page 75: Dismantling & Assembly

  6 Dismantling & Assembly References to check points In the text you will find references to the check point instructions in chapter 5 Service instructions on page 31. The references appear in the text as in the following example: Check point 5.3.10 Disc stack pressure on page 48.

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  6 Dismantling & Assembly For friction coupling and flat belt 1. Pliers for internal snap ring 2. Pliers for external snap ring 3. T-handle, extension rod and socket 16 mm 4. Adjustable wrench or spanner, width of jaws 36 mm 5.
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  6 Dismantling & Assembly…

• Page 78: Inlet/Outlet And Bowl

  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly Inlet/outlet and bowl G0073771…

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  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl 1. Safety device 2. Nut 3. Inlet/outlet housing 4. Interlocking switch (optional) 5. Support ring The support ring is removed from the frame hood top, at paring disc adjustment (Major Service) 6. Insert 7.
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  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly G0887751 15. Bowl hood 16. Top disc 17. Bowl discs 18. Wing insert 19. Bowl discs 20. Distributor 21. Sliding bowl bottom IS. Intermediate service kit MS.Major service kit…
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  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl G0074251 22. Cap nut 23. Upper distributing ring 24. Valve plug 25. Operating slide 26. Lower distributing ring 27. Bowl body 28. Nozzle SK. Sealing kit SK. Sealing kit DK.Discharge kit…

• Page 82: Inlet/Outlet And Bowl — Dismantling

  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly 6.1.1 Inlet/outlet and bowl — dismantling The frame hood and the heavy bowl parts must be lifted by means of a hoist. Position the hoist exactly above the bowl centre. Use an endless sling and a lifting hook with catch.

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  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl Unscrew nut clockwise and lift off inlet- outlet housing together with the connecting hoses. When removing the connecting hoses, do not drop the washer. Left-hand thread! G0821531 Remove the bolts and lift off frame hood (8). Unscrew lock ring (9) clockwise by using the special tool;…
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  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly Lift out inlet pipe (14) with the paring disc. G0070231 Preparations for unscrewing of bowl hood (15): Fit the spanner to the bowl hood and secure it with the bolt (a). Fit the compression tool and screw down the central screw (b) until it stops Compress the disc stack by tightening the nut (c) firmly.
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  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl 11. Lift out the top disc, the bowl discs with wing insert and the distributor. Screw the nut of the compression tool up against the eye bolt, turn the unit with the tool still attached upside down and hit it against a firm base.
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  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly 15. Lift out operating slide (25) using the special tool: lifting bolts for operating slide. G0070721 16. Lift out lower distributing ring (26). G0070821 17. Lift out bowl body (27) using the special tool. 18.

• Page 87: Inlet/Outlet And Bowl — Assembly

  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl 6.1.2 Inlet/outlet and bowl — assembly Be sure bowl parts are not interchanged. Out of balance vibration will reduce ball bearing life. Make sure that the following check points are carried out before and during assembly of the separator bowl.

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  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly G0074251 22. Cap nut 23. Upper distributing ring 24. Valve plug 25. Operating slide 26. Lower distributing ring 27. Bowl body 28. Nozzle…
• Page 89
  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl G0887751 15. Bowl hood 16. Top disc 17. Bowl discs 18. Wing insert 19. Bowl discs 20. Distributor 21. Sliding bowl bottom SK. Sealing kit DK.Discharge kit…
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  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly G0073771…
• Page 91
  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl 1. Safety device 2. Nut 3. Inlet/outlet housing 4. Interlocking switch (optional) 5. Support ring The support ring is removed from the frame hood top, at paring disc adjustment (Major Service) 6. Insert 7.

• Page 92: Check Point

  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly Clean the hollow part (b) of the spindle top and the radial hole (a). Wipe clean the spindle top and nave bore in the bowl body. Apply oil to the tapered end of the spindle, smear the oil over the surface and wipe off surplus with a clean cloth.

• Page 93: Threads On Bowl Hood And Bowl Body On

  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl Fit the upper distributing ring so that drill mark (a) is in line with hole (c) on the distributing ring. When the distributing ring is in correct position the guide pin (b) will enter hole (c). The two guide pin (b) in the distributing ring have to be fitted properly in the hole (c).

• Page 94
  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly Assemble the bowl discs with wing insert and top disc on the distributor. Note the angular positioning (six options). Ensure that the pins in the distributor fit properly into the holes of the top disc.
• Page 95
  6 Dismantling & Assembly 6.1 Inlet/outlet and bowl 14. Attach the spanner and tighten the bowl hood by using a tin hammer. Strike the spanner handle until the bowl hood lies tightly against the bowl body. In a new bowl, the assembly marks now will be in line with each other.

• Page 96: Paring Disc Height Adjustment

  6.1 Inlet/outlet and bowl 6 Dismantling & Assembly 18. Fit lock ring (9). Apply a thin layer of Molykote Paste 1000 to the threads and on contact and locating surfaces. Left-hand thread! G0074331 19. Fit frame hood (8) and O-ring (13). The two eye-bolts must be fitted in the holes nearest to the electric motor.

• Page 97: Bowl Spindle And Frame

  6 Dismantling & Assembly 6.2 Bowl spindle and frame Bowl spindle and frame 6.2.1 Bowl spindle and frame — dismantling Before dismantling the bowl spindle, the inlet and outlet housing, frame hood and bowl as well as the flat belt must be removed. Before dismantling, in the case of Major Service, or if the separator vibrates while running, see Check point…

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  6.2 Bowl spindle and frame 6 Dismantling & Assembly G01131A1…
• Page 99
  6 Dismantling & Assembly 6.2 Bowl spindle and frame 5. Deflector ring 6. Top bearing cover 7. Gasket 8. Fan 9. Buffer holder 10. Rubber buffer 11. Bowl spindle 12. Ball bearing holder 13. Ball bearing 14. Snap ring 15. Ball bearing 16.
• Page 100
  6.2 Bowl spindle and frame 6 Dismantling & Assembly Loosen but do not remove the motor adapter screws. Remove the water tank. Remove the brake. Remove the flat belt. G01133E1 Remove the screws and lift off frame top part (4). Lip seal ring (1) must be removed in the case of 3-year service, or if found damaged.
• Page 101
  6 Dismantling & Assembly 6.2 Bowl spindle and frame Clean the bowl spindle cone in place and remove deflector ring (5). G0113521 Remove, in the following sequence: Top bearing cover (6) Gasket (7) Fan (8) Buffer holder (9) Rubber buffer (10). Be very careful not to damage the wings of the buffer holder.
• Page 102
  6.2 Bowl spindle and frame 6 Dismantling & Assembly Screw the cap nut counter-clockwise (left-hand thread) onto the spindle top to protect the top and bore. Lift out spindle assembly (11), rubber buffer (10) and O-ring (20). Remove snap ring (14) by using a pair of pliers and pull off ball bearing holder (12).
• Page 103
  6 Dismantling & Assembly 6.2 Bowl spindle and frame 12. Pull off ball bearing (15) using a puller (B) and thrust washer (A). Pull off bearing (13) using the special mounting tool (C) and a hammer. Always discard a used bearing. G0076351 13.
• Page 104
  6.2 Bowl spindle and frame 6 Dismantling & Assembly 15. Remove the screen (2) from the frame top part (4). Discard the gasket (3). This gasket is not included in any service kit, but must be ordered separately. 16. Clean the oil sump. 17.

• Page 105: Bowl Spindle And Frame — Assembly

  6 Dismantling & Assembly 6.2 Bowl spindle and frame 6.2.2 Bowl spindle and frame — assembly The bowl spindle and frame is assembled in reverse sequence to dismantling. G01132b1 1. Lip seal ring Screen 3. Gasket 4. Frame, top part 3-YSK .Parts to be renewed at Three year service…

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  6.2 Bowl spindle and frame 6 Dismantling & Assembly G01131b1…
• Page 107
  6 Dismantling & Assembly 6.2 Bowl spindle and frame 5. Deflector ring 6. Top bearing cover 7. Gasket 8. Fan 9. Buffer holder 10. Rubber buffer 11. Bowl spindle 12. Ball bearing holder 13. Ball bearing 14. Snap ring 15. Ball bearing 16.
• Page 108
  6.2 Bowl spindle and frame 6 Dismantling & Assembly In case of 3-year-service. Fit a new O-ring (22) and assemble the frame intermediate part (21). Use a torque wrench and tighten the screws lightly crosswise at first. Then tighten all around to 45 Nm. Secure the screws with Loctite 242.
• Page 109
  6 Dismantling & Assembly 6.2 Bowl spindle and frame Inspect the tapered end and the hollow part of the bowl spindle for wear and clean if necessary. Assemble ball bearings (13 and 15). Heat the new ball bearings in oil to maximum 125 °C.
• Page 110
  6.2 Bowl spindle and frame 6 Dismantling & Assembly Check that the radial hole (Ø 1 mm) in the pump sleeve is clean, and fit the pump. G0114341 Fit ball bearing holder (12) and secure it with snap ring (14). Fit O-ring (20) and rubber buffer (19).
• Page 111
  6 Dismantling & Assembly 6.2 Bowl spindle and frame Assemble, in the following sequence: Rubber buffer (10) Buffer holder (9) Fan (8) Gasket (7) Top bearing cover (6) Make sure that the Ø 3 mm hole in fan (8) is clean and the lugs in the fan enter the recesses in the bowl spindle.
• Page 112
  6.2 Bowl spindle and frame 6 Dismantling & Assembly 10. Assemble frame top part (4). If lip seal ring (1) has been removed, fit a new one before the frame top part is put in place. Make sure the lip seal is turned the correct way. See illustration.
• Page 113
  6 Dismantling & Assembly 6.2 Bowl spindle and frame 12. Fit and adjust the flat belt, see on page Check point 5.4.2 Radial wobble of bowl spindle on page 50 13. Fit the water tank and tighten the screws. G01133A1…

• Page 114: Friction Coupling

  6.3 Friction coupling 6 Dismantling & Assembly Friction coupling If the separator does not attain full speed within about 2 minutes, the friction elements or the coupling may be worn or greasy. The friction elements must then be replaced with new ones or be thoroughly cleaned from grease.

• Page 115
  6 Dismantling & Assembly 6.3 Friction coupling G0372121 1. Snap ring 2. Snap ring 3. Ball bearings 4. Washer 5. Belt pulley 6. Coupling hub 7. Friction element 8. Cover 9. Snap ring 10. Washer 11. Spring washer 12. Screw MS.Set of friction elements included in the Major service Kit for 50 Hz or 60 Hz…

• Page 116: Friction Coupling — Dismantling

  6.3 Friction coupling 6 Dismantling & Assembly 6.3.1 Friction coupling — dismantling Check that the belt tightener is in backward position. Remove the motor adapter screws. Remove the water tank and the flat belt. Note that the tank must be lowered past spindle end (A) before it can be withdrawn (B).

