Alfalaval AFPX 617XGV-14/74CG User manual

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Alfa Laval Tumba AB
Separator Manuals, dept. PPDM
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
Printed in Sweden, 01-04
© Alfa Laval Tumba AB 2001
This publication or any part thereof may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.

Contents
3
1 Safety Instructions 9
2 Maintenance Directions 15
2.1 Periodic maintenance 15
2.1.1 Introduction 15
2.1.2 Maintenance intervals 15
2.1.3 Maintenance procedure 17
2.1.4 Service kits 18
2.2 Maintenance Logs 19
2.2.1 Daily checks 19
2.2.2 Lubrication of electric motor 19
2.2.3 Oil change 19
2.2.4 Intermediate Service (IS) 20
2.2.5 Major Service (MS) 22
2.2.6 3-year Service (3S) 24
2.3 Cleaning 26
2.3.1 Cleaning agents 26
2.3.2 Cleaning of bowl discs 27
2.3.3 External cleaning 28
2.4 When changing oil 29
2.4.1 Worm wheel and worm; wear of teeth 29
2.4.2 Oil change procedure 32
2.5 Lubricants 33
2.5.1 Lubrication chart, general 33
2.5.2 Recommended lubricating oils 35
2.5.3 Recommended oil brands 36
2.5.4 Recommended lubricants 37
2.6 Vibration 40
2.6.1 Vibration analysis 40
2.7 Common maintenance directions 41
2.7.1 Ball and roller bearings 41
2.7.2 Before shutdowns 45

4
3 Dismantling/Assembly 47
3.1 Introduction 47
3.1.1 General directions 47
3.1.2 References to check points 48
3.1.3 Tools 48
3.1.4 Tightening of screws 49
3.2 Intermediate Service (IS), dismantling 50
3.2.1 Inlet/outlet, frame hood 50
3.2.2 Bowl hood and disc stack 52
3.2.3 Bowl body and operating mechanism 58
3.2.4 Operating liquid device 62
3.3 Intermediate Service (IS), check points 65
3.3.1 Introduction 65
3.3.2 Corrosion 65
3.3.3 Cracks 67
3.3.4 Erosion and wear linings 68
3.3.5 Guide surfaces 72
3.3.6 Bowl hood seal ring 74
3.3.7 Bowl spindle taper and bowl body nave
taper 75
3.3.8 Lock ring; wear and damage 76
3.3.9 Operating mechanism 78
3.3.10 Sliding bowl bottom 79
3.3.11 Springs for operating mechanism 79
3.3.12 Valve plugs 80
3.3.13 Worm wheel and worm; wear of teeth 80
3.3.14 Inlet pipe and outlet paring disc 80
3.3.15 Vibration sensor 81
3.3.16 Speed sensor 81
3.3.17 Cover interlocking switch (option) 82
3.4 Intermediate Service (IS), assembly 83
3.4.1 Introduction 83
3.4.2 Lubrication 83
3.4.3 Operating liquid device 84
3.4.4 Bowl body and operating mechanism 86

5
3.4.5 Bowl hood and disc stack 92
3.4.6 Inlet/outlet, frame hood 101
3.5 Major Service (MS), dismantling 102
3.5.1 Introduction 102
3.5.2 Vertical driving device 104
3.5.3 Horizontal driving device 115
3.6 Major Service (MS), check points 120
3.6.1 Introduction 120
3.6.2 Lock ring; priming 120
3.6.3 Brake 122
3.7 Major Service (MS), assembly 124
3.7.1 Introduction 124
3.7.2 Horizontal driving device 125
3.7.3 Vertical driving device 130
3.8 Operating water module compact (OWMC) 142
3.8.1 Exploded view 142
3.8.2 Dismantling (MS service) 144
3.8.3 Check points 145
3.8.4 Assembly (MS service) 146
3.8.5 Air tank 146
Index 151

6

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.

8

9
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
10
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

11
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
12
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

13
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
14

15
2 Maintenance Directions
2.1 Periodic maintenance
2.1.1 Introduction
Periodic (preventive) maintenance reduces the
risk of unexpected stoppages and breakdowns.
Follow the maintenance logs on the following
pages in order to facilitate the periodic
maintenance.
2.1.2 Maintenance intervals
The following directions for periodic maintenance
give a brief description of which parts to be
cleaned, checked and renewed at different
maintenance intervals.
The maintenance logs for each maintenance
interval later in this chapter give detailed
enumeration of the check points that must be
done.
Daily checks consist of minor check points to
carry out for detecting abnormal operating
conditions.
Oil change
The oil change interval is every 1000-1500 hours
or at least once every year if the total number of
operating hours is less than 1000-1500 hours.
DANGER
Disintegration hazards
Separator parts that are either worn beyond
their safe limits or incorrectly assembled may
cause severe damage or fatal injury.

