Alfalaval S946 User guide

System Manual - English
S 946 Flex Separation Module
System Manual
English
S 946 Flex Separation Module
1
MAN Diesel & Turbo
MANAGUA
Order No.: 4500968861
Al Order No.: 84.6893.31
MAN Material: 11.63010-0244
MAN Diesel & Turbo MANAGUA
Order No.: 4500968861 Al Order No.: 84.6893.31

Process Data Sheets
1
Safety
2
S and P Flex Separation
System Description
3
Operating Instructions
4
Parameter List
5
Alarms and Fault
Finding
6
Installation System
Reference
7
Marine & Diesel Equipment
Separator Manual
With Spare Parts Catalogue
8
Printed June 2008
Document No. 587876-02
Configuration No. 108918-25
MAN Diesel & Turbo
MANAGUA
Order No.: 4500968861
Al Order No. 84.6893.31
S 946 Flex Separation Module
Anncillary Components
With Spare Parts Catalogue
9
ANNEX
10
2

MAN Diesel & Turbo SE
D-86224 Augsburg
Process data
Lubeoil Separator type S946
Delivery as Flex Modules
Order Managua
December 16th, 2014
3

General
ALCAPTM-System
●ALCAPTM was specially developed for cleaning of heavy fuel oils
●Max. density of the oils to be cleaned 1.010 kg/m³ at 15 °C
●Combination of purifier and clarifier within one machine, thus no more series arrangement of a
purifier followed by a clarifier necessary
●Continuous supervision of changes in water content in the clean oil outlet
●Measuring principle independent from the conductivity of the separated water
Separators of the S type 921 to 987 series
●Self cleaning ALCAPTM separators
●EPC 60 –control unit with multilingual clear text messages (English, German, French, Spanish,
Portuguese, Finnish,)
●Discharge without pressure pulse and remarkably reduced sludge tank load due to
CentriShootTM discharge system
●Maintenance free and easy to handle CentriLockTM bowl lock function
4

Process conditions
treated Oil
Lube Oil
viscosity
84 cSt/50°C
density
895 kg /m3 at 15°C
feed temperature
min. 50°C
separation temperature
95°C at normal conditions
max. effective capacity
5.000 l/h
colour
C3, RAL 9002
Separator
type
S946
quantity
1
separation principle
ALCAP
discharge system
centrishoot
clean oil discharge pressure
3.0 bar
electric motor, IE2
11,0 kW
sludge production (without water and solids), 1h discharge
153
Pump
working principle
screw pump
type
ALP 0075
quantity
1 per separator
pump capacity
5.090 l/h,
suction height
4,4 m
delivery height
approx. 2 bar
speed
1.700 1/min
electric motor, IE2
2,0 kW
Steam heater
type
CBM 30-40
quantity
1 per separator
steam pressure, temperature of the system
9 bar / 175°C
design steam pressure, temperature heater
6 bar / 164°C
pressure drop steam, oil
0,03 bar / 0,36 bar
oil temperature
50 --> 95°C
steam consumption
197 kg/h
duty margin
38%
max. operation pressure / temperature
16 bar, 225°C
Enviromental conditions
ambient temperature
max. 55°C
humidity
95 RH
altitude
max. 1.500m for 95°C separation temperature
installation of equipment
indoor
5

Electrical supply
voltage / frequency
440 V, 60 Hz
control voltage
230 V
valve operating voltage
24 V
Operating water
Hardness
< 180 g Ca CO3, 10° dH
chloride ions
<100 ppm NaCl
pH- value
6,5 - 9
suspended matter
max 10 ppm
particle size
max. 50 m
feed temperature
between +5 and 55°C
feed pressure
between 2 and 8 bar
required capacity of water
min. flowrate 11 l per minute
average water consumption per discharge
6,4 liter
Compressed air
feed pressure
between 5 and 8 bar
average air consumption
1,01 Nm3/h
Adjustments and set points
01MJV22 CT960 temperature transmitter
01MJV22 CT960 temperature alarm low
90°C
01MJV22 CT960 temperature alarm high
100°C
01MJV22 CP980 pressure transmitter clean oil discharge
01MJV22 CP980 pressure clean oil discharge alarms
high: 3,0 bar / low: 1,2 bar
6