• Page 117
  6 Dismantling & Assembly 6.3 Friction coupling Remove the screw (12), spring washer (11) and washer (10) from the friction coupling. G0170921 Complete dismantling of the friction coupling Lubricate and fit the special mounting and dismantling tool. Ease off the coupling. G0171051 A.
• Page 118
  6.3 Friction coupling 6 Dismantling & Assembly Remove snap rings (1 and 2) and drive off coupling hub (6). Turn the coupling, i.e. belt pulley (5) with bearings (3), the other way round and drive off the ball bearings and washer by using a tube.

• Page 119: Friction Coupling — Assembly

  6 Dismantling & Assembly 6.3 Friction coupling 6.3.2 Friction coupling — assembly Before the friction coupling is assembled, examine all parts thoroughly for wear and corrosion. Assemble the new ball bearings in belt pulley (5) by using a tube and a hammer. Apply Loctite 641 on the outer surfaces of ball bearings (3).

• Page 120
  6.3 Friction coupling 6 Dismantling & Assembly Wipe clean the motor shaft and apply a thin oil film on it. Fit the special mounting and dismantling tool to the motor shaft (by means of the small screw on one end of the tool) and press the friction coupling onto the shaft.

• Page 121: Change Of Belt

  Look into the slot in the frame hood to see if separator parts are rotating or not. G0467361 Alfa Laval ref. 9007861 Rev. 2 Remove water tank or cover and brake For separators with water tank: Remove the water tank by lowering the back end of the tank and then pulling it out of the frame.

• Page 122
  6.4 Change of belt 6 Dismantling & Assembly Remove belt Adjust the belt tightener to make sure there is a gap between frame pad and belt tightener. G1058411 Loosen but do not remove the motor adapter screws. G0076622 Remove the belt. Clean the raceways and the friction coupling.
• Page 123
  6 Dismantling & Assembly 6.4 Change of belt Remove the motor and the friction coupling. Lift the motor together with adapter and friction coupling. The capacity of the lifting equipment should be at least 50 kg. Lubricate the adapter and the frame surface. Make sure there is a sufficient film of lubricating paste between the adapter and the frame surface.
• Page 124
  6.4 Change of belt 6 Dismantling & Assembly Tighten belt Rotate the belt tightener until it makes contact with the frame pad. G1058611 Tighten the belt by rotating the belt tightener until the end lug of the screw is in contact with the motor adapter.
• Page 125
  6 Dismantling & Assembly 6.4 Change of belt Loosen the belt tightener. G1058411 Install water tank or cover and brake For separators with water tank: Install the water tank. For separators without water tank: Install the cover. Install the brake. Before starting the separator Wait at least 30 minutes before starting the separator.

• Page 126: Oil Filling Device

  6.5 Oil filling device 6 Dismantling & Assembly Oil filling device 6.5.1 Dismantling/assembly Drain off the oil, see 5.8 Oil change on page Unscrew nipple (4) and pull off the oil filling device. Then unbend the round safety wire (6) and pull off nipple (4).

• Page 127: Water Tank

  6 Dismantling & Assembly 6.7 Brake Water tank Remove the water tank (1). Note that the tank must be lowered past the spindle end (A) before it can be withdrawn (B). • Check the tank interior and clean out if necessary.

• Page 128: Checking Of Friction Element

  6.7 Brake 6 Dismantling & Assembly 6.7.2 Checking of friction element A worn or oily friction element will lengthen the stopping time. Remove bracket with the brake. Examine the friction element. • If the friction element is worn; Fit a new complete spindle (includes friction element).

• Page 129: Frame Feet

  6 Dismantling & Assembly 6.8 Frame feet Frame feet 6.8.1 Mounting of new frame feet When replacing the frame feet, the separator must be lifted. Remove the bowl before lifting the separator. Follow the Lifting instructions. Loosen the foundation bolts and lift the separator.

• Page 130
  6.8 Frame feet 6 Dismantling & Assembly…

• Page 131: Technical Reference

  7 Technical Reference Product description Alfa Laval ref. 9010797 Rev. 0 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 132: Directives & Standards

  7.2 Directives & Standards 7 Technical Reference Directives & Standards Alfa Laval ref. 591985 Rev. 5 Declaration of Incorporation of Partly Completed Machinery The machinery complies with the relevant, essential health and safety requirements of: Designation Description 2006/42/EC Machinery Directive…

• Page 133: Technical Data

  7 Technical Reference 7.3 Technical Data Technical Data Alfa Laval ref. 561687 Rev. 3 Maximum density feed 1100 kg/m sediment 2631 kg/m Power consumption idling 0,8 kW running (at max. capacity) 1,8 kW max. power consumption 2,8 kW (at starting-up)

• Page 134: Connection List

  7.4 Connection list 7 Technical Reference Connection list Alfa Laval ref. 561658 Rev. 1 Connection Description Requirements/limits Inlet for process liquid — Flow 7.11 Performance data, in- and outlet device on page 150 — Pressure 7.11 Performance data, in- and…

• Page 135
  7 Technical Reference 7.4 Connection list Connection Description Requirements/limits Unbalance sensors, vibration — Type: Mechanical switch — Frequency range: < 300 Hz — Vibration measurement range: < 4,5 g — Internal impedance: 4 kΩ ± 5% — Reset coil voltage: 48 V DC — Reset coil power: Max.

• Page 136: Basic Size Drawing

  7.5 Basic size drawing 7 Technical Reference Basic size drawing Alfa Laval ref. 565297 Rev. 2 G0922971 Connections 201 and 220 are turnable 90°. A. Maximum horizontal displacement during operation ± 20 mm. B. Maximum vertical displacement during operation ± 10 mm.

• Page 137: Dimensions Of Connections

  7 Technical Reference 7.5 Basic size drawing 7.5.1 Dimensions of connections Alfa Laval ref. 565297 Rev. 2 G0922961 All dimensions are nominal. Reservation for individual deviations due to tolerance. All connections to be installed non-loaded and flexible. Data for connections see 7.4 Connection list on…

• Page 138: Interface Description

  7.6 Interface Description 7 Technical Reference Interface Description Alfa Laval ref. 565810 Rev. 0 7.6.1 Scope This document gives information, requirements, and recommendations about operational procedures and signal processing for safe and reliable operation of the separator. It is intended to be used for designing auxiliary equipment and control systems for the separator.

• Page 139: Goal

  7 Technical Reference 7.6 Interface Description 7.6.4 Goal To eliminate situations that can cause harm, i.e. injury, damage to health or property and unsatisfactory process result are e.g.: Situation Effect Unbalance caused by uneven sediment Too high stress on bowl and bearing system accumulation in the bowl.

• Page 140
  7.6 Interface Description 7 Technical Reference Starting means: • The power to the separator motor is on. • The bowl is rotating and accelerating. Running means: • The power to the separator motor is on. • The bowl is rotating at full speed. •…

• Page 141: Handling Of Connection Interfaces

  7 Technical Reference 7.6 Interface Description 7.6.6 Handling of connection interfaces Electrical connections 701 Separator motor. The separator is equipped with a 3-phase DOL (Direct On Line) started motor. There shall be an emergency stop circuit designed according to EN 418 and a power isolation device according to EN 1037.

• Page 142
  7.6 Interface Description 7 Technical Reference Signal processing in STOPPING: • If the self check system triggers, an alarm shall be given.. Signal processing in NORMAL STOP: • If to high vibrations occur the system shall turn over automatically to SAFETY STOP. Fluid connections Complementary information is given in the document Connection List.
• Page 143
  7 Technical Reference 7.6 Interface Description • Displacing (the interface) before a discharge: 8.2.1 Operating water interface on page 8.3.1 Operating water interface on page 169. 220 and 221 Outlets Processing in STAND STILL: • Could be closed or open. Processing in other modes •…
• Page 144
  7.6 Interface Description 7 Technical Reference • The separator bowl is closed in a discharge sequence according to procedure in “Operating Water Interface”. • For service purposes there should be a counter to count number of discharges.

• Page 145: Water Quality

  Alfa Laval accepts no liability for consequences arising from unsatisfactory purified operating water supplied by the customer The following conditions must be fulfilled: 1.

• Page 146: Foundation Drawing

  7.8 Foundation drawing 7 Technical Reference Foundation drawing Alfa Laval ref. 548711 Rev. 2 G0645731 A. Centre of separator bowl. B. Center of motor C. 8 holes for foundation bolt D. Foundation bolt. Installation according to stated foundation force. E. Service side F.

• Page 147: Interconnection Diagram

  7 Technical Reference 7.9 Interconnection diagram Interconnection diagram Alfa Laval ref. 561723 Rev. 0 Reset Coil Common Heater G0931791 Vibration sensor (mechanical switch)

• Page 148: Electric Motor

  7.10 Electric motor 7 Technical Reference 7.10 Electric motor 7.10.1 Crompton Greaves Alfa Laval ref. 585146 Rev. 3 G0831191 A. M5 external earth B. ø20 conduit entry C. 4 holes drilled ø12 on a 165 P.C.D. equi-spaced as shown. D. Hole tapped M8x19 deep. To DIN 332 form D E.

• Page 149: Abb

  7 Technical Reference 7.10 Electric motor 7.10.2 ABB Alfa Laval ref. 552807 Rev. 7 G06062A1 A. Knock out openings for cable glands on both sides 2 x M25 B. Sheet-steel fan hood C. Drain holes with closable plugs to be positioned at lowest point for IM 3011 mounting position.

• Page 150: Performance Data, In- And Outlet Device

  7.11 Performance data, in- and outlet device 7 Technical Reference 7.11 Performance data, in- and outlet device Alfa Laval ref. 565805 Rev. 0 Maximum light phase counter pressure as a function of throughput and viscosity: g0931721 A. Max. light phase counter pressure, kPa B.

• Page 151
  7 Technical Reference 7.11 Performance data, in- and outlet device Alfa Laval ref. 565805 Rev. 0 Inlet pressure as a function of throughput and viscosity (30 cSt) g0931731 A. Pressure kPa B. Throughput m…
• Page 152
  7.11 Performance data, in- and outlet device 7 Technical Reference Alfa Laval ref. 565805 Rev. 0 Maximum heavy capacity as a function of gravity disc: g0931741 A. litres/hour B. Gravity disc…
• Page 153
  7.11 Performance data, in- and outlet device 7 Technical Reference…

• Page 154: Machine Plates And Safety Labels

  7.12 Machine plates and safety labels 7 Technical Reference 7.12 Machine plates and safety labels Alfa Laval ref. 556430 Rev. 3 G0635141 1. Machine plate Separator type Serial No / Year Product No Main group no Configuration no Designation Max allowed speed (bowl)

• Page 155
  7 Technical Reference 7.12 Machine plates and safety labels 3. Safety label W A R N I N G Text on label: Read the instruction If excessive vibration Separator must stop manuals before occurs, stop separator Warning rotating before installation, operation keep bowl filled with dismantling work is…

• Page 156: Storage An Installation

  The installation instructions are specifications, which are compulsory requirements. Any specific requirements from classification societies or other local authorities must be followed If the specifications are not followed, Alfa Laval can not be held responsible for any malfunctions related to the installation.

• Page 157: Protection And Storage Of Goods

  7 Technical Reference 7.13 Storage an Installation 7.13.2 Protection and storage of goods The separator must be stored indoors at 5 — 55 °C, if not delivered in a water-resistant box, designated for outdoor storage. G08736B1 If there is a risk for water condensation, the equipment must stand well ventilated and at a temperature above dew point.

