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Contents
Read this

2
3

first

Safety Instructions
Separator Basics
3.1 Basic principles of separation
3.2 Overview
3.3 Separating function
3.4 Mechanicalfunction
3.5 Definitions

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16
2A
21

28
32

Operating I nstructions
4.1 Operating routine

33

4-2

41

Cleaning the bowl

34

Service lnstructions

45

5.1 Periodicmaintenance
5.2 Maintenance Logs

46

eg

MS -

54

5.4
5.5
5.6

Gleaning

69

When changing oil

73

Common maintenance directions

74

5.7

Liftinginstructions

79

Check points

Dismantling/Assembly
6.1 General
6.2 Dismantling
6.3 Assembly
6.4 Feed and discharge pumps
6.5 Frame feet

49

81

82
83
93

102
111

Trouble-tracing

113

7.1 Troubletracng procedure


7.2 Mechanical function
7.3 Purification faults
7.4 Clarification faults

114

Technical Reference

123

8.1 Technicaldata
8.2 Basic size drawing,

124

114
120

122

separatorwithout pump

',28

8.3 Basic

size drawing,
separatorwith pump and no heater

8.4 Basic

129

drawing,
separatorwith pump and heater

8.5

Connection list,

with

8.6

size

pump

and

130

no heater / without pump

131

Gonnection list,

with

pump

and heater

'132

8.7 lnterface description


8.8 Lubricants
8.9 Drawings
8.f

0 Storage

and

133

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144

installation

155

lndex

165

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STOP

Study instruction manuals and observe the


warnings before installation, operation,
seruce and maintenance.

Not following the instructons can result


serious accidents.

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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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Read ffir's

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This manualis designed for operators and service


engineers working with the Alfa Lavalseparator
MAB 1049.-14124.

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For inforrnation concerning the functin of the


separator, see "3 Separator Basics" on page 15
and "4 Operating Instructions" on page 33.

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the separator has been delivered and installed


by Alfa Lavalas part of a processing system, this
manual is a part of the System Manual. ln this
case, study carefully all the instructions in the
System Manual.
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ln addition to this Separator Manual a Spare


Parts Catalogue, SPC is supplied.

This Separator Manual consists of:

Safety Instructions
i

Pay specialattention to the safety instructions for


the separator. Not following the safety instructions
can cause accidents resulting in damage to

equipment and serious injury to personnel.

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Separator Basics

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Read this chapter if you are not familiar with this


$pe of separator.

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Operati ng Instructions

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This chapter contains operating instructions for


the separator only.

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Read ths first

Service Instructions
This chapter gives instructions for daily checks,
cleaning, oil changes, seruicing and check points.

Dismantling I Assembly
This chapter contains step'by-step instructions for
dismantling and assembly of the separator for
service and repair.

Trouble-tracing
Refer to this chapter if the separator functions
abnormally.

lf the separator has been installed as part of a


processing system always refer to the Troubletracing part of the System Manualfirst.

Technical Reference

'

This chapter contains technical data concerning


the separator and drawings.

lnstallation
General information on installation planning.
Lifting instruction
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The centrifugalseparator includes parts that


rotate at high speed. This means that:

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Kinetic energy is high


Great forces are generated
Stopping iime is long

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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"

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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.

lncorrect operation and maintenance can result in


unbalance due to build-up of sediment, reduction
of materialstrengih, etc., that subsequently could
lead to serious damage and/or injury.

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The following basic safety instructions therefore


apply:

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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 mantenance
and operation, especially concerning
emergency stopping procedu res.
Use only Alfa Laval genuine spare parts
and the special tools supPlied'

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DANGER

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Disintegration hazards

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Use the separator only for the purpose
and parameter range specified by

Alfa Laval.

occurs, stop
separator and keep bowl filled with
liquid during rundown.
lf excessive vibration

When power cables are connected,


always check direction of motor rotation.
lf incorrect, vital rotating parts could
unscrew.

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ratio is correct for


power frequency used. lf incorrect,
subsequent overspeed may result in a
serious break down.
Check that the gear

Welding or heating of parts that rotate


can seriously affect material strength.
Wear on the large lock ring thread must
not exceed safety limit. Q-mark on lock
ring must not pass opposite Q-mark by
rnore than specified distance.

Inspect regularly for corrosion and


erosion damage. lnspect frequently if
process liquid

is

corrosive or erosive.

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Safety lnstrucfibns

DANGER
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 staing any
dismantling work.
Assemble the machine comPletelY

before start.
be in place.

All covers

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and guards must

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

WARNING
Crush hazards

Use correct lifting tools and follow lifting


instructions.

Do not work under a hanging load.

Noise hazards

Use ear protection in noisy


environments.

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CAUTION
Burn hazards

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Lubrication oiland various machine


surfaces can be hot and cause burns.

Gut hazards

Sharp edges on separator discs and lock


ring threads can cause cuts.

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Safety lnstructions

Warning signs in the 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
Type

of hazard

This type of safety instruction indicates a


situation which, if not avoided, could result in
fatal injury or fatal damage to health.

WARNING
Type

of hazard

This type of safety instruciion indicates a


situation which, if not avoided, could result in
disabling iniury or disabling damage to
health.
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CAUTION
Type

of

hazard

This type of safety instruction indicates a


situation which, if not avoided, could result in
light injury or light damage to health.

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This type of instruction indicates a situation


which, if not avoided, could result in damage
to the equipment.

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Safetqlnstructions

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Separator Basrbs
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Contents

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3.1 Basic principles of separation


3.1.1 Factors influencing the

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sepaiation result

16

17

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3.2 Overview

20

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3.3 Separatingfunction
3.3.1 Purification
3.3.2 Purifier bowl
3.3.3 Liquid seal
3.3.4 Position of interface
3.3.5 Clarification

21

z
23
24
- gravity disc

3.4 Mechanical function


3.4.1 Main parts
3.4.2 lnlet and outlet
3.4.3 Mechanical powertransmission
3.4.4 Brake
3.4.5 Sensors and indicators

3.5

24
26

28

28
29
?n

30

ot

Definitions

15

3.1

Basic prnciples of separation

Eeparator Basics

Basic prnciples of
separation

3.1

The purpose of separation can be:

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to free

a liquid

of solid

particles,

t0 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.

Sedim e ntatio n by gravity

Separation by gravity
A liquid mixture in a stationary bowlwillclear
slowly as the heavy particles in the liquid mixture
sink to the bottom under the influence of gravityA

lighter liquid rises while

a heavier liquid and

solids sink.

Continuous separation and sedimentation can be


achieved n a seling tank having outlets
arranged according to the difference in density of
the liquids.
Heavier particles in the liquid mixture will settlg
and form a sediment layer on the tank bottom.
Sedimentation in a seftling tank, with outlets making it
possible to separate the lghter liquid parts from the

heavier

Cenifugal separaton
ln a rapidly rotating bowl, the force of gravity is
replaced by centrifugalforce, 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 centrifugal solution

16

3 Separator

3.1.1

3.1 Basic principles of separation

Basics

Factors influencing the

separation result
Separatin g temperatu re
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

High vscosity (wik low temperature)


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Viscosity

Low viscosity facilitates separation. Viscosity can


be reduced by heating.

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Low viscosity (with high temperature)

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Density difference (specific gravity ratio)

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The greater the density difference between the


two liquids, the easier the separation. The density
difference can be increased by heating.

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High density

(with

low temperature)

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Low density (with high temperature)

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3.1

Basic principles of separation

Separator Basrcs
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Phase proportions

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An increased quantity of water in an oil will


influence the separating rsult through the
optimum transpoding capacity of the disc stack.
An increased water content in the oil can be
compensated by reducing the throughput in order
to restore the optimum separating efficiency.

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Size and shape of particles

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The round and smooth particle (A) is more easily


separated out than the irregular one (B).

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Rough treatment, for instance in pumps, may


cause a splitting of the particles resulting in
slower separation. Larger particles (1) are more
easily separated than smaller ones (2) even if

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they have the same density.

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The throughput

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lnfluence of size and shape

Sludge space - sludge

content

Sediment willaccumulate

on the

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inside periphery

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of the bowi. When the sludge space is filled up


the flow inside the bowlis influenced by the
sediment and thereby reducing the separating
efficiency. In such cases the time between
cleaning should be reduced to suit these
conditions.

Sludge accumulation

18

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The throughput sets the time allowed for the


separation of water and sediment from the oil. A
better separation result can often be achieved by
reducing the throughput, i.e. by increasing the
settling time.

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Separatw Basics

3,1

Basic principles of sepuation

Disc stack
A neglected disc stack containing deformed discs
or discs coated with deposits will impairthe

separating result.

Gravity disc
The position of the interface is adjusted by
altering the outlet diameter of the heavy liquid
phase, that is by exchanging the gravity disc.
A gravity disc with

a larger hole will move the


the bowlperiphery, whereas a
disc with a smaller hole will place it closer to the
bowl centre. For selection of gravity disc see
"3.3.4 Position of interface - gravity disc'on page
24.
interface towards

Gravity disc diameter adjust'the interface position

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3.2

Qverview

Separator Basics

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Overview
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The separator comprises a processing part and a


driving part. lt is driven by an electric motor.
Mechanically, the separator machine frame is
composed of a bottom part and a collecting cover.
The motor is flanged to the frame. The frame feet
have vibration damping.

The bottom part of the separator contains the


horizontal driving device, driving shaft with
coupling, a worm gear and a vertical spindle.

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The bottom part also contains an oil bath for the


worm gear, a brake and a revolution counter,
indicating speed.
The collecting cover contains the processing
parts of the separatot the inlet and outlets and
piping.

The liquid is cleaned in the separator bowl. This is


fitted on the upper part of the vertical spindle and
rotates at high speed inside the space formed by
the collectng cover.
All. connections have standardised numbers.
These numbers are used in the connection list
and the basic size drawing which can be found in
chapter "S Technical Reference'on page 123.

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20

SeparatorBasrbs

3.3

3.3 Separating function

Separating function

Unseparated process liquid is fed into the bowl


through the inlet pipe and is pumped via the
distributor towards the periphery of the bowl.
When the process liquid reaches holes of the
distributor; itwillrise through the channels formed
by the disc stack where it is evenly distributed.
The process liquid is continuously cleaned as it
flows towards the center of the bowl. When the
cleaned process liquid leaves'the disc stack it
rises upwards and leaves the bowl through outlet
(220). Separated heavy phase flows over the
gravity disc and leaves the bowlvia outlet (221).
The sludge and solid particles are forced out
towards the periphery of the bowl and collected
on the bowlwall, the sludge space.
The space between bowl hood and top disc is
normally filled with heavy phase.

21

3.3

SeParating function

SeParator Basics

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3,3.1

Purification

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Centrifugal force

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liquid

liquid Phase

Light liquid Phase

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Sediment (solids)

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BowlPads

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Diameter of inner outlet'

Dz

Hole diameter of gravitY disc'

Ds

Diameter of interface'

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3 Sqarator Basics

3.3 Sqarating

function

This bowl has two liquid outlets. The process


liquid flows through the centre and out under the

distributor.

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The liquid flows up and is divided among the

interspaces between the bowldiscs, where the


liquid phases are separated from each other by
action of the centrifugal force.
The heavy phase and any sediment move along
the underside of the bowldiscs towards the
periphery of the bowl, where the sediment settles
on the bowlwall. The heavy phase proceeds
along the upper side of the top disc towards the
neck of the bowl hood and leaves the bowl via the
gravity disc - the outer way (darkcoloured in
illustration).
The light phase moves along the upper side of the

bowldiscs towards the bowlcentre and leaves


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the bowl via the hole in the top disc neck


inner way (light coloured in illustration).

3.3.2

Purifier bowl

The figure shows the characteristic parts of a

purifier bowl:
a,

1.
2.

Top disc with neck.

The gravity disc, which should be chosen


according to directions in chapter "4.1.2
Selection of gravity disc" on page 35.

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Purifier bowl

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3.3 Sqarating

function

Sepuator Basics

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3.3.3 Liquid seal

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In a purifier bowl the liquid seal prevents the light


liquid phase from passing the outer edge of the
top disc, thus eliminating flow out through the
outer path. The bowl must therefore be filled with
sealing liquid before the process liquid is
admied. The sealing liquid will be displaced
slightly by the process liquid into a position that
forms the interface. The location of the interface
will be affected by the relative difference in
density between the phases, but is also
dependent on outer and inner diameters (Dt and
D, respectively).

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The sealing liquid:

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the light phase.

must not have higher


phase.

density than the heavy

can be soluble in the

heavy phase.

In most cases the heavy phase is used as sealing


liquid.
In some cases and only if the process liquid
contains a sufficient quantity of heavy phase
(more than 25%), the process liquid can be
supplied directly as the seal will form
automatically.

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Position of interface gravity disc

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The position of the interface is adjusted for


optimum separation by altering the pressure
balance of the two liquid phases oiland water
inside the separator.

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The purifier bowl is adiusted for separation liquid


mixtures with various specific gravity ratios by
altering the diameter of the outlet for the heavy
phase (Dr). The heavier or more viscous the light
phase and the largerthe liquid feed the srnaller
the diameter should be. For this purpose a
number of gravity discs with various hole
diameters is delivered with the separator.

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Exchange of gravity disc

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3 SeparaforBasrbs

3.3 Separating

function

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The gravity disc is

located inside the bowl hood. A


gravity discwith a larger hole will move the
towards the bowl periphery, whereas a
'nterface
with
a smaller hole will place it closer to the
disc
bowlcentre.
purifier bowl the position of the interface
should be located between the disc stack edge
and the outer edge of the top disc.
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When selecting a gravity disc for a purifier the


general rule is to use the disc having the largest
possible hole without causing a break of the water
seal.

Where to locate the interface depends on which


phase should be delivered pure, and on the
proportions between the amounts of the two
phases as well.

lf the light phase is wanted more free from the


neavy one, the interface should be placed
nearer the bowl periphery, however not more
than the outer edge of the top disc (the
gravity disc is too big), as this would break
he liquid seal.

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The heavier or more viscous the light phase


and the larger the liquid feed the smaller the
diameter should be.

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When the heavy phase (water) is wanted


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more
should be ptaced nearerthe bowl centre,
however not inside the outer edge of the
discs (the gravity disc is too small), as this
would prevent the liquid flow.

Gravity disc

25

3.3

Separatng fundion

Separator Basics

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3.3.5

Glarification

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Centrifugal force

This bowl has one liquid outletThe process liquid flows through the centre of the
distributor.

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Process

liquid

Bowlparts

The liquid flows up and is divided among the


interspaces between the bowl discs, where the
sediment is separated from the liquid by action of
the centrifugal force.
The sediment move along the underside of the bowl
discs towards the periphery of the bowl, where it
settle on the bowlwall.
The separation is influenced by changes in the
viscosiiy (separating temperature) or in the through-

Sediment (solids)

put

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SeparatorBasics

3.3 Separatng

tuncon

Clarifier bowl
The illustration shows characteristic parts of the
clarifier bowl:

1. Discharge collar
2. Bowl discwithout caulks (metal strips)

Clarifier bowl

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3.4 itqhanical

fundion

3.4

Mechanical function

3.4.'l

Main Parts

SeparatorBasics

1. Separator bowl.
2. Vertical driving device.
3. Horizontal driving device-

4.

Double PumP.

Separator with double PumP

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3.4 Mechanical function

Separator Basics

3.4.2 Inlet and outlet


The inlet and outlets consist of the following parts:

.
.
.
o

The inlet to pump (201 .1).


The outletfrom pump to heater (2O1.2).
The inlet

from

heater to separator (201.3).