2.1 Periodic maintenance 2 Maintenance Directions
16
Intermediate Service (IS)
Intermediate Service consists of an overhaul of
the separator bowl, inlet/outlet and operating
liquid device every 3 months or 2000 operating
hours. Seals in bowl and gaskets in inlet and
outlet devices are renewed.
Major Service (MS)
Major Service consists of an overhaul of the
complete separator and includes an Intermediate
Service every 12 months or 8000 operating
hours. Seals and bearings in the bottom part are
renewed.
3-year Service (3S)
3-year Service consists of renewing the frame
feet. The feet get harder with increased use and
age.
2nd year
Oil change
Intermediate Service = IS
Major Service = MS
Periodic maintenance schedule
Installation 1st year
MS MS
3rd year
MS
IS IS IS IS IS IS IS IS IS IS IS IS
3-year Service = 3S
3S

17
2 Maintenance Directions 2.1 Periodic maintenance
2.1.3 Maintenance procedure
At each Intermediate and Major Service, take a
copy of the maintenance log and use it for
notations during the service.
The Intermediate and Major Services should be
carried out in the following manner:
1. Dismantle the parts as mentioned in the
maintenance log and described in chapter ‘‘3
Dismantling/Assembly” on page 47.
Place the separator parts on clean, soft
surfaces such as pallets.
2. Inspect and clean the dismantled separator
parts according to the maintenance log.
3. Fit all the parts delivered in the service kit
while assembling the separator.

2.1 Periodic maintenance 2 Maintenance Directions
18
2.1.4 Service kits
Special kits of spares are available for the
periodical maintenance. These kits are designed
in accordance with the centrifuge maintenance
schedule as follows:
•IS; Intermediate service kit
•MS; Major service kit
•FS; Foundation service kit
A service kit is available also for servicing the
operating water module (OWMC).
For other services the spare parts have to be
ordered separately.
Note that the parts for IS are not included in the
MS kit.
The contents of the service kits are described in
the
Spare Parts Catalogue .
NOTE
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 if non-genuine
spare parts are used.
DANGER
Disintegration hazards
Use of imitation parts may cause severe
damage.
G0200911
Kits are available for Intermediate Service, Major
Service and for servicing the frame feet, but also for
OWMC

19
2 Maintenance Directions 2.2 Maintenance Logs
2.2 Maintenance Logs
2.2.1 Daily checks
The necessary daily checks to be carried out for a
safe operation are enumerated in chapter
Running in the Operator´s Manual .
2.2.2 Lubrication of electric motor
The bearings of the electric motor shall be
greased with intervals that is dependent of the
motor speed (50 or 60 Hz), ambient temperature
and if the bearing is located on the driving end or
non-driving end.
The recommended interval varies from 5500 up to
12000 operating hours.
Correct lubrication interval and recommended
type of grease can be found on a plate fixed on
the motor. The information can also be found in
chapter
Motor specifications in the Installation
Manual .
2.2.3 Oil change
The oilchange and check of worm gear should be
carried out every 1000-1500 hours of operation.
Note: In a new installation, or after replacement
of gear, change the oil after 200 operating hours
and clean the gear housing.
When the separator is running for short periods, the
lubricating oil must be changed every12 months even
if the total number of operating hours is less than
1000-1500 hours.
a) See chapter ‘‘2.5 Lubricants” on page 33 for
further information.
Main component and activity Part Page Notes
Horizontal driving device
Worm wheel shaft and gear housing
Check Worm wheel and worm 29
Renew Oila) in gear housing 32

2.2 Maintenance Logs 2 Maintenance Directions
20
2.2.4 Intermediate Service (IS)
Name of plant: Local identification:
Separator: AFPX 617XGV-14/74CG Manufacture No./Year:
Total running hours: Product No: 881218-01-01
Date: Signature:
Main component and activity Part Page Notes
Inlet and outlet
Clean and inspect Outlet housing –
Threads of inlet pipe and
paring disc 80
Renew O-rings, rectangular ring and
seal ring(s) –
Separator bowl
Clean and check Lock ring 74
Bowl hood 74
Top disc –
Bowl discs 27
Distributor –
Distributing cone –
Sliding bowl bottom 79
Bowl body –
Guide surfaces 72
Bowl spindle cone and bowl
body nave 75
Operating mechanism 78, 84
Check Corrosion 65
Cracks 67
Erosion 68
Galling of guide surface 73
Disc stack pressure 97
Renew O-rings and sealings –