• Page 158: Storage At Out Of Operation

  7.13 Storage an Installation 7 Technical Reference 7.13.3 Storage at out of operation If the separator is out of operation for more than 1 month: Lift out the bowl. Protect the spindle taper from corrosion by lubricating it with oil. Keep the separator and bowl well stored, dry and protected from mechanical damage.

• Page 159: Before Start-Up

  7 Technical Reference 7.13 Storage an Installation 7.13.4 Before start-up If the separator has been out of operation for: 1 months or longer • Pre-lubricate the spindle bearings. 6 months or longer • Perform an Intermediate service and make sure to pre-lubricate the spindle bearings.

• Page 160: Connections To Surrounding Equipment

  7.13 Storage an Installation 7 Technical Reference 7.13.5 Connections to surrounding equipment Local safety regulations If the local safety regulations prescribe that the installation has to be inspected and approved by responsible authorities before the plant is put into service, consult with such authorities before installing the equipment and have the projected plant design approved by them.

• Page 161: Reassembly And Start Up

  7 Technical Reference 7.13 Storage an Installation • Articles made of rubber or plastics (e.g. seals) must not be treated with anti-rust oil. 7.13.6 Reassembly and Start up • Clean away the anti-rust oil with white spirit. • Remove the silica gel bags from all units. •…

• Page 162
  7.13 Storage an Installation 7 Technical Reference A separator can be delivered with different types of protection: • Fixed on a pallet. The separator must be stored in a storage room well protected from mechanical damage as well as from rain and humidity. G0057111 Fixed on a pallet •…
• Page 163
  7 Technical Reference 7.13 Storage an Installation Transport Specification • During transport of the separator, the frame hood and bowl must always be removed from the machine. • When lifting a separator it must always be hung securely. See chapter Lifting instructions on page Crush hazards…

• Page 164: Planning Of Installation

  7.13 Storage an Installation 7 Technical Reference 7.13.8 Planning of installation Space for separator The separator shall be placed in such a way that suitable space for maintenance and repair is obtained. The space required for one or more separators can be calculated by consulting the drawings in the chapters Basic size drawing on page…

• Page 165
  7 Technical Reference 7.13 Storage an Installation Lifting height for transport of bowl Specification • A minimum height is required to lift the bowl, bowl parts and the bowl spindle, see chapter Foundation drawing on page 146. Recommendation • When two or more separators are installed it is recommended to plan the installation in such a way that parts from one separator do not have to be lifted over another separator.

• Page 166: Foundations

  7.13 Storage an Installation 7 Technical Reference 7.13.9 Foundations hung When lifting a separator it must always be securely Lifting instructions on . See chapter page 52 • 7.8 Foundation drawing on page 146. • The separator must be installed on a strong and rigid foundation to reduce the influence of vibrations from adjacent machinery.

• Page 167: Operating

  8 Operating Operating routine These operating instructions describe routine procedures to be followed before and during the start, running, and stopping sequences of the separator. If system documentation is available, always follow the operating instructions therein. If there is no system documentation, the instructions below are to be followed.

• Page 168: Clarifier Operation

  8.2 Clarifier Operation 8 Operating Clarifier Operation 8.2.1 Operating water interface Alfa Laval ref. 565849 Rev. 1 Proposed operation of operating water interface. Closing the bowl: Initialise by opening connection 372 for 1 second. Close the bowl by opening connection 373 for 40 seconds.

• Page 169: Purifier Operation

  8 Operating 8.3 Purifier Operation Purifier Operation 8.3.1 Operating water interface Alfa Laval ref. 565819 Rev. 0 Proposed operation of operating water interface for purifier execution. Closing the bowl and supplying liquid seal: Initialise by opening connection 372 for 1 second.

• Page 170: Selection Of Gravity Disc

  8.3 Purifier Operation 8 Operating 8.3.2 Selection of gravity disc The separator is delivered with a set of gravity discs with different diameters for purification operation. The hole diameter of the gravity disc sets the position of the oil/water interface in the separator.

• Page 171: Gravity Disc Nomogram

  8 Operating 8.3 Purifier Operation 8.3.3 Gravity disc nomogram Alfa Laval ref. 565798 Rev. 0 g0931711 Oil density, kg/m at 15 Oil temperature, °C, °F Gravity disc hole diameter, • mm Throughput, m The nomogram is based on the properties of fresh water.

• Page 172: Before First Start

  Check that the power frequency is in agreement with P003992A the machine plate. If incorrect, resulting overspeed 50 Hz? 60 Hz? may cause breakdown. Use the separation system for the purpose, and within the limits, specified by Alfa Laval. Failure to do so could cause a violent breakdown.

• Page 173
  8 Operating 8.4 Before first Start Check the oil sump level. Top up if necessary. • The oil level should be slightly above middle of the sight glass. Too much or too little oil can damage the separator bearings. G0868543…

• Page 174: Start After A Service

  8.5 Start after a service 8 Operating Start after a service Pay special attention to unusual conditions when starting the separator after a service. 8.5.1 Before normal start Check these points before every start. Make sure that the bowl is clean and that the separator is properly assembled.

• Page 175
  8 Operating 8.5 Start after a service Read the oil level. The line in the middle of the sight glass shows the minimum level. Refill if necessary. For grade and quality of oil see5.9 Lubricants on page Check the oil level Rotation Direction Check the rotation of the bowl by doing a quick start/stop.

• Page 176: Starting And Running-Up Procedure

  8.5 Start after a service 8 Operating 8.5.2 Starting and running-up procedure Open the water supply valve(s). Make sure that the water supply is on 150-600 kPa (1,5-6 bar). Water supply Start the separator. Be alert for unusual noises and conditions. Note the normal occurrence of critical speed periods.

• Page 177: Separation

  8 Operating 8.5 Start after a service Check the current to the separator motor to ensure that the separator has reached full speed: During start, the current reaches a peak and then slowly drops to a low and stable value. For normal length of the start-up period see Technical Data on page 133.

• Page 178: Stopping Procedure

  8.5 Start after a service 8 Operating 8.5.4 Stopping procedure Turn off the oil feed. Feed displacement water until water flows out through the water outlet. Then close this feed. Stop the separator. Wait until the separator has come to a complete standstill.

• Page 179: Safety Stop

  8 Operating 8.5 Start after a service 8.5.5 Safety stop If the separator begins to vibrate excessively during operation, stop it immediately by pushing the safety stop. The separator motor is switched off. • Keep the bowl filled during the run-down to minimize the excessive vibration.

• Page 180: After Safety Stop

  8.6 After Safety Stop 8 Operating After Safety Stop Separator standstill Dismantling work must not be started before all rotating parts have come to a complete standstill. Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work. I00293CB Avoid accidental start Entrapment hazard…

• Page 181
  8 Operating 8.6 After Safety Stop Separator reassembled The separator must be fully reassembled with all covers and guards in place and tightened before unlocking the power supply and starting the system. Breakdown hazard Assemble the separator completely before restart. All couplings, covers, and guards must be in place and properly tightened.

Похожие релизы

• Page 1
  Separator Manual High Speed Separator S 927 ventas@fdm.com.pe Specification No. 881201-08-03/3 fdmsac@gmail.com www.fdm.com.pe Book No. 9006916-02 rev. 3 whatsapp:959440045…
• Page 2
  Telephone: +46 8 530 650 00 +46 8 530 310 40 Telefax: © Alfa Laval Tumba AB 04-2014 The original instructions are in English This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB.

• Page 3: Table Of Contents

  Contents Read this first Safety instructions Warning signs in text Environmental issues Requirements of personnel Remote start Basic principles of separation Introduction Separation by gravity Centrifugal separation Separating temperatures Design and function Overview Drive section Process section Sensors and indicators Separating function 4.5.1 The liquid balance in the bowl…

• Page 4
  Service, dismantling, assembly Periodic maintenance 6.1.1 Maintenance intervals 6.1.2 Maintenance procedure 6.1.3 Tightening of screws 6.1.4 Service kits 6.1.5 Cleaning Maintenance logs Dismantling 6.3.1 Introduction 6.3.2 Tools 6.3.3 Frame hood 6.3.4 Bowl 6.3.5 Driving device 6.3.6 Centrifugal clutch Actions before assembly 6.4.1 Cleaning 6.4.2…
• Page 5
  7.1.6 Starting power too high 7.1.7 Starting power too low 7.1.8 Starting time too long Separating functions 7.2.1 Bowl opens accidentally during operation 7.2.2 Bowl fails to open for sludge discharge 7.2.3 Unsatisfactory separation result 7.2.4 Bowl fails to close Technical reference Product description 8.1.1…
• Page 6
  ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• 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 8
  ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 9: Read This First

  Alfa Laval separator If the separator has been delivered and installed by Alfa Laval as a part of a processing system, this manual should be viewed as part of the System Documentation. Study carefully all instructions in any System Documentation.

• Page 10
  1 Read this first Fault finding Refer to this chapter if the separator functions abnormally. If the separator has been installed as a part of a processing system, always refer to the trouble-tracing instructions, in the System Documentation. Technical reference This chapter contains technical data concerning the separator and drawings.

• Page 11: Safety Instructions

  • Ensure that personnel are competent and have sufficient knowledge of maintenance and operation, especially concerning emergency stopping procedures. • Use only Alfa Laval genuine spare parts and the special tools supplied. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 12
  If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown. • Use the separator only for the purpose and m /h parameter range specified by Alfa Laval. kg/m r/min • Check that the gear/pulley ratio is correct for power frequency used.
• Page 13
  2 Safety instructions Electrical hazard • Follow local regulations for electrical installation and earthing (grounding). • To avoid accidental start, switch off and lock power supply before starting any dismantling work. Crush hazards • Use correct lifting tools and follow lifting instructions.
• Page 14
  2 Safety instructions Flying objects • Risk for accidental release of snap rings and springs when dismantling and assembly. Wear safety goggles. Health hazards • Risk for unhealthy dust when handling friction blocks/pads. Use a dust mask to make sure not to inhale any dust ventas@fdm.com.pe fdmsac@gmail.com…

• Page 15: Warning Signs In Text

  2 Safety instructions Warning signs in 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 indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• Page 16: Environmental Issues

  2 Safety instructions Environmental issues Unpacking Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps. Wood and cardboard boxes can be reused, recycled or used for energy recovery. Plastics should be recycled or burnt at a licensed waste incineration plant.

• Page 17: Requirements Of Personnel

  2 Safety instructions Requirements of personnel Only skilled or instructed persons are allowed to operate the machine, e.g. operating and maintenance staff. • Skilled person: A person with technical knowledge or sufficient experience to enable him or her to perceive risks and to avoid hazards which electricity/mechanics can create.

• Page 18
  2 Safety instructions ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 19: Basic Principles Of Separation

  3 Basic principles of separation Introduction 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, • to separate and concentrate solid particles from a liquid.

• Page 20: Centrifugal Separation

  3.4 Separating temperatures 3 Basic principles of separation Centrifugal separation In a rapidly rotating bowl, the force of gravity is replaced by centrifugal force, which can be thousands of times greater. Separation and sedimentation is continuous and happens very quickly. The centrifugal force in the separator bowl can achieve in a few seconds what takes many hours in a tank under influence of gravity.

