Alfalaval MOPX 205 TGT-24 User manual

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ALFA LAVAL SEPARATION

MOPX 205 TGT-24

Separator Manual

Product No. 881034-01-08

Book No. 1270366-02 V2

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Alfa Laval Separation AB

Separator Manuals, dept. SKL

S-147 80 Tumba, Sweden

Telephone: +46 8 53 06 50 00

Telefax: +46 8 53 06 50 29

Printed in Sweden, 96-10

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

1 Read this first 7

2 Safety Instructions 9

3 Separator Basics 15

3.1 Basic principles of separation 16

3.2 Design and function 18

3.3 Separating function 27

3.4 Definitions 33

4 Operating Instructions 35

4.1 Operating routine 36

5 Service Instructions 43

5.1 Periodic maintenance 45

5.2 Maintenance Logs 49

5.3 Check points at Intermediate Service (IS) 56

5.4 Check points at Major Service (MS) 72

5.5 Lifting instructions 85

5.6 Cleaning 86

5.7 When changing oil 89

5.8 Vibration 93

5.9 Common maintenance directions 94

6 Dismantling/Assembly 99

6.1 Introduction 100

6.2 Inlet/outlet, frame hood (IS) 102

6.3 Bowl hood and disc stack (IS) 105

6.4 Bowl body and

operating mechanism (IS) 114

6.5 Paring disc device for operating water (IS) 121

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6.6 Vertical driving device (MS) 126

6.7 Horizontal driving device (MS) 138

6.8 Built-on oil feed pump 148

7 Trouble-tracing 157

7.1 Mechanical function 158

7.2 Separation faults, purifier and clarifier 163

7.3 Separation faults, purifier 166

7.4 Separation faults, clarifier 168

8 Technical Reference 169

8.1 Technical data 170

8.2 Connection list 172

8.3 Interface description 175

8.4 Water quality 179

8.5 Lubricants 180

8.6 Drawings 188

8.7 Storage and installation 202

Index 213

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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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1 Read this first

This manual is designed for operators and service

engineers working with the Alfa Laval separator

MOPX 205 TGT-24.

For information concerning the function of the

separator, see chapter ‘‘3 Separator Basics” on

page 15 and chapter ‘‘8 Technical Reference” on

page 169.

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

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1 Read this first

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 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

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2 Safety Instructions

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

rpm

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

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

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3 Separator Basics

Contents

3.1 Basic principles of separation 16

3.2 Design and function 18

3.2.1 Application 18

3.2.2 Overview 19

3.2.3 Mechanical power transmission 20

3.2.4 Sensors and indicators 21

3.2.5 Inlet pump (option) 22

3.2.6 Process main parts 24

3.3 Separating function 27

3.3.1 Purifier bowl 27

3.3.2 Clarifier bowl 29

3.3.3 Normal separation 30

3.3.4 Sludge discharge cycle 31

3.4 Definitions 33

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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

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3.1 Basic principles of separation 3 Separator Basics

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)

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3 Separator Basics 3.2 Design and function

3.2 Design and function

3.2.1 Application

The MOPX 205 TGT-24 is a high-speed

centrifugal separator intended for marine and

land applications. It is specifically designed for

cleaning of mineral oils from water and solid

particles (sludge). The cleaned oil is discharged

continuously, while the sludge is discharged at

intervals.

The separator can be operated either as a purifier

or as a clarifier. When operated as a purifier the

separator discharges the separated water

continuously.

When the oil contains only small amounts of

water the separator is operated as a clarifier,

discharging the water together with the solid

particles.

The separator has to be installed together with

devices for control of its operation. It can be

delivered with a built-on pump for oil inlet feed.

DANGER

Disintegration hazards

Use the separator only for the purpose and

parameters (type of liquid, rotational speed,

temperature, density etc.) specified in

chapter ‘‘8 Technical Reference” on page

169 and in the Purchase Order documents.

Consult your Alfa Laval representative before

any changes outside these parameters are

made.

G0685111

The MOPX 205 TGT-24 separator

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3.2 Design and function 3 Separator Basics

3.2.2 Overview

The separator comprises a processing part and a

driving part. It is driven by an electric motor (10).

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 (5) are

vibration damping.

The bottom part of the separator contains the

horizontal driving device (6), driving shaft with

couplings (8, 9), a worm gear (7) 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 is of disc type and also contains the

hydraulically operated discharge mechanism

which empties the bowl of sludge.

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 169, where also permissible

pressures and operating conditions are specified.

As option the separator can be equipped with a

feed inlet pump (4).

G0580361

1. Inlet and outlet device

2. Bowl

3. Vertical driving device with bowl spindle

4. Feed inlet pump (option)

5. Frame feet

6. Horizontal driving device

7. Worm gear

8. Friction coupling

9. Elastic coupling

10. Electric motor

201. Unseparated oil inlet

206. Sealing/displacement 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

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