Alfalaval MMPX 303SGP-11 User manual

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ALFA LAVAL SEPARATION
MMPX 303SGP-11
Separator Manual
Product No. 881099-01-04
Book No. 1270065-02 V2
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Alfa Laval Separation AB
Separator Manuals, dept. SKL
S-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
Printed in Sweden, 97-03
© Alfa Laval Separation AB 1997
This publication or any part thereof may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Separation AB.
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Contents
3
1 Read this first 7
2 Safety Instructions 9
3 Separator Basics 15
3.1 Basic principles of separation 16
3.2 Design and function 24
3.3 Definitions 32
4 Operating Instructions 33
4.1 Operating routine 34
5 Service Instructions 41
5.1 Periodic maintenance 42
5.2 Maintenance Logs 45
5.3 Check points at Intermediate Service 51
5.4 Check points at Major Service 63
5.5 3-year service 65
5.6 Lifting instructions 66
5.7 Cleaning 68
5.8 Oil change 71
5.9 Vibration 73
5.10 General directions 74
6 Dismantling/Assembly 79
6.1 Inlet/outlet and bowl 81
6.2 Bowl spindle and frame 99
6.3 Friction coupling 110
6.4 Flat belt and tightener 116
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6.5 Oil filling device 121
6.6 Water tank 122
6.7 Frame feet 123
7 Trouble-tracing 125
7.1 Trouble-tracing procedure 126
7.2 MMPX mechanical function 126
7.3 Purification and clarification faults 132
7.4 Purification faults 134
7.5 Clarification faults 136
8 Technical Reference 137
8.1 Technical data 138
8.2 Connection list 141
8.3 Interface description 143
8.4 Water quality 146
8.5 Lubricants 147
8.6 Drawings 156
8.7 Storage and installation 168
Index 179
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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.
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1 Read this first
This manual is designed for operators and service
engineers working with the Alfa Laval separator
MMPX 303SGP-11.
For information concerning the function of the
separator, see chapter ‘‘3 Separator Basics” on
page 15, and chapter ‘‘8 Technical Reference” on
page 137.
If the separator has been delivered and installed
by Alfa Laval as part of a processing system, this
manual is a part of the system documentation. In
this case, study carefully all the instructions in the
system documentation.
In addition to this separator manual a
Spare Parts
Catalogue, SPC is supplied.
This separator manual consists of:
Safety Instructions
Pay special attention to the safety instructions for
the separator. Not following the safety instructions
can cause accidents resulting in damage to
equipment and serious injury to personnel.
Separator Basics
Read this chapter if you are not familiar with this
type of separator. This chapter contains the
technical description and function description.
Operating Instructions
This chapter contains operating instructions for
the separator only.
S0068011
Separator Manual and Spare Parts Catalogue
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1 Read this first
8
Service Instructions
This chapter gives instructions for daily checks,
cleaning, oil changes, servicing and check points.
Dismantling / Assembly
This chapter contains step-by-step instructions for
dismantling and assembly of the separator for
service and repair.
Trouble-tracing
Refer to this chapter if the separator functions
abnormally.
If the separator has been installed as part of a
processing system always refer to the trouble-
tracing part of the system documentation first.
Technical Reference
This chapter contains technical data and
drawings concerning the separator.
Index
This chapter contains an alphabetical list of
subjects, with page references.
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2 Safety Instructions
The centrifugal separator includes parts that
rotate at high speed. This means that:
•Kinetic energy is high
•Great forces are generated
•Stopping time is long
Manufacturing tolerances are extremely fine.
Rotating parts are carefully balanced to reduce
undesired vibrations that can cause a breakdown.
Material properties have been considered
carefully during design to withstand stress and
fatigue.
The separator is designed and supplied for a
specific separation duty (type of liquid, rotational
speed, temperature, density etc.) and must not be
used for any other purpose.
Incorrect operation and maintenance can result in
unbalance due to build-up of sediment, reduction
of material strength, etc., that subsequently could
lead to serious damage and/or injury.
The following basic safety instructions therefore
apply:
•Use the separator only for the purpose
and parameter range specified by
Alfa Laval.
•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.
G0010411
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DANGER
Disintegration hazards
•Use the separator only for the purpose
and parameter range specified by
Alfa Laval.
•If excessive vibration occurs, stop
separator and keep bowl filled with
liquid during rundown.
•When power cables are connected,
always check direction of motor rotation.
If incorrect, vital rotating parts could
unscrew.
•Check that the gear ratio is correct for
power frequency used. If incorrect,
subsequent overspeed may result in a
serious break down.
•Welding or heating of parts that rotate
can seriously affect material strength.
•Wear on bowl and bowl hood threads
must not exceed safety limit. φ-mark on
bowl hood must not pass opposite
φ-mark by more than specified distance.
•Inspect regularly for corrosion and
erosion damage. Inspect frequently if
process liquid is corrosive or erosive.
S0051311S0055611
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2 Safety Instructions
DANGER
Entrapment hazards
•Make sure that rotating parts have come
to a complete standstill before starting
any dismantling work.
•To avoid accidental start, switch off and
lock power supply before starting any
dismantling work.
•Assemble the machine completely
before start. All covers and guards must
be in place.