• Page 21: Design And Function

  4 Design and function G08707A1 1. Process section The feed inlet and outlets are situated at the top of the separator. The liquid is cleaned in the rotating separator bowl inside the frame hood. 2. Sensors The separator is monitored by a speed sensor. An unbalance sensor and an interlocking switch are optional.

• Page 22: Overview

  4.1 Overview 4 Design and function Overview The separator comprises a process section and a drive section powered by an electric motor. The separator frame comprises a lower body and a frame hood. The motor is attached to the frame. The frame feet dampen vibration. The bottom part of the separator contains a flat belt transmission, a centrifugal clutch and a vertical spindle.

• Page 23: Drive Section

  4 Design and function 4.2 Drive section Drive section The separator bowl is driven by an electric motor via a belt transmission. The belt pulley on the motor shaft includes a centrifugal clutch. The centrifugal clutch (2) with friction pads ensures a gentle start and smooth acceleration, and at the same time prevents overloading of the belt and motor.

• Page 24: Process Section

  4.3 Process section 4 Design and function Process section The separation process takes place inside the rotating separator bowl. The feed and outlet of process liquid takes place in the in and outlet unit on top of the separator frame hood. Inlet and outlet The inlet and outlet unit consists of the following parts:…

• Page 25
  4 Design and function 4.3 Process section Separator bowl The separator bowl, with its sludge discharge mechanism, is built-up as follows: The bowl body and bowl hood are held together by a lock ring (Centrilock). Inside the bowl are the distributor and the disc stack. The disc stack is kept compressed by the bowl hood.

• Page 26: Sensors And Indicators

  4.4 Sensors and indicators 4 Design and function Sensors and indicators The separator is equipped with a speed sensor. As options, an unbalance sensor and an interlocking kit can be fitted. Speed sensor (optional) A speed sensor (3) indicates the speed of the separator.

• Page 27: Separating Function

  4 Design and function 4.5 Separating function Separating function The separator separates water and solids from the uncleaned oil. Water normally leaves the separator through the water outlet. During sludge discharge, solids (sludge) and water are removed through the discharge ports. 4.5.1 The liquid balance in the bowl The liquid levels in the bowl depend on many…

• Page 28: Liquid Flow

  4.5 Separating function 4 Design and function 4.5.2 Liquid flow Unseparated oil is fed into the bowl through the inlet pipe and travels via the distributor towards the periphery of the bowl. When the oil reaches slots in the distributor, it rises through the channels formed by the disc stack, where it is evenly distributed.

• Page 29: Discharge Of Sludge And Water (Alcap™ Concept)

  4 Design and function 4.5 Separating function 4.5.3 Discharge of sludge and water (ALCAP™ concept) As the sludge space fills up and water enters the disc stack, traces of water will escape with the cleaned oil. The increase of water content in the cleaned oil is the sign of reduced separation efficiency.

• Page 30: Discharge Of Water Through Water Outlet

  4.5 Separating function 4 Design and function 4.5.4 Discharge of water through water outlet G08862b1 Discharge of water through water outlet A. Unseparated oil B. Separated oil C. Water 1. Water paring tube 2. Water paring chamber 3. Holes in distributor 4.

• Page 31: Operating Instructions

  5 Operating instructions These operating instructions describe routine procedures to follow before and during the start, running and stopping sequences of the separator. If system documentation is available, always follow the operating instructions therein. If there is no system documentation, the instructions below are to be followed.

• Page 32: Start After Service

  5.1 Before first start 5 Operating instructions • Remove the oil pin and make sure that the oil level is above the lower end of the pin, see change on page 161. Too much or too little oil can damage the separator bearings.

• Page 33: Normal Operation

  5 Operating instructions 5.2 Normal operation Normal operation 5.2.1 Before normal start To achieve the best separation results, the bowl should be in a clean condition. Check: that all couplings and connections (1) are securely tightened to prevent leakages. Leaking hot liquid can cause burns.

• Page 34: Start

  5.2 Normal operation 5 Operating instructions 5.2.2 Start Start of separator: a. Open the water supply valve. b. Start the separator by pushing the start button at the starter unit. After every start the separator must always be run continuously for a minimum of 5 hour to ensure proper lubrication.

• Page 35
  5 Operating instructions 5.2 Normal operation Ensure that the separator is at full speed. The time by full speed can be checked by studying the ammeter. Current increases during start (1). When full speed has been reached, the current decreases to a stable value (2). For normal length of the start-up period, see Technical data on page 184.

• Page 36: Operating

  5.2 Normal operation 5 Operating instructions 5.2.3 Operating Checkpoints during operation. Burning hazard Lubricating oil and various machine surfaces can be hot and cause burns. a. Check all connections for leakage. b. Check that the feed has correct flow and temperature.

• Page 37
  5 Operating instructions 5.2 Normal operation 5.2.3.1 Sludge discharge Turn off the oil feed. Perform a displacement of the oil by adding hot water (not more than bowl volume). Perform a sludge discharge. a. Add opening water until a discharge sound is heard (max.

• Page 38: Stop

  5.2 Normal operation 5 Operating instructions 5.2.4 Stop Stopping the separator. Turn off the oil feed. Perform a displacement of the oil by adding hot water (not more than bowl volume). Perform a sludge discharge. a. Add opening water until a discharge sound is heard (max.

• Page 39: Emergency Stop

  G0871381 Disintegration hazard After an emergency stop, the cause of the fault must be identified. If all parts have been checked and the cause not found, contact Alfa Laval for advice before restarting the separator. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 40
  5.3 Emergency stop 5 Operating instructions ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 41: Periodic Maintenance

  6 Service, dismantling, assembly Periodic maintenance Periodic (preventive) maintenance reduces the risk of unexpected stoppages and breakdowns. Follow the maintenance log in this chapter in order to facilitate the periodic maintenance. 6.1.1 Maintenance intervals The following directions for periodic maintenance give a brief description of parts to be cleaned, checked and renewed at different maintenance intervals.

• Page 42
  6.1 Periodic maintenance 6 Service, dismantling, assembly Electric motor Motor service consists of an overhaul of the motor at max. 36 months or 24000 operating hours. Bearings, fan, seals and washers for the motor are renewed. Ancillary Verify correct flow at inspection service overhaul water valveblock at least every 36 months.

• Page 43: Maintenance Procedure

  6 Service, dismantling, assembly 6.1 Periodic maintenance 6.1.2 Maintenance procedure At each Inspection and/or Overhaul, take a copy of the maintenance log and use it to make notes during the service. An inspection and overhaul should be carried out as follows: 1.

• Page 44: Tightening Of Screws

  6.1 Periodic maintenance 6 Service, dismantling, assembly The use of service symbols in the dismantling/assembly instructions Parts that have to be renewed from the service kits (see below) are marked [i] and/or [o] in the assembly instructions. Example a. Fit the O-ring [i]. When dismantling and assembling between the service periods, some procedures do not have to be carried out.

• Page 45: Service Kits

  Overhaul kit. The contents of the kits are described in the Spare Parts Catalogue. Always use Alfa Laval genuine parts as otherwise the warranty may become invalid. Alfa Laval takes no responsibility for the safe operation of the equipment if non-genuine spare parts are used.

• Page 46: Maintenance Logs

  6.2 Maintenance logs 6 Service, dismantling, assembly Maintenance logs Name of ship/plant: Local identification: Separator: Manufacture No./Year: Total running hours. Product No: Signature: Date: Part [i] [o] Check Action Page Note In and outlet device — All parts Clean — All parts Check for corrosion — All parts Check for cracks…

• Page 47
  6 Service, dismantling, assembly 6.2 Maintenance logs Part [i] [o] Check Action Page Note — Lock ring Check for deformations Check for impact marks Check pin not deformed or loose — Bowl hood Renew seal ring Renew O-ring Renew seal ring and screws — Operating water ring Frame — Frame feet…
• Page 48
  6.2 Maintenance logs 6 Service, dismantling, assembly Part [i] [o] Check Action Page Note — Coupling hub Renew single row ball bearings Renew snap rings — Friction block Renew friction pads (if they are worn) or clean the pads if they are dirty Electrical motor — Bearings…

• Page 49: Dismantling

  6 Service, dismantling, assembly 6.3 Dismantling Dismantling 6.3.1 Introduction The frame hood and heavy bowl parts must be lifted by means of a hoist. Position the hoist exactly above the bowl centre. Use a lifting sling and lifting hooks with safety catches. The parts must be handled carefully.

• Page 50
  6.3 Dismantling 6 Service, dismantling, assembly Standard Tools G0911691 1. Screwdriver 2. Torque wrench (capacity 0-200 Nm) 3. Drift (Ø 4 mm) 4. Dial indicator with magnetic base 5. Hexagon head keys, various sizes 6. Heating equipment for bearings 7. Sliding calliper 8.

• Page 51: Frame Hood

  6 Service, dismantling, assembly 6.3 Dismantling 6.3.3 Frame hood G0863351 G1019211 1. Hook spanner (for the lock nut) G08634n1 1. Lock nut 2. Washer 3. Connecting housing 4. Spring 5. Screw 6. Arm 7. Screws 8. Frame hood 9. O-ring 10.

• Page 52
  6.3 Dismantling 6 Service, dismantling, assembly Removing the connecting housing. a. Remove connections before starting dismantling. b. Lubricate the inlet pipe thread c. Remove the lock nut, using the hook spanner, and the washer. The nut must not be removed before the separator has stopped.
• Page 53
  6 Service, dismantling, assembly 6.3 Dismantling Removing the spring and arm. G08636m1 A. Spring B. Screw C. Lock washer D. Arm a. Remove the spring (A) from the pin on the hood. b. Remove the screw (B) and lock washer (C) from the arm.
• Page 54
  6.3 Dismantling 6 Service, dismantling, assembly Removing the frame hood. a. Remove the screws (A) holding the frame hood. b. Loosen the hood by bending with a screwdriver (B) in all grooves in the hood. c. Lift off the frame hood. Do not place the hood upside down.

• Page 55: Bowl

  6 Service, dismantling, assembly 6.3 Dismantling 6.3.4 Bowl G0861621 G1019221 1. Compressing tool (lock ring) 2. Lifting eyes 3. Spanner for nut (nut/discharge slide) 4. Puller (discharge slide) 5. Lifting tool (distributor, spindle) 6. Puller (Bowl body) 7. Screw (lock ring) (M5) 8.