The inlet forwater seal (206).


The outlet

for

clean oil (220).

The outlet forwater (221).


Drain of frame (460).

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Separator with in- and outlet pump

.
.
.
.
.

The inlet

(201).

The inlet

for

The outlet

water seal

for

(206).

clean oil (220).

The outletforwater (221).


Drain of frame (460).

See drawings and connection lists on pages 128


to 132.

Separator without pump

29

3.4 Mechanical function

3.4.3

Separafor Basics

Mechanical power
transmission

The main parts of the power transmission


between motor and bowlare illustrated in the
figure.

The friction coupling ensures a gentle start and


acceleration and at the same time prevents
'overloading of the worm gear and motor.

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The worm gear has a ratio which increase the


bowlspeed severaltimes compared with the
motorspeed. For correct ratio see chapter "8.1
Technicaldata" on page 124.

,1

' . ii'3
i

To reduce bearing wear and the transmission of


bowlvibrations to the frame and foundation, the
top bearing of the bowlspindle is mounted in a
spring casing.
The worm wheel runs in a lubricating oil bath. The
bearings on the spindle and the worm wheelshaft
are lubricated by the oil splash produced by the
rotating worm wheel.

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1.
2.
3.
4.
5.
6.

Bowlspindle
Top bearing and spring casing
Worm wheel
Worm
Friction coupling
Worm wheelshaft

.i

3.4.4

Brake
";
'

The separator is equipped with a hand operated


brake to be used when stopping the separator.
The use of the brake reduces the retardation time
of the bowl and critical speeds willtherefore be
quickly passed.
The brake lining acts on

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the outside of the bowl

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body.

.:
Applying (A) and releasing (B) of brake

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Separator8asrbs

3.4.5

3.4 Mechanical function

Sensors and indicators

Revolution counter
A revolution counter indicates the speed of the
separator and is driven from the worm wheel

II

i.,

shaft. The correct speed is needed to achieve the


best separating results and for reasons of safety.
The number of revolutions on the revolution
counter for corect speed is shown in chapter "8
Technical Reference" on page 123. Referto name
plate for speed padiculars.

i
i

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Revolution counter - soeed indicator

Sight glass
The sight glass shows the oil level in the worm
gear housing.

Sight glass - oil level

Cover interlocking switch (option)


When required, the cover interlocking switch
should be connected to the stader equipment so
that starting of the motor is prevented when the
separator hood is not (completely) closed.

31

3.5

Definitions

3.5

SeparatorBasr-cs

Definitions

ffi

Back pressure

Pressure in the separator outlet.

Clarification

Liquicl/solids separ:ation with the intention of separating partictes, normally


solids, from a liquid having a lower density than the particles.

Clarifier disc

optional disc, which replaces the gravity disc in the separator bowl, in the
case of clarifier operation. The disc seals off the heavy phase (water) outlet in
the bowl, thus no liquid seal exists.

Density

Mass per volume unit. Expressed in kg/ms at specified temperature, normally at

An

15

Gravity disc

L:;

"C.

the bowl hood for positioning the interface between the disc stack and
outer edge of the top disc, This disc is only used in purifier mode.

Disc in
the

lnterface

Boundary layer between the heavy phase (outer) and the right phase (inner) in
a separator bowl.

Liquid seal

Liquid in the solids space of the separator bowlto prevent the light phase from
leaving the bowlthrough the heavy phase ouilet, in purifier mode.

Major Service (MS)

overhaul of the complete separator, including bottom pad. Renewal of seals


bowl, gaskets in inleVoutlet, seals and bearings in bottom part.

in

Purification

Liquid/liquid/solids separation with the intention of separating two intermixed


and mutually insoluble liquid phases of different densities. solids having a
higher density ihan the liquids can be removed at the same time. The lighter
liquid phase (oil), which is the major part of the mixture, shall be purified as far
as possible.

Sediment (sludge)

Solids separated from a liquid.

Throughput

The feed of process liquid to the separator per time unit. Expressed in m3/h or
tivh.

Viscosity

Fluid resist?nce against movement. Normally expressed in centistoke


(cSt = mm 2/sec), at specified temperature

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4.1

Operating routine

4.1.1
4.1.2
4,1.3
4.1.4
4.1 .5
4.1.6
4.1.7
4.1.8

Before

first start

34

of gravity disc
Before normal start
Starting and running-up procedure
At full speed
During operaiion

35

Stoppingprocedure

39

Emergency stop

40

Seleciion

Gleaning the bowf

4.2.1
4.2.2
4.2.3

34

Removal

of separated sludge

The

operating procedure:

35
37

Before start

38
39

41

+
Staft and run-up

41

Disc stack

42

Assembly the bowl

42

+
Running

+
Stop procedure

33

4. 1 Aperating routine

Operating Instructions

Operating routine

4.1

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These instructions are related only to the


separator itself.

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NOTE
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lf there is a system manual, always follow the


operating instructions of the system manual.
lf there is no system manual the instructions
below are to be followed

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4.1.1

Before first start

Technical demands for connections and logical


limitations for the separator is described in the
chapter"S TechnicalFleference" on page 123 and

the documents:

ll

Separator with double pump

Jr

a. Technicaldata
b. Basic size drawing

c. Connection
d.
e.

list

lnterface description
Foundation drawing

Before first start the following checkpoint shall be

checked:

Fnsure the machine is installed conectly dnd


that feed-lines and drains have been flushed
clean.
Fill

oil in the gear housing. Fill

up to the

middle of the sighlglass. Use the correct


grade of oil. The separator is delivered
without oil in theworm gear housing. For
grade and quality, see "8.8 Lubricants" on
page 136.

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4 Operating lnstructions

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4.1 Operating routine

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4.1.2

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Selection of gravity disc

The separator is delivered with a set of gravity


discs. The diameter (d) of the gravity disc (2) sets
the position of the interface in the separator. The
separation efficiency can be optimized by
selection of the conect diameter for each
process.

.
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Separator bowl with top disc and gravity disc

4.1.3 Before normal start

Check these points before every start.

1.

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Ensure the bowl is clean and that the


separator is properly assembled.

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Check separator is assembled

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2.

Make sure that all inlet and outlet couplings


and connections have been correctly made
and are properly tightened to prevent
leakage.

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Check pipe connecons

35

4
4.1

3.

OPerating Insgucto!:

OPerating routine
for the
that the hooks and screws
fully tightened'
collecting cover are

Check

cover
Haok bolts for collecting

4.

the sight
the oil level' The middle,of
Refill if
level'
indicat"t inl *inimum
quatitY' see "B'8
i..*r.ary'
1nd
Page 136'

Read
olass

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Check oil level

5.

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Retease the brat<e'

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to B
moving it from pos' A
Release the brake by

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6.

of rotation of the
Make sure the dkection
to the sign on
motor and bowtcorresponds
the frame'

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4 Operating

4.1.4
1.

lnstructi ons

4.1 Operating routine

Starting and runnng-up


procedure

After starting the separator, visuatly check to


be sure that the motor and separator have
started to rotate.

2. Check the direction of rotation. The revolution


counter should run counter-clockwise.

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Direction of rotation
:

Be alert for unusual noises or conditions.


Smoke and odour may occur at the stad
when friction pads are new.

.)

Smoke and adour

4.

Note the normal occurrence of critical speed


vibration periods.

Vibration

37

4.1

5.

Operating routine

Operating Instructions

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current indicates when the separator


has come to fullspeed.
Motor

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Current increases when the coupling engages...

6.

During start the current reaches a peak and


then slowly drops to a low and stable value.
For

normal length

of

the start-up period see


page 124.

"8,1 Technical data" on

DANGER
Disintegration hazards

.... to decrease to a stable value when full speed has


been reached.

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When excessive vibration occurs, stop


separator and keep bowl filled with liquid
during rundown.
The cause of the vibrations must be

identified and corrected before the separator


is restarted.

Excessive vibrations may be due to incorrect


assembly or poor cleaning of the bowl.

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4.1.5 At full speed


1. lf running the separator

as a purifie supply

' ii

liquid (water) to form the liquid seal, Continue


until liquid (watefl flows out through the
heavy phase (water) outlet. The liquid (water)

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should have the same temperature as the


process liquid and be supplied quickly.

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2. Close the liquid (water) feed.


3. Start the oil feed slowly to avoid breaking the
water seal. Then

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fillthe bowlas quickly as

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possible.

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4.

Adjust to desired throughput.


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4.1 Operating rwtine


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4.i.G

During operaton

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Do regular checks on:

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feed inlettemperature (if applicable)


collecting tank level
souod/vibration of the separator

motor current.

4.'1.7

ir

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Stopping procedure

lf running the separator as a purifier, feed


sealing water.

2. Turn off the feed.


3. StoP the seParator.
+. Pull the brake (A).
Wait untilthe separator has come to a
complete standstill (2-5 minutes).
Release the brake (B) when the separator
at standstill.

is

Pullthe brake from positon Bto A

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5.

Manualcleaning should be carried out before


next start up. See "4.2.1 Bemoval of
separated sludge".

--S

DANGER
Entrapmenthazards

Make sure that rotating pads have come to a


complete standstill before starting any
dismantling work.

Gv
E

'r:

The revolution counter and the motor fan


indicate if the separator is rotating or not.

39

4.1

4 Operating lnstructions

Operatng routine

I'
c

4.1.8

Emergency stop

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The emergency stop is always installed according


to localsafety regulations. lt is often a button
placed on the wall nearthe separator or on the
control equipment.

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lf the separator begins to vibrate excessively


during operation, stop it immediately by switching
off the separator motor, e.g. by pushing the
emergency stop buon.

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DANGER

Emergency stop

Disintegration haza rds


t

Evaeuate the area around the separator. The


separator may be hazardous when passing
its critical speeds during the run-down.

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.

NOTE
After an emergency stop
fault must be identified.

the cause

of the

lf all pads have been ohecked and the cause


remains unclea contact Alfa Lavalfor
advice.

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40

4 Operating Instructions

4.2 Cleanng the bowl

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4.2

Gleaning the bowl

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The separated sludge is accumulating on the


inside surface of the separator bowl. How often
the separator needs to be cleaned, depends on
the amount of sediment entering the separator.
High solids content or high throughput has the
consequence that the cleaning needs to be done
more often.

lntervals for a specific case must be based on


experience.
Information about sludge content in the feed can
by using a lab centrifuge or to
run the separator for 2 - 3 hours and then stop
and open the bowito check the amount of sludge.
be achieved either

Sludge accumulaon

Then prolong or shorten the cleaning interval.

4.2.1

Removal of separated
sludge

Remove the sludge collected on the inside of the


bowlds follows:

1.

Stop the separator as described in "4.1.7


Stopping procedure" on page 39.

DANGER
Entrapment hazards
Make sure that rotating Barts have come to a
complete standstll before starting any
dismantling work.

The revolution counter and the motor fan


indicate if the separator is rotating or not.

2.

Dismantle the bowl as described in "6.2.1


Bowl" on page 83.

41

4.2

4 Operating Instructions

Cleaning the bowl

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4,2.2 Disc stack

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When the sediment is not sticky, the disc stack


can be cleaned by "hurling".

1. Clean the other bowlparts.


2. Assemble the bowl.
3. Close and lock the collecting cover.
4. Run up to full speed without Iiquid feed.
5. After "hurling" either continue separation or
stop and

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Bowl cleaning by'hurling"

lf the sediment adheres firmly, dissolve it by


submerging the distributor and the disc stack in a
suitable detergent.
lf "hurling" has no effect, clean the discs one by
one.

Assembly the bowl

Each bowl constitutes a balanced unit. Exchange


of any major part may need rebalancing of the
bowl. To prevent mixing of parts, e.g. in an
installation comprising of several machines of the
same type, the major bowl parts carry the
machine manufacturing number or its last three
digits,
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NOTE

i1

not interchanged.
Out of balance vibration will reduce ball
Be sure.bowl parts are

bearing life.

The assembly procedure is described


"6.3.3 Bowl" on page 99.

42

in

'"-1

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open the bowl and remove the

sediment.

4.2.3

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4 Operating lnstructions

4.2 Cleaning the bovvl

Purifier and clarifier bowl

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Purifier bowl

Clarifier bowl

The arrows indicate position of guides in the bowl.

Lubrieation needed
Molykote 1000

The assembly procedure is described in


"6.3.3 Bowl" on page 99.

4l

4.2

Cteaning the bowl

4 OPeratrng I nstructions

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44

3q
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Service Instructions

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5.1

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Periodic maintenance

46

5.1.1 lntroduction
5.1.2 Maintenance intervals
5.1.3 Maintenance Procedure
5.1.4 Service kits

46

69

5.4 Cleaning

5.4.1
5.4.2
5.4.3

46
48

Externalcleaning

69

Cleaning agents

70

Cleaning of bowldiscs

72

48

5.5 When changing oil


5.2 Maintenance Logs

5.2.1 DailY checks


5.2.2 Oilchange
5.2.9 lS - Intermediate Service
5.2.4 MS-Major Service

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directions

5.7

74
74
75
77

78

Lifting instructions

57
58
59
60
6'1

5.3.8

BowlsPindle cone and


bowl bodY nave

62

5.3.9

CouPling disc of motor

63

5.3.15

56

Common mantenance

5.6.1 Vibration
5.6.2 Balland roller bearings
5.6.3 Friction couPling
5.6.4 Shutdowns

52

54

5.3.10 Friction Pads


5.3.11 Brake
5.3.12 ToP bearing sPrings
5.3.13 Ball bearing housing
5.3.14 Worm wheel and worm;

5.6

cl

5.3.1 Corrosion
5.3.2 Erosion
5.3.3 Cracks
5.3.4 Disc stack Pressure
5.3.5 Lock ring; wear and damage
5.3.6 Radial wobble of bowl spindle
5.3.7 Height Position of

il

50

AA

bowl/ bowl sPindle

'il

73

OilchangeProcedure

49

Points

5.3 MS - Gheck

5.5.1

49

73

64

64
65
65

wear of teeth

oo

Cover interlocking switch (option)

68

45

5.1

Feriodic maintenance

5.1

Periodic maintenance

5.1.1

Introduction

Service lnstructons

Periodic, prevqntive maintenance reduces the


risk of unexpected stoppages and breakdowns.
Maintenance logs are shown on the following
pages in order to facilitate periodic maintenance.

DANGER
Disintegration hazards
Separator parts that are worn beyond their
safe limits or incorrectly assembled may
cause severe damage

5.1,2

or fatal

Periodie m ai nten ance prevents stoppages

injury.

Maintenancentervals

The followi.tg directions for periodic maintenance


give a brief description of which parts to clean,
check and renew at different maintenance
interuals.

The Service Logs for each maintenance interval


later in this chapter give detailed enumeration of
the checks that must be done.
Daily checks consist of simple check points io
carry out for detecting abnormal operating
conditions.

Oilchange intervalis every 1500 hours or at


least once every year if the total number of
operating hours is less than 1500 hours.
Time of operation b.etween oil changes can be

extended from the normal 1500 hours to 2000


hours if a synthetic oil of group D is used.
In seasonal operation

change the oilbefore a new

period.
lS - Intermediate Service consists of an overhaul
of the separator bowl, inlet and outlet every 3

months or 2000 operating hours. Seals in bowl


gaskets in the inleVoutlet device are
renewed.

and

46

Maintenance log

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J,3

5 Servrbe Instructions

5.1

Periodic maintenance

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MS -

Major Service consists of an overhaulof the


complete separator every 12 months or 8000
operatng hours. An lntermediate Service is
performed, and the flat belt, friotion elements,
seals and bearings in the bottom part are
renewed.

