Alfalaval P 615 User manual

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P 615
Separator Manual
High Speed Separator
Product No. 881100-04-02/0
Book No. 577461-02 Rev. 3
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Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
© Alfa Laval Tumba AB 15 March 2007
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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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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Contents
577461-02
1 Safety Instructions..................................................... .7
1.1 Warning signs in text ............................................. 12
1.2 Environmental issues ............................................ 13
1.3 Requirements of personnel.................................. 14
2 Read this first & Separator Basics .............. .15
2.1 Read This First......................................................... 16
2.2 Design and function ............................................... 18
2.3 Definitions ................................................................. 26
3 Service Instructions ............................................... .27
3.1 Periodic maintenance............................................ 28
3.2 Maintenance Logs................................................... 31
3.3 Check points at Intermediate Service ............. 36
3.4 Check points at Major Service ........................... 48
3.5 3-year service........................................................... 51
3.6 Lifting instructions ................................................. 52
3.7 Cleaning ..................................................................... 53
3.8 Oil change.................................................................. 56
3.9 Vibration..................................................................... 58
3.10 General directions .................................................. 60
4 Dismantling/Assembly........................................... .65
4.1 Inlet/outlet and bowl .............................................. 68
4.2 Bowl spindle and frame ........................................ 86
4.3 Friction coupling ................................................... 100
4.4 Flat belt and tightener......................................... 107
4.5 Oil filling device..................................................... 112
4.6 Water tank ............................................................... 113
4.7 Brake ......................................................................... 113
4.8 Frame feet ............................................................... 115
5 Technical Reference.............................................117
5.1 Product description .............................................. 118
5.2 Technical data ....................................................... 119
5.3 Connection list....................................................... 120
5.4 Basic size drawing................................................ 122
5.5 Interface description ........................................... 124
5.6 Water quality .......................................................... 132
5.7 Lubricants................................................................ 133
5.8 Drawings .................................................................. 143
5.9 Storage and installation ..................................... 157
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577461-02
5.10 Protection and storage of goods...................... 158
6 Operating..................................................................... .167
6.1 Operating routine .................................................. 168
6.2 Before first Start.................................................... 168
6.3 Start after a service ............................................. 170
6.4 After Safety Stop ................................................... 177
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1 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.
G0010421
S0151211
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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.
S01512F1
S01512N1
S01512P1
S01512L1
S0151241
S01512G1
S01512H1
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1 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.
S01512O1
S0151261
S0151271
S01512M1
S01512Y1
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1 Safety Instructions
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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.
S0151291
S01512A1
S01512D1
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1 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.
S01512B1
S01512C1
S01512V1
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1.1 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
!
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
!
WARNING indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
!
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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1 Safety Instructions
1.2 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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1.3 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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2 Read this first & Separator Basics
Contents
2.1 Read This First 16
2.2 Design and function 18
2.2.1 Application 18
2.2.2 Design 19
2.2.3 Outline of function 19
2.2.4 Separating function 20
2.2.5 Sludge discharge function 22
2.2.6 Power transmission 24
2.2.7 Sensors and indicators 25
2.3 Definitions 26
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2.1 Read This First
This manual is designed for operators,
maintenance personnel and service
engineers working with the Alfa Laval
P 615 separator.
If the separator has been delivered and
installed by Alfa Laval as a part of a
processing system, this manual should be
viewed as part of the System
Documentation. Study carefully all
instructions in any System Documentation.
In addition to this Separator Manual a
Spare Parts Catalogue, SPC is supplied.
The Separator Manual consists of:
Safety Instructions
Pay special attention to the safety instructions
for the separator. Accidents causing damage to
equipment and/or serious injury to persons or
personnel can result if the safety instructions
are not followed.
Basic Principles of Separation
This chapter describes the purpose of
separation and separation principles.
Design and function
This chapter contains a description of the
separator.
Operating Instructions
This chapter contains operating instructions
for the separator only.
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2 Read this first & Separator Basics 2.1 Read This First
Service, Dismantling, Assembly
This chapter gives instructions for the
maintenance procedures. It also contains step-
by-step instructions for dismantling and
assembly of the separator for service and
repair.
Fault Finding
Refer to this chapter if the separator functions
abnormally.
If the separator has been installed as a part of a
processing system, always refer to the trouble-
tracing instructions, in the System
Documentation.
Technical Reference
This chapter contains technical data
concerning the separator and drawings.
