hy: Alfa Laval MMPxX 403 Separation System 1 Safety System Description Operating Instructions Parameter List Alarms and Fault Finding System Reference Installation Instructions on oOo ao fF Oo DN Separator Manual (incl. fautt finding) Spare Parts Catalogue 9 Component Descriptions (inci. fautt finding) 10 Optional Equipment Alfa Laval Marine & Power Printed Mar 1998 Product No. 1765592-01 Book No. 1817189-02Separation System Safety Printed Nov 1998 Book No. 1810160-02 V4 OER Cem: dak koAlfa Laval reserve the right to make changes at any time without prior notice. ‘Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local ‘Alfa Laval company. Published by: Alfa Laval Marine & Power AB S$ - 147 80 Tumba Sweden © Copyright Alfa Laval Marine & Power AB 1998.Contents 1 Safety Instructions 14.1 Important Factors Influencing Safety 1.2 Categories of Warning Signs 1.3 Summary of Essential Warnings 1810160-02 21810160021 Safety instructions Safety ( CAUTION Slip hazard Oil leakage may make the floor slippery and cause injuries The bolts on the main flange of the heater must be checked prior to installation and start up. NOTE Be sure to study all relevant documentation supplied and become familiar with the function and operation of the system and each particular unit. 1810160-02 1. Safety Instructions 1.1. Important Factors Influencing Safety The centrifugal separator includes parts that rotate at high speed, generate high centrifugal forces, and take a long time to stop rotating, Materials are carefully chosen and parts are designed with extremely fine manufacturing tolerances, Rotating parts are carefully bal- anced to reduce vibration and wear and tear and to withstand stress and fatigue. ‘The separation system is designed and supplied for a specific function (type of liquid, rotational speed, temperature, density, etc.) and must be used for this function only, and strictly within Alfa Laval’s specifications. Incorrect operation or maintenance is likely to result in an imbalance due to build up of sediment, reduction of material strength, etc. that could lead to serious injury or damage. These compulsory safety instructions apply: ‘© Use the separator only for the purpose and parameter fange specified by Alfa Laval. ‘© Strictly follow the instructions for installation, operation and maintenance Ensure that personnel are fully trained and competent in operation, maintenance and emergency procedures. 1810160-021 Safety Instructions Use only Alfa Laval genuine spare parts and the special tools supplied, NOTE If safety instructions and installation, operating, and maintenance instructions in this manual are not strictly followed, Alfa Laval can not be held responsible for any malfunction or injuries resulting. 1.2 Categories of Warning Signs Pay attention to the safety instructions in this, manual, Below are definitions of the three grades of warning signs used when there is a risk to personnel. p DANGER Type of hazard This type of safety instruction indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. ) WARNING Type of hazard ‘This type of safety instruction indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. _ Safety 1810160-02 Safety p WARNING Disintegration hazard Failure to clean the separator bowl, including operating system, at required intervals or after alarms and stop of bowl may cause imbalance with risk of injury to personnel. Noise hazard Excessive noise can cause damage to hearing if no ear protection is used Burn hazard Physical contact with steam from the valve will cause scalding. Q CAUTION Burn hazard Process pipes, lubrication oil and various machine surfaces can be hot and cause burns. 1810160-02 1. Safety Instructions1 Safety Instructions Safety Safety 1 Safety Instructions j\ WARNING Disintegration hazard Never reset an alarm without first finding and remedying the cause. Operating water shortage may result in sludge discharge failure and cause sludge accumulation and heavy imbalance. If the separator has been operated at overspeed, it could be severely damaged and must be checked before restarting. Contact Alfa Laval for instructions. Each new bunker requires rewiew of the discharge time setting. If the interval between sludge discharges is too long, there is risk of heavy side breakdown, Experience has shown that if intervals between sludge discharges are too long, a compact and hard sludge cake can accumulate. On discharge, this cake may break up and be discharged unevenly causing imbalance in the bowl. If imbalance is excessive, there is risk for serious mechanical damage and injury to personnel. ‘ CAUTION Type of hazard This type of safety instruction indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This sign is used when there is a risk to equipment. NOTE This type of instruction indicates a situation which, if not avoided, could result in damage to equipment. This sign is also used when there is a need to stress important information. NOTE This sign is used to stress important information, e.g, how to read this, system manual. 1810160-02 1810160-021 Safety Instructions 1.3 Summary of Essential Warnings DANGER Disintegration hazard Using the separation system outside limits specified by Alfa Laval could cause breakdown. Do not start the separator after an emergency stop without first remedying the cause of the emergency. After an emergency stop the separator bow] must be manually cleaned before starting up again. If the interval between sludge discharges is too long, there is a risk of heavy side breakdown. If the separator is not assembled and connected properly it may lead to disintegration. If power cables have been altered always check the rotation direction, If the separator rotates in reverse vital rotating parts could unscrew. Excessive vibration may cause breakdown. Safety i i 1810160-02 Safely 1 Safety Instructions DANGER Disintegration hazard Do not discharge a vibrating separator, Vibration can increase if only part of solidified sludge is discharged. Do not enter the room after an emergency stop while the separator is still rotating, Running the separator at overspeed due to wrong frequency may cause disintegration. If the separator rotates in reverse vital rotating parts could unscrew. Entrapment hazard Do not switch on without all covers and guards in place. Do not begin maintenance work while the machine is still rotating. 