S-type Separation System

Operating Instructions
Printed Book No. Apr 2005 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 & Diesel Equipment SE - 147 80 Tumba Sweden

Copyright Alfa Laval Tumba AB 2005.

Contents
1 Operating................................................... 2
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.12.1 Before Startup ...................................2 Operators Panel ................................5 Startup .................................................6 Manual Startup..................................7 During operation .............................11 Stop.....................................................14 Emergency Stop .............................15 After Emergency Stop ..................16 Cleaning In Place ...........................17 Automatic Operation.....................18 Remote Operation ..........................20 Emergency Operation ...................21 Manual Operation of the Separation System..................................................21

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 Operating
1.1 Before Startup
1
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.
ING WARN

Breakdown hazard
Assemble the separator completely before start. All couplings, covers, and guards must be in place and properly tightened. Non compliance may lead to breakdown.

ING WARN

Electrical hazard
Follow local regulations for electrical installation and earthing (grounding).

ING WARN

Breakdown hazard
Check that the power frequency is in agreement with the machine plate. If incorrect, resulting overspeed may cause breakdown. 50 Hz? 60 Hz?
P0 0 3 6 0 6 A

ING WARN
Use the separation system for the purpose, and within the limits, specified by Alfa Laval. Failure to do so could cause a violent breakdown.

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P0 0 3 5 9 4 A

S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 OPERATING

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.
NOTE
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.
ON CAUTI
If power cable polarity has been reversed, the separator will rotate in reverse, and vital rotating parts can loosen.

NOTE
To make this check, the Mode Selector Switch should be in the CIP position.
P0 0 3 5 9 3 A

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

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.
P003682A

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 1 Technical Data in the System Reference/ Installation Instructions booklet.

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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 installation as follows:

16 15 10

OP
TT PT MT PT

HEATER
PT

SEPARATION STOP

ALARM

When the parameters have been set, End I/O (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 list booklet.

NOTE
Make sure that the operators panel is active (LED green) before operating.

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P00361HB

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.

EPC-50

INFO

DISCHARGE

Standst.
ENTER

OP ACTIVE

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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.
CIP
M AN

AUT
G046604A

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.

M AN

AUT
G046605A

The CIP mode is for use with Cleaning in Place equipment. See Cleaning In Place on page 17.
CIP

M AN

CIP
G046606A

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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.

Start the oil feed pump from the pump starter.

M AN

CIP

AUT

If necessary, vent air from the heater through the relief valve (if applicable). Switch on the heater from the operator panel (if applicable).
NOTE
The operators panel must be active to allow operation.

OP
TT PT MT PT HEATER 16 15 10 PT SEPARATION STOP

EPC-50

INFO

DISCHARGE

OP A CTIVE

ENTER
ALARM

Press the SEPARATION button to activate the EPC-50.

TT PT MT PT HEATER 16 15 10 PT

OP

SEPARATION STOP

EPC-50

INFO

DISCHARGE

OP A CTIVE

ENTER
ALARM

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P00361LB

P0 0 3 6 1 J B

G046600A

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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

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.
NOTE
If this is the first start, answer YES.
P0 0 3 6 1 3 A
M AN

Assembled according to manual? + = YES, = NO

P003614A
CIP

If the bowl has been dismantled and assembled according to the instructions in the Service Manual, press the + button.

Bowl cleaned? + = YES, = NO

An automatic calibration of the system is carried out. See display.

.

Push the separator start button.

AUT

P003614A G046601A

If the bowl has been cleaned press the + button.

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P0 0 3 6 1 4 A

If the bowl has been dismantled press the + button.

S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 OPERATING

Listen and observe. Vibration may occur during start up, when passing critical [Link] 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 stopped 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.
ING WARN
P003606A

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.

NOTE
If the system is equipped with a vibration sensor, and has control of heater and feed pump, the Auto Start can be used.

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

The separator speed, and Start. are shown alternately in the display until the separator is at full speed.
16 15 10

OP
TT PT MT PT HEATER PT SEPARATION STOP

EPC-50

INFO

DISCHARGE

OP A CTIVE

ENTER
ALARM

10 Check the oil feed temperature by pressing

the + button until TT1 is shown on the display.

11 Wait until the oil feed temperature is correct:

P00361KB

Heavy fuel mode 98 C Lube oil mode 95 C (trunk engines), or 90 C (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.
TT PT MT PT HEATER 16 15 10 PT

OP

SEPARATION STOP

EPC-50

INFO

DISCHARGE

OP A CTIVE

ENTER
ALARM

13 Adjust the backpressure to the normal running

P00361LB

value. Normal running backpressure is determined at commissioning. See the System Reference/Installation Instructions booklet.

10

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 OPERATING

1.5 During operation

Operator panel information

Observe the operator panel information: Heater operation LED lit (green) Separator system operation LED lit (green) 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.
NOTE
Regularly check connections. Tighten if necessary.

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

NOTE
The values displayed in the examples below are not recommendations.
TT PT MT PT HEATER PT

OP

16

15

10

SEPARATION STOP

More operational information may be read as required, by pressing the + button repeatedly.

