Alfalaval MAB 206S-24 User manual

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ALFA LAVAL SEPARATION
MAB 206S-24
Separator Manual
Product No. 881240-22-12
Book No. 1270282-02 V3
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Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
© Alfa Laval Tumba AB May 2008
This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.
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Contents
1
1 Read this first 5
2 Safety Instructions 7
2.1 Warning signs in text 12
2.2 Environmental issues 13
2.3 Requirements of personnel 14
3 Separator Basics 15
3.1 Basic principles of separation 16
3.2 Design 19
3.3 Separating function 23
3.4 Definitions 27
4 Operating Instructions 29
4.1 Operating routine 30
4.2 Cleaning the bowl 39
5 Service Instructions 47
5.1 Periodic maintenance 48
5.2 Maintenance logs 52
5.3 Check points at Intermediate Service (IS) 60
5.4 Check points at Major Service (MS) 70
5.5 Cleaning 80
5.6 When changing oil 84
5.7 Common maintenance directions 85
5.8 Lifting instructions 90
6 Dismantling/Assembly 91
6.1 General 92
6.2 Inlet/outlet, collecting cover and bowl (IS) 94
6.3 Vertical driving device (MS) 106
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6.4 Horizontal driving device (MS) 118
6.5 Feed pump (option) 128
7 Trouble-tracing 137
7.1 Mechanical function 138
7.2 Purification faults 144
7.3 Clarification faults 146
8 Technical Reference 147
8.1 Technical data 148
8.2 Basic size drawing, without pump 154
8.3 Connection list, without pump 155
8.4 Basic size drawing, with pump 156
8.5 Connection list, with pump 157
8.6 Interface description 158
8.7 Lubricants 161
8.8 Electric components 176
8.9 Machine plates and safety labels 182
8.10 Storage and installation 184
Index 193
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Read and understand 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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4
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5
1 Read this first
This manual is designed for operators and service
engineers working with the Alfa Laval separator
MAB 206S-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
6
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.
Index
This chapter contains an alphabetical list of
subjects, with page references.
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2 Safety Instructions
The centrifuge 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.
G0010421S0151211
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2 Safety Instructions
8
Disintegration hazards
•When power cables are connected,
always check direction of motor rotation.
If incorrect, vital rotating parts could
unscrew.
•If excessive vibration occurs, stop
separator and keep bowl filled with
liquid during rundown.
•Use the separator only for the purpose
and parameter range specified by
Alfa Laval.
•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.
S01512F1S01512N1S01512P1S01512L1S0151241S01512G1S01512H1
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2 Safety Instructions
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 hazard
•Follow local regulations for electrical
installation and earthing (grounding).
•To avoid accidental start, switch off and
lock power supply before starting any
dismantling work.
Crush hazards
•Use correct lifting tools and follow lifting
instructions.
Do not work under a hanging load.
S01512O1S0151261S0151271S01512M1S01512Y1
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2 Safety Instructions
10
Noise hazards
•Use ear protection in noisy
environments.
Burn hazards
•Lubrication oil and various machine
surfaces can be hot and cause burns.
Skin irritation hazards
•When using chemical cleaning agents,
make sure you follow the general rules
and suppliers recommendation
regarding ventilation, personnel
protection etc.
•Use of lubricants in various situations.
S0151291S01512A1S01512D1
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2 Safety Instructions
Cut hazards
•Sharp edges on bowl discs and threads
can cause cuts.
Flying objects
•Risk for accidental release of snap rings
and springs when dismantling and
assembly.
Health hazard
•Risk for unhealthy dust when handling
friction blocks/pads. Use a dust mask to
make sure not to inhale any dust.
S01512B1S01512C1S01512V1
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2 Safety Instructions
12
2.1 Warning signs in 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
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
Type of hazard
WARNING indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Type of hazard
CAUTION indicates a potentially
hazardous situation which, if not avoided,
may result in minor or moderate injury.
NOTE
NOTE indicates a potentially hazardous
situation which, if not avoided, may result
in property damage.
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2 Safety Instructions
2.2 Environmental issues
Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused,
recycled or used for energy recovery.
Plastics should be recycled or burnt at a licensed
waste incineration plant.
Metal straps should be sent for material recycling.
Maintenance
During maintenance oil and wear parts in the
machine are replaced.
Oil must be taken care of in agreement with local
regulations.
Rubber and plastics should be burnt at a licensed
waste incineration plant. If not available they
should be disposed to a suitable licensed land fill
site.
Bearings and other metal parts should be sent to
a licensed handler for material recycling.
Seal rings and friction linings should be disposed
to a licensed land fill site. Check your local
regulations.
Worn out or defected electronic parts should be
sent to a licensed handler for material recycling.
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2 Safety Instructions
14
2.3 Requirements of
personnel
Only skilled or instructed persons are allowed to
operate the machine, e.g. operating and
maintenance staff.
•Skilled person: A person with technical
knowledge or sufficient experience to enable
him or her to perceive risks and to avoid
hazards which electricity/mechanics can
create.
•Instructed person: A person adequately
advised or supervised by a skilled person to
enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.
In some cases special skilled personnel may
need to be hired, like electricians and others. In
some of these cases the personnel has to be
certified according to local regulations with
experience of similar types of work.
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3Separator Basics
Contents
3.1 Basic principles of separation 16
3.1.1 Introduction 16
3.1.2 Factors influencing the
separation result 17
3.2 Design 19
3.2.1 Overview 19
3.2.2 Bowl disc stack 20
3.2.3 Power transmission 20
3.2.4 Brake 21
3.2.5 Inlet pump (option) 21
3.2.6 Paring disc 21
3.2.7 Sensors and indicators 22
3.3 Separating function 23
3.3.1 Bowl 23
3.3.2 Purifier bowl 23
3.3.3 Clarifier bowl 25
3.4 Definitions 27
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3.1 Basic principles of separation 3 Separator Basics
16
3.1 Basic principles of
separation
3.1.1 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.
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
3.1.2 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.
G0011021
High viscosity (with low temperature)
G0011121
Low viscosity (with high temperature)
G0011221
High density (with low temperature)
G0011321
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 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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