1810160-02ky: Alfa Laval MMPX Separation System System Description Printed Mar 1998 Book No. 1810028-02 V4 EMER EEUU aioeAlfa Laval reserve the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local Alfa Laval company. Published by: Alfa Laval Separation AB Marine & Power Division S- 147 80 Tumba ‘Sweden © Copyright Alfa Laval Separation AB 1998.3 The MMPX Process MMPX System Description 3.3 Defi Preset time between sludge discharge sequences (Parameter value) ion of Terms Water seal (Parameter value) Displacement water Purifier Clarifier 10 When this time has elapsed after a sludge discharge, the next discharge is initiated. Water, added to the separator bowl to prevent oil from escaping at the water outlet, Used only in purifiers. Water, added to the separator bowl to displace the oil and ensure there is no loss of oil at sludge discharge. A separator that cleans the oil from water and sludge with continuous evacuating of separated water. ‘A separator that cleans the oil from sludge and traces of water. 1810028-02 Contents 1 Scope 2 System Overview 21 System Layout 2.2 The Oil Flow 3 The MMPX Process. 3.1. Purifying 3.2 3.3 re10028-021810028-02 MMPX System Description 3 The MMPX Process 3.2 Clarifying ‘When the MMPX separator is used as a. clarifier, the water inlet to the separator bowl is closed, ‘The separator is equipped with a clarifier disc, which seals off the water outlet. Process Cycle 1. The feeding of unprocessed oil to the centre of the separator bow! starts. 2. During the separation process sludge accumulates at the periphery of the separator bowl, Cleaned oil is fed from the separator by the integrated paring disc. If the unprocessed oil contains water, it is accumulated between the oil and the sludge. 3. After the preset time between discharge sequences, the oil feeding stops. 4, A sludge discharge is initiated, ‘The next process cycle starts with resuming of the oil feeding. 1810028-023 The MMPX Process MMPX System Description 4, After the preset time between discharge sequences, the oil feeding stops. 5. Displacement water is added to the bowl. ‘The displacement water eliminates the risk of oil loss at the following sludge discharge. 6. A sludge discharge is initiated while the displacement water is still flowing. ‘The next process cycle starts with adding of water for a new water seal. 8 1810028-02 1 Scope The MMPX separation systems are designed for cleaning of lubricating and fuel oils in marine and power applications and can handle the following types of oil: © distillate * marine diesel oil intermediate fuel oil © heavy fuel oil with a maximum viscosity of 600 cSt © detergent lubricating oil © R&O lubricating oil 1810028-0214 Scope MMPX System Description 3 The MMPX Process The terms used in this process description are explained in section “3.3 Definition of ‘Terms” on page 10. For information about parallel and serial systems, sce the “Installation Instructions” for the relevant MMPX system, 3.1. Purifying ‘When the MMPX separator is used as a purifier, a water seal is added to the separator bow! through the water inlet. ‘The separator is equipped with a gravity disc, chosen according to factors as oil temperature, density, and feed rate. This choice decides the position of the interface between oil and water seal. ‘The gravity disc leaves the water outlet from the bow! open. Process Cycle L.A specific amount of water is added to the separator bowl to form a water seal. 2. The feeding of unprocessed oil to the centre of the separator bowl starts, 3. During the separation process sludge and water accumulate at the periphery of the separator bowl. Cleaned oil is fed from the separator by the integrated paring disc. Excessive water leaves the bowl through the water outlet to the sludge tank. 2 1610028-02 1810026-022 System Overview 2.2 The Oil Flow The unprocessed oil is fed by a positive displacement pump, operating at a constant flow. Depending on the oil type, the oil may need to be heated Afier the heater the change over valve directs the oil to the separator. The separated oil passes the manually operated back-pressure regulating valve to the receiving tank. The oil can also be directed back to the tank, bypassing the separator, This is the case when the oil temperature is outside the preset range, during separator start and stop procedures, and during alarm conditions, MMPX System Description 1810028-02 2 System Overview In the MMPX process, heated oil is fed through the MMPX separator to clean the oil from solid particles and water. An MMPX system comprises: © An MMPX separator, * Ancillary equipment including a control unit, * Optional equipment such as an oil feed pump and an oil heating system. ‘The MMPX separating systems can be operated as single, parallel or serial systems. ‘An MMPX separator operates as a purifier or as a clarifier, ‘When operating as a purifier, cleaned oil eaves the separator through the oil outlet, separated water leaves through the water outlet, and sludge accumulates at the periphery of the separator bowl. When operating as a clarifier, cleaned oil leaves the separator through the oil outlet while separated water and sludge accumulate at the periphery of the separator bowl. In both cases, the control unit initiates a sludge discharge at preset intervals. Sludge and water are then discharged through sludge ports at the periphery of the bowl and collected in an intermediate tank or a sludge tank, 1810028022 System Overview MMPX System Description MMPX System Description 2 System Overview 2.1 System Layout lem] Symbol | Designation Function : Pneumaticaly controlled | Leads the unprocessed oll tothe separator or back The MMPX system layout is illustrated by the KY change over valve to the tank (recirculation). following symbol diagram. 