• Page 56
  6.3 Dismantling 6 Service, dismantling, assembly G08626y3 ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 57
  6 Service, dismantling, assembly 6.3 Dismantling 1. Lock ring 2. Bowl hood 3. Seal ring 4. O-ring 5. Top disc 6. O-rings 7. Inlet and outlet pipe 8. Paring tube 9. Splash sealing 10. Bowl disc (without caulks) 11. Bowl discs 11a.Bowl discs (smaller diameter) 12.
• Page 58
  6.3 Dismantling 6 Service, dismantling, assembly Removing the lock ring. a. Fit the compressing tool (A). b. Fit the clamps (C) and the screws (B) to stop. Be sure not to cover the threaded holes for the lock ring. c. Compress the disc stack by alternately tightening the inner screws (F) on the compressing tool in increments of 5 Nm up to a maximum of 15 Nm.
• Page 59
  6 Service, dismantling, assembly 6.3 Dismantling Removing the bowl hood. a. Remove the compressing screws (A). b. Loosen the screws (B) on the clamp tool. Remove the tool. Remove the lock ring. See removing the bowl hood with optional hydraulic tool (if purchased) on next page. c.
• Page 60
  6.3 Dismantling 6 Service, dismantling, assembly Removing the bowl hood using the hydraulic tool (optional). First remove the lock ring according to instructions a -b, on previous page. a. Fit the larger stud bolt (A) into the in- and outlet pipe (must rest on the cap nut). b.
• Page 61
  6 Service, dismantling, assembly 6.3 Dismantling Removing the seal ring. a. Place the bowl hood on a support and tap out a piece of the seal ring (A) using a drift in the holes. Risk for eye injury from flying seal ring parts or from splashing fluid The seal ring breaks when removed from the bowl hood and may cause trapped fluid to splash.
• Page 62
  6.3 Dismantling 6 Service, dismantling, assembly Removing the paring tube. a. Remove the top disc (A) from the inlet and outlet pipe. To avoid damaging the paring tube, turn it towards the centre of the pipe. b. Remove the splash sealing (C). c.
• Page 63
  6 Service, dismantling, assembly 6.3 Dismantling Removing the disc stack and distributor. G08631C1 A. Lifting tool B. Disc stack C. Bowl discs D. Pin a. Assemble the lifting tool (A) with the pin (D). b. Fit the assembled tool into the distributor and ease off the disc stack using a spanner or wrench.
• Page 64
  6.3 Dismantling 6 Service, dismantling, assembly Removing the nut. Before the nut can be loosened, the bowl body must first be secured to prevent it from rotating. a. Fit a lifting sling on one of the compressing tool clamps (A). Fit the clamp (A) to the bowl body.
• Page 65
  6 Service, dismantling, assembly 6.3 Dismantling Removing the discharge slide. a. Fit the lifting tool (A) by pressing the puller rods (E) towards each other and position them into the two slots on the bowl body (F). Slide metal ring (D) down over bowl nave. b.
• Page 66
  6.3 Dismantling 6 Service, dismantling, assembly 10. Removing the cap nut. a. Remove the cap nut (A). Left-hand thread! G08606F1 A. Cap nut 11. Removing the bowl body. G0860741 A. Lifting tool B. Lifting eye a. Fit the lifting tool (A) to the bowl body. b.
• Page 67
  6 Service, dismantling, assembly 6.3 Dismantling 12. Turn the bowl body upside down. G0860841 Crush hazard Support the bowl body when turning to prevent it from rolling. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 68
  6.3 Dismantling 6 Service, dismantling, assembly 13. Removing the holder. G0860951 A. Screw B. Holder C. Threaded hole D. Washer a. Remove and discard the screws (A) and washers (D). New screws and washers are included in the Inspection kit. b.
• Page 69
  6 Service, dismantling, assembly 6.3 Dismantling 14. Removing the operating slide. a. Lift off the operating slide. If the ring sticks, use two M8 screws in threaded holes to raise the operating slide holder up and away from the bowl body. G08610N1 A.
• Page 70
  6.3 Dismantling 6 Service, dismantling, assembly 16. Removing the guide ring. [O] a. Gently pry loose the guide ring and remove it from the bowl. Discard the guide ring. A new guide ring is included in the Overhaul kit. Do NOT remove the guide ring if only an Inspection service is performed.
• Page 71
  6 Service, dismantling, assembly 6.3 Dismantling 17. Removing the operating water ring. G0861141 A. Screw B. Ring C. Threaded hole a. Remove and discard the screws (A). New screws are included in the Inspection kit. b. Lift off the ring (B). If the ring sticks, use two M8 screws in threaded holes (C) to raise the operating slide holder up and away from the bowl body.

• Page 72: Driving Device

  6.3 Dismantling 6 Service, dismantling, assembly 6.3.5 Driving device G0857821 G08579G1 1. Puller (spindle pulley, ball bearing) 2. Tool (bearing housing) 3. Cover puller (neck bearing cover) 4. Lifting tool (spindle assembly) 5. Drift (bottom bearing) 6. Sleeve (ball bearing in top bearing seat) 7.

• Page 73
  6.3 Dismantling 6 Service, dismantling, assembly ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 74
  6.3 Dismantling 6 Service, dismantling, assembly G0859871 ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 75
  6 Service, dismantling, assembly 6.3 Dismantling 1. Seal ring 2. Operating water cover 3. O-ring 4. O-rings 5. O-ring 6. Pipe 7. Elbow 8. Bushing 9. Deflector ring 10. Seal ring 11. Neck bearing cover 12. O-ring 13. O-ring 14. Fan 15.
• Page 76
  6.3 Dismantling 6 Service, dismantling, assembly Empty the oil sump. Unscrew the oil plug (A) and empty the oil sump. G08685A1 A. Oil plug Removing the belt cover. a. Remove the screws (1). b. Remove the belt cover (2). G0858191 1.
• Page 77
  6 Service, dismantling, assembly 6.3 Dismantling Loosen the flat belt, by tilting the motor. a. Loosen, but do not remove, the screws holding the motor. Start with the two screws (4) at the bottom. b. Remove the two upper screws so that the motor can be tilted.
• Page 78
  6.3 Dismantling 6 Service, dismantling, assembly Removing the operating water cover. G0858951 A. Screw B. Operating water cover C. Threaded holes a. Remove the screws (A). b. Lift off the operating water cover (B). If the cover (B) sticks, fit two M8 screws to the threaded holes (C) and tighten.
• Page 79
  6 Service, dismantling, assembly 6.3 Dismantling Removing the neck bearing cover and deflector ring. G0859081 A. Tool B. Mounting screw C. Screw D. Cover E. Frame a. Attach the tools (A). b. Fasten the tool to the cover using mounting screw (B).
• Page 80
  6.3 Dismantling 6 Service, dismantling, assembly Prepare for removal of spindle assembly. a. To facilitate later removal of the plugs, loosen (but do not remove) the plugs (A) on the bearing housing. b. Remove the screws (B) If the housing sticks, fit two M10 screws to the threaded holes and tighten.
• Page 81
  6 Service, dismantling, assembly 6.3 Dismantling Lifting the spindle assembly from the frame. a. Fit the lifting tool (1) to the spindle end. b. Slowly raise and lift out the spindle assembly using a hoist. Crush hazard Do not rotate the spindle assembly during lifting. The spindle assembly may otherwise come loose from the lifting tool.
• Page 82
  6.3 Dismantling 6 Service, dismantling, assembly Place the spindle assembly upside down on a support. Make a support (1) with a free space (A) between the spindle top and the floor. G08592c1 A=5 mm Always use a support as per this sketch when overhaul service is performed on the spindle assembly.
• Page 83
  6 Service, dismantling, assembly 6.3 Dismantling Removing the air deflector. a. Remove the screws (2) and the air deflector (1). G08592b1 1. Air deflector 2. Screw ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 84
  6.3 Dismantling 6 Service, dismantling, assembly 10. Removing the fan. a. Turn the spindle assembly the right way up. b. Place a spanner (or similar) on the spindle pulley key-grip (1), as holder-up. c. Fit the pin spanner and remove the fan (2). Left-hand thread! G0923981 1.
• Page 85
  6 Service, dismantling, assembly 6.3 Dismantling 11. Removing the oil mist generator. a. Turn the spindle assembly up-side down and remove the oil mist generator (1) by using spanners. b. Remove the two nozzles (2) using an Allen key. G1036811 1.
• Page 86
  6.3 Dismantling 6 Service, dismantling, assembly 13. Removing the top bearing housing. a. Turn the spindle assembly over. G0858251 1. Composite spring 2. Plug 3. Spindle 4. Axial springs b. Remove the snap ring (5). Risk for eye injury from flying snap ring Use the correct pliers for dismantling of snap ring to avoid accidental release.
• Page 87
  6 Service, dismantling, assembly 6.3 Dismantling 14. Removing the ball bearing. a. Fit the cap nut (1) on the spindle to protect the threads. b. Use the puller tool (2) to remove the top bearing seat from the spindle. Take care not to damage the vibration indicator (3) when separating the top bearing seat from the spindle.
• Page 88
  6.3 Dismantling 6 Service, dismantling, assembly 15. Removing the labyrinth ring. a. Remove the ring (1) using a screwdriver. Be careful not to damage the groove G08586m1 Labyrinth ring. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 89
  6 Service, dismantling, assembly 6.3 Dismantling 16. Removing the bottom bearing holder. a. Fit the tool (4) into the bottom bearing holder and attach the socket (3), extension rod (2) and T-handle (1). G08586J1 1. T-handle 2. Extension rod 3. Socket 4.
• Page 90
  6.3 Dismantling 6 Service, dismantling, assembly c. Remove the O-rings (1), (2) and strainer (4) G08586n1 1. O-ring 2. Bottom bearing holder 3. O-ring 4. Strainer ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 91: Centrifugal Clutch

  6 Service, dismantling, assembly 6.3 Dismantling 6.3.6 Centrifugal clutch G0864751 Entrapment hazard To avoid accidental start, switch off and lock-out power supply before starting any dismantling work. Make sure that machine has come to a complete standstill before starting any dismantling work (takes about 20 minutes from switch off).

• Page 92
  6.3 Dismantling 6 Service, dismantling, assembly If belt cover and drive belt not has been removed proceed with this before removing the motor. See page Removing the motor. a. Disconnect the electrical cables. Electrical hazard To avoid electrical shock, switch off and lock power supply before starting dismantling work.
• Page 93
  6 Service, dismantling, assembly 6.3 Dismantling Removing the friction blocks. a. Remove the snap ring (3), cover (2) and friction blocks (1). Flying objects Risk for accidental release of snap ring. Wear safety goggles. G08652g1 1. Friction blocks (3=60 Hz) 2.
• Page 94
  6.3 Dismantling 6 Service, dismantling, assembly Checking the condition of the friction blocks. [o] Inhalation hazard When handling friction blocks/pads wear a mask to avoid inhalation of dust. Do not use compressed air to remove dust. Remove dust using vacuum or a damp cloth. If the blocks are worn: Fit new friction blocks.
• Page 95
  6 Service, dismantling, assembly 6.3 Dismantling Removing the coupling from the motor (complete dismantling of centrifugal clutch). a. Attach a socket with extension rod and handle (1) to the screw. Place a piece of wood (2) according to the illustration. Push the handle to start the rotor moving, when the handle hits the piece of wood, the weight and movement of the rotor loosens…
• Page 96
  6.3 Dismantling 6 Service, dismantling, assembly Removing the coupling from the motor using the optional hydraulic tool. First remove the screw, spring washer and washer according to instructions a -b, on previous page. G08654Q1 1. Sleeve 2. Nut 3. Hydraulic cylinder 4.
• Page 97
  6 Service, dismantling, assembly 6.3 Dismantling Attach the hose from the hand pump to the hydraulic oil inlet (4). Ease off the friction coupling by pumping the handle on the pump until stop. Release pressure on the hand pump and adjust the nut on the stud bolt.
• Page 98
  6.3 Dismantling 6 Service, dismantling, assembly Dismantling of the coupling assembly. a. Remove the snap rings (1). Flying objects Risk for accidental release of snap ring. Wear safety goggles. b. Drive out the coupling hub (3). c. Turn the coupling the other way round and drive out the ball bearings (5) using the mounting tool.

