Alfalaval S 927 User manual

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Separator Manual
High Speed Separator
S927
Specification No. 881201-08-03/3
Book No. 9006916-02 rev. 3
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Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Te l e fa x : [phone]
©AlfaLavalTumbaAB04-2014
The original instructions are in English
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 Read this first 9
2 Safety instructions 11
2.1 Warning signs in text 15
2.2 Environmental issues 16
2.3 Requirements of personnel 17
2.4 Remote start 17
3 Basic principles of separation 19
3.1 Introduction 19
3.2 Separation by gravity 19
3.3 Centrifugal separation 20
3.4 Separating temperatures 20
4 Design and function 21
4.1 Overview 22
4.2 Drive section 23
4.3 Process section 24
4.4 Sensors and indicators 26
4.5 Separating function 27
4.5.1 The liquid balance in the bowl 27
4.5.2 Liquid flow 28
4.5.3 Discharge of sludge and water (ALCAP™ concept) 29
4.5.4 Discharge of water through water outlet 30
5 Operating instructions 31
5.1 Before first start 31
5.1.1 Start after service 32
5.2 Normal operation 33
5.2.1 Before normal start 33
5.2.2 Start 34
5.2.3 Operating 36
5.2.4 Stop 38
5.3 Emergency stop 39
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6 Service, dismantling, assembly 41
6.1 Periodic maintenance 41
6.1.1 Maintenance intervals 41
6.1.2 Maintenance procedure 43
6.1.3 Tightening of screws 44
6.1.4 Service kits 45
6.1.5 Cleaning 45
6.2 Maintenance logs 46
6.3 Dismantling 49
6.3.1 Introduction 49
6.3.2 Tools 49
6.3.3 Frame hood 51
6.3.4 Bowl 55
6.3.5 Driving device 72
6.3.6 Centrifugal clutch 91
6.4 Actions before assembly 99
6.4.1 Cleaning 99
6.4.2 Inspection for corrosion 101
6.4.3 Inspection for cracks 102
6.4.4 Inspection for erosion 103
6.4.5 Exchange of frame feet 105
6.4.6 Lubrication of bowl parts 106
6.5 Assembly 107
6.5.1 Centrifugal clutch 108
6.5.2 Driving device 115
6.5.3 Bowl 134
6.5.4 In and outlet device 152
6.5.5 Unbalance sensor (optional) 156
6.5.6 Speed sensor (optional) 158
6.5.7 Actions after assembly 159
6.6 Oil change 161
6.6.1 Lubricating oil 161
6.6.2 Check oil level 162
6.6.3 Oil change procedure 162
6.6.4 Lubrication chart 163
6.6.5 Recommended lubricants 165
6.6.6 Lubricating oils 169
6.7 Lifting instructions 171
6.7.1 Lifting the separator 171
6.7.2 Lifting the bowl 173
7 Fault finding 175
7.1 Mechanical functions 175
7.1.1 Separator vibration 175
7.1.2 Smell 176
7.1.3 Noise 176
7.1.4 Speed too low 176
7.1.5 Speed too high 176
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7.1.6 Starting power too high 177
7.1.7 Starting power too low 177
7.1.8 Starting time too long 177
7.2 Separating functions 178
7.2.1 Bowl opens accidentally during operation 178
7.2.2 Bowl fails to open for sludge discharge 178
7.2.3 Unsatisfactory separation result 178
7.2.4 Bowl fails to close 179
8 Technical reference 181
8.1 Product description 181
8.1.1 Directives and standards 182
8.2 Technical data 184
8.3 Connection list 185
8.4 Interface description 187
8.4.1 Scope 187
8.4.2 References 187
8.4.3 Definitions 187
8.4.4 Goal 188
8.4.5 Description of separator modes 188
8.4.6 Remote start 190
8.4.7 Handling of connection interfaces 190
8.5 Demand specification water 196
8.6 Drawings 197
8.6.1 Basic size drawing 197
8.6.2 Foundation drawing 198
8.6.3 Interconnection diagram 199
8.6.4 PX sealing diagram 200
8.6.5 Electric motor 201
9 Installation 203
9.1 Introduction 203
9.2 Upon arrival at the storage area 204
9.2.1 Transport 204
9.2.2 Protection and storage of goods 205
9.3 Planning of installation 206
9.3.1 Important measurements 206
9.3.2 Maintenance service 207
9.3.3 Connections to surrounding equipment 208
9.4 Storage at out of operation 209
9.5 Before start-up 209
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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,
maintenance personnel and service engineers
working with the Alfa Laval 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 descriptionofthe
separator.