3 ok Separator Cleans the oil by removing water and solid 4 A particles. High pressure switch Senses high prescure in the ol outlet. 5 (For system without intermediate tank) Low pressure switch ‘Senses low pressure in the oil outlet. 8 Pressure gauge Displays the pressure in the oil outlet. 7 Manually controlled Regulates the clean oil back pressure, 8 {SS4 | reguiating vaive Solenoid vaive block, water | Distributes separator opening and closing water, 9 bd water seal water, and displacement water. £ Contro| unit ‘Supervises the separator system. : 10 The MMPX system The inlet and outlet arrows indicate the following: A Unprocessed oil inlet D Water inlet B Cleaned oil outlet E Sludge outlet C — Oilrecirculation ttem | Symbol | Designation Function OD Displacement pump Feeds unprocessed oil to the separator. 1 AY Heater Heats unprocessed oil to separation temperature. 2 4 1810028-02 1810028-02 5ky: Alfa Laval MMPxX Separation System Operating Instructions Printed Nov 2000 Book No. 1810029-02 V5 ENEMA: akiAlfa Laval reserves the right to make changes at any time without prior notice ‘Any comments regarding possible errors and omissions or ‘suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local Alfa Laval company. Published by: Alfa Laval Marino & Power AB SE - 147 80 Tumba ‘Sweden, © Copyright Alfa Laval Marine & Power AB 2000.Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents with fatal injuries. In order to make the information clear only foreseeable conditions have been considered, No warnings are given, therefore, for situations arising from unintended usage of the machine and its tools. A Summary of the safety information is found in the Safety chapter under divider 1.2 Operating MMPxX Operating Instructions Dismantling work must not be started before all rotating parts have come to a complete standstill, A DANGER Entrapment hazard Do not begin maintenance work while the machine is still rotating. A DANGER Disintegration hazard After an emergency stop the separator bowl must be manually cleaned before starting up again. ‘The separator must be reassembled and all covers and guards in place before unlocking the power supply and starting the system, Q DANGER Entrapment hazard Do not switch on without all covers and guards in place. 181002902 Contents 1 Scope 1 2 Operating 3 2.14 Start up Check List 3 2.2 Startup 5 2.3 Intervals Between Sludge Discharges 2.3.1 Background 2.3.2. Recommended intervals between sludge discharges 7 23.3 Fuel oil cleaning 8 2.3.4 Lubricating oil cleaning 9 2.3.5 Bowlinspection n 2.4 Intervals Between Bowl Cleaning 2 25 — Operating Check List 14 2.6 Check of Gravity Disc Size During Operation 18 2.7 Stop 19 2.8 Emergency Stop 21 2.9 After Emergency Stop 21 te10020-021810029-02 MMPX Operating Instructions 2.8 Emergency Stop If an emergency situation occurs press the ‘emergency stop button and evacuate the room. Do not return until the separator has come to a complete stop. ) DANGER Disintegration hazard Do not enter the room after an emergency stop while the separator is still rotating. 2.9 After Emergency Stop ‘The cause of the emergency must be remedied before attempting to restart the separator. If the cause is not found a major service must be performed and all moving parts thoroughly checked. DANGER Do not start the separator after an emergency stop without first remedying the cause of the emergency, To avoid accidental start, switch off and lock the power supply before dismantling. Consult the “Separator Manual” and the “Alarm List” about emergency procedures. 1810029-02 2 Operating 2120 2 Operating MMPX Operating Instructions 9, In order to empty the bowl, restart the separator drive motor from the separator starter and let it run for about 30 seconds. 1810029-02 1 Scope ‘The MMPX separation system is designed for cleaning of fuel and lubrication oil for marine and power diesel engines. 1810029-021 Scope MMPX Operating Instructions 1810029-02 MMPX Operating Instructions 2 Operating 2.7 Stop To stop the system: 1 Stop the system from the control unit: A sludge discharge is initiated, Separator stop sequence operation LED flashes (yellow), ‘The LED changes to steady when the sludge discharge is completed. Stop the heater from the control unit. If the heater is not connected to the control unit it must be switched off independently. ‘Wait until the oil feed temperature starts to drop, read the temperature on the control unit display by pressing the alarm reset button, If the temperature sensor is not linked to the control unit read the temperature indicator situated after the heater. Stop the oil feed pump at the pump starter. Observe when the separator is switched off by the control unit, i.e. when the starter ammeter reading drops to zero. Apply the brake after the EPC 41 display shows OFF. ‘Wait until the separator has come to a complete stop (3-5 minutes; depends on size). Release the brake. 1810029-02 192 Operating MMPX Operating Instructions 2 Operating 2.6 Check of Gravity Disc Size During Operation 1. Carry out a discharge (for uninterrupted time during check). 2. Close the isolating valves for both 2.1 Start up Check List pressure switches PS41 and PS42 (to avoid pressure alarms during check), Separator 3, Note the normal backpressure in the oil 1, Check that the separator is assembled and outlet. connected correctly. 4, Close regulating valve RV4 completely. DANGER 5. Check that oil flows out through the Av sludge outlet. Disintegration 6. Re-open regulating valve RV4. hazard 7. Check to sce if oil is still flowing out If the separator is not assembled and through the sludge outlet, Also observe connected properly it may lead to the backpressure. disintegration, If oil is still flowing out, the gravity disc is the correct size. ‘The backpressure is low. Go to item 8. 