• Page 99: Actions Before Assembly

  6 Service, dismantling, assembly 6.4 Actions before assembly Actions before assembly 6.4.1 Cleaning [i], [o] Clean the separator parts according to the diagram below. Afterwards, protect all cleaned carbon steel parts against corrosion by oiling. Electrical hazard Never wash down a separator with a direct water stream.

• Page 100
  — Remove the bowl discs from the Use Alfa Laval bowl disc distributor and place them individually in the cleaning agent. Mix 1 part cleaning agent. cleaning agent to 10 parts water.

• Page 101: Inspection For Corrosion

  Evidence of corrosion attacks should be looked for and rectified each time the separator is dismantled. Disintegration hazards Always contact your Alfa Laval representative if you suspect that the depth of the corrosion damage G0205241 exceeds 0,2 mm for bowl body and bowl hood (0,5 for other parts) or if cracks have been found.

• Page 102: Inspection For Cracks

  Disintegration hazards Always contact your Alfa Laval representative if you suspect that the depth of the damage exceeds 0,2 mm for bowl body and bowl hood (0,5 for other parts).

• Page 103: Inspection For Erosion

  Dents and pits having a granular and shiny surface. Inspect the bowl and inlet/outlet parts for erosion damages. Always contact your Alfa Laval representative if you suspect that the depth of the damage exceeds 0,2 mm for bowl body and bowl hood (0,5 for other parts). Do not continue to use the separator until it has been inspected and cleared for operation by Alfa Laval.

• Page 104
  6.4 Actions before assembly 6 Service, dismantling, assembly Surfaces particularly subjected to erosion are: G1033631 a. The sealing edge of the discharge slide. b. Bowl body and holder. c. Holder and operating slide. d. The underside of the distributor in the vicinity of the distribution holes and wings. e.

• Page 105: Exchange Of Frame Feet

  6 Service, dismantling, assembly 6.4 Actions before assembly 6.4.5 Exchange of frame feet The frame feet have to be changed occasionally due to rubber deterioration from age. When replacing the frame feet, the separator must be lifted. Follow the instructions in Lifting instructions on page 171.

• Page 106: Lubrication Of Bowl Parts

  6.4 Actions before assembly 6 Service, dismantling, assembly 6.4.6 Lubrication of bowl parts Apply a thin layer of Molykote, or equivalent lubrication, on all the contact surfaces shown in the illustration. G09117j1 A. Molykote 1000 1. Bowl hood 2. Bowl body 3.

• Page 107: Assembly

  6 Service, dismantling, assembly 6.5 Assembly Assembly Entrapment hazard To avoid accidental start, switch off and lock power supply before starting assembly work. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 108: Centrifugal Clutch

  6.5 Assembly 6 Service, dismantling, assembly 6.5.1 Centrifugal clutch Assembly of the coupling. a. Slip the belt pulley (1) over the coupling hub and place them on a firm and level foundation. Disintegration hazard If the belt pulley must be renewed, check that the new pulley has the correct diameter.

• Page 109
  6 Service, dismantling, assembly 6.5 Assembly Fitting the coupling to the motor. Make sure that the key (1) is in place on the motor shaft. See mounting with optional hydraulic puller tool (if purchased) on next page. a. Clean the motor shaft and apply a thin oil film.
• Page 110
  6.5 Assembly 6 Service, dismantling, assembly Fitting the coupling to the motor with optional hydraulic tool. Make sure that the key (1) is in place on the motor shaft. a. Clean the motor shaft and apply a thin oil film. b.
• Page 111
  6 Service, dismantling, assembly 6.5 Assembly Fitting the friction blocks. a. Fit the friction blocks (2) onto the guide pins (1). Be sure that the pins on the back of the blocks project into the grooves in the clutch hub. 50 Hz = 5 Friction blocks 60 Hz = 3 Friction blocks b.
• Page 112
  6.5 Assembly 6 Service, dismantling, assembly Fitting the motor. a. Fit a lifting sling to the motor. Use a shackle from the separator lifting tool. Weight of motor with coupling: approx. 60kg. b. Lower the motor (while supported) on to the separator frame.
• Page 113
  6 Service, dismantling, assembly 6.5 Assembly Fitting the flat belt. Clean the inside of the frame before fitting the flat belt, and make sure that there is no oil on the belt. a. Lift up the belt (1) to the middle (centre) of the spindle pulley.
• Page 114
  6.5 Assembly 6 Service, dismantling, assembly Fitting the belt cover. a. Fit the belt cover. b. Tighten the screws. G08581A1 1. Screw 2. Belt cover ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 115: Driving Device

  6 Service, dismantling, assembly 6.5 Assembly 6.5.2 Driving device Assembling the bottom bearing holder (where necessary) Clean the strainer before fitting. a. Fit the wing insert (1), O-ring (4) and strainer (5). b. Secure the wing insert (1) with the screw (3) secured with Loctite 222 G08661h1 c.

• Page 116
  6.5 Assembly 6 Service, dismantling, assembly Fitting the bottom bearing holder. a. To secure the bottom bearing holder (3) into the frame, apply Loctite 222 on the surfaces directly above the upper O-ring. b. Thread the bottom bearing holder (3) into the frame and fit the tool into the bottom bearing housing.
• Page 117
  6 Service, dismantling, assembly 6.5 Assembly Fitting the labyrinth ring. a. Lubricate (A) and fit the labyrinth ring (2). [o] G08663a1 1. Frame 2. Labyrinth ring A. Lubrication ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 118
  6.5 Assembly 6 Service, dismantling, assembly Fitting the ball bearing to the top bearing seat. a. Heat the top bearing seat (1) in oil to minimum 110 °C and maximum 125 °C, either using hot clean oil or induction heater (induction heater is recommended).
• Page 119
  6 Service, dismantling, assembly 6.5 Assembly Fitting the top bearing seat with bearing to the spindle. a. Heat the top bearing seat (1) and bearing to minimum 110 °C and maximum 125 °C, either using hot clean oil or induction heater. Burn hazard Use protective gloves when handling any heated parts.
• Page 120
  6.5 Assembly 6 Service, dismantling, assembly Fitting the top bearing housing. a. Fit the axial springs (2) to the top bearing housing. [o] b. Carefully lower the bowl spindle (1). Make sure that the springs enter the recesses on the top bearing seat. c.
• Page 121
  6 Service, dismantling, assembly 6.5 Assembly Fitting the spindle pulley. a. Screw on the cap nut on the spindle. b. Turn the spindle assembly upside down and let the spindle rest on the cap nut. It is of utmost importance to use cap nut and the support as the neck bearing may be forced out of its position and damage the neck bearing when the bottom bearing is mounted otherwise.
• Page 122
  6.5 Assembly 6 Service, dismantling, assembly Fitting the self-aligning roller bearing. [o] a. Lubricate the bearing with clean oil. b. Heat the bearing (1) to minimum 30 °C and maximum 50 °C. Burn hazard Use protective gloves when handling any heated parts.
• Page 123
  6 Service, dismantling, assembly 6.5 Assembly Fitting the oil mist generator. G08669f1 1. Nozzle 2. Oil mist generator 3. Threads Clean the oil mist generator and nozzles before assembly. a. Apply Loctite 222 and screw the two nozzles (1) into the pump (2) so that they lie level with the pump edge using an Allen key.
• Page 124
  6.5 Assembly 6 Service, dismantling, assembly 10. Fitting the fan. a. Turn the spindle assembly to up-right position. Ensure that the spindle is seated against the inner ring of the ball bearing. b. Apply a thin layer of oil and fit the O-ring (1) into the fan.
• Page 125
  6 Service, dismantling, assembly 6.5 Assembly 11. Fitting the air deflector. a. Turn the spindle assembly up-side down and fit the air deflector (1). b. Tighten screws (2). G08592A1 1. Air deflector 2. Screw ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 126
  6.5 Assembly 6 Service, dismantling, assembly 12. Lowering the spindle assembly into the frame. a. Turn the assembly and remove the cap nut from the spindle. Fit the lifting tool (1) to the spindle assembly and lift it. Crush hazard Do not rotate the spindle assembly during lifting.
• Page 127
  6 Service, dismantling, assembly 6.5 Assembly c. Carefully lower the spindle assembly and position the bolt holes over the threaded frame holes. Make sure that the bottom bearing, enters the bottom bearing holder (4) correctly. Do not use force. Cut hazard Do not put fingers between the frame and air deflector while lowering the assembly.
• Page 128
  6.5 Assembly 6 Service, dismantling, assembly 13. Fitting the flat belt. Clean the inside of the frame before fitting the flat belt, and make sure that the belt is clean. a. Lift up the belt (1) to the middle (centre) of the spindle pulley.
• Page 129
  6 Service, dismantling, assembly 6.5 Assembly 14. Fitting the neck bearing cover and deflector ring. G08680T1 1. Seal ring 2. O-rings 3. Neck bearing cover 4. Deflector ring a. Apply a thin layer of oil and fit the O-rings (2) and seal rings (1).
• Page 130
  6.5 Assembly 6 Service, dismantling, assembly 15. Fitting the operating water cover. a. Check that the operating water channel (5) is not clogged. Clean if necessary. [o] A blocked operating water channel can lead to failure of the separator discharge function. b.
• Page 131
  6 Service, dismantling, assembly 6.5 Assembly 16. Measuring the radial wobble of the bowl spindle. G0858721 A=max. 0,04 mm a. Fit a dial indicator in a support and fasten it in position as illustrated. Use the flat belt to turn the spindle. Permissible radial wobble: max.
• Page 132
  6.5 Assembly 6 Service, dismantling, assembly 17. Fitting the belt cover. a. Fit the belt cover (2). b. Tighten the screws (1). G08581A1 1. Screw 2. Belt cover ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…
• Page 133
  6 Service, dismantling, assembly 6.5 Assembly 18. Fill oil in the oil sump. The separator should be level and at standstill when oil is filled. a. Remove the oil pin (1), plug (3) and washer (4). b. Fit new washer (6) and refit the drain plug (5).

• Page 134: Bowl

  6.5 Assembly 6 Service, dismantling, assembly 6.5.3 Bowl Check for impact marks and corrosion in bowl body nave and on spindle taper.[i], [o] a. Remove any impact marks using a scraper and/or a whetstone. Disintegration hazard Impact marks may cause the separator to vibrate while running.