ABB Motors Technical Data Sheet - DOL
and Generators
Project Location
Department/Author Customer name Customer ref. Item name
3GAA131315-KDEAL1
Our ref. Rev/Changed by Date of issue Saving ident Pages
A31-10-2011
No. Definition Data Unit Remarks
1Product TEFC, 3-phase, squirrel cage induction motor
2Product code 3GAA131315-KDEAL1
3Type/Frame M3AA 132 SMB 2
4Mounting IM2111
5Rated output PN9,5 kW
6Service factor 1
7Type of duty S1(IEC) 100%
8Rated voltage UN460 VD ± 5 % (IEC 60034-1)
9Rated frequency fN60 Hz ± 2 % (IEC 60034-1)
10 Rated speed nN3510 r/min
11 Rated current IN17,5 A
12 No-load current 4,6 A
13 Starting current Is/IN8,5 Fullfilled IEC 60034-12 des. N,H
14 Nominal torque TN30 Nm
15 Locked rotor torque TS/TN2,5
16 Maximum torque Tmax/TN4
17 Minimum torque Tmin/TN2,5
18 Speed at minimum torque 0r/min
Load characteristics (IEC 60034-2-1:2007) Load % Current A Efficiency % Power factor
19 PLL determined from residual loss 100 17,0 90,9 / IE2 0,93
20 75 13,1 91,5 0,9
21 50 9,4 91,2 0,84
22 Start 145 0,5
23 Maximum starting time from hot 15 s
24 Maximum starting time from cold 27 s
25 Insulation class / Temperature class F / B
26 Ambient temperature 55 °C
27 Altitude 1000 m.a.s.l.
28 Enclosure IP55
29 Cooling system IC411 self ventilated
30 Bearing DE/NDE 6308-2Z/C3 - 6208-2Z/C3
31 Type of Grease
32 Sound pressure level (LP dB(A) 1m) 68 dB(A) at load
33 Moment of inertia J = ¼ GD2 0,01865 kg-m2
34 Balancing
35 Vibration class
36 Position of terminal box Top
37 Terminal box entries; no, dimens.
38 Number of power terminals
39 Direction of rotation CW or CCW
40 Weight of rotor 13 kg
41 Total weight of motor 77 kg
42 Dimension drawing no.
43
44
45
Ex-motors
46
47
48
Option Variant Codes / Definition
49 Rating plate
50 VHz kW RPM CosPh A
51 380-420D 50 9,5 2915 0,91 17,5
52 660-690Y 50 9,5 2915 0,91 10,1
53 440-480D 60 9,5 3510 0,91 17,5
54
55
Remarks:
Data based on situation 13-11-2010
All data subject to tolerances in accordance with IEC
Guaranteed values on request
7

ABB Motors Technical Data Sheet - DOL
and Generators
Project Location
Department/Author Customer name Customer ref. Item name
1,00001
Our ref. Rev/Changed by Date of issue Saving ident Pages
A21.11.2012 untitled.xls 1(3)
No. Definition Data Unit Remarks
1Product TEFC, 3-phase, squirrel cage induction motor
2Product code 3GAA 102 213-BSE
3Type/Frame M2AA 100 LC 4
4Mounting IM3001, B5(flange)
5Rated output PN2,2 kW
6Service factor 1
7Type of duty S1(IEC) 100%
8Rated voltage UN460 VY ± 5 % (IEC 60034-1)
9Rated frequency fN60 Hz ± 2 % (IEC 60034-1)
10 Rated speed nN1760 r/min
11 Rated current IN4,2 A
12 No-load current 2,5 A
13 Starting current Is/IN9,1 Fullfilled IEC 60034-12 design N,H
14 Nominal torque TN11,9 Nm
15 Locked rotor torque TS/TN3,4
16 Maximum torque Tmax/TN4,5
17 Minimum torque Tmin/TN3,4
18 Speed at minimum torque 0r/min
Load characteristics (IEC 60034-2-1:2007) Load % Current A Efficiency % Power factor
19 PLL determined from residual loss 100 4,2 87,6 / IE2 0,75
20 75 3,5 87 0,67
21 50 3,0 84,3 0,54
22 Start 38 0,58
23 Maximum starting time from hot 15 s
24 Maximum starting time from cold 27 s
25 Insulation class / Temperature class F / B
26 Ambient temperature 40 °C
27 Altitude 1000 m.a.s.l.
28 Enclosure IP55
29 Cooling system IC411 self ventilated
30 Bearing DE/NDE 6306-2Z/C3 - 6205-2Z/C3
31 Type of Grease
32 Sound pressure level (LP dB(A) 1m) 57 dB(A) at load
33 Moment of inertia J = ¼ GD2 0,009 kg-m2
34 Balancing
35 Vibration class
36 Position of terminal box Top
37 Terminal box entries; no, dimens.
38 Number of power terminals
39 Direction of rotation CW or CCW
40 Weight of rotor 8kg
41 Total weight of motor 25 kg
42 Dimension drawing no.
43
44
45
Ex-motors
46
47
48
Option Variant Codes / Definition
49
50
51
52
53
54
55
Remarks:
Data based on situation 2012-04-10
All data subject to tolerances in accordance with IEC
Guaranteed values on request
8