Electrical hazards
•Follow local regulations for electrical
installation and earthing (grounding).
S0051111
S0051011
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WARNING
Crush hazards
•Use correct lifting tools and follow lifting
instructions.
•Do not work under a hanging load.
Noise hazards
•Use ear protection in noisy
environments.
CAUTION
Burn hazards
•Lubrication oil and various machine
surfaces can be hot and cause burns.
Cut hazards
•Sharp edges on separator bowl discs
and threads can cause cuts.
S0051711S0051611S0055411S0054311
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2 Safety Instructions
Warning signs in the text
Pay attention to the safety instructions in this
manual. Below are definitions of the three grades
of warning signs used in the text where there is a
risk for injury to personnel.
DANGER
Type of hazard
This type of safety instruction indicates a
situation which, if not avoided, could result in
fatal injury or fatal damage to health.
WARNING
Type of hazard
This type of safety instruction indicates a
situation which, if not avoided, could result in
disabling injury or disabling damage to
health.
CAUTION
Type of hazard
This type of safety instruction indicates a
situation which, if not avoided, could result in
light injury or light damage to health.
NOTE
This type of instruction indicates a situation
which, if not avoided, could result in damage
to the equipment.
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3 Separator Basics
Contents
3.1 Basic principles of separation 16
3.1.1 Factors influencing the separation
result 17
3.1.2 Purification 20
3.1.3 Clarification (optional) 22
3.2 Design and function 24
3.2.1 Application 24
3.2.2 Design 25
3.2.3 Outline of function 25
3.2.4 Separating function 26
3.2.5 Sludge discharge function 28
3.2.6 Power transmission 30
3.2.7 Sensors and indicators 31
3.3 Definitions 32
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3.1 Basic principles of separation 3 Separator Basics
16
3.1 Basic principles of
separation
The purpose of separation can be:
•to free a liquid of solid particles,
•to separate two mutually insoluble liquids with
different densities while removing any solids
presents at the same time,
•to separate and concentrate solid particles
from a liquid.
Separation by gravity
A liquid mixture in a stationary bowl will clear
slowly as the heavy particles in the liquid mixture
sink to the bottom under the influence of gravity.
A lighter liquid rises while a heavier liquid and
solids sink.
Continuous separation and sedimentation can be
achieved in a settling tank having outlets
arranged according to the difference in density of
the liquids.
Heavier particles in the liquid mixture will settle
and form a sediment layer on the tank bottom.
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.
The separation efficiency is influenced by
changes in the viscosity (separating temperature)
and in the throughput.
G0010711
Sedimentation by gravity
G0010811
Sedimentation in a settling tank, with outlets making it
possible to separate the lighter liquid parts from the
heavier
G0010911
The centrifugal solution
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3 Separator Basics 3.1 Basic principles of separation
3.1.1 Factors influencing the
separation result
Separating temperatures
For some types of process liquids (e.g. mineral
oils) a high separating temperature will normally
increase the separation capacity. The
temperature influences oil viscosity and density
and should be kept constant throughout the
separation.
Viscosity
Low viscosity facilitates separation. Viscosity can
be reduced by heating.
Density difference
The greater the density difference between the
two liquids, the easier the separation. The density
difference can be increased by heating.
G0011011
High viscosity (with low temperature)
G0011111
Low viscosity (with high temperature)
G0011211
High density (with low temperature)
G0011311
Low density (with high temperature)
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3.1 Basic principles of separation 3 Separator Basics
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Phase proportions
An increased quantity of water in a oil will
influence the separating result through the
optimum transporting capacity of the disc stack.
An increased water content in the oil can be
compensated for by reducing the throughput in
order to restore the optimum separating
efficiency.
Size and shape of particles
The round and smooth particle (A) is more easily
separated out than the irregular one (B).
Rough treatment, for instance in pumps, may
cause a splitting of the particles resulting in
slower separation. Larger particles (1) are more
easily separated than smaller ones (2) even if
they have the same density.
The throughput
The throughput sets the time allowed for the
separation of water and sediment from the oil. A
better separation result can often be achieved by
reducing the throughput, i.e. by increasing the
settling time.
Sludge space - sludge content
The sediment accumulates along the bowl wall. If
the sludge is allowed to fill up the space outside
the discs the flow in the bowl is influenced, and
the separating efficiency is reduced. In such
cases the time between discharge of sediment
should be reduced to prevent this effect.
Disc stack
A neglected disc stack containing deformed discs
or discs coated with deposits will impair the
separating result.
Gravity disc
The position of the interface is adjusted by
altering the outlet diameter of the heavy liquid
phase, that is by exchanging the gravity disc.
2 1
A
B
m³/h
µm
G0613311
Influence of size and shape
G0601211
Sludge accumulation
S0068611
Gravity disc diameter sets the oil/water interface
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3 Separator Basics 3.1 Basic principles of separation
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3.1 Basic principles of separation 3 Separator Basics
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3.1.2 Purification
Centrifugal force Bowl parts
Process liquid D1Diameter of inner outlet.
Heavy liquid phase D2Hole diameter of gravity disc.
Light liquid phase D3Diameter of interface.
Sediment (solids)
D
1
D
2
D
3
G0503731
D
1
D
2
D
3
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