• Page 135
  6 Service, dismantling, assembly 6.5 Assembly Fitting new valve plugs on the operating slide. [i] a. Carefully tap in new valve plugs, using a clean, soft-faced hammer. Make sure that the plugs are fitted as described in the illustration. G0874871 ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe…
• Page 136
  6.5 Assembly 6 Service, dismantling, assembly Fitting the guide ring. [o] a. Pointwise apply a small amount of silicone grease in the groove on bowl body (2) and mount the guide ring (1) into the groove on bowl body. Secure that the guide ring is fully inserted into the groove and that it is secured in its position by the silicone grease.
• Page 137
  6 Service, dismantling, assembly 6.5 Assembly Fitting the operating slide. a. Apply a thin layer of silicone grease and fit the rectangular ring (6) on the operating slide and the rectangular ring (8) and O-ring (7) on the bowl body (3). [i],[o] b.
• Page 138
  6.5 Assembly 6 Service, dismantling, assembly Fitting the operating slide holder. a. Fit the holder (1) over the operating slide. b. Apply a thin layer of molykote grease and fit and tighten new screws (2) and washers (3) to a torque of 30 ± 2 Nm. [i], [o] It is very important NOT to refit used screws and washers.
• Page 139
  6 Service, dismantling, assembly 6.5 Assembly Fitting the operating water ring. a. Assemble the seal ring (5) into the operating water ring (2). [i], [o] It is very important not to refit used screws. Always fit new ones included in the Inspection kit! b.
• Page 140
  6.5 Assembly 6 Service, dismantling, assembly Lifting the bowl body onto the spindle taper. a. Put a drop of oil on the spindle taper (1). b. Wipe off the spindle taper (1) and nave bore (2) with a dry cloth. c.
• Page 141
  6 Service, dismantling, assembly 6.5 Assembly Fitting and tightening the cap nut. a. To prevent the bowl body from rotating when fitting the cap nut; Fit one of the clamps (2) to the bowl body and one of the screws (4) for the frame hood in the frame.
• Page 142
  6.5 Assembly 6 Service, dismantling, assembly Fitting the discharge slide. a. Apply a thin layer of silicone grease and fit the rectangular ring (1). [i], [o] b. Apply a thin layer of silicone grease and fit the O-ring (3). [i], [o] c.
• Page 143
  6 Service, dismantling, assembly 6.5 Assembly 10. Assembly of the disc stack. a. Fit the discs (1) one by one onto the distributor. The distributor has a guide rib (4) for the correct positioning of the bowl discs. Begin with the smaller discs (1a) followed by discs (1b).
• Page 144
  6.5 Assembly 6 Service, dismantling, assembly 11. Fitting the disc stack assembly to the bowl body. a. Fit the lifting tool (1) into the distributor. b. Lower the disc stack into the bowl using sling and hoist. The guide pin (2) on the bowl body should face the drill mark (3) on the distributor.
• Page 145
  6 Service, dismantling, assembly 6.5 Assembly 12. Assembling the paring tube and bearing holder. a. Apply a thin layer of silicone grease to the O-ring (2). Fit the O-ring and bearing bushing (1) to the paring tube (3).[i], [o] b. Fit the flanged bushing (4) to the bearing holder.
• Page 146
  6.5 Assembly 6 Service, dismantling, assembly 13. Mounting the paring tube and fitting the inlet and outlet pipe. a. Insert the paring tube (2) into the inlet and outlet pipe. b. Fit and tighten the screw (4) c. Apply a thin layer of silicone grease and mount the splash sealing (1).
• Page 147
  6 Service, dismantling, assembly 6.5 Assembly 14. Fitting the top disc. a. Move the paring tube (1) to the centre. To avoid damaging the paring tube, turn it towards the centre of the pipe. b. Lower the top disc (2). The drill mark (3) on the top disc should face the guide pin on the bowl body.
• Page 148
  6.5 Assembly 6 Service, dismantling, assembly 15. Fitting the bowl hood. a. Apply a thin layer of silicone grease and fit the O-ring (1). [i], [o] b. Fit the seal ring (2). Press the ring down evenly into the groove all around. [i], [o] c.
• Page 149
  6 Service, dismantling, assembly 6.5 Assembly 16. Fitting the lock ring. a. Place the lock ring (1) on the bowl hood (4) with its guide pin (5) close to the corresponding hole (6) in the bowl body (2). Make sure that the groove in the bowl body which retains the lock ring is clean.
• Page 150
  6.5 Assembly 6 Service, dismantling, assembly d. Measure gap C of lock ring and make sure it does not exceed 3 mm. If the lock ring gap is greater than 3 mm, the lock ring is damaged and must be replaced with a new one immediately.
• Page 151
  6 Service, dismantling, assembly 6.5 Assembly 17. Checking the disc stack pressure. [i] a. Remove bowl hood, top disc and inlet and outlet pipe. b. Add one disc (1) to the disc stack. c. Refit the disc without caulks (2), the top disc and bowl hood.

• Page 152: In And Outlet Device

  6.5 Assembly 6 Service, dismantling, assembly 6.5.4 In and outlet device Fitting the frame hood. [i], [o] a. Turn the paring tube (1) so that the frame hood (2) can pass the paring tube. b. Apply a thin layer of silicone grease and fit the O-ring (3) onto the frame hood .

• Page 153
  6 Service, dismantling, assembly 6.5 Assembly Control measurement of paring disc height. [o] Alfa Laval ref. 593336 Rev. 0 a. Remove the guide screw (A). b. Measure the distance (D) through the screw hole. Assemble the correct number of height adjusting rings (B).
• Page 154
  6.5 Assembly 6 Service, dismantling, assembly Fitting the spring and arm. [o] a. Fit the spring (2) on the arm (3) and fit the arm to the top of the paring tube end (4) with the screw (1). b. Fit the spring to the pin (5) on the frame hood and make sure that it is properly attached on both ends.
• Page 155
  6 Service, dismantling, assembly 6.5 Assembly Fitting the connecting housing. a. Lubricate the inlet pipe thread. b. Fit the connecting housing (1) over the inlet/outlet pipe. Make sure that the screw, on top of the frame hood, enters the guide hole at the underside of the connecting housing.

• Page 156: Unbalance Sensor (Optional)

  6.5 Assembly 6 Service, dismantling, assembly 6.5.5 Unbalance sensor (optional) Fitting the unbalance sensor holder. a. Remove the cover (1). b. Fit the O-ring (3) on the holder (2). Fit the screw (4) into the holder and mount the holder into the separator frame (6). If removing the sensor holder;…

• Page 157
  6 Service, dismantling, assembly 6.5 Assembly Adjusting the unbalance sensor a. Fit the sensor (1) into the holder. Do not forget the nut (2). b. Adjust the sensor so that a value of 1,5 appears on the display. c. When correct distance is achieved tighten the nut against the holder.

• Page 158: Speed Sensor (Optional)

  6.5 Assembly 6 Service, dismantling, assembly 6.5.6 Speed sensor (optional) Adjusting the speed sensor. a. Adjust the speed sensor. Distance A = 73 ± 0,1 mm. b. Fit the sensor to the frame, see 4.4 Sensors and indicators on page G08734E1 A.

• Page 159: Actions After Assembly

  6 Service, dismantling, assembly 6.5 Assembly 6.5.7 Actions after assembly 6.5.7.1 Control of machine plates and safety labels Check that the following signs are attached.[o]. Xxxxxxxxxxxxxxxxxx. Xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxx. Xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxx. Xxxxxxxxxxxxxxx. W A R N I N G Xxxxxxxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxx.

• Page 160
  6.5 Assembly 6 Service, dismantling, assembly Check legibility. Following texts should be read on the labels. Machine plate Separator type Serial No / Year Product No Main group no Configuration no Designation Max. allowed speed (bowl) Direction of rotation (bowl) Speed motor shaft El.

• Page 161: Oil Change

  6 Service, dismantling, assembly 6.6 Oil change Oil change The separator should be level and at standstill when oil is filled or the oil level is checked 6.6.1 Lubricating oil Do not mix different oil brands. Always use clean vessels when handling lubricating oil.

• Page 162: Check Oil Level

  6.6 Oil change 6 Service, dismantling, assembly This does not exclude, however, the use of other brands, provided they have equivalently high quality properties as the brands recommended. The use of other oil brands and lubricants than recommended, is done on the exclusive responsibility of the user or oil supplier.

• Page 163: Lubrication Chart

  6 Service, dismantling, assembly 6.6 Oil change 6.6.4 Lubrication chart Alfa Laval ref. 567329-01 Rev. 3 G0875481 1. Bowl spindle bearings 2. Bowl spindle taper 3. Bowl 4. Rubber seal rings 5. Friction clutch bearings 6. Electric motor 7. Plug thread…

• Page 164
  6.6 Oil change 6 Service, dismantling, assembly Lubricating points Type of lubricant Interval 5 Friction clutch bearings The bearings are pre-lubricated No need for extra lubrication. with grease. 6 Electric motor Follow the manufacturer’s Follow the manufacturer’s instructions. instructions. 7 Plug thread Lubricating oil.

• Page 165: Recommended Lubricants

  Lubricant recommendation for hygienic and non-hygienic applications Alfa Laval ref. 553217 01 Rev. 13 Lubricants with a Alfa Laval part number are approved and recommended for use. The data in the below tables is based on supplier information in regards to lubrication properties.

• Page 166
  6.6 Oil change 6 Service, dismantling, assembly Paste for assembly of metallic parts, hygienic applications (NSF registered H1 is preferred) Part no Remark Quantity Designation Manufacturer Molykote D paste Dow Corning 537086-07 50 g Molykote P-1900 Dow Corning NSF Registered H1 (22 Jan 2004) Molykote TP 42 Dow Corning…
• Page 167
  6 Service, dismantling, assembly 6.6 Oil change Silicone grease/oil for rubber rings, hygienic and non-hygienic applications Part no Remark Quantity Designation Manufacturer Bel-Ray No-Tox Food Grade NSF Registered H1 (16 Silicone grease December 2011) Dow Corning 360 Dow Corning Tested according to Medical Fluid and complies with all National Formulary…
• Page 168
  6.6 Oil change 6 Service, dismantling, assembly Always follow the lubrication recommendations of the bearing manufacturer. Grease for ball and roller bearings in electric motors Part no Quantity Designation Manufacturer Remark Energrease LS2 Energrease LS-EP2 Energrease MP-MG2 APS 2 Castrol Spheerol EPL 2 Castrol Multifak EP2…

• Page 169: Lubricating Oils

  6 Service, dismantling, assembly 6.6 Oil change 6.6.6 Lubricating oils Alfa Laval ref. 567330 01 Rev. 5 Paraffinic mineral lubricating oil, category (ISO-L-) HM 68 Trade names and designations might vary from country to country. Please contact your local supplier for more information.

• Page 170
  6.6 Oil change 6 Service, dismantling, assembly Recommended oil brands – Special hygienic demands Viscosity grade (ISO 3448/3104) VG 68 / Viscosity index (ISO 2909) VI>95 Conform to U.S. Food and Drug Administration (FDA) requirements of lubricants with incidental food contact, Title CFR 21 178.3570, 178.3620 and/or those generally regarded as safe (US 21 CFR 182).

• Page 171: Lifting Instructions

  6 Service, dismantling, assembly 6.7 Lifting instructions Lifting instructions Alfa Laval ref. 567319 Rev. 2 6.7.1 Lifting the separator G08684b1 A. Weight to lift: 275 kg B. Sling length: Min. 750 mm 1. Bolts, Tightening torque 35-45 Nm Disconnect all connections.