2. Check the oil sump level: it should be If there is no oil flowing out, the gravity above the min, line on the sight glass disc is too small. The backpressure remains normal. Stop the separator and fit a larger NOTE gravity disc. Restart and repeat the test. Too little oil can lead to damage of the 8. Reset the system: separator bearings. © Carry outa discharge. Reset normal backpressure in the oil outlet using regulating valve RV4. Open both pressure switches PS41 and Starter PS42, 3. Power on. 18 1810029-02 1810029-02 32 Operating MMPX Operating Instructions Control Unit 4, Ensure that the mode selector switch points to L (local), 5. Power on. ‘The display reads “OFF”. 6. Close the door. 7. Check that the direction of rotation of the bow! corresponds with the sign on the frame; do a quick start/stop and look at the motor fan rotation, ) DANGER Disintegration hazard If power cables have been altered always check the rotation direction, If the separator rotates in reverse vital rotating parts could unscrew. Air Valve Block 8. Ensure that there is correct air supply by reading the pressure gauge situated on the valve block; see “System Reference”. Plant set value: min. max. | 1810029.02 MMPX Operating Instructions 2 Operating Avoid contact with hot machine surfaces. 0 CAUTION Burn hazard Process pipes, lubrication oil and various machine surfaces can be hot and cause burns. Use ear protection if noise levels are high. p WARNING Noise hazard Excessive noise can cause damage to hearing if no ear protection is used. 1810029.02 Ky 172 Operating MMPX Operating Instructions Check the back pressure: read the pressure gauge situated by the low pressure switch on the clean oil outlet line. Plant set value: ‘Check the intermediate tank level by looking at the level indicator on the tank. Empty, if necessary, by opening the left hand valve on the air block. However, the control unit normally empties the tank after each discharge. If excessive vibration occurs press the emergency stop bution and evacuate the room, A DANGER Disintegration hazard Do not discharge a vibrating separa- tor. Vibration can increase if only part of solidified sludge is discharged. Check all connections for leakage, A Oil leakage may make the floor slippery and cause injuries. CAUTION Slip hazard 16 1810029-02 MMPX Operating Instructions 2.2 Startup starter, 2 Operating 1. Start the oil feed pump from the pump 2. Switch the heater on from the control unit. If the heater is not connected to the control unit it must be switched on independently. ZB 3, Start the separator from the starter unit, 4, Listen and observe. Vibration may occur during start up, when passing critical rpm (revolutions per minute). This is normal and should pass without danger. If vibration increases, or continues at full speed, press the emergency stop button. ‘The cause of vibration must be determined and corrected before starting again! ( DANGER tegration hazard Excessive vibration may cause breakdown. 1810029-02no Operating MMPX Operating Instructions Ensure that the separator is at full speed. At full speed the starter ammeter reading has decreased from a high starting value to a low steady value; the idling value (slightly lower than the normal operating value). Cheek the oil feed temperature on the control unit display by pressing the alarm reset button. If the temperature sensor is not linked to the control unit read the temperature indicator situated after the heater. Wait until the oil feed temperature is correct: lube oil; + for cross head engines 90°C + for trunk piston engines 95 °C fuel oil; + for the correct separation temperature see the “Technical Data” in the “System Reference”. Start up the system from the control unit. Operation LED lit (green). v 1810029.02 MMPX Operating Instructions 2 Operating Observe the control unit front panel information: © heater operation LED lit (green): only if the heater is connected to the control unit. © separator system operation LED lit (green). * activated valve LED lit (green). During normal operation the time to next sludge discharge is shown on the right of the display. More information may be read, as required, by pressing the alarm reset button repeatedly (the values are always shown to the right): 1. the oil feed temperature. For the correct separation temperature see the “Technical Data” in the “System Reference” If the temperature sensor is not linked to the control unit read the temperature indicator situated after the heater. 2. the oil feed temperature (if a second sensor for heater control is connected). 3. the accumulated operating time! in hours. N.B. The values displayed in the pictures to the right are examples and not recommendations. Continue pressing until the display returns to normal: i.e. the time to next sludge discharge. 1. How to interpret the displayed figures as hours: (000 ~ 999 = actual value in hours 1000 - 9990 hours 10000 — 99900 hours 100000 = 999000 hours 1810029-02 152 Operating MMPX Operating Instructions 2.5 Operating Check List Compulsory 200 hour Service A compulsory service must be carried out when the system has completed 200 hours of operation after installation or after a gear has been replaced. 1. Check that all units are in good condition and function correctly. 2. Change the oil in the separator oil sump. Consult the “Separator Manual”. The level should be above the min. line on the sight glass. NOTE Neglecting or delaying an oil change may result in damage to separator bearings. 3. Tighten all connections. During operation: Check visually that there is oil in the sump. NOTE Too little oil can lead to damage of the separator bearings. Check that the starter ammeter reading is the normal low and steady value, 14 s810029-02 MMPX Operating Instructions 2 Operating 2.3. Intervals Between Sludge Discharges 2.3.1 Background N WARNING Disintegration hazard Experience has shown that if intervals between sludge discharges are too long, a compact and hard sludge cake can accumulate. On discharge, this cake may break up and be discharged unevenly causing imbalance in the bowl. If imbalance is excessive, there is risk for serious mechanical damage and injury to personnel. Recommendations are given regarding initial intervals between sludge discharges for different applications. The setting may subsequently have to be changed after actual inspection of the bowl. 2.3.2 Recommended intervals between sludge discharges Many factors influence accumulation and hardening of sludge between the discharges. so the appropriate interval depends on local conditions. However, in order to have a reasonable starting point the following table shows recommended initial discharge intervals and operating times to first inspection. 