EPC-50
INFO
DISCHARGE

OP A CTIVE

ENTER
ALARM

TT1 PT1

98 C 1.4 1.4 1.4 89

10300

PT4 PT5

Rpm

Run time 5 hours

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P003625A

Accumulated operating time in hours

P0 0 3 6 1 U A

Speed

P0 0 3 6 1 TA

Water transducer value

MT

P00361OA

Pressure, water outlet

P0 0 3 6 1 PA

Oil pressure, oil outlet

P00361QA

Oil pressure, oil inlet

P0 0 3 6 1 R A

Oil feed temperature. For the correct separation temperature see the System Reference/Installation Instructions booklet.

P0 0 3 6 1 MB

To return to normal display, i.e. the trigger value, and time to next sludge discharge, continue pressing the + button.

S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 OPERATING

ON CAUTI

ING WARN

Burn hazard
Avoid contact with hot surfaces. Process pipes, various machine surfaces, and processed liquid can be hot and cause burns.

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.

TT

PT MT PT

B PT

OP
HEATER

EPC-50
INFO

SEPARAT ION STOP

DISCHAR GE

ENTER
OP ACTIVE

ALARM

ON CAUTI

ING WARN

Slip hazard
Check all connections for leakage. Oil leakage may make the floor slippery.

Noise hazard
Use ear protection if noise levels are high

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P0 0 4 0 7 2 A

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1.6 Stop
To stop the system:

Stop the system by pushing the SEPARATION button on the operators panel. The yellow LED for separator stop sequence starts 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.
TT PT MT PT HEATER 16 15 10 PT

OP

SEPARATION STOP

EPC-50
INFO
DISCHARGE

OP A CTIVE

ENTER
ALARM

N CAUTIO

Breakdown hazard
Stop the separator by means of the control unit, and not by turning off the motor.

ON CAUTI
Never attempt to clean the bowl by manual discharge in connection with stop.

14

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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.
ING WARN

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.
ING WARN

If unusually strong vibration occurs, press the Emergency Stop button and leave the room Do not enter the room after an emergency stop while the separator is still rotating.

NOTE
In order to be able to restart, the system must be at standstill, and then the EPC power switched off on.

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G04659BA

Disintegration hazard

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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.

R DANGE
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

ING WARN

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
ING WARN

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

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 OPERATING

Separator reassembled

The separator must be fully reassembled with all covers and guards in place and tightened before unlocking the power supply and starting the system.
ING WARN

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.

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P003594A

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.
NOTE
If local control is needed (for example in an emergency situation), turn the switch to manual mode. This will automatically override the Pr3 setting.

NOTE
The first startup must always be carried out manually. The system can thereafter be run automatically as long as no changes are made to it between runs.

Press the SEPARATION button

TT PT MT PT HEATER 16 15 10 PT

OP

SEPARATION STOP

EPC-50

INFO

DISCHARGE

OP A CTIVE

ENTER
ALARM

Before the separator can be started, a number of questions scroll across the display which have to be answered:

18

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 OPERATING

Has the bowl been dismantled? + = YES, = NO

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.
P003613A

Assembled according to manual? + = YES, = NO

P003614A

If the bowl has been dismantled and assembled according to the instructions in the Service Manual, press the + button.

Bowl cleaned? + = YES, = NO

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.)
TT PT MT PT HEATER

OP

If the system is to be restarted, the system valves can remain in operating positions.

16

15

10

PT SEPARATION STOP

EPC-50

INFO

DISCHARGE

OP A CTIVE

ENTER
ALARM

P003614A

If the bowl has been cleaned press the + button.

P0 0 3 6 1 4 A

If the bowl has been dismantled press the + button.

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P0 0 3 6 1 L B

1 OPERATING

S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1.11 Remote Operation

Remote Operation
NOTE
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

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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. Nc (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/m3, 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:

1 2 3 4 5 6

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 there 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.
NOTE
Remove the jumpers after emergency operation.

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

When the separator is up to speed and the correct oil flow and temperature are achieved, close the bowl. Open SV15 for time specified in timer Ti60 (See Parameter List booklet).Wait 15 seconds. Open SV16 for time specified in timer Ti62. The bowl is now closed.

8 9

Temperature, flow, and backpressure must remain constant throughout. Remove the water outlet pipe at D.

22

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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:

Time (secs.) 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 600/860/861/865/866

40 40 70 30 50

0.7 1,1 1.9

4.5

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.

ING WARN

Breakdown hazard
During operation open SV16 for about 5 seconds every 10 to 15 minutes to ensure that the bowl remains closed.

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G065011A

3.0

1 OPERATING

S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

Discharge

1 2 3

Close oil feed V1 using SV1. Close water outlet V5 using SV5. Open SV10 to add displacement water as follows:
Time (secs.) 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 600/860/861/865/866

60 49 79 44 59

0.9 1.3 2.1 4.0 5.4

4 5 6

Open SV15 until a discharge is heard (about 3 seconds). Wait 15 seconds. Open SV16 for time specified in timer Ti62.

24

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

1 OPERATING

Open SV10 as follows:

Time (secs.) 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 600/860/861/865/866

40 40 70 30 50

0.7 1,1 1.9 3.0 4.5

8 9

Open V1. Open V5. throughout.

ING WARN

10 Maintain backpressure at normal setting

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.

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S-TYPE SEPARATION SYSTEM OPERATING INSTRUCTIONS

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