3-year servce conssts of service of the coupling


bearings, service of frame intermediate part and
renewal of frame feet. The rubber feet get harder
with increased use and age.

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Service schedule

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_1

Intermediate Service

lS

Major Service : MS
S-year Service

Other
Check and prelubricate spindle bearings of
separators which have been out of serviee for 6
months or longer,

NOTE
Do not interchange bowlparts!

of parts, e.g. in an
installation comprising several machines of
the same type, the major bowl parts carry the
machine manufacturing number or its last
three digits.
To prevent mixing

47

5,1

Periodic maintenance

Service Instructions

..-1

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5.1.3

i i.
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'

Maintenanceprocedure

At each Intermediate and Major Seruice, take a


copy of the Service Log and use it for notations
during the service.

An lntermediate and Major Service

''.

should be

,;

carried out in the following manner:

1.

't

Dismantle the parts as mentioned in the


Service Log and described in Chapter "6
Dismantling/Assembly" o n page 8'1.

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the separator pas on clean, soft


surfaces such as palfets.

3.

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Place

2.

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I

Inspect and clean the dismantled separator


parts according to the Service Log.

allthe parts delivered in the Service kit


while assembling the separator as described
in chapter "6 DismantlinglAssembly" on page
Fit

The assembly instructions have


references to check points which should be
carried out during the assembly.
81.

5.1.4

Service kits

Specialservice kits are available for Inlermediate


Service (lS) and MajorService (MS).
For other services the spare parts have to be
ordered separately
Note that the parts for lS are not included in the
MS kit.

The contents of the service kits are described in


the Spare Parts Catalogue.

Spare parts kits are available for lntermediate Service

and Maior Seruice

...]

E,

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NOTE

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Always use Alfa Laval genuine parts as


otherwise the warranty will become invalid.

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Lavaltakes no responsibifity forthe safe


operation of the equipment if non-genuine
spare parts are used.
Alfa

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5 Service lnstructions

5.2

5.2 Maintenance

Logs

Maintenance Logs

Keep a log of inspection and maintenance


performed. Parts repeatedly renewed should be
given gpecialconsideration. The cause of
repeated failures should be determined and
corrected. Discuss your problems with an
Alfa Laval representative and, when necessary
request a visit by an Alfa Laval Service engineer.
Rate of corrosioh and erosion and notification of
cracks should also be a part of this log. Nqte the
extent of damage and date the log entries so thal
the rate of deterioration can be observed.

5.2.1

Daily

checks

The following steps should be carried out daily.

Main component and activity

Part

Page

Notes

lnlet and outlet


Check for leakage

Collecting cover

Separator bowl
Check for vibration and noise

74

Worrn wheelshaft and gear casing


Check for vibration and noise
Oil levelin gear housing

Check

50

Electrical motor
Check for heat, vibration and noise

1) See manufacturer's

-1)

instruction

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49

5.2 Maintenance

Logs

Seruce lnstructions

5.2.2 Oil change


The oilchange and check of worm gearshould be
carried out every 1500. hours of operation.
Main component and

activity

Part

Page

Notes

Worm wheel shatt and gear housing

"

Check

Worm wheeland worm

66

Renew

Oil " in gear housing

50

When using a group D oil, time of operation


between oil changes can be extended from the
normal 15O0 hours to 2OOO hours.
When the separator is running for short periods,
the lubricating oilmust be changed every 12
months even if the total number of operating
hours is less than 1500 hours (2000 h).
In a new installation, or after replacement of gear,
change the oil after 200 operatng hours.

See

chapter "8 Technical Reference'on page

123 for further information.

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5,2 Maintenance Logs

"nh 5.2.3 lS - Intermediate Service

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Separator: MAB 1048-14/24
Total running hours:

Manufacture No.fYear:

Date:

Signature:

Name of

Local identification:

Product

No.:

881241-08-14

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nenew all parts included in the lntermediate Service kit (lS) and do the following activities.

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Main component and activity

Part

Page

Notes

,ii

Inlet and outlet, frame


Clean and inspect

Housings and frame hood

Separator bowl
Clean and inspect

Bowl hood
Top disc

Bowl discs

72

Distributor

Check

Threads on lock ring and bowl


body

59

Galling of guide surface

59

Corrosion, erosion, cracks

54-57

Power transmission
Change

Oilin oilsump

73

Electricalmotor
Lubrication (if nipples are fitted)

See sign on motor

Signs and labels on separator


Check attachment and legibility

Safety labelon hood

153

Other plates and labels

51

5.2

Maintenance Logs

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Service lnstructions

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5.2.4

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MS-Major Service

Name of plant:

Separator:

iffi,

Local identification:

Manufacture No.l/ean

MAB 1048.-14124

No.:

Totalrunning hours:

Product

Date:

Signature:

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881241-08-14

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Main component and

activity

Pa

Page

Notes

Inlet and outlet


Clean arid inspect

Threads of inlet

Separator bowl
Clean and check

Lock ring

59

Bowl hood
Top disc
Gravity disc

Bowldiscs

72

Distributor

Bowlbody

Renew
Worm

Corrosion

54

Erosion

56

Cracks

57

Disc stack pressure

58

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O-rings and sealings

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wheel shaft and gear housing

Check

Worm wheeland worm

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66

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Radial wobble of worm wheel

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shaft
Renew

Axial play of coupling disc

63

Oilin gear housing

50

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Seruice lnstructions

Main component and activity

5.2 Maintenance Logs

Part

Page

Notes

Vetical driving device


Clean and check

Bowlspindle

62

Buffers

Ballbearing housing
indentations

60

Radial wobble of bowl spindle

60

Ball bearings and top bearing


springs

62

Clean and check

Spring and brake shoe

64

Renew

Brake plug

64

Clean and check

Friction coupling

77

Renew

Friction pads

77

Lipsealring

77

Vibration dampers

111

Position of coupling disc

63

Safeg label on collecting


cover

153

Cover interlocking switch

68

Renew

Brake

Friction coupling

Frame feet
l:

Renew

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Electricalmotor
l'"

Clean and check

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Lubrication (if nipples are fitted)

Signs and labls on separator

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Check attachment and readability,


replace if needed

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Mon itoring equipment (option)


Functon check

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5.3

5 Sevice lnstructions

MS - Check points

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5.3

i..ii

MS - Check points

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5,3.1

Corrosion

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Evidence of corrosion attacks should be looked


for and rectified each time the separator is
dismantled. Main bowlparts such as the bowl
body, bowl hood and lock ring must be inspected
with particular care for corrosion damage.

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DANGER

Disintegration hazard
Inspect regularly for corrosio n damage.
lnspect frequently if the process liquid is
corrosive.

Always contact your Alfa Laval representative if


you suspect that the largest depth of the
corrosion damage exceeds 1 ,0 mm or if cracks
have been found. Do not continue to use the
separator until it has been inspected and given
clearance for operation by Alfa Laval.

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Main

bowl parts
i

Cracks or damage forming a line should be


considered as being particularly hazardous.

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Non-staintess steeland cast iron pas

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Corrosion (rusting) can occur on unprotected


surfaces of non-stainless steel and cast iron.
Frame parts can corrode when exposed to an
aggressive environment.

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Stainless steel
Stainless steel parts corrode when in contact with
either chlorides or acidic solutions. Acidic
solutions cause a general conosion. The chloride
corrosion is characterised by localdamage such
as pitting, grooves or cracks. The risk of chloride
corrosion is higher if the surface is:

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Corrosion forming a line


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5 Service lnstructr'ons

.
.

5.3 MS - Check

points

Exposed to a stationary solution.


In a crevice.

Covered by deposits.
Exposed to a solution that has a low pH
value.

Corrosion damage caused by chlorides on


stainless steelbegins as smalldark spots that
can be difficult to detect.

Inspect closely for all types of damage by


corrosion and record these observations
carefully.
Polish dark-coloured spots and other
corrosion marks with a fine grain emery cloth.
This may prevent further damage

DANGER

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Polish corrosion spots

Disintegration hazard

Pits and spots forming a line may indicate


cracks beneath the surface.
All forms of cracks are a potential danger
and are totally unacceptable.
Renew the part if corrosion can be suspected
of affecting its strength or function.

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5 Service lnstructions

5.3 MS - Checkpoints
Other metal parts
Separator parts made of materials otherthan
steel, such as brass or other copper alloys, can
also be damaged by corrosion when exposed to
an aggressive environment. Possible corrosion
damage can be in the form of pits and/or cracks.

5.3.2

Erosion

Erosion can occur when particles suspended in


the process liquid slide along or strike against a
surface. Erosion can become intensified locally
by flows of higher velocity.

DANGER

Max.

I mm

Maximum depth of damage

Disintegration hazard
Inspect regularly forerosion damage. Inspect

frequently if the process liquid is erosive.

Always contact your Alfa Laval representative if


the largest depth of any erosion damage exceeds
1.0 mm. Valuable information as to the nature of
the damage can be recorded using photographs,
plaster impressions or hammered-in lead.
Erosion is characterised by:

.
.

Burnished traces in the material.


Dents and pits having
surface.

a granular and shiny

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Surfaces particularly subjected to erosion are:

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The underside of the distributor in the vicinitv


of

2.

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the distribution holes and wings.

The internalsurface of the bowl body that


faces the conicalpart of the distributor.

Look carefully for any signs of erosion damage.


Erosion damage can deepen rapidly and.
consequently weaken parts by reducing the

thickness of the metal.

Erosion check points

56

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5 Seruice lnstructions

5.3

MS - Check points

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DANGER

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Disintegration hazard

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Erosion damage can weaken parts by


reducing the thickness of the metal.

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Renew the pa if erosion can be suspected


of affecting its strength or function.

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5.3.3

Gracks

Cracks can initiate on the machine after a period


of operation and propagate with time.
.

Cracks often initiate in an area exposed to


high cyclic material stresses. These are
called fatigue cracks.

Cracks can also initiate due to corrosion in an


agg ressive environ ment.

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Although very unlikely, cracks may also occur


due to the low temperature embrittlement of
certain materials.

The combination of an aggressive environment


and cyclic stresses will speed-up the formation of
cracks. Keeping the machine and its parts clean
and free from deposits will help to prevent

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corrosion attacks.

DANGER
Disintegration hazard

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All forms of cracks are potentially dangerous


as they reduce the strength and functional
ability of components.

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Always renew a part if cracks are present.

is particularly impoant to inspect for cracks in


rotating parts.
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57

5.3

MS

- Check points

5 Seruice lnstrucrtona

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Always contact your Alfa Laval representative if


you suspect that the largest depth of the damage
exceeds 1.0 mm. Do not continue to use the
separator until it has been inspected and cleared
for operation by Alfa Laval.

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5,3.4

Disc stack pressure

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The lock ring (1) should press the bowl hood (2)
firmly against the bowlbody (3). The hood in turn
should exe a pressure on the disc stack (4),

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clamping it in place.

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NOTE

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lnsufficient pressure in disc stack can cause


out of balance vibration and reduced lifetime
of ball bearings.

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Compress the disc stack by tightening the lock


ring, see chapter "6.3.3 Bowl" on page 99.

Correct pressure is obtained when it is possible to


tighten the lock ring so far Qy hand that the
$-mark on the lock ring is positioned 60" - 90'
before the mark on the bowl hood.

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To achieve this, add an appropriate number of


discs to the top of the disc stack beneath the top

disc.

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Then advance the lock ring by giving the spanner


handle some blows tillthe Q-marks are passed
and the bowl is fullv assembled.

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5.3 MS - Check points

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5.3.5

Lock ring; wear and damage

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Excessive wearor impact marks on threads,

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guide and contact surfaces of the lock ring, bowl


hood and bowlbody may cause hazardous
galling.
Check the thread condition by tightening the lock
ring after removing the disc stack and bowl hood

O-ring from the bowl.


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DANGER

'!.

Disintegration hazards

h"

Wear on large lock ring thread must not


exceed safety limit. The Q-mark on lock ring
must not pass opposite Q-mark by more than
the specified distance.

li'^-

new bowlthe alignment marks on the lock


ring and the bowlhood are exactly opposite each
In a

other.

thread wear is obserued, mark the bowl hood at


the new position of the alignment mark on the
lock ring by punching in a new alignment mark.
lf

Contact Your Alfa.Laval representative

.
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lf the originalmark on the lock ring passes


the corresponding mark on the bowl hood by
more than 250 which corresponds to 45 mm.
lf the alignment marks become illegible. The
thread wear needs to be inspected and the
new position of alignment marks determined.

Maximum wearA=28

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Damage

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The positions of the threads, contact and guide


surfaces are indicated by arrows in the
illustration.

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Clean the threads, contact and guide surfaces


with a suitable degreasing agent.

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Check for burrs and protrusions caused by


impact. Watch your fingers for sharp edges.

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59

5,3

MS

5 Sevice

- Checkpotnts

Instructtons

lf damage is established, rectify using a


whetstone or fine emery cloth (recommended
grain size 240).
lf the damage is considerabler use a fine singlecut file, followed by a whetstone.

5.3.6
.

Radialwobble of bowl
spindle

Spindle wobble is indicated by rough

bowlrun

(vibration).

The bowt spindle wobble should be checked if the


bowl spindle has been dismantled or if rough bowl
running (vibration) occurs.

NOTE
Spindle wobble willcause rough bowl run.
This leads to vibration and reduces lifetime

of

ballbearings.

Check the wobble before mounting the bowl.

Maximum spindle wobble 0,15 mm

Before measuring, make sure that the buffer


plugs are properly tightened.

Fit a

the

.
.
.

dial indicator in a suppod and fasten it to

frame.

Remove the motor to get access to the


coupling drum. Use the coupling drum to
revolve the spindle manually.

Measure the wobble at the top of the tapered


end of the spindle. Maximum permissible
radial wobble is 0.15 mrn.

wobble is too large, renew allthe ball


bearings on the spindle.
lf

Measure wobble after assembly. lf it is still


excessive, the spindle is probably damaged and
must be renewed, contact your Alfa Laval

representative.

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Rotate spindle by hand

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Service Instructons

5.3 MS - Check points

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5.3.7

Height positon of
bowl

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bowl/

spindle

Wheneverthe bowl spindle has been rernoved, its


height position relative to the frame must be
checked.
The bowl must be in place in the separator. The
lock ring tightened. Make sure the alignment
marks Q on bowl hood and lock ring are in front of
each other.

For correct height position the distance (H)


between the top face of the large lock ring and the
top rim of frame must be 34-36 mm.
Alfa Laval ref.537541,

eu. 0

Adjustment is made with adjustment rings (1)


under the thrust bearing at the bottom of the
spindle.

61

5.3 MS - Checkpoints

5.3.8

Seruice Instructions

Bowl spindle cone and bowl


body nave

lmpact marks on the spindle cone or in the bowl


body nave may cause poor fit and out-of-balance
vibrations.

(!#,

The bowl spindle and the nave should also be


checked if the bowl spindle has been dismantled
or if the bowl runs roughlY.
Corrosion may cause the bowl to stick firmly to
the spindle cone and cause difficulties during the
next dismantling.

Remove any impact marks with a scraper


and/or whetstone,

Rust can be removed by using a fine-grain emery


cloth (e.9. No. 320). Finish with polishing paper
(e.9. No.600).

Oilthe bowl spindle

to

prevent corrosion

NOTE
Always use a scraper with great care. The
conicity must not be marred.
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5 Service lnstructions

5.3 MS - Checkpoints

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5.3.9

Coupling disc of motor

The position of the coupling disc on th motor


shaft is establishing the location of the friction
pads inside the coupling.
lf the coupling disc is loosened without first
marking its position on the motor shaft, the
correct position must be determined again.

