"service manual"
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1. cross head engines Diesel oil mode 40 C 12 Standby is displayed when the separator has reached the correct speed and the oil is at the correct temperature The process starts automatically 13 Adjust the backpressure to the normal running value Normal running backpressure is determined at commissioning See the System Reference Installation Instructions booklet 10 1810571 02 OP O O i SEPARATION O STOP OP ACTIVE O OP P00361KB P00361LB S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 1 5 During operation Operator panel information Observe the operator panel information e Heater operation LED lit green e Separator system operation LED lit green e Activated valve LED lit green During normal operation the ALCAP trigger signal is shown on the left of the display and the time to next sludge discharge is shown on the right Any alarm is indicated on the display For further information see the Alarms and Fault Finding booklet Regularly check connections Tighten if necessary 1810571 02 11 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS The values displayed in the examples below are not recommendations More operational information may be read as required by pressing the button repeatedly To return to normal display i e the trigger value and time to next sludge discharg2. list booklet Make sure that the operators panel is active LED green before operating 1810571 02 5 P00361HB 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 3 Startup The control panel mode switch has three positions MANUAL AUTO and CIP The MANUAL mode is for use on all Separation Unit systems The AUTO mode is for use on systems supplied for fully automatic control and or fully automatic remote control The following general rules apply for use of the AUTO mode The EPC 50 must have control of the oil feed pump The EPC 50 must have control of the heater The EPC 50 must have control of vibration monitoring The cover interlock must be fitted The CIP mode is for use with Cleaning in Place equipment See Cleaning In Place on page 17 6 1810571 02 GO46604A GO46605A GO46606A S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 1 4 Manual Startup The first startup must always be carried out manually Before startup make sure that all the main supply valves for air oil and water are open Open heating media supply valve if applicable Switch on the power supplies Make sure the mode selection switch is in the MANUAL position 1 Start the oil feed pump from the pump starter 2 lf necessar
3. Air Valve Block Use the pressure gauge situated in the air valve block to check that the air Supply is correct 500 700 kPa or 5 7 Bar For further information concerning air see chapter 1 Technical Data in the System Reference Installation Instructions booklet Operating Water Pressure Check that the operating water pressure is sufficient 200 600 kPa or 2 6 Bar For further information concerning water see chapter 7 Technical Data in the System Reference Installation Instructions booklet 4 1810571 02 P003682A S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 1 2 Operators Panel General principle for changing control parameters The Enter button is used to enter into a parameter list enter into a parameter accept store a new parameter value The or the buttons are used to change the value flashing in the display window Process parameters Set the process parameters to suit the E 7 installation as follows _ a 5 10 P e A 1 Push Enter Parameter no 1 in the process parameter list is shown You have now come to the process parameter list Go through the list and set parameters When the parameters have been set End 1 0 flashing shows Push Standst now shows in the display For information on how to set discharge intervals see chapter 3 Process Parameters in the Paramete
4. OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS Discharge Close oil feed V1 using SV1 Close water outlet V5 using SV5 Open SV10 to add displacement water as follows Amount bowl filled litre SU 200 81 1 816 821 826 SU 300 820 825 830 831 835 836 SU 400 840 841 845 846 SU 500 850 851 855 856 SU 600 860 86 1 865 866 Open SV15 until a discharge is heard about 3 seconds Wait 15 seconds Open SV16 for time specified in timer Ti62 24 1810571 02 S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 7 Open SV10 as follows Amount bowl filled litre SU 200 811 816 821 826 SU 300 820 825 830 831 835 836 SU 400 840 841 845 846 SU 500 850 85 1 855 856 SU 600 860 861 865 866 8 Open V1 9 Open V5 10 Maintain backpressure at normal setting throughout Breakdown hazard Discharging of the bowl and supervision of the operation is now completely manual and under the direct responsibility of the engineer who has placed the separation system in the manual control mode 1810571 02 25 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 26 1810571 02
5. S type Separation System Aa Operating Instructions LENGE Printed Apr 2005 Book No 1810571 02 V 6 Alfa Laval reserves the right to make changes at any time without prior notice Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local Alfa Laval company Published by Alfa Laval Tumba AB Marine amp Diesel Equipment SE 147 80 Tumba Sweden Copyright Alfa Laval Tumba AB 2005 Contents 1 Operating 2 1 1 Before Startup 2 1 2 Operators Panel 5 1 3 Startup es 6 1 4 Manual Startup 000 0 7 1 5 During operation 0 11 tO SIOD cce e 14 1 7 Emergency Stop 0 00 15 1 8 After Emergency Stop 16 1 9 Cleaning In Place 17 1 10 Automatic Operation 18 1 11 Remote Operation 20 1 12 Emergency Operation 21 1 12 1 Manual Operation of the Separation OVSE isn E 21 1810571 02 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 Operating 1 1 Before Startup k Check that the separator is correctly assembled and connected to power supply of correct voltage and frequency The EPC 50 Control Unit must be ON Breakdown hazard Assemble the separator completely before start All couplings cover