• Page 172
  6.7 Lifting instructions 6 Service, dismantling, assembly When lifting and moving the separator, follow normal safety precautions for lifting large heavy objects. Crush hazard A falling separator can cause accidents resulting in serious injury and damage. Never lift the separator by any other method than described in this manual.

• Page 173: Lifting The Bowl

  6 Service, dismantling, assembly 6.7 Lifting instructions 6.7.2 Lifting the bowl When lifting and moving an assembled bowl, always follow these instructions. Fit the lifting tool with lifting eyes to the bowl assembly. Check that the lock ring is mounted correctly before lifting the complete bowl.

• Page 174
  6.7 Lifting instructions 6 Service, dismantling, assembly ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 175: Fault Finding

  7 Fault finding These fault finding instructions are for the separator only. If a fault occurs, study the System Documentation fault finding section (if applicable). Mechanical functions 7.1.1 Separator vibration Disintegration hazard If excessive vibration occurs, stop separator and keep bowl filled with liquid during rundown.

• Page 176: Smell

  7.1 Mechanical functions 7 Fault finding 7.1.2 Smell Cause Corrective action Normal occurrence during start while the friction None. blocks are slipping. If smell continues when separator is at full speed, stop the separator and replace friction blocks. Oil level in oil sump too low. Check oil level and add oil if necessary.

• Page 177: Starting Power Too High

  7 Fault finding 7.1 Mechanical functions 7.1.6 Starting power too high Cause Corrective action Incorrect transmission parts (60 Hz belt pulley for 50 Hz power supply). Stop and change the belt transmission to suit the power supply frequency. Wrong direction of rotation. Change electrical phase connections to the motor.

• Page 178: Separating Functions

  7.2 Separating functions 7 Fault finding Separating functions 7.2.1 Bowl opens accidentally during operation Cause Corrective action Strainer in the operating water supply is clogged. Clean the strainer. No water in the operating water system. Check the operating water system and make sure the valve(s) are open.

• Page 179: Bowl Fails To Close

  7 Fault finding 7.2 Separating functions 7.2.4 Bowl fails to close Cause Corrective action Nozzle in operating slide clogged. Clean nozzle. Hoses reversed. Adjust. Rectangular ring in discharge slide is defective Renew rectangular ring. Valve plugs in operating slide missing or Renew valve plugs.

• Page 180
  7.2 Separating functions 7 Fault finding ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 181: Technical Reference

  8 Technical reference Product description Alfa Laval ref. 9006045 Rev. 2 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 182: Directives And Standards

  8.1 Product description 8 Technical reference 8.1.1 Directives and standards Alfa Laval ref. 589764 Rev. 4 Supplier: ……………………Supplier address: ……………………Separator type: …………….Product specification: …………….Configuration number: …………….Serial number: …………….Declaration of Incorporation of Partly Completed Machinery…

• Page 183
  The technical construction file for the machinery is compiled and retained by the authorized person Tomas Zetterling within the Product Centre for High Speed Separators, Alfa Laval Tumba AB, SE-14780 Tumba Sweden. By reasoned request all relevant technical documentation will be sent by post to national authorities.

• Page 184: Technical Data

  8.2 Technical data 8 Technical reference Technical data Alfa Laval ref. 598392 Rev. 0 Value Unit Subject General technical data: Motor power: 5,5 / 6,4 kW 50Hz/60Hz Jp reduced to motor 5,12 / 3,53 50Hz/60Hz Gear ratio: 50 Hz 283 / 70…

• Page 185: Connection List

  8 Technical reference 8.3 Connection list Connection list Alfa Laval ref. 567321 Rev. 2 Connection Description Requirements/limits Inlet for process liquid — Max. Allowed density 8.2 Technical data on page 184. — Allowed flow Max. 4,5 m³/h — Allowed temperature Min.

• Page 186
  8.3 Connection list 8 Technical reference Connection Description Requirements/limits Motor for separator — Allowed frequency variation ± 5% (momentarily during 5 seconds) ± 10% Speed sensor for bowl spindle 8.4 Interface description on page 187. — Type Inductive proximity switch — Supply voltage, nominal ≤1,2 mA — With sensor activated (near metal)

• Page 187: Interface Description

  8 Technical reference 8.4 Interface description Interface description Alfa Laval ref. 564834 Rev. 3 8.4.1 Scope This document gives information, requirements, and recommendations about operational procedures and signal processing for safe and reliable operation of the separator. It is intended to be used for designing auxiliary equipment and control systems for the separator.

• Page 188: Goal

  8.4 Interface description 8 Technical reference 8.4.4 Goal To eliminate situations that can cause harm, i.e. injury, damage to health or property and unsatisfactory process result are e.g.: Situation Effect Unbalance caused by uneven sediment Too high stress on bowl and bearing system accumulation in the bowl.

• Page 189
  8 Technical reference 8.4 Interface description If above conditions are not fulfilled the separator will be in SERVICE mode. Stand still means: • The power to the separator motor is off • The bowl is not rotating. Starting means: • The power to the separator motor is on.

• Page 190: Remote Start

  8.4 Interface description 8 Technical reference 8.4.6 Remote start This machine may be started from a remote location under the following conditions; • First start after any kind of service or manual cleaning must be supervised locally in order to ensure that no mistakes has been made during assembly.

• Page 191
  8 Technical reference 8.4 Interface description 740 Speed sensor A proximity sensor of inductive type according to Namur standard is giving a number of pulses per revolution of the bowl (see Connection List). Signal processing in STARTING: • The separator should be stopped automatically according to NORMAL STOP procedure and an alarm should be given when the accumulated time for acceleration is longer…
• Page 192
  8.4 Interface description 8 Technical reference Signal processing in RUNNING: • If the speed exceeds “Bowl speed, synchronous” in Technical Data with more than 5% for a period longer than 1 minute or momentarily during maximum 5 seconds more than 10% the separator shall be stopped automatically by NORMAL STOP and a high speed alarm shall be given.
• Page 193
  8 Technical reference 8.4 Interface description The vibration monitor shall include self check function to be performed at least at initiation of STARTING. If vibrations exceed the second alarm level the separator shall be stopped the quickest way possible and it shall not been restarted until the reasons for the unbalance have been found and measures to remove them have been taken.
• Page 194
  8.4 Interface description 8 Technical reference Signal processing in STARTING, RUNNING and CLEANING: • If the circuit is broken the separator should be stopped automatically by NORMAL STOP. This is to minimise the risk of having access to moving parts. Fluid connections Complementary information is given in the document Connection List.
• Page 195
  8 Technical reference 8.4 Interface description 375 Inlet for discharge and make-up liquid Processing in all modes: • It is recommended to supervise the supply pressure. If pressure is too low (see Connection List), start should be interlocked and if it happens in PRODUCTION or CLEANING turn over to STAND BY should take place.

• Page 196: Demand Specification Water

  Alfa Laval accepts no liability for consequences arising from unsatisfactorily purified operating water supplied by the customer. The following conditions must be fulfilled: 1.

• Page 197: Drawings

  8 Technical reference 8.6 Drawings Drawings 8.6.1 Basic size drawing Alfa Laval ref. 574283 Rev. 0 G1028611 A. Tightening torque 160 Nm. B. Maximum horizontal displacement at the inlet and outlet connections during operation ± 5 mm. C. Maximum vertical displacement at the sludge connection during operation ±…

• Page 198: Foundation Drawing

  8.6 Drawings 8 Technical reference 8.6.2 Foundation drawing Alfa Laval ref. 574284 Rev. 1 G1028711 A. Centre of separator bowl. B. Holes for foundation bolts (8x). C. Centre of motor. D. Min. lifting capacity required during service: 300 E. Max. height of largest component incl. lifting tool.

• Page 199: Interconnection Diagram

  8 Technical reference 8.6 Drawings 8.6.3 Interconnection diagram Alfa Laval ref. 561786 Rev. 5 G1019311 Wiring without junction box Wiring of connector “X”: Wire colour codes: Junction box RD=A BK=Black BU=B BN=Brown 740: Speed sensor WT=C BU=Blue 752: Unbalance sensor, (position…

• Page 200: Px Sealing Diagram

  8.6 Drawings 8 Technical reference 8.6.4 PX sealing diagram Alfa Laval ref. 566570 Rev. 0 G08697d1 A. No sealing B. Operational envelope C. Non physical Separator bowl speed: 12129 r/min Separator bowl number: 564214-01 References density for Feed: 1100 kg/m References density for Wet solids: 2327 kg/m Max.

• Page 201: Electric Motor

  8 Technical reference 8.6 Drawings 8.6.5 Electric motor Alfa Laval ref. 9011208 Rev. 4 G10288g1 Manufacturer: ABB Motors Type of mounting Degree of protection Type: M3AA 112 MB2 Poles: IM 2111 IP 55 G0541421 Bearings: D-end 6306-2Z/C3 N-end 6206-2Z/C3 For complete information about motor variants, please contact your Alfa Laval representative.

• Page 202
  8.6 Drawings 8 Technical reference ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe whatsapp:959440045…

• Page 203: Installation

  The installation instructions are specifications, which are compulsory requirements. Any specific requirements from classification societies or other local authorities must be followed. If the specifications are not followed, Alfa Laval can not be held responsible for any malfunctions related to the installation. ventas@fdm.com.pe fdmsac@gmail.com www.fdm.com.pe…

• Page 204: Upon Arrival At The Storage Area

  9.2 Upon arrival at the storage area 9 Installation Upon arrival at the storage area Ensure that the separator delivered is suitable for the application. 9.2.1 Transport When lifting the separator, make sure that tools and lifting devices are fastened securely. See 6.7.1 Lifting the separator on page 171.

• Page 205: Protection And Storage Of Goods

  9 Installation 9.2 Upon arrival at the storage area 9.2.2 Protection and storage of goods The separator must be stored indoors at 5 — 55 °C, if not delivered in a water-resistant box, designated for outdoor storage. G08736B1 If there is a risk for water condensation, the equipment must stand well ventilated and at a temperature above dew point.

• Page 206: Planning Of Installation

  9.3 Planning of installation 9 Installation Planning of installation 9.3.1 Important measurements G0873711 Important measurements are: minimum lifting height for lifting bowl parts shortest distance between driving motor and wall space for control and operation free passage for dismantling and assembly space for maintenance work space on floor for machine parts during maintenance work…

• Page 207: Maintenance Service

  9 Installation 9.3 Planning of installation 9.3.2 Maintenance service G08738N1 A work bench should be installed in the separator room. Hot water, compressed air and diesel oil should be available near the work bench to make maintenance work easier. An overhead hoist with capacity of 300 kg is required for transport of bowl parts to the working bench.

• Page 208: Connections To Surrounding Equipment

  9.3 Planning of installation 9 Installation 9.3.3 Connections to surrounding equipment Local safety regulations If the local safety regulations prescribe that the installation has to be inspected and approved by responsible authorities before the plant is put into service, consult with such authorities before installing the equipment and have the projected plant design approved by them.

• Page 209: Storage At Out Of Operation

  9 Installation 9.5 Before start-up Storage at out of operation If the separator is out of operation for more than 1 month: Lift out the bowl. Protect the spindle taper from corrosion by lubricating it with oil. Keep the separator and bowl well stored, dry and protected from mechanical damage.