1.

Measure the distance on the frame.

Frame distance

2.

t;

Measure the distance on the motor.

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Motor distance

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The coupling disc is in correct positicn when
frame distance (1) is 32 mm largerthan motor
distance (2), see the illustration.

Position of coupling disc

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5.3

MS

- Checkpoinfs

5.3"10 Friction pads


Worn or oily pads will cause a long running-up
period. Renew allthe pads even when only one of
them is worn.
lf the pads are oily:

the pads as well as the inside of the


coupling drum with a suitable degreasing

Clean

agent.

Roughen up the friction surfaces of the pads


with a coarse file.
Fricon pads

5.3.11 Brake
A worn or oily brake lining will lengthen the
stopping time. Remove the bracket with the
brake. Examine the friction element.

Renew the lining when


worn down.

the friction material

is

Remove rivet head by drilling.


Punch out

rivet,

Fasten the new lining to brake shoe with


a new rivet.

the friction element is oily: Clean the brake


lining and the outside surface of the bowl
body with a suitable degreasing agent.
lf

Checking the brake


Afterthe brake assembly has been fitted, release
the brake and rotatethe bowl slowly by hand. lf a
scraping noise is heard, the friction element is
probably touching the bowl surface.
Fornormal stopping time see "8.1 Technical data"
on page 124.

64

Friction lining

Service Instructions

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5 Service lnstructions

5,3

MS - Check points

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5.3.12 Top bearing springs


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Weakened or broken. butfer sprngs (2) may give


rise to machine vibration (rough bowl running).
The condition (stiffness) of a spring can hardly be
determined without using special testing
equipment. So, an estimation of the spring
condition must be based on the knowledge of the

machine run before the overhaul. lt is


recommended, however, to renew allthe springs
at the annualoverhaul.
In case of a sudden spring fracture, all springs
should be renewed even when only one spring
has broken.

5.3.13 Ball bearing housing

Defective contact surfaces for the buffers on


the ball bearing housing may give rise to
machine vibration (rough bowl running).

Examine the contact surface for the buffers (1 ) on


the ball bearing housing (3). ln case of defects
(indentations deeper than 0.1 mm) renew the
housing as wellas buffers and springs.

1. Radial buffer

2. Buffer spring
3. Ball bearing housing
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5.3

MS

5 Service Instructions

- Checkpoints

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5.3.14 Worm wheel and worm;


wear of teeth
Check the teeth of worrn wheel and worm for
wear, see " Tooth appearance examples" on page

67.

Examine the contact surfaces and compare the


tooth profiles. The gear may operate satisfactorily
'even when worn to some degree.

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NOTE

Renew both worm wheel and worm at the


same time, even if only one of them is worn.

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wheel
2. Worm (part of bowl spindle)
1. Worm

NOTE
Presence of metalchips in the oilbath is an
indication that the gear is wearing
abnormally.

When using mineral-type oil in the worm gear


housing, the presence of black deposits on the
spindle parts is an indication that the oil base has
deteriorated seriously or that some of the oil
additives have precipitated. lf pits are found on
the worm

geal

the cause

could be that the

additives are not suitable for this purpose.


ln allthese cases it is imperative to change to a
hightemperature oil. See chapter "8.8
Lubricants" on page 136.

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5.3

MS - Check poinfs

Tooth appearance examples


Satisfactory teeth
Uniform wear of contact sudaces. Surfaces are
smooth.
!

Good contact surfaces willform on the teeth


when the gear is subjected to only moderate load
during its running-in period.

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Satisfactory teeth

Worn teeth
Permissible wear is as a rule 1/3 of the thickness
of the upper part of a tooth, provided that

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the wear is uniform over the whole of the


flank of a tooth
and all teeth are worn in the same way.
Worn teeth

Spalling
Small bits of the teeth have broken off, so-called
spalling. This is generally due to excessive load
or improper lubrication. Damage of this type need
not necessitate immediate replacement, but
careful checking at short intervals is imperative.

Spalling

Pitting
Small cavities in the teeth, so-called pifting, can
occur'through excessive load or improper
lubrication. Damage of this type need not
necessitate immediate rep lacement, but caref ul
checking at short intervals is imperative.

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Pitting

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67

5.3

MS - Check points

Serurce Instructions

5.3.15 Cover interlocking switch


(option)
Alfa

Laval

rd.505868, reu.2 / 557fr7, rau.

Switch rating, voltage: Max. 500 V

current: Max. 3 A
For other technical information see chapter "8.5
Connection list, with pump and no heater/without
pump" on page 131, .8.6 Connection list, with
pump and heate" on page 132 and chapter "B.T
lnterface description" on page 133.

760. Cover interlocking

68

switch (frame top part)

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Service lnsfrucfibns

5.4 Cleaning

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5.4

Cleaning

5.4.1

External cleaning

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The externalcleaning of the frarne and motor


snouH be restricted to brushing, sponging or
wiping while the motor is running or is still hot.

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Use a sponge or cloth and a brush when cleaning

Never wash down a separator with a direct water


stream.

,
;

Totally enclosed rnotors can be damaged by


direct hosing to the same extent as open motors
and even more than those, because:

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Some operators believe thatthese motors are


sealed, and normally they are not.

A water jet played on these motors will


produce an internal vacuum, which will suck
the water between the metal-to-metal contact
surfaces into the windings, and this water
cannot escape.

Never wash down a separatorwith a direct water


stream or playing a water jet on the motor

Water directed on a hot motor may cause


condensation resulting in short-circuiting and
. ,
internalcorrosion.

Be careful even when the motor is equipped with


a protecting hood. Never pfay a water jet on the

ventilation grill of the hood.

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69
Ftr

5.4

5 Eeruice lnstructions

Cleaning

5.4.2

Gleaning agents

When using chemicalcleaning agents, make sure


you follow the generalrules and supplier's
recommendatio ns regarding ventilation,
protection of personnel, etc.

For separator bowl, inlet and outlet


A chemical cleaning agent must dissolve the
deposits quickly without attacking the material of
the separator parts.

For cleaning of lube oil separators the most


important function of the cleaning agent is to
be a good solvent for the gypsum in the
sludge. lt should also act as a dispersant and
emulsifier for oil. lt is recommended to use
Alfa Laval cleaning liquid for lube oil
separators which has the above mentioned
qualities. Note that carbon steel parts can be
damaged by the cleaning agent if submerged
for a long time.

oil sludge

mainly consists of complex


organic substances such as asphaltenes.
The most important propedy of a cleaning
liquid for the removal of fuel oil sludge is the
ability to dissolve these asphaltenes.
Fuel

Alfa Laval cleaning liquid of fueloil


separators has been developed for this
purpose. The liquid is water soluble, non-flammable and does not cause corrosion of
brass and steel. lt is also gentle to rubber and
nylon gaskets in the separator bowl.Before
use, dilute the liquid with water to a
concentration of 3-5%. Recommended
cleaning temperature is 5G70'C.

CAUTION
Skin

irritation hazard

Read the instructions on the label of the


plastic container before using the cleaning
liquid.

Always wear safety goggles, gloves and


protective clothing as the liquid is alkaline
and dangerous to skin and eyes.

70

Alfa Laval eleaning liquid for lube and fuel oil


separators s available in 25 litres plastic containers

5 Seruice lnstructions

5.4

Cleaning

For pas of thedriving devices


Use

white spirit, cleaning-grade kerosene or

diesel oil.

1. Worm wheel

2. Worm

Oiling (protect sudaces against corrosion)


Protect cleaned carbon steel parts against
corrosion by oiling. Separator parts that are not
assembled after cleaning must be wiped and
coated with a thn layer of clean oil and protected
from dust and dirt.

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71

5 Service lnstructions

5.4 Cleaning

5.4.3

Gleaning of bowl discs

Bowldiscs
Handle the bowl discs carefully so as to avoid
damage to the surfaces during cleaning.

NOTE
Mechanicalcleaning is likely to scratch the
deposits to form
quicker and adhere more firmly
disc surfaces causing

A gentle chemicalcleaning is therefore

preferable to mechanical cleaning.

Remove the bowldiscs from the distributor


and lay them down, one by one, in the

1.

cleaning agent.

the discs remain in the cleaning agent


untilthe deposits have been dissolved. This
will normally take between two and four

2.

Let

Put the discs one by one into the cleaning agent

hours.

Finally clean the discs

3.

with a soft brush.

CAUTION
Cut hazard
The discs have sharp

edges.

I
Clean the discs with a soft brush
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72
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5 Serube Instructions

5.5 When changing oil

5.5 When changing oil


Check at each oilchange
[:.t'11

Check the teeth of both the worm wheel and


worm for wear, see "5.3.14 Worm wheel and
worm; wear of teeih" on page 66.

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5.5.1 Oil change procedure


NOTE
Before adding or renewing lubricating oil in
the worm gear housing, the information
concerning different oil groups, handling of
oils, oil change intervals etc. given in
"8.8 Lubricantg" on page 136 must be well
known.

i'

t.

1.

Place a collecting tray under the drain hole,


remove the drain plug and drain off the oil.

CAUTION
Btrn hazards
Lubricating oiland various machine surfaces
can be sufficiently hot to cause burns.

2.

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'[,

Fill new oil in the worrn gear housing. The oil


level should be slightly above middle of the
sight glass
The correct oilvolume is 0.8litres.

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Check oillevel

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73

5.6 Common maintenance drections

5 Service lnstructions
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5.6

Gommon
mantenance

directions

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5.6.1 Vibration

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Vibration or noise often indicates that something


is incorrect.
Use vibration analysis nstrument to periodically
check and record the level of vibration. See the

illustration where to take measurements.


The level of vibration should not exceed 9.0 mm/s
(RMS). Stop the separator and identify the cause.
lf the separator begins to vibrate excessively
during operation, proceed as described in "4.1.8

l,

Emergency stop" on page 40.

.i1

74

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5.6 Common maintenance directions

Seruice lnstrucbns

5.6.2 Balland roller bearings


Specialdesign bearings forthe bowl spindle

2
3

The bearings used for the bowlspindle are


specialto withstand the speed, vibration,
temperature and load characteristics of high-

speed separators
Only Alfa Lavalgenuine spare pads should be
used.
A bearing that in appearance looks equivalent to
the correct may be considerably different in

various respects: inside clearances, design and


tolerances of the cage and races as well as
material and heat treatment.

1.
2.
3.
4.

Outer race
Ball/roller
lnner race
Cage

NOTE
Using an incorrect bearing can cause a
serious breakdown with damage to
equipment as a result.
Do not re-fit a used bearing. Always replace
it

with a new.

Dismantling
no driving-off sleeve is
included in the tool kit, remove the bearing from
its seat by using a puller. lf possible, let the puller
engage the inner ring, then remove the bearing
with a steady force untilthe bearing bore
completely clears the entire length of the
cylindrical seat.
For bearings where

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The puller should be accurately centred during


dismantling; otherwise, it is easy to damage the
seating.

NOTE

For bearngswhere no driving-offsleeve rb includedin


the tool Rit, use a puller when removing bearings

Do not hit with a hammer directly on the


bearing.

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75
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5.6 Common maintenance

5 Sevice lnstrucfions

directions

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Gleaning and inspection

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Check shaft (spindle) end and/or bearing seat in


the housing for damage indicating that the
bearing has rotated on the shaft (spindle) and/or
in the housing respectively. Renew the damaged
pat(s), if the faults cannot be remedied by
polshing.

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.6i;

Assembly

r'

Leave new bearings in originalwrapping until


ready to fit. The anti-rust agent protecting a
new bearing should not be removed before

.l

USE.

the greatest cleanliness when handling


the bearings.
Use

To

facilitate assembly and also reduce the

risk of damage, first clean and then lightly oil


the bearing seating on shaft (spindle) or
alternatively in housing, with a thin oil.

Clean and lghtly oilthe bearng seating before


assemb/y

When assembling ball bearings, the bearings


must be heated in oil to max. 125 "c.

NOTE
Heat

the bearing

in

a clean container.

Use only clean oilwith

250

a flash

point above

"c.

The bearing must be well covered by the oil


and not be in direct contact with the sides or
the bottom of the container. Place the
bearing on some kind of support or

The bearing must not be in direct contact with the

container

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suspended in the oil bath.

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WARNING

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Bum

hazards

Use protective gloves


heated bearings.

76

when

i
handling the

5 Service Instructions

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5.6 Common maintenance directions

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There are severa basic rules for assembling


cylindrical bore bearings:

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Never directly strike a bearing's rings,

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cage or rolling elements while


assembling- A ring may crack or metal
fragments break off.
Never apply pressure to one ring in order
to assemble the other.

Use an ordinary hammer. Hammers with


soft metal heads are unsuitable as
fragments of the metal may break off and
enter the bearing.
Make sure the bearing is assembled at a
right angle to the shaft (spindle).

lf necessary use a driving-on sleeve that


abuts the ring which is to be assembled with
an interference fit, othenvise there is a risk
that the rolling elements and raceways may
be damaged and premature failure may
follow.

Use a driving-on sleeve for bearings that are not


heated

5.6.3

Friction couplng

the separator does not attain full speed within


about 2 minutes, the friction elements or-the
coupling may be worn or greasy, The friction
elements must then be replaced with new ones or
thoroughly cleaned from grease.
lf

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Before the friction coupling is assemblec,


examine all parts thoroughly for wear and
corrosion.

A worn coupling increase

start-up time

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77,'

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5.6 Common maintenance drqtions

Service lnstructions
,,,

5.6.4

Shutdowns
tr..$

lf the separator is shut down for a period of time,


the following must be carried out:

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Remove the bowl, according to instructions in


chapter "6 Dismantling/Assembly" on page

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81.

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NOTE

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The bowl must not be left on the spindle


during standstill for more than one week.

Vibration in foundations can be transmifted


to the bowl and produce one-sided loading of

Dismantling for shutdown

the bearings.
The resultant indentations in the ball bearing
races can cause premature bearing failure.
s:.

*tf

Protect cleaned carbon steel pas against


corrosion by oiling. Separator parts that are
not assembled after cleaning should be wiped
and protected against dust and dirt.

Grings

be removed.

The

lf the separator has been shut down for more


than 12 months, a Major Service (MS) should
be carried out.

should

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5 Eervcelnsfrucfions
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5.7 fting instructions

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5.7

Lifting instructions

Nfa Laval ref.558102" rcu 0

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For lifting parts and assemblies of pads use lifting


slings, working load limit (WLL): 300 kg.

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Lifting the separator

1.

Remove the separator bowl, see dismantling


instructions in "6.2.1 Bowl" on page 83.

2.

Attach endlesi slings or cables to the


separator as illustrated. Check that the.
hinged bolts fixing the separator cover is
tightened.

3.

Lft and handle with care.

Weight to lifk 200 kg.

NOTE
Remove the separator bowl before lifting to
prevent bearng damage.

WARNING
Crush hazards
A dropped separator can cause accidents
resulting in serious injury to persons and
damage to equipment.

Do not lift the separator in any other way

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79

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5
5.7

Lifting instructions

BO

Service lnstructions

DismantlinglAssemblY

Gontents
6.1

General

82

6.1.1
6.1.2
6.1.3

References to check Points

82

Tools

82

Tightening of screws

82

6.2 Dismantling

B3

6-2.1
6.2.2
6.2.3

Bowl

83

Vertical driving device

86

Horizontal driving device

89

93

6.3 Assembly

6.3.1 Horizontal driving device


6.3.2 Vertical driving device
6.3.3 Bowl

93

96
qq

6.4 Feed and discharge PUmPS

102

6.4.1 GenraldescriPtion
6.4.2 Dismantling
6.4.3 AssemblY

102

Mounting

107

111

6.5 Frame feet

6.5.1

103

of new frame feet

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81.