6. always be carried out manually The system can thereafter be run automatically as long as no changes are made to it between runs 1 Press the SEPARATION button OP O ia N HEATER O SEPARATION 4 gt DISCHARGE OP ACTIVE Before the separator can be started a number of questions scroll across the display which have to be answered 18 1810571 02 P00361LB S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING Has the bowl been dismantled YES NO 2 If the bowl has been dismantled press the button If no work has been carried out on the bowl press the button The start sequence begins and the text Start appears in the display Assembled according to manual YES NO 3 If the bowl has been dismantled and assembled according to the Instructions in the Service Manual press the button Bowl cleaned YES NO 4 ifthe bowl has been cleaned press the button An automatic calibration of the system is carried out See display To stop the process press the SEPARATION button see 1 6 Stop page 14 If the system is to be restarted the system valves can remain in operating positions 1810571 02 POO3614A P003613A POO3614A POO3614A 19 POO361LB 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 11 Remote Operation Remo
7. e continue pressing the button Oil feed temperature For the correct separation temperature see the System Reference Installation Instructions booklet Oil pressure oil inlet Oil pressure oil outlet Pressure water outlet Water transducer value Accumulated operating time in hours 12 1810571 02 OP g a N HEATER O Ea SEPARATION O STOP s I 0 i OP ACTIVE O a A ALARM Run time 5 hours P00361UA P00361TA P003610A P00361PA POO361QA POO361RA P003625A P00361MB S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING Burn hazard Avoid contact with hot surfaces Process pipes various machine surfaces and processed liquid can be hot and cause burns Slip hazard Check all connections for leakage Oil leakage may make the floor slippery 1810571 02 Breakdown hazard If strong vibration occurs press the emergency stop button and evacuate the room Never discharge a vibrating separator Vibration may then become violent and result in breakdown Noise hazard Use ear protection if noise levels are high 13 POO4072A 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 6 Stop To stop the system 1 stop the system by pushing the SEPARATION button on the operators panel The yellow LED for separator stop sequence Star
8. ere is a Heatpac EHM electric heater use jumpers in the power unit to bridge terminals X12 11 X12 6 X12 11 X12 9 and X12 11 X12 7 Switch on the heater and use the switch to regulate the temperature Remove the jumpers after emergency operation 1810571 02 21 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 22 7 When the separator is up to speed and the 9 correct oil flow and temperature are achieved close the bowl Open SV 15 for time specified in timer Ti6O See Parameter List booklet Wait 15 seconds Open SV16 for time specified in timer Ti62 The bowl is now closed Temperature flow and backpressure must remain constant throughout Remove the water outlet pipe at D 1810571 02 GO65022A S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 10 Screw in screw A to move the paring tube to its innermost position 11 Open SV10 as follows Amount bowl filled litre SU 200 811 816 821 826 SU 300 820 825 830 831 835 836 SU 400 840 841 845 846 SU 500 850 851 855 856 SU 600 860 86 1 865 866 12 Open SV1 to open oil feed V1 13 Open SV5 This will open the water outlet valve V5 14 Carefully screw out screw A until water starts to come from D 15 Lock screw A in position penne Breakdown hazard During operation open SV16 for about 5 seconds every 10 to 15 minutes to ensure that the bowl remains closed 1810571 02 23 GO65011A 1
9. m after an emergency stop while the separator is still rotating In order to be able to restart the system must be at standstill and then the EPC power switched off on 1810571 02 15 GO4659BA 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 8 After Emergency Stop Separator standstill Dismantling work must not be started before all rotating parts have come to a complete standstill Entrapment hazard Make sure that rotating parts have come to a complete standstill before starting any dismantling work The rotation indicator lamp where applicable must be off Avoid accidental start Entrapment hazard To avoid accidental start switch off and lock power supply before starting any dismantling work Make sure that separator has come to a complete standstill before starting any dismantling work Remedy the cause The cause of the emergency must be remedied before attempting to restart the separator If the cause is not found an overhaul must be performed on the separator and all moving parts thoroughly checked Disintegration hazard Do not start the separator after an emergency stop without first remedying the cause of the emergency Make sure that the bowl is clean before restart 16 1810571 02 100293AA S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING Separator reassembled The separator must be fully reassembled with all cover
10. ritical soeeds This is normal and should pass without danger If vibration increases or continues at full speed press the emergency stop button and stand clear until the vibration stops The separator and heater are stooped when the emergency stop button is pushed The feed pump stops max 3 minutes afterwards The emergency stop will only reset when the speed sensor indicates zero speed Once the zero speed signal has been received the alarm reset button can be pushed The message Switch power on off will be displayed This refers to the EPC 50 power indside the control cabinet The cause of vibration must be determined and corrected before starting again see the Alarms and Fault Finding booklet Breakdown hazard Always observe the separator during start up after assembly If strong vibration occurs stop by using the Emergency Stop button and evacuate the room If the system is equipped with a vibration sensor and has control of heater and feed pump the Auto Start can be used 1810571 02 POO3606A 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 9 The separator speed and Start are shown alternately in the display until the separator is at full soeed 10 Check the oil feed temperature by pressing the button until TT1 is shown on the display Wait until the oil feed temperature is correct Heavy fuel mode 98 C Lube oil mode 95 C trunk engines or 90 C