1810029-02 72 Operating MMPX Operating Instructions 2.3.3 Fuel oil cleaning Recommendations Type of fuel Initial intervals be- | Time to first bow! in- tween discharges | spection Distilate (1.5 - 6 o8t/40 °C) 4 hours 1 week Matine Diesel Oil (max, 14 Sv40 °C 2 hours 1 week Heavy Fuel Oil 0.5 hours 2 days Conditions may change completely when bunkers are changed. Therefore, great care must be given to the discharge interval setting for each new bunker. In case the actually used discharge interval exceeds the recommended initial value, the interval setting has to be reduced, according to the table above, when a new, unfamiliar bunker is separated. Use of unstable fuel or mixing of incompatible fuel oils may give precipitation of sludge and overloading of the separator. 8 1810029-02 MMPX Operating Instructions 2 Operating Note: 1. A low pressure/low flow alarm with no apparent external cause (incorrect flow, temperature etc.) is a sign that the bowl needs immediate cleaning. Never neglect to investigate and remedy the cause of such alarms. 2. Cleaning of the operating system is normally required whenever product- wetted parts of the bowl are manually cleaned, 3, In cases where an uneven sludge cake remains in the bowl after a discharge, this, induces a particularly heavy imbalance when not covered by liquid. This may occur in total discharge type separators and when starting separators without previous cleaning. Therefore, always after each stop, inspect the bowl for cleanliness from sludge, and if required clean it before restart, This should be done when the separator has been in operation for 24 hours or more after the last inspection or cleaning. 0 WARNING Disintegration hazard Failure to clean the separator bowl, including operating system, at required intervals or after alarms and stop of bowl may cause imbalance with risk of injury to personnel. 1810029-02 132 Operating MMPX Operating Instructions 2.4 Intervals Between Bowl Cleaning Suitable intervals between cleaning vary according {o the process parameters and installation. The intervals can only be determined by bowl inspections at actual operating conditions. Indicated below are some of the conditions, where experience has shown that the interval between cleaning has to be closely monitored and possibly shortened. General: ¢ Installation not in accordance with Alfa Laval specifications and recommendations, * Poor operating water quality. For fuel oll separators: © HFO with excessive or extraneous contaminants. © Separation of fuel containing stuffing box oil, spent lubricating oil or recovered from sludge tanks. For lubricating oil separators: * Diesel engine condition bad. © Separation of piston rod stuffing box oil in the case of crosshead diesel engines. # Inadequately cleaned piston rod stuffing box oil recycled to system oil. 12 1810029-02 MMPX Operating Instructions 2 Operating 2.3.4 Lubricating oil cleaning © Continuous operation: In a new lubricating oil system the oil is initially clean but as it gets dirtier the interval between discharges will have to be shortened until a “steady state” is reached, Following information refers to systems in “steady state”. Recommended intervals for Crosshead engines Type of oil Type of separator Initial discharge | Time to first bow in- spection Main lubricating oil system ‘hour 1 week MOPX Main lubricating oil system 0.5 hours 1 week MMPX Stutfing box oil 5 min. After each batch | MMPX When separating stuffing box oil, the specialised “MMPX Box Oil Cleaning Plant” is primarily recommended. Please note that the recommended initial discharge interval is 5 minutes and that it must never exceed three times this value. Recommended intervals for Trunk engines Type of oll Initial discharge | Time to first bow in- spection Main lubricating oil system 0.5 hours 2 days © If separator has been out of operation: If the separator has been out of service for 24 hours or longer, while the engine has been running, the interval between discharges has to be shortened. In this case the recommendation is: * Discharge interval 5 minutes until the whole oil volume has passed twice through the separator. * After that resume normal discharge interval. 1810029-02 cE}2 Operating MMPX Operating Instructions © Intermittent operation: For installations whiere one separator serves one engine which is temporarily stopped the following recommendations apply: If the engine is to be stopped for 24 hours or less: + Operate the separator continuously. If the engine is to be stopped for more than 24 how + Keep the separator in operation for 8 hours after the engine is stopped. + Start the separator 8 hours before the engine is started again, Doing so most of the suspended particles and condensed water will be removed from the system and not settle in the sump tank. For installations where one separator serves more than one engine the following recommendations apply: + Continuous use of the separator whenever possible. + Frequent switches between the engine systems to be cleaned, In a typical case with one separator serving 2-4 auxiliary engines switching after maximum 24 hours of cleaning. + Discharge interval: Engine has been in operation with- | Engine has not been in operation ‘out cleaning of the system oil since last cleaning of system oil Discharge interval 5 min. ‘Normal discharge interval Duration until the whole oil volume. has passed twice through the separator ‘After that resume to normal discharge interval 10 1810029-02 MMPX Operating Instructions 2 Operating 2.3.5 Bowl inspection To check if the initially selected interval is appropriate, the bow] should be inspected after a short test period shown in the previous tables. If sludge space is clean: Interval may be prolonged with steps of 15 minutes, but it must not exceed three times the recommended initial interval. “Sludge space is clean” means that no noticeable amount of hard sludge remains in the sludge space. If sludge space is dirty: Interval has to be shortened. When the bowl is opened for routine cleaning, the sludge space should always be inspected and evaluated, If necessary, the interval between discharges should then be changed accordingly. N.B. Alfa Laval assumes no responsibility for the actual choice of discharge intervals, as these entirely depend on local conditions. 