Alfalaval MAB 103B-24 User manual

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ALFA LAVAL SEPARATION
MAB 103B-24
Separator Manual
Product No. 881145-09-01
Book No. 1270118-02 V4
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Alfa Laval Separation AB
Separator Manuals, dept. SKL
S-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
Printed in Sweden, 97-08
© 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.
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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 Overview 19
3.3 Separating function 20
3.4 Mechanical function 23
3.5 Definitions 27
4 Operating Instructions 29
4.1 Operating routine 30
4.2 Cleaning the bowl 37
5 Service Instructions 43
5.1 Periodic Maintenance 44
5.2 Maintenance Logs 46
5.3 MS - Check points 52
5.4 Cleaning 66
5.5 When changing oil 70
5.6 Common maintenance directions 72
5.7 Lifting instructions 76
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4
6 Dismantling/Assembly 77
6.1 General 78
6.2 Dismantling 79
6.3 Assembly 89
6.4 Feed and discharge pumps 97
6.5 Oil filling 102
6.6 Brake 103
6.7 Frame feet 104
7 Trouble-tracing 105
7.1 Trouble tracing procedure 106
7.2 MAB mechanical function 106
7.3 Purification faults 112
7.4 Clarification faults 114
8 Technical Reference 115
8.1 Technical data 116
8.2 Basic size drawing 122
8.3 Connection list 124
8.4 Basic size drawing, for heater 125
8.5 Connection list, for heater 127
8.6 Interface description 128
8.7 Lubricants 131
8.8 Drawings 139
8.9 Storage and installation 151
Index 161
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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.
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6
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7
1 Read this first
This manual is designed for operators and service
engineers working with the Alfa Laval separator
MAB 103B-24.
For information concerning the function of the
separator, see ‘‘3 Separator Basics” on page 15,
and ‘‘4 Operating Instructions” on page 29.
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 Manual. In this
case, study carefully all the instructions in the
System Manual.
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
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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 Manual first.
Technical Reference
This chapter contains technical data concerning
the separator and drawings.
Installation
General information on installation planning.
Lifting instruction.
Index
This chapter contains an alphabetical list of
subjects, with page references.
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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 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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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
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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).
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
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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
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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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2 Safety Instructions
14
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15
3 Separator Basics
Contents
3.1 Basic principles of separation 16
3.1.1 Factors influencing the separation
result 17
3.2 Overview 19
3.3 Separating function 20
3.3.1 Purifier bowl 20
3.3.2 Position of interface - gravity disc 21
3.3.3 Clarifier bowl 22
3.4 Mechanical function 23
3.4.1 Inlet and outlet 23
3.4.2 Mechanical power transmission 24
3.4.3 Brake 25
3.4.4 Inlet and outlet pump 25
3.4.5 Sensors and indicators 26
3.5 Definitions 27
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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.
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 temperature
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 (specific gravity ratio)
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
18
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 by reducing the throughput in order
to restore the optimum separating efficiency.
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
Sediment will accumulate on the inside periphery
of the bowl. When the sludge space is filled up
the flow inside the bowl is influenced by the
sediment and thereby reducing the separating
efficiency. In such cases the time between
cleaning should be reduced to suit these
conditions.
Disc stack
A neglected disc stack containing deformed discs
or discs coated with deposits will impair the
separating result.
G0601211
Sludge accumulation
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3 Separator Basics 3.2 Overview
3.2 Overview
The separator comprises a processing part and a
driving part. It is driven by an electric motor (6).
Mechanically, the separator machine frame is
composed of a bottom part, a top part and a
collecting cover. The motor is flanged to theframe
as shown in the illustration. The frame feet have
vibration damping.
The bottom part of the separator contains the
horizontal driving device (1), driving shaft with
couplings, a worm gear and a vertical spindle.
The bottom part also contains an oil bath for the
worm gear, a brake and a revolution counter,
indicating speed.
A pump (3) is attached to the driving spindle and
located on the side of the bottom part. This pump
has dual function. It is the feed inlet pump and the
clean oil discharge pump.
The frame top part and the collecting cover
contain the processing parts of the separator, the
inlet and outlets and piping.
The liquid is cleaned in the separator bowl (4).
This is fitted on the upper part of the vertical
spindle and rotates at high speed inside the
space formed by the frame top part and collecting
cover.
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 115.
G0588411
1. Horizontal driving device, friction coupling
and worm gear
2. Collecting cover.
3. Inlet and outlet gear pump
4. Separator bowl
5. Inlet / outlet
6. Electric motor
G0599611
Inlet and outlet connections
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3.3 Separating function 3 Separator Basics
20
3.3 Separating function
Unseparated oil is fed into the bowl through the
inlet pipe and is pumped via the distributor
towards the periphery of the bowl.
When the oil reaches holes of the distributor, it will
rise through the channels formed by the disc
stack where it is evenly distributed.
The oil is continuouslycleaned as it flows towards
the center of the bowl. When the cleaned oil
leaves the disc stack it rises upwards, flows over
the gravity disc and leaves the bowl through
outlet (220). Separated water, sludge and solid
particles are forced towards the periphery of the
bowl and collected in the sludge space.
The space between bowl hood and top disc are
normally filled with water.
3.3.1 Purifier bowl
The illustration shows characteristic parts of the
purifier bowl:
1. Top disc with neck
2. The gravity disc, which should be chosen
according to directions in chapter ‘‘4.1.2
Selection of gravity disc” on page 30.
This bowl has two liquid outlets. The process
liquid flows through the distributor to the
interspaces between the bowl discs, where the
liquid phases are separated from each other by
action of the centrifugal force. The heavy phase
and any solids move along the underside of the
bowl discs towards the periphery of the bowl,
where the solids settle on the bowl wall.
The heavy phase flows along the upper side of
the top disc towards the neck of the bowl hood
and leaves the bowl via the gravity disc the outer
way.
The light phase flows along the upper side of the
bowl discs towards the bowl centre and leaves
the bowl via the hole in the top disc neck the inner
way.
G0613211
Process flow through separator bowl
G0589011
Purifier bowl
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