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6 DismantlinglAssembly

6.1 Qeneral

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General

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The parts must be handled carefully. Don't place


parts directly on the floor, but on a clean rubber
mat, fibreboard or a suitable pallet.

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6.1,1

References

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to check points

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In the text you will find references to the check


point instructions in Chapter 5. The references

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appear in the text as in the following example:

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Gheck point
"5.3.4 Disc stack pressure" on page 58.

In this example, look up check point "5.3.4 Disc


stack pressure" on page 58 for further

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instructions.
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6.1.2

Tools

Special tools from the tool kit shall be used for


dismantling and assembly. The specialtools are
specified in the Spare Parts Catalogue.
For lifting parts and assemblies of parts use lifting
slings, working load limit (WLL): 300 kg.

6.1.3

Tightening of screws
li

When tightening screws, use the torques stated in


the table below unless othenvise stated. The
figures apply to lubricated screws tightened with a

t::

torque wrench.
METRIC THREAD

;i

Torques in Nm
Stainless
steel

Carbon
steel

M6

M8

17

20

M10

33

39

M12

57

68

M16

140

155

M20

275
470

325

Thread

M24

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570

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82

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6 Dism antling/Assem bly

6.2
.

6.2

Dismantling

Dismantling

To avoid accidental start, switch off and lock

power supply.

DANGER
Entrapment hazards

Lock power supply

Make sure that rotating parts have come to a


complete standstill before starting any
dismantling work.

The revolution counter indicates if separator


parts are rotating or not.

Do not dismantle any parts before complete standstill

6,2.1
1.

Bowl

Be sure the bowl has stopped rotating

.=

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evo I uti o n counter i n dicates rotati o n

83

6.2 Dismantling

6 DismantlinglAssembly
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2.

Loosen the hook bolts


collecting cover.

and remove the

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Hook bolts

Tighten both lock screws.


The bowl parts can remain hot for a
considerable time after the separator has
come to a standstill.

Tighten both lock screws

4.

Unscrew the small lock ring by using the


special tool, "Spanner for small lock ring".

Left-hand thread!

Small lock ring

84

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6.2

6 DismantlinglAssembly

Dismantling

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5. Unscrew the large lock ring by using the


specialtool;'spanner for lock rtng" and a tin
hammer.

Left-hand thread!

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Large lock ring

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6.

4,>{G

Lift off gravitY disc.

IH

Note! lf the gravity disc has to be replaced


owing to changed operating conditions'
Lm out the top disc, disc stack and distributor.

t.rr..

CAUTION
Cut hazard
Sharp edges on the separator discs may
cause cuts.

7.

Unscrew the caP nut.


Release the two lock screws.
Lift out the bowl body using the hand tool.

1.
2.
3.

Cap nut
Both lock screws

Lift bowl body from spindle

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85

6.2

Dismantling

Dismantling/Assematy

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Soak and clean allparts thoroughly in


suitable cleaninQ agent, see "5.4 Gleaning"

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on page 69.

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Remove Grings and renew them with spares


from the Major Service kit.

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Check point
"5.3.1 Conosion" on page 54,
'5.3.2 Erosion" on page 56,
"5.3.3 Crabks'on page 57.

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6.2,2

Vertical driving device

Remove the outlet housings, feed and discharge


pumps and raise the collecting cover. Remove
also the separator bowl.

'i

Before dismantling, in the case of 8000 hours


service, or if the separator vibrates while running:

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Gheck point
"5.3.6 Radialwobble of bowl spindle" on
page 60.
Drain off the oil

Force out the conical pin of the worm wheel.

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::,,:,, 6 Dismantling/AssemblY

6.2 Dismantling

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2. Push worm wheel aside.

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3. Loosen the sPring casng'


vertical driving device'

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4.

Loosen the buffers and remove housing'

87

6.2 Dismantling

5.

Dismantling/Assembly

Flemove the collar.

Left-hand thread!

6.

Use

the pullertoolto dismantle the upper ball

bearing.
i

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7.

Remove the snap ring.

WARNING
Riskfor eye injury by flying
snap

nng

Use the correct pliers for dismantling and


assembly of snap ring to avoid accidental
release.

88

Dism antlinglAssem

bly

8.

Remove the ball bearing sleeve together with


thrust ball bearing and height adjusting
ring(s).

9.

Pull off lower ball bearing gently.

6.2 Dismantling

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6.2.3
1.

Horizontal driving devjce

Drain gear housing from oil see "5.5.1 Oil


change procedure" on page 73. Remove
guard for worm wheel and force out the
conicalpin in worm wheel.

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6.2 Dismantling

2.

Dismantling/Assembty

Bemove lock ring, sight gtass and seal ring


for machine with feed and discharge
pump).
For machine without pump go to point 5.
(valid

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3.

Loosen screws of inspection box.

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4.

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Remove coupling guard and force out the


tubular pin in coupling half on horizontal
driving shaft.

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Dism antlinglAssem bly

5.

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6.2

Dismantling

Loosen end shield. Remove pump together


with inspection box.
For machine without pump: Loosen and
remove guard. Force out the pin at shaft end
and remove space sleeve.

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6.

Remove the rnotor.

7.

Renew the pads on the friction blocks.


When refitting the blocks make sure the
arrow on each block points-in the same
direction of rotation See the arrow on the
frame.

Ei
I

Secure the blocks with washer and split pin.


lf the friction elements are worn: Fit new
ones.
Renew allfriction elements even if only
one is worn.
lf the friction elements are only greasy:
Clean the friction elements and the inside of
the coupling drum with a degreasing agent.

"
E

8.

Loosen the three screws holding the sealing


washer.

91

6.2

9.

Dismantlng

Dismantling/Assembly

Knock gently on shaft end to get the bearings


out of their seats. Then use the worm wheel
to knock off bearing from shaft. Remove

bearing and worm wheel.


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10. Remove the horizonial driving shaft

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the puller tool to pull off the protecting


cover and ballbearing. Protect end of worm
wheel shaft with a washer.
Use

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6 Dism antling/Assem bly

6.3

6.3

Assembly

Assembly

Clean all parts in a degreasing agent and renew


parts supplied in the Spare pads kits.

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Check pont
"5.3.1 Corrosion" on page 54,
"5.3.2 Erosion" on page 56,
"5.3.3 Cracks" on page 57,
"5.3.12 Top bearing springs" on page 65,
"5.3.13 Ball bearing housing" on page 65,
"5.3.14 Worm wheel and worm; wear of
teeth" on page 66.

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6.3.1

.[r

Horizontal driving device

1.

Fit protection cover on worm wheel shaft.


Heat bearing in oil before rnounting onto
shaft.

2.

Clean the ball bearing housing in the frame


and oil the outer race of the ball bearing.
Fit the gasket and enter the shaft through the
bearing seat in the frame.

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93

6.3 Assembly

Dismantling/Assematy
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3.

'l

Enter the worm wheel on shaft and force the


worm wheel shaft to its position in the frame,
so that the ballbearing enters conectly into
its seat.

Observe that largest ends of the holes for


conical pin in shaft and worm wheelshould
point in same direction.

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DANGER
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Disintegration hazard

u,

-4"

*3

When replacing the gear, always make sure


that the new worm wheel and worm have the
same number of teeth as the old ones.

4.

94

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,,,9

Secure the protection cover with the three


screws.
Fit the 'loose'ball bearing. Secure the worm
wheelwith the conical pin.

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6 Dismantling/Assembly

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6.3 Assenbly

:
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Lift the motor in position and tighten the motor


bolts.

i"

lf the coupling disc has been loosened


without first marking its position on the motor
shaft, the correct position for position of
coupling disc must be determined again.

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Check pont
"5.3.9 Coupling disc of motof'on page 63.

\-'.=

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DANGER
Disinteg ration hazards
When power cables have been connected,
always check direction of rotation. lf
incorrect, vitalrotating parts could unscrew
causing disintegration of the machine.

6. Fit coupling half on worm wheel shaft before


mounting the pump.Remember the gasket.
Fit the coupling guard with two screws.
For machine without pump fit distance
sleeve and pin at the end of horizontal shaft.
Fit and secure the guard.

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95

6.3

Assembly

6.3.2

DismantlinglAssematy

Vertical driving device

Before assembling the bowl spindle, make sure


the relevant checks have been carried out.

Wipe off and oil the bearing seat before fitting the
ballbearing
lnspect the tapered end of the bowl spindle and
assemble ball bearings.

'Heatthe

new ballbearings in oilto max. 125 "C.

NOTE
Always fit new bearings.
lf any doubt how to mount roller bearings in a
correct way, see the detailed description in
chapter "5.6.2 Balland roller bearings" on

page 75.

.:

1.

Fit

the two bearings onto the shaft.

CAUTION
Burn

?
f,

hazards

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,'2

Use protective gloves

heated bearings.

when

f'a

r{
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handling the

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6e!

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96

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6 Dism antlinglAssembly

2.

Fit ball bearing housing and throw-off collar.


Left-hand thread!

3.

Fit the ball bearing sleeve together with thrust

6.3

Assembly

bearing and height adjusting ring.

4.

Secure the assembly with the snap ring.

WARNING
Risk for eye injury by flying
snap ring
Use the correct pliers for dismantling and
assembly of snap ring to avoid accidental
release.

97

6 Dismantling/Asse
6.3

mblY

AssemblY

to rest on shoulder of
Flace spring casing
Fit buffers and
rpp"t'ri olaring housing'
casing' Tighten the caps'

ililg"

into

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6.

right position at the


Place the gasket in the
frame'
nottom of itre seParator

7.

Fit

ir

and lor19r.]ne
the cap nut to the spindle
tnu
tt"I-t^..1]t
asse;b into the separator screws'
tighten the three

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6.3

DismantlinglAssem bly

6.3.3

Assembly

Bowl

Make sure that the check points are carried out


before and during assembly of the separator
bowl.

Gheck points
"5.3.8 Bowlspindle cone and bowl body
nave" on page 62.

'{:.:\,1
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1.

Wipe off spindle top and nave bore in the


bowl body. Apply a few drops of oil onto the
taper, smear it over the sudace and wipe it off
with a clean cloth.

2.

Ft the distributor

3.

Make sure the guides are in correct position.

il
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with the disc stack.


Fit the top disc and bowl hood.

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99

6,3

4.

'

Assembly

Secure the bowl from rotating. Screw in

6 Dismantling/Assembty

both

lock screws.

tr'fl
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5.

i!:

4..,J

Degrease lock ring threads, contact and


locating faces (see arrows above). Apply
Molykote 1000 paste to the threads and faces
stated.
Brush in the paste according to the
manufactu rer's directio n.

6.

Tighten lock ring counter-clockwise (left-hand


thread) untilbowlhood lies tightly against
bowl body (in a new bowl marks will now be in
line with each other.

Left-hand thread!

WARNING

ij

Disintegration hazard
The assembly mark on the lock ring must
never pass the mark on the.bowlhood by
more than 25" (0r45 mm).

t/

Gheck point

'i-

"5.3.4 Disc stack pressure" on page 58.


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Dism antling/Assem bly

7.

6.3

Assembly

Release both lock screws and tighten clamp


bolts.

NOTE
The two lock screws must be fufly released
to prevent risk of damage to bowl body,

Fit the connecting hoses if they have been


removed. Make sure to fit their gasket rings

101

6.4

6 Dismantling/Assembly

Feed and dscharge pumps

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'$tf,al

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6.4

Feed and discharge

ffi

pumps

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6.4.1 Generaldescription
1.

'

Examine valve cone and valve seat.

2.

'd
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Bushings:

,1,
.'-J

Renew the bushings if they are scratched or


there is a play between shaft and bushing.

3.

;:1.

Relieflsafe$ valve:

"j

Wearing seals:

Renew the seals if the surface is rough,


crackled or dented by the impeller.

Double pump

4.

Lipseal rings:
Renew the rings at the annualoverhaul.
lmportant! Turn the rings the right way
round.

Flexible coupling:
I

Check wear on flexible element.


i.;

6.

::

lmpeller shaft:

tl

Check wear on sealing surface on the


impeller shaft.
7.

i
1

Disengagement:
The feed pump can be disengaged by turning
the impeller (6), thereby placing the driving
blade of the impeller in the recess of the
shield.

1.
2.
3.
4.
5.
6.
7.

Bushings

Wearing seals
Upsealrings
Flexible coupling
Impeller shaft

Disengagement

Axialplay

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102

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6 Dismantling/Assembty

8.

6.4 Fed and discharge

pumps

Axialplay:
The totalaxialplay (1) must be 0.1 - 0.3 mm.
lf the play is too large even though the
wearing seals have been renewed, it can be
compensated by adding a brass leaf liner.
nsert the liner at (2).lf the play is too small,
grind off the bearing holder (3).
f

Axial play 0.1 - 0.3 mm

6.4.2
1.

Dismantling

Remove the pipe connections of the pump.

Screw off the lock ring of the sight glass.


Remove the upper gasket and the sight
glass.
Remove the screws of the control housing.

Lift the control housing with the lower gasket


and the connecting piece.
Unscrew the oil drain plug and empty the
gear housing of oil.

',I

103

6.4 Feed and discharge pumps

2.

6 Dismantling/Assembty

Remove the guard over the flexible coupling.

Drive out the tubular pins from the worm


wheel shaft and impeller shaft. Turn the bowl
by hand untilthe pins are in a convenient
position.

Undo the fourscrews holding tne pump


shield, remove shield.
Do not lose the valve cone and spring.
I

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104

6 Dismantling/Assembly

5.

Insert two screws into the centre hole of the


impeiflers. Use the screws as a handle to
withdraw the impellers.

6.

Remove the impellers for inlet pump.

7.

Repeat step 5 and.6 for the outlet pump


impellers.

6.4 Feed and discharge pumps

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105

6.4 Feed and discharge pumps

8.

Undo the four screws holding the pump


housing. Remove housing, do not lose valve
cone and spring.

9.

Check that the lipseal rings are in good

6 Dism antling/AssemDry

condition.
lf the seal rings are worn or damaged:
Remove the pump shield frorn the separator
frame, knock out the old sealring(s) and
replace them.

106

6 Dismantling/Assembly

6.4.3

6.4 Feed and discharge pumps

Assembly

1.

Fit new lipseal rings. Be sure to turn it the


right way around, the closed side should point
outwards to air. Start with the one at
pumpside of the shield.

2.

Lift pumpshield in place and secure it with


one screw at top of shield, do not tighten it
fully. Be careful not to damage the seal ring
when entering the worm wheelshafl.

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Fit and secure the coupling half with the


larger pinhole on worm wheelshaft. Put the
flexible element in place.

107

6.4 Feed and discharge pumps

4.

Place the Gring in PumP housing.

the spring
pump shield.
Put

and

valve cone in place in the

6 Dismantltng/asset uty
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5.

Place the bushing with shoulder in pump


shield (flat side vertical pointing to center).
Enter the other bushing into pump housing
with flat side to center.

Fit housing by entering over the bushing in


shield. Ensure that valve cone enters the
valve seat.
Fit and tighten the screws'

6.

Put the wear gaskets one at each side of the


outlet impellers, then place the bushings one
in opposite direction to the other on impeller
I

shaft.

.;

Keep all parts together and push the package


in to pump housing.

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108

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Dism antling/Assem bly

7.