11. s and guards must be in place and properly tightened Non compliance may lead to breakdown Electrical hazard Follow local regulations for electrical installation and earthing grounding Breakdown hazard Check that the power frequency is in agreement with the machine plate If incorrect resulting overspeed may cause breakdown Use the separation system for the purpose and within the limits specified by Alfa Laval Failure to do so could cause a violent breakdown 2 1810571 02 P003594A POO3606A S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 2 Check the oil sump level If necessary unscrew the level stick plug and top up until oil starts to run from the oil filling hole Too much or too little oil can damage the separator bearings Rotation Direction To check the rotation of the bowl do a quick start stop The motor fan must rotate in a clockwise direction If power cable polarity has been reversed the separator will rotate in reverse and vital rotating parts can loosen To make this check the Mode Selector Switch should be in the CIP position 1810571 02 PO003593A G0868542 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS
12. s and guards in place and tightened before unlocking the power supply and starting the system Breakdown hazard Assemble the separator completely before restart All couplings covers and guards must be in place and properly tightened Non compliance may lead to breakdown 1 9 Cleaning In Place The use of Cleaning In Place CIP equipment is recommended for best separation results For further information on the CIP equipment see the CIP booklet bookno 1817261 Before connecting the CIP equipment to the Separator the switch on the control cabinet must be turned to the CIP position This is to avoid accidental pumping of oil when the pipeline is opened up For instructions on how to connect the CIP equipment to the Separator see the Service Manual booklet For recommended CIP intervals see chapter 1 Technical Data in the System Reference Installation Instructions booklet 1810571 02 17 POO3594A 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 10 Automatic Operation For automatic operation the system must be equipped for automatic start Make sure the mode selection switch is in the AUTO position and Pr3 has the correct setting If local control is needed for example in an emergency situation turn the switch to manual mode This will automatically override the Pr3 setting The first startup must
13. te Operation After maintenance the system must be started locally If in Remote and is pushed in answer to the question Has the bowl been dismantled the system reverts to local control Follow the instructions in chapter 1 10 Automatic Operation page 18 20 1810571 02 S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 1 12 Emergency Operation In the event of a water transducer failure the system can still be operated by setting parameter Pr 4 in the EPC to standby mode see the Parameter List booklet The transducer is then disabled and the time to discharge automatically changes to 15 minutes Ne not connected is shown on the display All Alcap functions are disabled Water is removed only during a discharge A reminder alarm is activated after 24 hours If the system oil contains plenty of water and the oil density is less than 991 kg m emergency operation as described below is possible 1 12 1 Manual Operation of the Separation System In the event of extemely high water content the system can be run manually by a competent engineer using the following instructions Ensure all oil system manual valves are in the correct position Set the selection switch on the control unit to the MANUAL position Fit a jumper between terminals X9 1 and X9 2 in the EPC Start the feed pump Start the separator Heat the oil to the correct separating temperature Where th
14. ts to flash A sludge discharge is initiated The stop sequence LED changes to steady yellow and the green LED for separation system operation goes out when the sludge discharge is completed Stop is displayed If the heater is controlled by the EPC 50 it is switched off automatically When the oil feed temperature has started to drop the oil feed pump is switched off automatically When the separator comes to a complete standstill Standst is displayed Breakdown hazard Stop the separator by means of the control unit and not by turning off the motor 14 Never attempt to clean the bowl by manual discharge in connection with stop 1810571 02 OP ACTIVE A ALARM P00361SB S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING If the system is switched off for reasons other than high vibration it is not necessary to wait for the separator to slow down before restarting the process See 1 4 Manual Startup page 7 Breakdown hazard The system must not be restarted with the separator rotating if high vibration alarm has been given 1 7 Emergency Stop If an emergency situation occurs press the emergency stop button and evacuate the room Do not return until the separator has come to a complete standstill Disintegration hazard If unusually strong vibration occurs press the Emergency Stop button and leave the room Do not enter the roo
15. y vent air from the heater through the relief valve if applicable switch on the heater from the operator panel if applicable The operators panel must be active to allow operation 3 Press the SEPARATION button to activate the EPC 50 1810571 02 GO46600A P00361JB POO361LB 1 OPERATING S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS Before the separator can be started a number of questions scroll across the display which have to be answered Has the bowl been dismantled YES NO 4 Ifthe bowl has been dismantled press the button If no work has been carried out on the bowl press the button The start sequence begins and the text Start appears in the display If this is the first start answer YES Assembled according to manual YES NO 5 Ifthe bowl has been dismantled and assembled according to the instructions in the Service Manual press the button Bowl cleaned YES NO 6 Ifthe bowl has been cleaned press the button An automatic calibration of the system is carried out See display 7 Push the separator start button 8 1810571 02 POO3614A PO003613A POO3614A POO3614A GO46601A S TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS 1 OPERATING 8 Listen and observe Vibration may occur during start up when passing c
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