1810029-02 ‘Sludge space in bowl. Parts to be inspected: A 8B. c. D. E Top disc Bow! hood Sludge space Disc stack Sliding bow! bottom aMMPxX Separation System Parameter List List No. \31830-6181-7 Printed Mar 1998 Book No. 1810141-02 V4 Alfa Laval Marine & PowerAlfa Laval reserve the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local ‘Alfa Laval company. Published by: Alfa Laval Separation AB Marine & Power Division $- 147 80 Tumba ‘Sweden © Copyright Alfa Laval Separation AB 1998,7 Sequence Diagram 7.2 Clarifier mode MMPX Parameter List ‘The duration of the monitoring functions and output signals when the separator is operated as a clarifier is illustrated in the diagram. [Valve [Terminal Activated function |Standby|Starting | Separation |Sludge dlecharge_ [Stopping Relay sequence _|sequence [sequence lsequence [Sensor ‘OFF [Pao [Pam [P54 | Pad | Pet [P70 [Pre [Pre [Pra ||Pea [Pot [POF [ORF 3 [Ws [ads | ws oma [ros [ros [Os [ios] a0e | Ss [rode Mon. functions High intermediate — usa jxre [0 isa x73 |High eve! oo psa2 [x74 — |Lowooll pressure —— x82 xe [Emergency stop! —$—$——— a, xs [x84 | Vibrations! ———— tt X93 |Hoator faut [peeeeeenremrfessne ens eenerennefeten snes etn anenteentmneine TTY X13 | High ofl temperature” a Trt |x11:1-3. | Low oil temperature? —— [Output signals X1:1-2 |Motor starter — 4 [Blocking vibration xs1 [xase [Bice — Mvi |x4:4 Jil separator -_ — Mve {x51 Tank drain — - Displacement! MVI0 X52 Sealing water Mv15. |x8:3. Bowl opening water — Mv16 {x54 Bowl closing water? Cc 24 Emergency stop (XS2) is normally connected on terminal X84. f optional vibration switch (XS1) is installed, it willbe connected on ferminal X84. Emerg the EPC is in stand-by mode (OFF) and t! stopped. yency stop (XS2) will hen be connected on system power supply. If ie emergency stop Dutton is pushed, the separator motor wil be ‘With optional sensor T1 installed PSO will not star if the temperature is too low or too high. During P81 intermittently 2 seconds every 15 minutes. 1810141-02 Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents with fatal injuries. In order to make the information clear only foreseeable conditions have been considered. No warnings are given, therefore, for situations arising from unintended usage of the machine and its tools. A summary of the safety information is found in the Safety chapter under divider 1.7 Sequence Diagram 7.1 Purifier mode ‘The duration of the monitoring functions and output signals when the separator is operated as a purifier is illustrated in the diagram. (Valve | Terminal Activated function [Standby staring Separation] Sludge alacharge [Stepping Relay sequence ‘sequence |sequence lsequence Sensor rE |pan [PE [BSS Tosa wan | wer [Pvo [ore [Pr [Pra ra [Pee [POS OFF Ts [as sos Oss mh oe Telos ]e [we se fee Mon. tnetione High intermediate uss [x73 [High level saz x74 |Lowoll pressure a XS2 | K8:4 lEmergency stop! —_—_ xsi |xe:4 | Vibrations* Saas — x93 {Heater taut 11 |x11:1-3.|High ottemperature? 11 /x11:1-8 |Low oi temperature? — [Output signals - x12 feotr starter Pepe Peery “ [Blocking vioation xst |x2a4 [Block a vi |x4:4 [Oil to separator ———_ — ave [xs |Tankerain — lm vio |x5:2 | Displ/Sealing water — = vis |x8:3 [Bow opening water bam ivie|x5:4 Bow closing water? - ae 1. Emargoncy stop (XS2) is normally connacted on terminal X84. eptonal bration ewitch (XS1) is installed, it wll be connected on terminal X84, Emorgoncy stop (XS2) wil ton bo eommectod on system power SUDA}. 2. Withoptional sensor TT1 italod P50 wil not star Ifthe fomperature i 100 low 0 too righ. 3. During PST iniormatinly 2 seconds every 15 minutes. 1810141-02 va 236 Additional Parameter Information MMPX Parameter List P54 Oil feed on during stabilizing period Oil admitted to separator bow! during a stabilizing period. If more than 30 seconds is needed for the purifier and 60 seconds for the clarifier it may indicate a malfunction. 6.3.2 Separation Sequence P60 Tank drain During P60 draining of the intermediate tank takes place. Conditions for activation of this function are selected by P26, P61 Time between sludge discharges The same as Pl (setting one parameter will set both to the same value). Bowl closing water is supplied for 2 seconds every 15 minutes. NB. In series operation the time sequence for the clarifier must be longer than for the purifier, in order to synchronize sludge discharges initiated from the purifier, 6.3.3 Sludge Discharge Sequence P70 Displacement water Filling of displacement water to the bow! eliminates the risk of oil loss at the next sludge discharge. If more than 40 seconds are required, this indicates a malfunction. N.B. If P2=C (clarifier mode), then P70 starts but the valve is not activated (i.e. no displacement water added). 22 P72 P78 NB. Sludge discharge Sludge discharge initiated by MV15 admitting water to the separator bowl. If more than 4 seconds are required, this indicates a malfunction, Sealing water Sealing water is used in the bowl to prevent oil from discharging through the water outlet in a purifier. The amount of sealing water in the bowl is balanced by the gravity disc. Insufficient volume of water will lead to a broken water seal. If broken water seal occurs during sludge discharge sequence the time setting can be increased, P78 should be set according to experience. If P2 = C (clarifier mode), then P78 starts but no conditioning water is added. 