Alfalaval FOPX 609TFD-24 User manual

ALFA LAVAL SEPARATION
FOPX 609TFD-24
Separator Manual
Product No. 881244-02-03
Book No. 1270843-02 V1

Alfa Laval Separation AB
Separator Manuals, dept. SKL
S-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
Printed in Sweden, 97-08
© 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.

Contents
3
1 Read this first 7
2 Safety Instructions 9
3 Separator Basics 15
3.1 Basic principles of separation 17
3.2 Design and function 19
3.3 Definitions 29
4 Operating Instructions 31
4.1 Operating routine 32
5 Service Instructions 37
5.1 Periodic maintenance 39
5.2 Maintenance Logs 43
5.3 Check points at Intermediate Service (IS) 50
5.4 Check points at Major Service (MS) 67
5.5 Lifting instructions 81
5.6 Cleaning 83
5.7 When changing oil 87
5.8 Vibration 91
5.9 Common maintenance directions 93
6 Dismantling/Assembly 97
6.1 Introduction 99
6.2 Inlet/outlet, frame hood (IS) 101
6.3 Bowl hood and disc stack (IS) 106
6.4 Bowl body and operating mechanism (IS) 120
6.5 Operating water device (IS) 131
6.6 Vertical driving device (MS) 140
6.7 Horizontal driving device (MS) 154

4
7 Trouble-tracing 167
7.1 FOPX mechanical functions 168
7.2 FOPX separating functions 172
7.3 Vibration switch (option) 175
8 Technical Reference 177
8.1 Technical data 179
8.2 Basic size drawing 181
8.3 Water quality 189
8.4 Lubricants 190
8.5 Drawings 199
8.6 Storage and installation 206
Index 217

5
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.

6

7
1 Read this first
This manual is designed for operators and service
engineers working with the Alfa Laval separator
FOPX 609TFD-24.
For information concerning the function of the
separator, see chapter ‘‘3 Separator Basics” on
page 15 and chapter ‘‘8 Technical Reference” on
page 177.
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.
Operating Instructions
This chapter contains operating instructions for
the separator only.
S0068011
Separator Manual and Spare Parts Catalogue

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 concerning
the separator and drawings.
Index
This chapter contains an alphabetical list of
subjects, with page references.

9
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 thatcan 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

2 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.
kPa m /h
3
3
o
C
rpm
Hz
kg/m
S0051311S0055611

11
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).
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.
S0051111
S0051011
S0051711S0051611

2 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
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.

2 Safety Instructions
14

15
3 Separator Basics
Contents
3.1 Basic principles of separation 17
3.2 Design and function 19
3.2.1 Overview 19
3.2.2 Mechanical power transmission 20
3.2.3 Sensors and indicators 21
3.2.4 Process main parts 23
3.2.5 Separating function 26
3.2.6 Sludge discharge cycle 27
3.3 Definitions 29

16

17
3 Separator Basics 3.1 Basic principles of separation
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.
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

3.1 Basic principles of separation 3 Separator Basics
18
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.
G0011021
High viscosity (with low temperature)
G0011121
Low viscosity (with high temperature)
G0011221
High density (with low temperature)
G0011321
Low density (with high temperature)

19
3 Separator Basics 3.2 Design and function
3.2 Design and function
3.2.1 Overview
The separator comprises a processing part and a
driving part. It is driven by an electric motor (9).
Mechanically, the separator machine frame is
composed of a bottom part, a top part and a
frame hood. The motor is flanged to the frame as
shown in the illustration. The frame feet (6) are
vibration damping.
The bottom part of the separator contains the
horizontal driving device (4), driving shaft with
couplings (7, 8), a worm gear (5) and a vertical
spindle (3).
The bottom part also contains an oil bath for the
worm gear, a brake and a revolution counter.
The frame top part and the frame hood contain
the processing parts of the separator, the inlet,
outlets and piping (1).
The liquid is cleaned in the separator bowl (2).
This is fitted on the upper part of the vertical
spindle and rotates at high speed in the space
formed by the frame top part and frame hood. The
bowl also contains the discharge mechanism
which empties the sludge from the bowl.
The main inlets and outlets are shown with
connection numbers in the illustration. These
numbers correspond with the numbers used in
the connection list and the basic size drawing
which can be found in chapter ‘‘8 Technical
Reference” on page 177.
G0580311
1. Inlet and outlet device
2. Bowl
3. Vertical driving device with bowl spindle
4. Horizontal driving device
5. Worm gear
6. Frame feet
7. Friction coupling
8. Elastic coupling
9. Electric motor
201. Unseparated oil inlet
206. Displacement/conditioning water inlet
220. Clean oil outlet
221. Water outlet
222. Sludge discharge outlet
372. Bowl opening water inlet
376. Bowl closing and make-up water inlet

3.2 Design and function 3 Separator Basics
20
3.2.2 Mechanical power
transmission
The main parts of the power transmission
between motor and bowl are illustrated in the
figure.
The friction coupling ensures a gentle start and
acceleration and at the same time prevents
overloading of the worm gear and motor.
The worm gear has a ratio which increases the
bowl speed several times compared with the
motor speed. For correct ratio see chapter ‘‘8.1
Technical data” on page 179.
To reduce bearing wear and the transmission of
bowl vibrations to the frame and foundation, the
top bearing of the bowl spindle is mounted in a
spring casing.
The worm wheel runs in a lubricating oil bath. The
bearings on the spindle and the worm wheel shaft
are lubricated by the oil splash produced by the
rotating worm wheel.
Brake
The separator is equipped with a brake to be
used when stopping the separator. The use of the
brake reduces the retardation time of the bowl
and critical speeds will therefore be quickly
passed.
The brake lining acts on the outside of the
coupling pulley.
G0246431
1. Bowl spindle
2. Top bearing and spring casing
3. Worm wheel
4. Worm
5. Friction coupling
6. Worm wheel shaft
G0246321
Applying (1) and releasing (2) of brake