6.4 Fed

and discharge pumps

Repeat point 6 for inlet impellers.


Note that the tongue on impeller shaft should
fit in the slot of outlet impeller shaft.
Press gently until the impeller shaft is visible
at the coupling side. Enter the coupling half
on shaft and press the package in place.

Fit and tighten the six screws for bearing


shield.
Secure the coupling half with the pin.
Rotate the bowl to align the holes.

ri
I

10. Place O-ring in the groove in pump housing


and the spring and valve cone in purnp shield.
Fit pump shield and fasten it with four screws.

109

6.4 Feed and dscharge pumps

11

Fasten

Dismantling/Assemoty

the guard over the flexible coupling.

12. Fit control housing and its pipes.


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13. Connect all pipings.
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Dism antling/Assembly

6.5 Framefeet

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6.5

Frame feet

When renewing the frame feet, the separator


must be lifted.
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See

"5.7 Lifting instructions" on page 79.

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NOTE

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Always remove the bowl before lifting the


separator.

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When lifting and moving the separator, follow


normal safety precautions for lifting large heavy
objects.

6.5,1

Mounting of new frame feet

1. When the separator

has been lifted, remove

the old vibration dampers

(3).

2. Fit the new vibration dampers on the bolts.


3, Lift the separator in to position.
4.

Tighten the nut (2) with t6 Nm.


Hold the nut firmly and secure with the lock
nut (1). Repeat for the other frame feet.
Frame foot with vibration damper
1. Lock nut
2. Nuf
3. Vibration damper

111

6
6.5

Frame

Dismantling/AssembY

feet

112

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Trouble-tracing

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7.1 Trouble tracing procedure

7.2 Mechanicalfunction
7.2.1 The separator does not start
7.2.2 Stari-up time too long
7.2.3 Starting power too low
7.2.4 Starting power too high
7.2.5 Separator vibratesexcessively
during starting sequence
7.2.6 Separator vibratesexcessively
during

7.2.7
7.2.8
7.2.9

normal running

114

115
115

116

117
tlI

118
118
118

the problem is not solved


in the System Manual's
Troubletracing, continue
with this chapten

lf
119

120
120

result

Outgoing water contaminated


bY oil

Broken

Study the
System Manual's
Troubletracing
chapter first.
(if applicable)

16

Noise
Speed

Trouble.tracing

114

117

7.3 Purification faults


7.3.1 Unsatisfactoryseparation

7.3.3

114

Smell

too high
7 -2.1A Speed too low
7 -2.11 Stopping time too long
7.2.12 Water in oil sump
7.2.13 Liquid flows through bowl
casing drain

7.3.2

114

water seal

7.4 Clarification faults


7.4.1 Unsatisfactory separation result
7.4.2 Oil discharge through water outlet

't20
121

122
122

122

113

7.1 Trouble tracing procedure

lroufJrc-Lrauiltg
{tr'
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Trouble tracing
procedure

7,1

FT
F'F"1

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;'r+-'

This chapter applies to trouble'tracing conceming


functions of the separator only. lt does not include
the other equipment in your processing system.

il
i.-i. 'l

Always start with trouble-tracing instructions in


the System Manual, and if required, continue with
the instructions below. lf the problem still is not
solved, contact your Alfa Laval representative.

7.2

Mechanical function

7.2.1

The seDarator does not start

Possible cause

Action

No power supply to motor.

Check power supply.

Bowl lock screws stop rotation.

Release lock screws.

7,2.2

"l

Sta-up time too long

i
{

Possible cause

Action

Brake applied.

Release brake.

r-

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Friction pads worn or oily.


Motor

failure.

lncorrect power supply (50 Hz instead of

Fit new friction pads.

i$
{"

Repair.

Use conect power supply. See machine plate.

60 Hz).

Bearings damaged or worn.

a:

Installnew bearings.

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114

i!

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7 Trouble-tracing

7.2 Mechanical function

,t:,i1

Possible cause

Action

Motor failure.

Repair the motor.

Friction pads worn.

Fit new friction pads.

Friction pads oily.

Fit new friction pads.

Possible cause

Action

Bowl lock screws stop rotation.

Release lock screws.

Brake is on.

Release brake.

Motor failure.

Repairthe motor.

Gear worn out.

Renew worm wheeland worm.

Bearing damaged or worn.

lnstallnew bearings.

Incorrect transmission (50 Hz gear and


60 Hz powersupply).

OnNeeR: Disintegration hazard

STO P im

mediately! nstall correct transm issio n.


|

Contact your local Alfa Laval representative. The


bowlmust be inspected.

Wrong direction of rotation.

STOP.

Adjust motor power connection.

115

7.2 Mechanical functian

7,2.5

7 Troublelracing

Separator vibrates
excessively during startng
sequence

NOTE Some vibration is normalduring stading sequence when the separator passes through
its criticalspeeds.
Possible cause

Action

Bowlout of balance due to:


poor cleaning

incorrect assembly

OnftegR: Disintegration hazard

too few discs


insufficiently tightened bowl hood

STOP immediately! ldentifu and rectify cause.

bowl assembled with pas from other


separators.
Vibration dampers in frame feet wom out.

Fit new vibration dampers.

Bowlspindle bent (max. 0,15 mm).


Top

and/or bottom bearing damaged or

Fit a new bowlspindle.


Fit new bearings.

worn.
Top

bearing springs defective.

Fit new springs.

''8

..:]
:

7,2.6

Separator vibrates

excessively during normal


running
Possible cause

Action

Uneven sludge deposits in sludge space.

STOP and clean bowl.

Bearings damaged or worn.

Fit new bearings.

Vibration-damping rubber washers worn

Fit new frame feet washers every four years.

out.

Spindle top bearing spring(s) broken.

116

Renew all springs.

7 Trouble-tracing

7.2.7

7.2 Mechanicalfunction

Smell

Possible cause

Action

Normal occurrence during start as the


(new) friction blocks slip.

None.

Brake is applied.

Release the brake.

Top

and/or bottom bearing overheated.

Fit new bearings.

7.2.8 Noise
1,,,
-

Action

Possible cause
Oil level in oilsump is

["'

l.'

Top

too

low.

and/or boom bearing damaged or

STOP and read oil leveland add oil.

Fit new bearings.

worn.
I

Friction pads wom.

Fit new friction pads.

ll
I

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7.2.9

Speed

too high

Possible cause
Incorrect transmission (50 Hz gear
running on 60 Hz power supply).

Action

onHc

STO P

ER :

Disintegraon hazard

immediately! lnstall correct transm ission.

Contact your local Alfa Laval representative. The

bowl must be inspected.

Frequency of power supply too high.

Check.

117

7 Trouble-tracing

7.2 Mechanicalfunon

7.2.1A Speed too low


Possible cause

Action

Brake is on.

Release the brake.

Friction Pads worn or oilY.

Fit new friction pads or clean ihe old ones


oily.

Motorfailure.

Repair the motor.

Top/bottom bearings damaged or worn,

Fit new bearings.

Bearing overheated/damag ed.

Fit new bearings.

lncorrect transmission (60 Hz gear


running on 50 Hz Power suPPlY ).

Make sure that the gear is intended for 50 Hz power


supply.

if

they are

7.2,1'l Stopping time too long


Possible cause

Action

Brake lining worn oroily.

Fit new brake lining or clean the old one if it is oily.

7.2.12 Water in oil sump


Possible cause

Action

Bowl casing drain obstructed.

Glean. Change oil.

Leakage at top bearing.

Fit a new seal ring and change oil.

Condensation.

Glean the oil sump. Change oit.

f:
.ic

t:
!

118

7 Trouble-tracing

7.2 Mechanical

function

7.2.13 Liquid flows through bowl


casing drain

:
I

Possible cause

Action

Broken water seal.

Stop feed and feed water to create water seal.

Too high throughput

Reduce the feed.

The supply of displacernenUsealing water


is not sufficientdue to clogged strainer,
kinked hose or low water pressure.

Straighten the hose or clean the strainer. Make sure


the water pressure is 200-600 kPa (2-6 bar).

Seal ring on gravity/clarifier disc


defective.

Fit a new seal ring.

Bowl hood sealring defective.

Fit a new

Bowl speed too low.

Make sure cunent is on and brake is off. lnspect


motor and power transmission.

seal ring.

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119

7.3 Punfication

faults

Trouble-tracing
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7.3 Purification faults

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7.3.1

UnsatisfactoryseParation

rtr

result

1..

rt

Possible cause

Action

Gravity disc hole ioo small.

Use a gravity disc with a larger hole.

lncorrect separating temperature.

Adjust temperature.

Throughput too high,

Reduce throughput.

Sludge space in bowlis filled.

Empty the sludge basket in the bowl.

Disc stack clogged.

Clean the bowl discs.

Bowlspeed too low.

See "7.2.10 Speed too loW'on page 118.

7.3.2

Outgoing water
contamnated bY oil

Possible cause

Action

Gravity disc hole too large.

Use a gravity disc with a smaller hole.

Seal ring under the gravity disc defective.

Fit a new seal ring.

120

J,

7 Trouble-tracing

-ir't

7.3 Purifrcation faults

i'
-i'l

''

7.3.3

Broken water seal

.,1:

Possible cause

Action

Gravity disc too large.

Use a gravity disc with a smaller hole.

Separation temperature too low.

Increase temperature.

Throughput too high.

Reduce throughput.

Sealing water volume too small.

Supply more water.

Seal ring under Eavity disc defective.

Fit a new seal ring.

Disc stack clogged.

Clean the bowldiscs.

Bowl speed too low.

Use correct speed. See "7.2.10 Speed too


page 11 8.

Bowl incorrectlv assembled.

Examine and make correct.

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121

7.4 Clarification

7 Trouble'tacng

faults

7,4

Glarification taults

7.4.'l

UnsatisfactoryseParation
result

Possible cause
Separating temPerature too low.

Adjust.

ThroughPut too high.

Reduce throughPut.

Feed oil contains water.

Re-assemble and operate the separator as a purifier'

Disc stack clogged.

Clean the bowl discs.

Sludge space in bowlfilled'

Empty the sludge basket.

BowlsPeed too

See "7.2.10 Speed too lo'on page 118'

low.

-4.2 Oil discharge through water


outlet

Possible cause
Valve(s) in outlet line closed.

'Clean the bowl discs.

Disc stack clogged.

Seal ring under gravity

disc is defective'

Bowl incorrectlY assembled.

122

Open the valve(s) and adjust to normal back


pressure.

Fit a new seal ring.


Examine and make conect.

Technical Reference

Gontents
8.1 Technicaldata
8.2

8.3

8.4

124

Drawings
8.9.1
8.9.2

Basic size drawing,


separatorwithout pump

128

Basic size drawing,


separatorwith pump and
no heater

129

Basic size drawing,


separator with pump and heater

130

8.5 Connection

8.9

144

Cross-section, complete separator 144


Cross-section,

device
purifier bowl
clarifier bowl
pump

horizontaldriving

146
8.9.3 Cross-section,
147
8.9.4 Cross-section,
148
8.9.5 Cross-section,
8.9.6 Cross-section, water inlet device 150
151
8.9.7 Electric motor, 1.1 kW
152
8.9.8 Electric motor, 1.5 kW
8.9.9 Machine plates and safety labels 153

installation

list,

with pump and no heater/


without pump

131

list,
with pump and heater

145

8.10 Storage and


8.10.1 Storage and transport of goods
8.10.2 Planning and installation
8.10.3 Foundaons

155
155
156
159

8.6 Gonnection

8.7 Interface

description

8.7.1 Definitions
8.7.2 Component

t,
I

8.7.3

132

133
133

description and

signal processing

134

Function graph and


running limitations

135

8.8 Lubricants

136

8.8.1
8.8.2
8.8.3
8.8.4

Lubrication chart, general

136

Recommendedlubricatingoils

138

Recommended oil brands

139

Recommendedlubricants

142

l'

1.

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123

8.1 Technicaldata

8 Tshnical Reference

itiil

:i

Technical data

8.1

tGJ

*F

Alfa Laval

ref.55818, rev0

Units according to ISO Standard.

The rnanufacturer reserves the right to change


specificatio ns without notice ,ir',,:

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Product number

881241-08-14

Separator type

MAB 1048-14124

Application

Continuous purification of mineral oil from solid particles


and water.

.t

Intended for marine and land applications.

The flash point of the oilto be separated must be minimum

60'c.

Designed in accordance
with standards

89/392 EEC
91/368 EEC
93/44 EEC

Safety of machines. Use of the


machine in applications subjected
to hygienic demands requires a
well adapted cleaning program.

EN 292-2

Hydraulic capacity

Maximum

The Council Directive of the


European Communities. (CEmarking is possible if manual is
included in the delivery).

2.0 ms/h

r:

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Max.

density of sediment

1600 kg/mg

Max.

density of feed

991 kg/ms, (mechanicalsafety max. 1100 kg/ms)

Feed temperature

Minimum 0'C
Maximum +100 "C

Ambient temperature

Minimum +5'C
Maximum +55 "C

Motor (with pump)

4-pole 1.5 kW standard motor, 50 or 60 Hz, 3-phase.

Directon-line start.
lf Y/D-start is used maximum 5 seconds in Y position.

Motor (without pump)

4-pole 1.1 kW standard motor, 50 or 60

Hz, 3-phase.

Direct on-line start.

lf Y/D-start is used maximum 5 seconds in Y position.

124

I
t
t

8 TechnicalReference

8.1 Technicaldata

lt-

Power consumption

idling

0.5 kw

running (at max.


capacity)

1.8 kW
1.3 kW

(at starting-up)
,l

Speed

:::f

the bowl spindle which must not


is
on the name plate of the
stamped
be exceeded,
machine.

The prescribed speed of

Gear ratio

50:10

49:12

Maximum speed of

5O Hz

60 Hz

500

1800

rotation, rpm

Motor shaft speed

79-83 95-100

Revolution counter
speed

7500

Bowl speed

Starting time

2 - 3 minutes

Stopping time

Running down with


brake applied

7350

min.

1.4 minutes
max. 3.0 minutes

minutes (average)

without brake

Maximum running time


without flow

empty bowl

480 minutes

filled bowl

480 minutes

Inlet pump, built-on

Capacity:

50 Hz

Pump type 534391-82


Pump type 534391-83

Suction lift
Delivery head

2.58 m3/h
2.15 m3/h
1.30 m3/h
1.08 m3/h
Max.4mwg(manometric)
Max. 15 m wg (manometric)

Capacity:

50 Hz

Pump type 534391-82


Pump type 534391-83

2.86 m3/h
2.38 m3/h
1.43 mslh
1.19 m3/h
15 - 25 m wg (depending on flow
and viscosity)

l,

60 Hz

f.i
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I

Outlet puDF, built on

v'1
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Delivery head

Sludge and waterspace


volume

60 Hz

1.26 likes

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8.1 Technicaldata

Technical Heferencv
i,,J.

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Required water quality

Fresh water

FT')

r,ffL

fl"tl

Lubrication

see "8.8.1 Lubrication chad, general" on page 136.

'ii:;l

Lubricating oil volume

0.8 litres

Weight

Separator without
motor

,:-1

i1

';

Motor

Net

.1

Approx. 16 kg

Approx.25 kg

fx
,1-

.,
According to "Basic
equipmenf'

Weight

280 kg gross

0.79 mg

Sound power level

9.3 bel(A) ISO 3744

Sound pressure level

78 dB(A) ISO 3744

Vibration level

Max. for separator in


use

9 mm/s (RMS)

Materials

Bowlspindle, lock ring

steel

Frame, lower and


upper pafis

cast iron ("centriblue" finishl)

Collecting cover

silumin (grey finishl)

Bowl body and hood,


stainless steel
disc stack, gravity disc
Other bowl parts

brass

Other inlet and outlet


pas

stainless steel, brass, cast iron


I)An epoxy enamel

Any risk for corrosion and erosion has to be investigated in each case by the application
centre.
Futher restrictions and instructions are found in the set of complementary documents.