Operating instructions
This chapter contains operating instructions for
the separator only.
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.
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1 Read this first
Fault finding
Refer to this chapter if the separator functions
abnormally.
If the separator has been installed as a part
ofaprocessingsystem,alwaysrefertothe
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 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.
G0010421
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.
Applies not only to the process but also to
cleaning and service liquids.
•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.
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2 Safety instructions
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. kPa m /h
3
3
o
C
Hz
kg/m
r/min
• Check that the gear/pulley ratio is correct for
power frequency used. If incorrect, subsequent
overspeed may result in a serious break down.
50Hz
60Hz
• Welding or heating of parts that rotate can
seriously affect material strength.
• Inspect regularly for corrosion and erosion
damage. Inspect frequently if process or
cleaning liquid is corrosive or erosive.
Entrapment hazards
• Make sure that rotating parts have come to a
complete standstill before accessing parts
inside the machine or starting any dismantling
work. If there is no braking function the run
down time can exceed two hours.
• To avoid accidental start, switch off and lock
power supply before starting any dismantling
work.
Assemble the machine completely before start.
All covers, connections and guards must be in
place.
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2 Safety instructions
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.
•Donot work under a hanging load.
Noise hazards
• Use ear protection in noisy environments.
Burn hazards
• Lubrication oil, machine parts and various
machine surfaces can be hot and cause burns.
Wear protective gloves.
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.
Cut hazards
• Sharp edges, especially on bowl discs and
threads, can cause cuts. Wear protective
gloves.
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2 Safety instructions
Flying objects
• Risk for accidental release of snap rings and
springs when dismantling and assembly. Wear
safety goggles.
Health hazards
• Risk for unhealthy dust when handling friction
blocks/pads. Use a dust mask to make sure not
to inhale any dust
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2 Safety instructions
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.
D
!ANGER
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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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
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.
2.4 Remote start
If the separator is operated from a remote
position where the separator cannot be seen
or heard the power isolation device shall be
equipped with an interlock device to prevent that
a remote start command could result in liquid
being fed to the separator when it is shut down
for service.
The first start after the separator has been taken
apart or been standing still for a long time shall
always be manually supervised locally.
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2 Safety instructions
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3 Basic principles of separation
3.1 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.
3.2 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.
G0870111
Continuous separation and sedimentation can
be achieved in a settling tank having inlet and
outlet arranged according to the illustration.
Heavier particles in the liquid mixture will settle
and form a sediment layer on the tank bottom.
AB
C
D
G0870221
A. Lighter liquid
B. Heavier liquid
C. Gravity
D. Sediment layer of heavier particles
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3.4 Separating temperatures 3 Basic principles of separation
3.3 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.
The separation efficiency is influenced
by changes in the viscosity, separating
temperatures and in throughput.
AB
C
G0870321
A. Lighter liquid
B. Heavier liquid
C. Centrifugal force
3.4 Separating temperatures
For some types of process liquids a high
separating temperature will normally increase
the separation capacity. The temperature
influences viscosity and density and should be
kept constant throughout the separation.
Viscosity Density difference
Viscosity is a fluids resistance against movement.
Low viscosity facilitates separation. Viscosity can
be reduced by heating.
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.
AB
G10348k1
A. High viscosity
B. Low viscosity
AB
G10348j1
A. High density (with low temperature)
B. Low density (with high temperature)
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