6.3.4 Stopping sequence P83 NB. Tank drain During P83 draining of the intermediate tank takes place. Displacement water. Oil feed off Before the separator is stopped displacement water is added to the bowl to displace the oil and ensure there is a minimum loss of oil. If P2 = C (clarifier mode), then P84 starts but no displacement water is added. Separator motor off The separator motor is automatically switched off. Restarting is blocked for 3 minutes. 1810141-02. Contents 1 Scope 1 2 Process Parameters 3 3 Installation Parameters . 5 4 Timer Sequence Parameters 7 5 Service Mode Parameters 90, 94, and 95 9 5.1 Countdown of Timers P50 - P89 9 5.2 Alarm Log 10 5.2.1 Examples of Logged Alarms 11 5.3 Timer function 13 6 Additional Parameter Information 15 6.1 Process Parameters 15 6.2 Installation Parameters 20 6.3 Timer Sequence Parameters 21 6.3.1 Starting Sequence 2 6.3.2 Separation Sequence 22 6.3.3 Sludge Discharge Sequence 22 6.3.4 Stopping sequence 22 7 Sequence Diagram 23 71 Purifier mode 23 7.2 Clarifier mode 24 saror4t-o2MMPxX Parameter List 6 Additional Parameter Information N.B. Ifa different type of heater is installed P40 Pal P43 181014102 6.3 (P37 = 0), only a start/stop signal is available from the EPC-41 control unit. If a steam heating system is connected to the EPC-4l and if the system i ‘equipped with an optional shut-off valve, and provided P37= 0 or 2, the valve is opened when the heater is started. P50 The valve is shut: P52 when the heater is stopped at high temperature alarm © at power failure * at EPC stand-by mode ‘Temperature reading Degrees Celsius (°C) or Fahrenheit (°F) temperature readings available. PS, P6 and P7 have to be set according to °C or °F, Max. start time for heater Sets the maximum allowed start time for the heater. Minimum temperature limit (P6) must be reached within this, time, P53, Extra alarm function Extra alarm functions can be connected. By setting P43 to | the oil feed to the separator will be stopped when the extra alarm occur. NB. N.B, 1810141-02 Timer Sequence Parameters 6.3.1 Starting Sequence Sludge discharge To ensure that the bowl is always emptied at start (e.g. after power failure). Bowl closing water For proper closing of the separator bowl during start-up sequence. If more than 60 seconds is required, it may indicate a malfunction. Sealing water Sealing water is used in the bowl to prevent oil from discharging through the water outlet in a purifier, The amount of sealing water in the bowl is balanced by the gravity disc. ‘During the starting sequence, sufficient water must be admitted to the empty bow! to establish an adequate water seal. Insufficient water will lead toa broken water seal. If a broken water seal occurs during the starting sequence the time setting can be increased. P53 should be set according to experience. Before increasing the sealing water, make sure that the appropriate gravity disc is fitted to the separator bowl. This function is blocked in the clarifier mode (P2 = C, and P51 =“---"). 216 Additional Parameter Information MMPX Parameter List PIS 6.2 P20 P26 P23 HFO / DO selection of oil type P34 To prevent false alarm (A7-10) when cleaning diesel oil the type of oil must be specified. Once P5, P6 and P7 are set for HFO or DO they automatically follow the selection of P15. If P15 = “HFO” and PS is set > 0 then PS for DO is automatically reset to 50 °C (120 °F). If P15 = “do” then P53 =P70 = 0. See PS for the relationship between P5, P35 P6, P7 and PIS. Installation Parameters Separator type When P20=2.1 the specific functions for the MMPX are automatically set. Tank drain action = Drain valve or optional pump activated after discharge. For timing see timer P60. P36 1 = Drain valve or optional pump activated when level indicating switch, LSI 4, is activated. For timing see timer P60. EPC-41 address If the separator works as a single unit P37 the EPC-41 address is always 1. ‘When using more than one separator in the same system (parallel or series) each interconnected EPC-41 control unit must be identified. The EPC-41 address shows the order in which the control units ate linked. See also P3 for the relationship between the parameters, Alarm delay time Activation of most alarm functions can be delayed up to 30 seconds, except for © emergency / vibration alarm high temperature alarm, which have a fixed delay time of 2 seconds. If operating two separators in series, P34 for the clarifier separator must be 3 seconds longer. Low temperature alarm delay after MV1 change over ‘When the oil feed change over valve changes position the flow rate and thus the oil temperature may be influenced, By delaying the temperature alarm, a false alarm is avoided as the oil temperature has time to stabilize. P35 should be set according to plant application, If delay time above 120 seconds is necessary, check the heating system and the installation layout. Remote control Remote control can be applied in form of: ¢ extemal switches ¢ external computers Heater type ‘The EPC-41 control unit is designed for control of: * Heatpac EHS-62 (P37 =1) ¢ Heater with heating media control valve (P37=2) 1910141-02 1 Scope This parameter list is valid for the MMPX separation systems, including the EPC-41 control unit with PROM: 31830-6213-1. 1810141-021 Scope MMPX Parameter List MMPX Parameter List 6 Additional Parameter Information How to set P8 and P9: If the temperature varies with regularly repeated oscillation, setting of the proportional band and integral time is necessary. © Increasing the value of parameter P8 (proportional band width) will resuit in a slower and more stable control action * Increasing the value of parameter P9 (integral time) also results in slower response from the EPC-41. We recommend that you follow these guidelines: 1, Set P9 = 10 minutes. 2, Decrease P-band (P8) band in steps until the process reaches the point where it starts to oscillate with a constant amplitude. Test the stability after each step by introducing a step-change of load or set point, 3. When you have discovered the Constant amplitude point where the process oscillates with a constant amplitude note the following figures: ‘A= The value of P-band (P8). B= The time for one full period in seconds. 