Alfalaval AFPX 517XGV-14CG User manual

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Alfa Laval Separation AB
Separator Manuals, dept. SKEL
S-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
Printed in Sweden, 99-01
© Alfa Laval Separation AB 1999
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.

Contents
1
1 Safety Instructions 5
2 Separator Basics 11
2.1 Basic principles of separation 12
2.2 Mechanical function 14
2.3 Separating function 19
2.4 Sediment discharge function 21
2.5 Factors influencing the separating result 24
2.6 Interval between sediment ejections 26
2.7 Bowl cleaning (washing) 27
2.8 Definitions 28
3 Operating Instructions 29
3.1 Operating routine 30
4 Maintenance Directions 37
4.1 Periodic maintenance 38
4.2 Maintenance Logs 41
4.3 Check points at Intermediate Service (IS) 48
4.4 Lifting instruction 68
4.5 Cleaning 69
4.6 When changing oil 72
4.7 Vibration 76
4.8 Common maintenance directions 77

2
5Dismantling – Assembly 81
5.1 Introduction 82
5.2 Machine top part 84
5.3 Inlet / Outlet 86
5.4 Separator bowl 90
5.5 Paring disc device for operating water 107
5.6 Operating water module (OWM) 112
5.7 Frame parts 115
5.8 Vertical driving device 117
5.9 Horizontal driving device 135
5.10 Remote controlled brake (pneumatic) 144
5.11 Worm wheel guard
(with revolution counter) 146
5.12 Parts for mounting of motor and
foundation feet 147
6 Trouble-tracing 151
6.1 Introduction 152
6.2 Mechanical functions 152
6.3 Separating functions 155
7 Technical Reference 161
7.1 Technical data 162
7.2 Basic size drawing 166
7.3 Connection list 168
7.4 Interface description 172
7.5 Quality requirements 178
7.6 Lubricants 180
7.7 Foundation drawing 186
7.8 Motor data 188
7.9 Machine plates and safety labels 190
7.10 Interconnection diagram for monitoring kit 192
7.11 Storage and installation 193

3
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.

4

5
1 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

1 Safety Instructions
6
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 the large lock ring thread must
not exceed safety limit. φ-mark on lock
ring 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.
S0051311
S0055611

7
1 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).
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.
S0051111S0051011
S0051711
S0051611

1 Safety Instructions
8
CAUTION
Burn hazards
•Lubrication oil and various machine
surfaces can be hot and cause burns.
Cut hazards
•Sharp edges on separator discs and lock
ring threads can cause cuts.
S0055411S0054311

9
1 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.

1 Safety Instructions
10

11
2 Separator Basics
Contents
2.1 Basic principles of separation 12
2.1.1 Introduction 12
2.1.2 Separation by gravity 12
2.1.3 Centrifugal separation 12
2.1.4 Separating temperatures 13
2.2 Mechanical function 14
2.2.1 Bowl 14
2.2.2 Power transmission 16
2.2.3 Motor and starter 18
2.3 Separating function 19
2.3.1 Normal separation 19
2.4 Sediment discharge function 21
2.4.1 General information 21
2.4.2 Operating water system 22
2.5 Factors influencing the
separating result 24
2.5.1 Viscosity and density 24
2.5.2 Size and shape of particles 24
2.5.3 Phase proportions 24
2.5.4 Optimum output 24
2.5.5 Properties of the sediment 24
2.5.6 Disc stack 25
2.5.7 Back pressure regulation 25
2.5.8 Gravity disc
(for purifier /concentrator) 25
2.5.9 Sediment ejection 25
2.6 Interval between sediment
ejections 26
2.7 Bowl cleaning (washing) 27
2.7.1 Introduction 27
2.7.2 Check on cleaning 27
2.8 Definitions 28

2.1 Basic principles of separation 2 Separator Basics
12
2.1 Basic principles of
separation
2.1.1 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.
2.1.2 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.
2.1.3 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

13
2 Separator Basics 2.1 Basic principles of separation
2.1.4 Separating temperatures
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)

2.2 Mechanical function 2 Separator Basics
14
2.2 Mechanical function
2.2.1 Bowl
G0737641
Purifier bowl

15
2 Separator Basics 2.2 Mechanical function
The bowl body (14) and the bowl hood (6) which
make up the casing of the bowl are held together
by the large lock ring (5).
Housed in the bowl are the distributor (9), the
distirbuting cone (11) and the disc set (8), where
the separation takes place. Uppermost in the disc
set is the top disc (7).
Replacement of certain parts necessitates
rebalancing of the bowl.
1. Lock ring, small
(left-hand threaded)
2. Paring chamber cover
3. Paring disc for heavy phase
4. Gravity disc
5. Lock ring, large
(left-hand threaded)
6. Bowl hood
7. Top disc
8. Bowl discs
9. Distributor
10. Cap nut (left-hand threaded)
11. Distributing cone
12. Lining (erosion protection)
13. Sliding bowl bottom*
14. Bowl body
14a. Sediment port*
15. Draining nozzle (3 pcs) for
operating water*
16. Operating slide*
17. Sleeve with wings (conveyor)*
18. Spring support with springs*
The parts by which the sediment ejections are effected are marked with an
asterisk (*) in the list above.
G0708511

2.2 Mechanical function 2 Separator Basics
16
2.2.2 Power transmission
1. Electric motor (Note! Special motor with built-in
thermistors, used for separators with flexible coupling)
2. Flexible coupling
3. Worm wheel shaft
4. Top bearing
5. Bowl spindle
6. Worm
7. Worm wheel
8. Cooling coil for oil
bath
9. Cooling water inlet/
outlet for coil
}
Worm gear
10. Box for electric and thermistor
connections
G0567641

17
2 Separator Basics 2.2 Mechanical function
The motor (1) rotates the bowl through the
coupling (2) and the worm gear (6, 7). The worm
gear serves to adept the bowl speed to the motor
speed. The number of revolutions of the bowl is a
few times higher than that of the motor.
The bearings on the bowl spindle (5) and the
worm wheel shaft (3) are lubricated by the oil mist
produced by the worm wheel (7), which dips into
the oil bath in the worm gear housing.
The worm gear has been specially designed to
operate at a low sound level.
To keep the oil temperature low, a cooling coil is
installed in the worm gear housing for some
machines.
The oil is cooled by the water flowing though the
coil (8).

2.2 Mechanical function 2 Separator Basics
18
2.2.3 Motor and starter
This separator has a flexible coupling and for this
reason the motor must be able to endure long
run-up times.
The motor supplied with the separator has some
extra features compared with a standard three
phase motor with the same kW rating. It has a
higher class of insulation, a higher rotor
resistance and larger iron masses. These
features counteract the temperature rise in the
motor when starting. Furthermore, the motor is
provided with thermal sensors in the form of
thermistors in the stator windings. The
thermistors must be connected to a special
tripping device in the starter.
These motors have been designed by Alfa Laval
as “Control-torque motors” - abbreviated to
CT motors
.
The overload protection (e.g. in the form of
bimetal relays) in the starter must be connected
into the D circuit. The protection must be
inoperative during the run-up period.
Notice that the sediment discharge process will
produce an increase in current consumption.
1. Thermistors Run-up period: Y-connected
Operation: D-connected
G0665121