position no.:
Betriebsdaten 1 Betriebsdaten 2
operating data 1 operating data 2
medium
series (3S / ALP)
ALP ALP
size
75 75
suction pressure bar 0,0 0,0
total pressure bar 2,0 2,0
difference pressure bar
2,0 2,0
viscosity mm²/s 84 54
revolution 1/min 1700 1700
temperature °C 50 60
20
capacity l/h 5134,1 5096,2
m³/h 5,13 5,10
power requirement kW 0,77 0,70
min. suction pressure (abs.) mWs / mWC 5,94 6,05
NPSH required mWs / mWC 2,25 2,14
noise level pump dB (A) 57,1 57,1
torque Nm 4,3 4
efficiency (total) %37,1 40,2
efficiency (volumetric) %97,1 96,4
axial velocity m/s 2,0 2,0
moment of inertia kgm2 0,0001645 0,0001645
capacity
subject to change (04/2013)
&ND&Field1051744:VI&Field1051745:Auslegung&Field64:20.09.2012&Field1051747:148414&Field1056706:0010&Field1:gasc
17. Dezember 2014
Version: 14.4.1 COPY RIGHT by KRAL
Three-screw Pump Sizing
performance data
power required
Lube Oil
starting torque
www.alfalaval.com, E-mail: [e-mail]
Alfa Laval Kolding A/S, P O Box 802, 6000 Kolding, Denmark; Tel.: [phone]
0
0,2
0,4
0,6
0,8
1
0 0,5 1 1,5 2 2,5
0
10
20
30
40
50
60
70
80
90
100
0 0,5 1 1,5 2 2,5
0,0
1,0
2,0
3,0
4,0
5,0
0 500 1000 1500 2000
operating data 1
operating data 2
pressure (bar)
revolution (1/min)
pressure (bar)
torque (Nm)
power requirement (kW)
capcity (l/min)
project no.:
1
1
9

10

S and P Flex Separation
Safety
Printed
Book No.
Feb 2008
584610-02 V 1
11

Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2008.
12

584610-02 1
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS
1 Safety Instructions
1.1 Key Factors for Safe
Operation
The separation system is designed and supplied
for a specific function (type of liquid, rotational
speed, temperature, density, etc.). The system
must be used for this function only, and strictly
within Alfa Laval´s specifications.
Incorrect operation or maintenance may result
in a heavy unbalance, reduction of material
strength, etc. that could lead to serious
breakdown with fatal injury or damage to
property.
For safe operation, strictly follow the
instructions for installation, operation and
maintenance in this manual.
Important – read this!
The centrifugal separator includes parts
that rotate at very high speeds, generating
huge forces. It is therefore essential for the
safe operation of this separator system that
you read and understand this manual,
including the warning signs and safety
precautions presented in this manual.
Failure to do so may cause a fatal accident.
P003702A
P003623A
13

1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY
2584610-02
The following is compulsory for safe
operation:
1Never start up a separator before the bowl is
completely assembled, and all fastenings
securely tightened.
2Never discharge a vibrating separator. Always
stop with the emergency stop button.
3Never begin to disassemble a separator
before it has come to a complete standstill.
4Always set the discharge intervals according
to instructions in the instruction book.
5Never ignore alarms. Always eliminate the
cause before resuming operation.
6Never use the separator for other liquids than
those specified by Alfa Laval.
7Never operate a separator with a different
power supply frequency than stated on the
machine plate.
8Clean the operating system regularly to avoid
sludge discharge malfunction.
9Ensure that personnel are fully trained and
competent in installation, operation,
maintenance, and emergency procedures.
10 Use only Alfa Laval genuine spare parts and
the special tools supplied.
14