4. Calculation of optimal parameter B settings, P-band T-time P8=22xA PI=0.8xB ‘The settings above give a rather good result but may be adjusted according to individual characteristics in different loops 2 1810141-02 1810141-02 196 Additional Parameter Information MMPX Parameter List P4 PS P6 18 Sludge discharge signals from purifier to clarifier The number of sludge discharges initiated by the first separator (purifier) before a discharge signal is sent to the second separator to start its sludge discharge sequence. P4 should be set in the purifier controller. High temperature alarm PS should be set sufficiently above the temperature set point P7. 5~10°C (10-20 °F) higher than P7 is recommended. If PS = 0 (monitoring temperature sensor (Pt 100) not connected) then P6 = P7 =“---". PS, P6 and P7 can be set both for heavy fue] oil (HFO) and for diesel oil (DO), see P15. If both oils are to be used, the following must be done: 1, Set P5, P6 and P7 for “HFO" (P15 is factory set to “HFO"). 2. Change P15 to “do”. 3. Go back to PS and set PS, P6é and P7 for DO. If only diesel oil is to be used for the installation, the following must be done: 1. Set PS greater than 0, 2, Change P15 to “do”. 3. Go back to P5 and set P5, P6 and P7 for DO. Low temperature alarm Should be set sufficiently below the temperature set point P7. 5-10°C (10-20 °F) lower than P7 is recommended. P8 ‘Temperature set point To be set according to plant application. See also PS and P6. P-band (Proportional band) If P37 = 0 then PS a If P37 = | or 2 then P8 is automatically preset to 40%. L-time (Integral time) IfP37 = 0 then P9=*- --", If P37=1 or 2 then P9 is automatically preset to 1.2 minutes, 1810141-02 2 Process Parameters ‘The EPC-41 control unit controls the separa- tion process, It can be programmed for differ- ent separation systems and different condi- tions within the system, by setting parameters. ‘The process parameters can be easily adjusted, as often as required, to meet changes in the operating conditions, e.g. oil temperature, alarm points, time between sludge discharges. Each separator has its own EPC-41 control unit. Up to three separation systems can be interconnected via cables between their con- trol units. The separators can work in parallel or series operation. Only two separators can work in series; the third must work in parallel oract as a stand-by. The first separator in series should always be defined as a purifier and the second as a clarifier. NOTE P2 is factory set to P (purifier). If you change it to C (clarifier) you get all the factory settings for a clarifier, which is shown in columa “Factory set value, Clarifier” in the tables. Q WARNING Disintegration hazard If the time between sludge discharges is set too long, sludge accumulation and bowl imbalance may occur. 1810141-022 Process Parameters MMPX Parameter List Factory set value | Plant Parameter Description or unit Range set Purifier | Clarifier! yaiue Pit | Max. time between | Minutes 0-999 30 30 sludge discharges | P1 = P61 Changing of P1 automatically changes P61. P2' | Purifier/Clarifier mode | P = Purifier Porc P © = Clarifier P3! | Series configuration 0 = No separator in series 0, 12, 13, 23 9 0 12 = The 1st and the 2nd sepa- rator work in series 19 = The 1st and the Ord separa tor work in series 23 = The 2nd and the 3rd sepa- rator work in series Pa? | Sludge discharge sig-| 1 = Every purifier discharge 14 eee ee nal from puriier to. | 2 = Every 2nd purifier aaritier discharge 3 = Every 3rd purifier discharge| 4 = Every 4th purifier cischarge| IPS = 0 then P4 = Ps! | High temperature | °C or °F 0-115°Cor | 0 ° alarm 0-255 °F P6' | Lowtemperature | °C or *F 0-115 °Cor |---| --- alarm 0-255 °F P7' | Temperature set point| °C or °F o-110°%Cor | --- | - 0-240 °F pet | P-band % 10-500 = Pe! | |-time Minutes 0.1 -10.0 P10 to By” Not used pete eee P15! | HFO/ DO selection of | HFO = Heavy Fuel Oil HFO or do | HFO | HFO type of oll do = diesel oi For lubricating oil select HFO P16to Big | Not used sf 1. For more information, see"Additional Parameter Information” on page 16. 4 1810181-02 MMPX Parameter List P3 Series configuration Up to three EPC-41 control units can be linked together. Only two of the three connected separators can work in series. The first separator in series should always be defined as a purifier and the second separator as a clarifier. ‘The relationship between the parameters P2, P3 and P23 is shown in the following table. ‘The Ist linked control unit must always have the power on (the separator does not need to be operating) when the 2nd and the 3rd separators are operating in series, 6 Additional Parameter Information Type of operation | First linked control unit] Second linked control unit] Third linked control unit Single operation: P2 = P (Purifier) = a PS = 0 (No separator in series) P2a= 1 (Single unit) Parallel operation: | P2 = P P2=P P3=0 P3=0 P23= 1 (Istlinked | P23= 2 (2nd linked control P23= 3 (Grd linked control control unit unit) unit) ‘Series operation Pas? Pe = 6 (Clarif P2=P stand 2nd separator:| P3= 12(1and2in | P3 = 12 P3=0 series) Page 2 P23. 3 Pade 1 This separator works as a stand-by unit: i.e. in parallel operation or not used. Series operation a= P P=? P= 0 4st and 3rd separator: | P3 = 18 (1 and 3 in P3= 13 series) Page 2 P2a= 3 Pea. This separator works as a stand-by unit Series operation P2=P P2=P P2- 0 2nd and 31d separator:| P3 = 0 P3 = 23 (2 and 3in series) | P3 = 23 P23= 1 P2322 P23= 3 This separator works as stand-by unit. 1810141-02 176 Additional Parameter Information MMPxX Parameter List 3 Installation Parameters "Type of oi! Initial discharge | Time to first bow! inspection] Distilate (1.5 - 6 cSt /40 °O) ‘hours 1 week Marine Diesel Oil (max. 13 St / 40 °C} 2 hours 1 week Intermediate / Heavy Fuel Oil 0.5 hour 2 days 1 Het NOTE Lubricating oil cleaning The interval between discharges must EPC-41 parameter P21 is factory set be shortened if the separator has been to 50 Hz, If connected to a 60 Hz out of service for 24 hours or longer supply an alarm will occur. