Alfalaval S 821 User manual

S 821 & S 826
Separator Manual
High Speed Separator
Product No. 881201-05-01/2 & 881201-06-01/3
Book No. 578701-02 Rev. 1

2
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax:[phone]
© Alfa Laval Tumba AB 14 August 2006
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.

Contents
578701-02
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 Basic Principles Of Separation....................... .15
3.1 Separation By Gravity............................................ 15
3.3 Temperatures ........................................................... 16
4 Design............................................................................... .17
4.1 Overview .................................................................... 18
4.3 The Process Section .............................................. 20
4.4 Sensors....................................................................... 24
4.5.1 The liquid balance in the bowl ...................................... 25
4.5.3 Discharge of sludge and water ..................................... 26
4.5.4 ALCAPTM concept......................................................... 26
5 Operating Instructions.......................................... .29
5.1 Before First Start-up .............................................. 29
5.2 Start After Service.................................................. 30
5.4 Start............................................................................. 31
5.5.1 Sludge discharge during operation .............................. 35
5.7 Emergency Stop ...................................................... 39
6 Service, Dismantling, Assembly..................... .41
6.1 Periodic Maintenance ............................................ 41
6.1.1 Maintenance intervals ................................................... 41
6.1.2 Maintenance procedures .............................................. 41
6.1.3 Tightening of screws ..................................................... 42
6.1.4 Service kits .................................................................... 42
6.1.5 Cleaning ........................................................................ 42
6.3.1 Introduction.................................................................... 46
6.3.2 Tools .............................................................................. 46
6.3.5 Driving device ............................................................... 61
6.4.1 Cleaning ...................................................................... 80
6.4.2 Inspection for corrosion ............................................... 82
6.4.3 Inspection for cracks ................................................... 83
6.4.7 How to lubricate bowl parts with slide laquer ............... 87
6.4.8 Check for galling on operating slide and bowl body ... 88
6.5.1 Centrifugal clutch .......................................................... 89
6.5.6 Speed sensor .............................................................. 128
6.6.1 Control of machine plates and safety labels .............. 129
6.7.2 Check oil level ............................................................. 132

578701-02
6.7.3 Oil change procedure ................................................. 132
6.7.6 Lubricating oils ............................................................ 138
6.8 Lifting instructions ............................................... 139
6.8.1 Lifting the separator .................................................... 139
7 Fault Finding ...............................................................141
7.1 Mechanical Functions ......................................... 141
7.1.1 Separator vibration ...................................................... 141
7.1.2 Smell............................................................................ 142
7.1.3 Noise ........................................................................... 142
7.1.4 Speed too low.............................................................. 142
7.1.5 Speed too high ............................................................ 142
7.1.6 Starting power too high ............................................... 143
7.1.7 Starting power too low................................................. 143
7.1.8 Starting time too long .................................................. 143
7.2.1 Bowl opens accidentally during operation.................. 144
7.2.2 Bowl fails to open for sludge discharge...................... 144
7.2.3 Unsatisfactory separation result.................................. 144
8 Technical Reference.............................................147
8.1 Product description .............................................. 147
8.2 Technical Data ....................................................... 148
8.4.1 Scope .......................................................................... 151
8.4.2 References .................................................................. 151
8.4.3 Definitions.................................................................... 152
8.4.4 Goal ............................................................................. 152
8.4.5 Description of separator modes.................................. 153
8.4.6 Remote start ................................................................ 154
8.4.7 Handling of connection interfaces .............................. 154
8.6.1 Basic size drawing ...................................................... 162
9 Installation ...................................................................167
9.1 Introduction ............................................................ 167
9.2.1 Transport...................................................................... 168
9.2.2 Protection and storage of gods
..................................................................................... 169
9.3.1 Important measurements ............................................ 170
9.4 Storage at out of operation ............................... 173
9.5 Before start-up ....................................................... 173

5
1 Read This First
This manual is designed for operators,
maintenance personnel and service
engineers working with the Alfa Laval S
821 & S 826 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.

1 READ THIS FIRST
6
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.

7
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

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

9
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

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

11
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

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
!
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.

13
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.

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.