584610-02 3
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS
1.2 Warning Sign
Definitions
Below are definitions of the warning signs used.
Danger – serious injury or death
This type of safety sign or instruction
indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
Example:
DANGER
!
Entrapment hazard
Make sure that rotating parts have come to a
complete standstill before starting any
dismantling work.
Warning – serious injury or death
This type of safety sign or instruction indicates
a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Example:
WARNING
!
Disintegration hazard
If unusually strong vibration occurs, press the
Emergency Stop button and leave the room.
Do not enter the room after an emergency stop
while the separator is still rotating.
Caution – minor or moderate injury
This type of safety sign or instruction indicates
a situation which, if not avoided, could result in
minor or moderate injury.
‘CAUTION’ used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
equipment damage.
Example:
CAUTION
!
Burn hazard
Various machine surfaces can be hot and cause
burns.
15

1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY
4584610-02
1.3 Summary of Safety
Hazards
Below follows a selection of the warnings which
have been used in the text of this instruction
manual to ensure safe installation, start-up,
operation, stop, and maintenance. Further
warnings are to be found in the appropriate
places throughout the manual.
Start-up
Check that the separator is correctly assembled
and connected to power supply of correct voltage
and frequency. The control panel must be ON.
Be specially observant during start-up. If there
is any abnormal vibration, immediately stop the
separator and investigate the cause. Clean the
bowl if it contains sediment.
WARNING
!
Breakdown hazard
Assemble the separator completely before start. All
couplings, covers, and guards must be in place and
properly tightened. Failure to do so may lead to
breakdown.
WARNING
!
Electrical hazard
Follow local regulations for electrical installation and
earthing (grounding).
WARNING
!
Breakdown hazard
Check that the power frequency is in agreement with
the machine plate. If incorrect, resulting overspeed
may cause breakdown.
X024761A
P003606A
50 Hz?
60 Hz?
16

584610-02 5
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS
WARNING
!
Use the separation system for the purpose, and within
the limits, specified by Alfa Laval. Failure to do so
could cause a violent breakdown.
CAUTION
!
If power cable polarity has been reversed, the
separator will rotate in reverse, and vital rotating
parts can loosen.
CAUTION
!
Check the oil level before start. Top up when
necessary. Do not overfill.
17

1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY
6584610-02
Operation
WARNING
!
Excessive vibration
If vibration increases, or continues at full speed,
keep bowl filled and stop the separator.
The cause of the vibration must be determined and
corrected before starting again!
Excessive vibration may be due to incorrect
assembly or insufficient cleaning of the bowl.
WARNING
!
Breakdown hazard
If strong vibration occurs, press the emergency
stop button and evacuate the room.
Never discharge a vibrating separator. Vibration
may then become violent and result in breakdown.
WARNING
!
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.
WARNING
!
Burning hazard
Lubricating oil and various machine surfaces can be
hot and cause burns.
WARNING
!
Noise hazard
Use ear protection if noise levels are high.
P003606A
18

584610-02 7
S AND P FLEX SEPARATION SAFETY 1 SAFETY INSTRUCTIONS
WARNING
!
Breakdown hazard
Never reset an alarm without first finding and
remedying the cause.
WARNING
!
Disintegration hazard
Do not discharge a vibrating separator. Vibration
can increase if solidified sludge is only partially
discharged.
CAUTION
!
Burn hazard
Avoid contact with hot surfaces. Process pipes,
various machine surfaces, and processed liquid
can be hot and cause burns.
CAUTION
!
Slip hazard
Check all connections for leakage.
Oil leakage may make the floor slippery.
If speed or starting power is not correct:
WARNING
!
Stop and change the belt transmission to suit the
power supply frequency.
X023716A
19

1 SAFETY INSTRUCTIONS S AND P FLEX SEPARATION SAFETY
8584610-02
Stop
CAUTION
!
Breakdown hazard
Stop the separator by means of the control unit, and
not by turning off the motor.
Never attempt to clean the bowl by manual discharge
in connection with stop.
Emergency stop
WARNING
!
Disintegration hazard
If unusually strong vibration occurs, press the
Emergency Stop button and leave the room
Do not enter the room after an emergency stop
while the separator is still rotating.
WARNING
!
Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the
emergency.
Make sure that the bowl is clean before restart.
X024579A
20