Installation
This chapter contains specifications and
recommendations concerning separator
installation.
NOTE
A complete reading of this manual by personnel in
contact with the machine is essential to safety.
Do not allow personnel to clean, assemble, operate
or maintain the separator until they have read and
fully understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the machine and the work to be carried
out.
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2.2 Design and function 2 Read this first & Separator Basics
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2.2 Design and function
2.2.1 Application
The P 615 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 handles the following types of
lubricating oils and low viscosity fuel oils:
•Distillate, viscosity 1,5 - 5,5 cSt/40 °C
•Marine diesel oil, viscosity 13 cSt/40 °C
•Intermediate fuel oil and heavy fuel oil
(viscosity 30-380 cSt/50 °C)
•Lubricating oil of R & O type, detergent or
steam turbine.
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.
WARNING
!
Disintegration hazards
Use the separator only for the purpose and
parameters (type of liquid, rotational speed,
temperature, density etc.) specified in chapter
5 Technical Reference, page 117 and in the Purchase
Order documents.
Consult your Alfa Laval representative before any
changes outside these parameters are made.
G0464881
The P 615 separator.
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2 Read this first & Separator Basics 2.2 Design and function
2.2.2 Design
The P 615 separator comprises a frame
consisting of the frame lower part, the
intermediate part and the frame top part with a
frame hood.
The separator bowl (C) is driven by an electric
motor (A) via a flat-belt power transmission (D)
and bowl spindle (B). The motor drive is
equipped with a friction coupling to prevent
overload.
The bowl is of disc type and hydraulically
operated at sludge discharges. The hollow bowl
spindle (B) features an impeller which pumps
closing water from a built-in tank to the
operating system for sludge discharge.
The main inlets and outlets are shown with their
connection numbers in the illustration. The
connections are listed in chapter 5 Technical
Reference, page 117, where also the basic size
drawing can be found.
2.2.3 Outline of function
The separation process takes place in the
rotating bowl. Unseparated oil is fed into the
bowl through the inlet (201). The oil is cleaned in
the bowl and leaves the separator through the
outlet (220) via a paring chamber.
Impurities heavier than the oil are collected in
the sludge space at the bowl periphery and
removed automatically at regular intervals.
Permissible pressures and operating conditions
are specified in chapter 5 Technical Reference,
page 117.
The processing parts of the separator are shown
in the illustration on next page.
There are no contacting surfaces between
process rotating parts (the bowl) and stationary
parts (inlet, outlet, feed devices), and the
interfacing surfaces are not sealed. As the
separation process is carefully balanced
regarding pressures and fluid levels, any
leakages will not occur as long as the correct
running conditions are maintained.
G0739541
Sectional view
Main parts, inlets and outlets
A Electric motor
B Bowl spindle
CBowl
D Flat belt
E Closing water tank
F Brake handle
201 Oil inlet
220 Oil outlet
221, 222 Water/sludge outlet
372 Opening water inlet
373 Bowl closing water
377 Overflow
462 Drain
463 Drain
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2.2.4 Separating function
Liquid flow
Separation takes place in the separator bowl to
which unseparated oil is fed through the inlet
pipe (201). The oil is led by the distributor (T)
towards the periphery of the bowl.
When the unseparated oil reaches the slots of
the distributor, it will rise through the channels
formed by the disc stack (G) where it is evenly
distributed into the disc stack.
The oil is continuously separated from water and
sludge as it will flow towards the center of the
bowl. When the cleaned oil leaves the disc stack
it rises upwards and enters the paring chamber.
From there it is pumped by the paring disc (F)
and leaves the bowl through the outlet (220).
Separated sludge and water move towards the
bowl periphery. In purification separated water
rises along the outside of the disc stack, passes
from the top disc channels over the edge of the
gravity disc (K) and leaves the bowl into the
common sludge and water outlet (221) of the
separator.
Heavier impurities are collected in the sludge
space (H) outside the disc stack and are
discharged at intervals through the sludge ports
(L).
G0112361
F Paring disc
G Disc stack
H Sludge space
I Top disc
K Gravity disc
L Sludge ports
R Bowl body
S Bowl hood
T Distributor
U Paring chamber cover
201 Oil inlet
206 Water seal and
displacement water
inlet
220 Oil outlet
221 Water outlet
372 Opening water inlet
373 Bowl closing water
377 Overflow
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