126

fu:l'

"i

Volume

..,

.,

L[-*

Complete bowl

Shipping data

ii

weight approx. 149 kg

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8 TechnicalReference

8.1 Technicaldata

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Kw
2.O

il

50 Hz

1950 Uh
1950 l/h

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Power consumption at start-up, power input vs time


A.
B.

c.

Power input (kW)

1)
2)
Start-up time (min) 3)

Idling

Feed pump -20 kPa

(02 ba) ; Outlet pump O kPa (O bar)

pump -40 kPa (-0.a baQ


Feed pump_-20 kPa (-0.2 bar)
Feed

; Outlet pump 150 kPa (1.5 bar)


; Outlet pump 250 kPa (2.5 bar)

127

8.2

Basic size drawing, separator without pump

8.2

Alfa Lava! ref.

Tuhnca! HeIeetr.v

Basic size drawing,


separator without
pump
5581&,

reu. 0

'1

t"'3

$$.
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A. Screw 3/8-l6UNC
B. Tightening torque 16 Nm, locked with lock nut
for connections see "8.5 Connection list, with pump
no
heater/ without pump" on page 131.
and

Vertical force not exeeeding

kMfoot

Data

Horizontalforce not
exceeding 8 kN/foot

All

connections

to be

installed nonloaded and flexible.


:,,1-

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128

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8 Technical Reference

8.3 Basic size drawng, separator with pump and no heater

t1
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I 8.3 Basic size drawingn


separator with pump
''=J

r"

?nd no heater

:(

AJfaLaval

":

ref.566281, rat

11

"t

395

tl I

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:

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A. R 3/4u, BSP 3/4


B. R 1 1/4,,BSP11/4
c, D. B 'lu, BSP
E. 1/2-13 UNC
F. Wew

Vertical force not exceedi ng

kNlfoot

'

Horizontalforce not
exceeding 8 kN/foot

for connections see "8.5 Connection list, with pump


and no heater i without pump" on page 13'1.
Data

Al!

connections to be installed nan-loaded and flexible.

129

8.4

Basic size drawing, separator with

8,4

pump and heater

Tshnical Reference

Basic size drawingn


separator with pump
and heater

Alfa Laval ref. 558164; reu. A

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A. Screw 3/8-16UNC
B. Tightening torque 16 Nm, locked wth lock nut
Datafar connections see "8.6 Connection list, with pump
and heatec' on page 132.

Vertical force not exceeding

'i::::'d

I kMfoot

i
,

Iiorizontalforce not
exceeding I kN/foot
'

All connections to be installed non-loaded and flexible.

1.1"

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Reference

8.5 Connection lst, with pump and no

heater

/ without pump

8.5 Connection list,


wth pump and no
heater / without pump
flfa laval ref. 558165, rat

r:Ll
i

Connection No.

Description

Requirements/limit

201

lnlet for process liquid


- Allowed temperatures

Min. 0 oC, max. 100 "C

206

lnlet for water seal

220

Outlet for light phase (oil from pump)

221

Outlet for heavy phase (water)

460

Drain of frame

701

Motor for separator


deviation from nominalfrequency
(momentarily during maximum 5 seconds)

- Max.
760

Fresh wqte6 approx.


2.5 litres (depending on
gravity disc)

No counterpressure

!5%
+10o/o

Cover interlocking switch (delivered as option)

Type: Double, two-way microswitch


Switch rating: Voltage

Curient

Max. 500 V

Max.3 A

ll

ti

131

8.6 Connection

8.6

list,with pump and heater

Technrcan Hereertuv

Gonnection list,
wth pump and heater

Alta Laval ref. 558166, rev 0

Connection No.
201.1

Description

for process liquid, (to pump)


Allowed temperatures

Requirements/limit

lnlet
-

Min. 0 "C, max. 100 "C

201.2

Outlet for process liquid, (from pump to heater)

201.3

Inlet

for process liquid, (from heater to separator)

206

Inlet

for water seal

220

Outlet for light phase (oil from pump)

No counterpressure

221

Outlet for heavy phase (water)

No counterpressure

460

Drain of frame

741

260

Fresh water, approx.


2.5 litres (depending on
gravity disc)

Motor for separator


- Max. deviation from nominalfrequency

+5o/o

(momentarily during maximum 5 seconds)

!1Oo/o

Cover interlocking switch (delivered as option)


Type: Double, two-way microswitch
Switch rating: Voltage"
Current

Max. 500 V

Max. 3 A

:l
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132

;:*-

8 Technical Reference

8,7 lnterface

description

il

lnterface description

8.7

fi

Alfa Laval

ii
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ref. 557119,

tev 2

ln addition to the Gonnection List this document


describes limitations and conditions for safe
control, monitoring and reliable operation.
At the end of the document a function graph and

running limitations are to be found.

8.7.1

Definitions

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Standstillmeans:

.
.

The machine

is

assembled correctly.

All connections are installed according to


Connection List, lnterconnection Diagram
nd Interface Description.

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Start means:

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The power

to the

separator is on.

The acceleration is superuised to ensure that


a certain speed has been reached within a
cedain time. See "8.1 Technicaldata'on
Page124.

I,

Normal stop means:

Stopping of the machine at anytime with feed


or safetylbackup liquid and with brake
applied.

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133

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8,7 lnterface descnption

B T*hnicalReference

Safety stop means:


li.l

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The machine must be stopped in the quickest and


safest way due to vibrations or process reasons.

-+

Comply with following conditions:

.
.

The bowl must be kept filled.

The machine must not be restarted before the


reason for the Safety stop has been
investigated and action has been taken.

iF;

ln case of emergency condition in the plant, the


machine must be stopped in a way that is
described in EN 418.

8.7.2

Gomponent description and


signal processng

Electrical connections
Separator motor

701

The separator is equipped with a 3-phase DOLstarted (direct on line) motor. The separator can
also be started by a Y/D starter, but then the time
in Y-position must be maximised to 5 seconds.

Gover interlocking switch 760 (option)


The cover of the separator is equipped with an
interlocking switch. When the cover is closedthe
interlocking circuit in the sta.ter control is closed
and the separator could be started.
Signal processing:
The circuit is closed when the collecting cover of
the separator is closed.
The interlocking switch should be connected so
that starting of the motor is prevented when the
separator collecting cover is not closed.

f'{
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134

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8 Technical Reterence

8.7 Intertace descriPtion

Lc l
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8.7.3 Function graPh and running

1-"1

'

limitations

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A. Stand still
B. Starting mode
C. Running

D.

E.

mode
StoP mode
SafetY stoP mode

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135

8.8 Lubricants

TechnicalReferenee

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8.8 Lubricants

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8.8.1
Alfa Laval ref.

iii.

Lubrication chart, general

582'l

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Lubricating points

Lubricants

Bowlspindle ballbearings and buffers are


lubricated by oilmist

Lubricating oilas specified in "8.8.2


Recommended lubricating oils'on page 138
Lubricating oil (only a few drops for rust
protection)

Buffers of bowl spindle

Lubricating oil

Bowl:

Pastes as specified in "8.8.4 Recomrnended


lubricanis" on page 142

bowl hood, and cap nut

Grease as specified in "8.8.4 Recommended


lubricants" on page 142

Friction coupling ball bearings

The bearings are packed with grease and


sealed and need no extra lubrication

Electric motor (if nipples are fitted)

Follow manufacturer's instructions

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Oil GrouPs:

Group A oil: a high quality gear oil on


paraffin base with stable AW (antiwear)
additives.
.

Group B oil: a high quali$ gear oil on


paraffin base with stable EP (extreme
pressure) additives.

GrouP D oil: a synthetic base oilwith


additives stable at high operating

r],e'.]
:lt, l

:;
,!

,:

temperatures.

mix different oil brands or oils from


difierent oilgroups.
Do not

:ri,

Always use clean vessels when handling

lubricating oil.

,,

136

i
i

lf not specified otherwise, follow the supplier's


recommendation about method of application

Rubber seal rings

Alfa Laval Lubricating

'i...:

Bowlspindle taper

Sliding contact surfaces and pressure loaded


surfaces such as lock rings, threads of lock rings,

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8 TechnicalReference

8.8

Lubricants

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Great attention must be paid not to contiaminate


the lubricatingoil. Of particular importance is to
avoid mixing of different types of oil. Even a few
drops of motoroilmixed into a synthetic oil may
result in severe foaming.
Any presence of black deposits in a mineral type
oil is an indication that the oilbase has
deteriorated seriously or that some of the oil

additives have precipitated. Always investigate


why black deposits occurs.
lf it is necessary to change from one group of oil
brand to another it is recommended to do this in
connection with an overhaul of the separator.
Clean the gear housing and the spindle parts
thoroughly and remove all deposits before filling
the new oil.

'1

NOTE

,l

Always clean and dry parts (also tools)


before lubricants are applied.

NOTE
Check the oil level before start. Top up when
necessary. Oilvolume see "8.1 Technical
data" on page 124.

to use the lubricants


recommended in our documentation. This does
not exclude, however, the use ofother brands,
provided they have equivalently high quality
properties as the brands recommended. The use
of oil brands and lubricants other than
recommended, is done on the exclusive
responsibility of the user or oil supplier.
It is of utmost importance

i.i

,4

Applying, handling and storing of lubricants

J=

Always be sure to follow lubricant manufacturer's


instructions.

ti

137

8.8 Lubricants

8.8.2 Recommended

Technical Reterence

lubricating

oils
Alfa Laval ref. 553219-10, rcu 0

of lubricating oils are


approved.They are designated as Alfa Laval
lubricating oilgroups A,B and D.

Three different groups

The numerical value after


viscosity grade.

the letter states the


rr<

The corresponding commercial oil brands

t.

" Alfa Laval lubricating oilgroup fu


22|, on page 139, ",Alfa Laval lubricating oil
group 8/220" on page 140 and " AIfa Laval
lubricating oil group A/2zA'on page 141.

according to

Ambient temPerature
Between +5 and +45
Between

t2

and +65

'G

Alfa Laval lubricating oil


group

Time in operation
Oil change interval

Al22A W220

1500 h

Dt220

2000 h

;"1

Note:

a new installation or after change of gear


transmission, change oil after 200 operating
In

hours.

When the separator is operated for short


periods, lubricating oil must be changed'
every 12 months even if the total number of
operating hours is less than stated in the
recommendations above.
Check and prelubricate spindle bearings on
separators which have been out of service for
6 months or longer.
In seasonal operation: change oil before
every operating period.

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138

8 TechnicalReference

8.8

Lubricants

:,

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8.8.3

Recommended oil brands

NOTE
The data in below tables is based on supplier information in regards to
lubrication properties. Trade names and designations might vary from
country to country, contact your local supplier for more information.

Brands with Alfa Lavalaticle number are approved and recommended for
use.

Affa Laval lubricating


Alfa Laval

ret. 55321&01,

reu.

oil group Al22A

Alfa Lavallubrication oilgroup A


Viscosity grade VG (lSO 344813104)
Viscosity index Vl (lSO 2909)

220
>92

Manufacturer

Designation

Castrol

Alpha ZN22O

ELF

Polytelis 220

Esso/Exxon

Nuto 220
Tersso 220
Terrestic 220

Mobil

DTE OiIBB

Optimol

Ultra220

Shell.

Morlina 220
Tellus 220

Texaco/Caltex

RegalOil22O
Paper Machine Oil Premium22O

139

8.8 Lubricants

B T*hnical Reerence

;;
F*.,{

Alfa Laval lubricating oil group


Alfa

Laval

rd. 553218-02, rat

r.,.i,

8,1220
ffix

i,.*1

Alfa Laval lubrication oil group

Viscosity grade VG (lSO 3448/3104)

220
>92

Viscosity index Vl (lSO 2909)

Manufacturer

Designation

Bel-Ray

06-220

BP

Energol GR-XP 220

Castrol

Alpha SP 220

Chevron

Ultra Gear 220


Gear Compound EP 22O

ELF

Epona 2220

Esso/Exxon

Spartan EP 220

Fina

Giran 220

Mobil

Mobilgear 630
(Mobilgear SHC 220) * Synthetic

Optimol

Optigear BM 220

Q8/Kuwait Petroleum

Goya220

Shell

Omala 220
(Delima HT 320) " Synthetic

TexacolCaltex

Meropa 220

These oils must be used when the frame temperature is above 80 "C.
lf you can't verify the temperature by measuring, a rough estimate is that
80 "C is when you can touch the surface of lower part of frame for a short
time only.
J

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r.,

140

8 Technical Reference

8.8 Lubricants

Alfa Lavallubrication oilgroup D


Viscosity grade VG (lSO 344813104)
Viscosity index Vl(lSO 2909)

Manufacturer
Alfa Laval

220
>135
Designation

542690-80
542690-81
542690-82
542690-83

BP

Enersyn HTX 220

Castrol

Afphasyn EP 22O

ELF

Epona SA 220

Mobil

SHC 630

Shell

Delima HT 22O
Paolina220

(20 litres)
(4 litres)
{208 litres)
(1 litre )

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141

8 TshnicalReference

8.8 Lubricants

8.8.4
Alia

Laval ref.

Recommended lubricants
559217-01, ran 7

NOTE
The data in below tables is based on supplier information in regards to lubrication properties.
Trade narnes and designations might vary from country to country, contact your local supplier for
more information.
Brands with Alfa Laval article number are approved and recommended for use.

Pastes for non'food applications:

Alfa LavalNo.

Manufacturer

Designation

Fuchs Lubritech

Gleitmo 805K
Gleitmo 705K

Dow Corning

Molykote 1000 (Paste)


Molykote 1000 (Paste)
Molykote G-rapid plus (Paste)

Rocol

Antiscuffing (ASP) (Paste)

Klber

Wolfracoat C (Paste)

537086-02 (1 000 g)
537086-03 (1 00 g)
537086-04 (50 g)

Bonded coatings:
Manufacturer

Designation

Alfa LavalNo.

Fuchs Lubritech

Gleitmo 900 (Varnish or spray)

Dow Corning

Molykote D321R (Spray)


Molykote D321 R (Varnish)

535586-01 (300 ml)


535586-02 (60 ml)

/-:

Silicone grease for rubber rings:


Manufacturer

Designation

Dow Corning

Molykote
Molykote

Alfa LavalNo.

11

1 (Compound)

11

1 (Compound)

Fuchs Lubritech

Gleitmo 750

Klber

Unisilkon L 250

Wacker

Silicone P (Paste)

539474-02 (100 g)
539474-03 (25 g)

.J

142

:l

8 Technical Reference

8.8

Lubricants

Greases for balland roller bearings:

NOTE
Always follow the specific recommendation for lubrication as advised by the
manufacturer.

Manufacturer

Designation

BP

Energrease MM-EP2
Energrease LS2

Castrol

APS 2
EPL 2

Chevron

Dura-Lith Grease EP2

Etf

Epexa 2

Esso/Exxon

Beacon EP2
Unirex N2

Fina

Marson

Mobil

Mobilith SHC 460


Mobilux EP2

Gulf

Gulflex

Q8/Kuwait
Petroleum

Rembrandt EP2

Shell

Alvania EP Grease 2
Albida Grease EP2

SKF

LGEPZ or LGMT2

Texaco

Multifak AFB 2

Alfa Laval No.