15
3 Basic Principles Of Separation
The purpose of separation can be to
•free a liquid of solid particles,
•separate two mutually insoluble liquids
with different densities while removing
any solids present at the same time,
•separate and concentrate solid particles
from a liquid.
3.1 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.
G0870111
G0870211
Gravity
Sediment layer of
heavier particles
Heavier
liquid
Lighter
liquid

3.2 CENTRIFUGAL SEPARATION 3 BASIC PRINCIPLES OF SEPARATION
16
3.2 Centrifugal Separation
In a rapidly rotating bowl, the force of gravity
is replaced by centrifugal force, which is many
times greater.
Separation and sedimentation is continuous
and takes place very quickly.
The centrifugal force in the separator bowl can
achieve in a few seconds that which takes many
hours in a tank under influence of gravity.
The separation efficiency is influenced by
changes in the oil viscosity, separating
temperatures and in throughput.
3.3 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
Viscosity is a fluids resistance against movement.
Low viscosity facilitates separation. Viscosity can be
reduced by heating.
Density difference
Density is mass per volume unit. The greater the density
difference between the two liquids, the easier the
separation. The density difference can be increased by
heating.
G0870311
Lighter liquid
Heavier liquid
Centrifugal force
G0885911
High viscosity Low viscosity
G0886011
High density difference.
Low density difference

17
4Design
G0870641
Process section
The feed inlet and outlets
are situated at the top of
the separator.
The liquid is cleaned in the
rotating separator bowl
inside the frame hood.
Drive section
The rotating separator
bowl is driven by a flat
belt transmission with
friction coupling.
Frame feet
The separator rests
on vibration damping
frame feet.
Sludge outlet
Separated solids are discharged at
preset intervals.
Electric motor
The rotating bowl is driven
by the electric motor via a
belt transmission.
Sensors
The separator is monitored
by a speed sensor. An
unbalance sensor and a
interlocking switch is
optional.
Lubrication system
Lubricates the bearings driven
by the flat belt transmission

4.1 OVERVIEW 4 DESIGN
18
4.1 Overview
The separator comprises a process section and
a drive section powered by an electric motor.
The separator frame comprises a lower body
and a frame hood. The motor is attached to the
frame. The frame feet dampen vibration.
The bottom part of the separator contains a flat
belt transmission, a centrifugal clutch and a
vertical spindle. The lower body also contains
an oil sump for lubrication of spindle bearings.
The frame hood contains the processing parts
of the separator; the inlets, outlets and piping.
The process liquid is cleaned in the separator
bowl. The bowl is fitted on the upper part of a
vertical spindle and rotates at high speed
inside the frame hood. The bowl also contains
the discharge mechanism which empties the
sludge during operation.
A speed sensor, and the optional unbalance
sensor and lock switch, are parts of the
equipment for monitoring the separator
functions.

19
4 DESIGN 4.2 THE DRIVE SECTION
4.2 The Drive Section
The separator bowl is driven by an electric
motor via a belt transmission. The belt
pulley on the motor shaft includes a
centrifugal clutch.
G0870741
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 dampened
bearing seat.
The bearings on the spindle are
lubricated by the oil spray produced
by an oil pump mounted on the
lower end of the spindle.
The centrifugal clutch with friction
pads ensures a gentle start and
smooth acceleration, and at the
same time prevents overloading of
the belt and motor.
Flat belt
The flat belt transmission has a
ratio which increases the bowl
speed several times compared
with the motor speed.

4.3 THE PROCESS SECTION 4 DESIGN
20
4.3 The Process Section
The separation process takes place inside
the rotating separator bowl. The feed and
outlet of process liquid takes place in the in
and outlet unit on top of the separator
frame hood.
Inlet and outlet
The inlet and outlet unit consists of the
following parts:
A connection house for pipe connections.
A pipe with a paring disc and a paring tube is
located inside the connection house. The pipe
has channels for incoming and outgoing process
liquid.
The paring disc and paring tube pump the
cleaned oil and water respectively out of the
bowl.
The paring tube can move radially. During
separation it surfs on the liquid surface. It is
balanced by a spring.
Under certain operating conditions, the paring
tube radial position can be locked in place by
two adjustable screws on the connection house.
The paring disc and tube are located inside and
at the top of the separator bowl.
The inlet and outlet device is held together
against the frame hood by a nut on the end of
the inlet pipe.
Height adjusting rings determine the height
position of the paring disc and paring tube
relative to the bowl.