Grease

EPL 2A

MP2

143

8
8.9

Drawings

Technical Reference

i
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8.9 Drawings

i' i :r i]

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8.9.1

Gross-section'comPlete
separator

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ComPlete seParatol

144

8 TechnicalReference

8.9

Drawings

:.i

8.9.2 Gross'section, horizontal


driving device

t;t'
I
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Horizontal driving device

145

8.9

Drawings

Teohnical Reference

8.9.3 Cross'secton,puritierbowl

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Purifrer

bowl
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I

146
t

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8.9.4

8.9

Drawings

Gross.section,clarifierbowl

Clarifier bowl

147

B Techntcal Reference
8.9 Drawings

lffi,.,
't..;i

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8.9,5

Gross'section'pump

I.

.
3.
4.
E

6.
7.
B.

9.

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Sealing ring
GouPling
Retaining ring
Sealing ring
PumP imqeller
PumP imPeller
Shield

tubutar sPrns PinPtt"a tubular sPring Pn

ll"a

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148

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8 Technical Reference

1.

8.9

Drawings

CouPling guard

t'
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149

8 T*hnical

Reference

B-9 Drawings

8.9.6

Gross'section' water inlet


device

Hose niPPle
Pac!<ing

Sight glass

Packing
,

rtBn

150

r. 1

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8 TechnicalReference

8.9.7
AltaLaval

8.9

Drawings

Electric motor, 1.1 kW

rd. ffi1590,

rett 3

"'-$

A. Knockout openings for cable glands on both sides, 2 x a23


B. Sheef-sfeelfan hood
C. 4

holes o12

Manufacturer
Manufacturers drawing
Standards
Size
Type
Weight
Poles
fnsulation class
Bearings

ABB Motors
Cat. BfuMarine motors GB 98-05
IEC 34 series, 72,79,85
IEC 90S
M2AA 90S
13 kg

cooling
Specification
Note!

lC 41 (lEC 34-6)
Totally enclosed three-phase motor for marine service

Method of

Type of mounting
(rEc 34-7)

{:)

4
F

DE:6305-22C3

Motor bearings are permanently lubricated


Degree of
protection
(rEc 34-5)

tM 3001

P 55

tM 3011

lP 55

rM 3031

lP 55

151

8.9 Drawings

8.9.8
Alfa

Laval ref,

TwhnicalReference

:,t,i3

"FtE
_;.."!

Electric motor, '1.5 kW

ffi

551614, reu 3

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thg ..

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A. Knockout openings for cable glands on both sides, 2 x s23


B. Sheet-steelfan hood
C. 4 holes a12

ABB Motors
Manufacturer
Manufacturers drawing CAT. BAJMarine motors GB 98-05
IEC 34-series, 72, 79, 85
Standards
tEc 901
Size
M2AA gOL
Type
16 kg
Weight
4
Poles
F
Insulation class
DE:6305-22C3
Bearings
NDE: 6204-2VC3
tc 41 (rEc 34-6)
Method of cooling
Totally enclosed three.phase motor for marine seruice
Specification
Motor bearings are permanently lubricated
Note!

Type of mounting
(rEc 34-7)

tM 3001

Degree

of

protection
(rEc 34-5)

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lP 55
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tM 3011

tP 55

lM 3031

tP 55

152

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8 TechnicalReference

8.9 Drawings

8.9.9

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Alfa Laval

ret.

Machine plates and safety


labels
558097, rev.

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4. Machine plate

Separator

MAB 1048-14t24

Manufacturing serial No i Year

XXXX

Product No

881241-08-14

Frame

549807-01i02t03tM

Bowl

524724-92t82

Max. speed (bowl)

7500 r/min. (50 Hz),7350 r/min. (60 Hz)

Direction of rotation (bowl)

<-

Speed motor shaft

1500

El. current frequency

50/60 Hz

Recommended motor power

1.1 / 1.5 kW (with pump)

Max. density of feed

1100 kg/mg

Max. density of sediment

1600 kg/mg

'

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'1.

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rocess temperature min.lmax.

/min. (50 Hz), 1800 r/min. (60 Hz)

0/100"c

153

8.9 Drawings

Technical Reference

...it

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1. Safety label
Text on label:

DANGER
Read the instruction manuals before installation,

operation and maintenance. Consider inspection


intervals.

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Failure to strictly follow instructions can lead to

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fatalinjury.

lFl

lf excessive vibration occurs, stop separator and


keep bowl filled wiih liquid during rundown.

. i'll'{

'

Out of balance vibration will become worse if bowl

is not full.
Separator must stop rotating before any
dismantling work is started.

2. Name plate

3. Power supply frequency

5. Arrow
lndicating direction of rotation of horizontal driving
device. .

6. Stop,

follow lifting instruction

This transport labelis not permanently fixed to the

separator.

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154

,,17

8 Technical

*-:.1

8.10 Storage and installation

Reference

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-ii

8.10 Storage and

,t

installation

',j

8.10.1 Storage and transPort of

^:l

goods

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Storage

Specfication

'1
I

Upon arrival to the store, check all components


and keep them:

'i

1.

Well stored and protected from mechanical


damage.

2.
3.

Dry and protected from rain and humidity.

Organized in the store in such a way that the


goods will be easily accessible when
installation is about to take place.

A separator can be
of protection:

delivered with difierent types


Fixed on a pallet

Fixed on a pallet.

The separator must be stored in a storage


room well protected from mechanical damage
and also dry and protected from rain and
humidity.
In a wooden box

which is not water tight-

The separator must be stored dry and


protected from rain and humiditY.
In a specialwater-resistant box for outdoor

ln a wooden box which is not water tight

storage.
The separatorand 'rts parts have been treated
with an anti-corrosion agent. Once the box
has been opened, store dry and protected
from rain and humidity.

The packaging for outdoor storage is only to


specialorder.

,:
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a special

water-resistant box for outdoor storage

155

8.10

Storage and inskllation

TshnicalReference
l'i"+l

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Transport
rFr

Sper,ification

'f;" 1 l. ,,

During transport of the separator, the frame


hood

and bowlmust always be removed

from the machine.

ii,

it must always be
hung securely. See chapter "5.7 Lifting
instructions" on page 79.

,til,-

When lifting a separator

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WARNING

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Crush hazard
Use correct lifting tools

and follow lifting

instructions.

During erection, allinlets and outlets to


separators and accessories must be covered
to be protected from dirt and dust.

8.10.2 Planning and installation


Introduction
The requirements forone or more separators can
be established by consulting the following
documents.

o
.

o
o
o

Basic size drawing


Connection list
Interfacedescription
Interconnectiondrawing

Check the drawings when planning he installation

Foundation drawing
Lifting drawing

These are included in this chapter "S Technical


Reference" on page 123.

156

8 Technical Reterence

8.10 Etorage and installation

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lmportant measurements
lmportant measurements are the minimum lifting
height for lifting tackle, shortest distance between
driving motor and wall, free passage for
dismantling and assembly, maintenance and
operation.

your installation with sufficient room for the


controls and operation so that instruments are
easily visible. Valves and controls must be within
Plan

requirements for maintenance work, work


benches, dismantled machine parts or for a
seruice trolleY.

Suitable space must be obtained for the maintenance


work

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Space

for separator

The separator shall be placed in such a way that

suitable space for maintenance and repair is


obtained.

Specification

See the "Basic size drawings" on pages 128,


129 and 130 for the service space required
with the separator installed.

Recommendation

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The spanner lor the large lock ring shuld


have sufficient space to make a complete
turn without hiing any of the ancillary
equipment surrounding the separator.

157

8 TwhnicalReference

8J A $orage and installaton

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Lifting height for transport of bowl

ffi\
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Specifcation

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A minimum height is required to lift the bowl,


bowl parts and the bowl spindle.

,iJ

Recommendation

;-,fr

When two or more separators are installed,


the lifting height may have to be increased to
enable parts from one separatorto be lifted
and moved over an adjoining assembled
separator.

$. :
3

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NOTE
Remove the separator bowl before lifting.

WAHNING
Crush hazard
Use correct lifting tools

and follow lifting

instructions.
Do not

work under

Space for

Do not lift the separator in any other way

hanging load.

oil changing

Specification

The plug for gearbox oil draining must not be


blocked by floor plate arrangement, etc.

re

t=8,

Recommendation

should be possible to place a portable


collecting tray under the gearbox drain plug
for changing oil.

lt

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Place

the separator in such way that makes the oil

"1

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change easy

158
i

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8 TechnicalReference

8.1

0 ttorage and installation

8.10.3 Foundations
Specitication

.
.

The separator should be installed at floor


level, see the "Basic size drawings" on page
130, 129 and 128.
The separator must be installed on a strong
and rigid foundation to reduce the influence of
vibrations from adjacent machinery.

the separator frame on the foundation as


follows:
Fit

1.

Place the separator without vibration


dampers (3) in position.

2.

Check that the bolts do not press against the


edges of the holes, otherwise the elasticity of
the mounting of the separator frame will be
impeded.

3.

Check that the separator frame is horizontal


and that allfeet rest on the base plane.

,j

4. Fit height adjusting washers required.


5. Lift the separator, fit the vibration dampers
(3), lower and check that the bolts do not
press againstthe edges of the holes.

6.

Frame fot with vibration damper

1.
2.
3.

Lock nut
Nuf
Vibraton damper

Fit the nut (2)and tighten with 16 Nm. Hold


the nut firmly and secure with the lock-nut (1).
Repeat for the other frame feet.

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159

8.10

Storage and installation

160

B Technical Reference

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It is our ambition to

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Alfa Laval Separation AB, Separator Manuals, dept. SKEL, S-147 80 Tumba, Sweden.
Fax: +46 I 53031040,
Your name:

Company:

Address:

City:

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Product

MAB 1O4B-14124

Book No.:

1270276-02V6

Date:
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wish to order extra copies of this manual, please copy this page and give it to your local
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MAB

1048'14124

Book

No.:

1270276-O2VG

Date:

Gomments:

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169

164

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lndex

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B
Basic
Basic size drawing
Separator with pumP and heater
Separator with pumP and no heater
Separator without PumP

128
130

129
128

Glarification
Definition
Oil discharge through water outlet
Unsatisfactory separation result
Clarifier disc
Definition
Cleaning

Bowldiscs

Bearings

Assembly of bowl spindle bearings


Ball bearing housing damage
Maintenance directions

96
65
75

Bowl

Assembly
Dismantling
Lock ring damage
Bowlcleaning
Procedure
Bowldiscs
Cleaning
Disc stack pressure
Bowlspindle
Assembly
Dismantling
Brake

Check point
Function
Broken water seal

99
83

59
A-l

al

72
58
96

86
g4
30
121

G
Centrifu gal separation

Check points

Ball and roller bearings


Ball bearing housing
Bowl body nave
Bowl spindte cone
Brake
Corrosion
Coupling disc of motor
Cover interlocking switch
Cracks
Disc stack Pressure
Erosion

Friction pads
Height position of bowl / bowlspindle
Lock ring / wear and damage
Radial wobble of bowl sPindle
Tooth aPPearence
Top bearing sPrings
Worm wheeland worm

75
65
62
62

64
54
63
68
57
58
56

64
61

50
60
67
65
66

122
32
72
69

External cleaning
Fuel oilseparators
Lube oil separators

IU
70

Time intervals
Connection list
Separator with pump and heater
Separator with pump and no heater /
without pump
Corrosion
Check points
Maintenance logs
Oiling of parts
Shutdowns
Coupling
Exchange of friction elements
Friction pads
Function
General maintenance
Cover interlochng switch (option)
Cracks
Check poinis
Maintenance logs

16

32
122

41

131

132
131

49
14

tl

78
9'l

64
en
77
31

57
49

D
49
Daily checks
124
Density of feed
58
Disc stack pressure
Drawings
130
Basic size drawing with pump and
Basic size drawing with pump and no heater 129
128
Basic size drawing without
147
Clarifier
144
Gomplete
151, 152
Electric
145
Horizontaldriving
plates
153
and safety
Machine
148,149
146
Purifier
150
Water

heater
pump

bowl
separator
motor
device
labels
Pump
bowl
inletdevice

lc
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165

..'3 i
.

'F1"

Electric motor. See Motor


Emergency stop
Erosion

Main parts
Maintenance

Check points

Maintenance logs
Excessive vibration during normal running
Excessive vibration during starting sequence

40, 134

Ball and roller bearings

56

49
116
116

lntervals
Procedure
Service kits
Major service
Materials

F
Foundation
Frame feet
Vibration dampers exchange

159

G
Gear
Number of teeth
Wear of gear teeth
Gravity disc
Definition

Dismantling
Selection

Maximum running time without flow


Metal surfaces
Corrosion
Cracks

111

125
66
32
85
35

Erosion
Gear teeth wear

Motor
Coupling disc
Drawing
Motor cleaning
Power consumption durng start

Assembly
Check points
Description

93
95
30

Dismantling

89

lnstallation
Check points
Planning of installation

34
156

lnterface
Definition
Interface description

32
133

75
46

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48

.,-.-..'

52
126

79
119

Loc* ring
Wear and damage

59

Lubricants
Before first start

Lubrication chart, general, oil groups

Oilchange interval
Oilchange procedure
Oillevel
Recommended lu bricatin g oils
Recommended oilbrands
Volume of lubricating oil

34
136
138
73

73

f=-:,

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125

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56
66
.

63
151, 152

69

38,127

126

P!*

126

34
73
31

121

120

P
Periodic maintenance
Power consumption
Power transmission

Axial play
Bushings

Capacity
Check points
Dismantling
lmpeller shaft
Lipring seals
Shear pin coupling
Wearing seals

fA
,I

54
57

oil
Before first start
Oilchange procedure
Sight glass
Oil discharge through water outlet
Outgoing water contaminated by oil

48

46
125
J

30

Pump

Lifting instruction
Liquid flows through bowlcasing drain

t'i

Description

.iii:{
4

Noise

Sound power level


Sound pressure level

Horizontal driving device

'Ft-r-,.,

20

";r,

*, :i

103

102
125
102
102
102
102
102
102

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138
139

'\

126

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Start

Purification

Broken water seal


Definition
Outgoing water contaminated by oil

'-

Start procedure
Unsatisfactory separation resu lt

121
32

120
38
12A

Purifier bowl
,("=
l1
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Characteristic parts
Gravity disc

lr

4=

22

23

t'

Check points
Starting power troo high
Starting power too low
Starting time
Start-up time too long
Stopping procedure
Stopping time too long
Storage

37
35
115
115

125
114
39
118

155

R
Ready for start

133

Revolution counter

Function
Speed

31

32
114

125

Rotor

Assembly
Dismantling

99
83
37

Running-up procedure

S
o

Safety Instructions
Separated sludge

Cleaning the

Throughput
Definition
Trouble tracing

Unsatisfactory separation result

v
Vertical driving device
Assembly
Check point
Dsmantling

bowl

Separation

24
2g
17
1l

Optimum separation
Purification

Temperature
Viscosity
Separator

Stopping time

125

Separator does not start


Separator vibration level
Seruice intervals
Service kits
Service logs
Shear pin coupling
Shuidowns
Sludge and waterspace volume

114
126
46

Smell
Speed

117

Speed too low

118

48

ol
103
78

125

'120

Vibration
Criticalspeed
Spindle wobble
Vibration checking

Vibration level

96
86
86
37
60

74
126

w
Warning signs
Water in oilsump
wear of teeth
Weight
Worm gear
Function

Wear of teeth

13

118

66
126
30
66

125

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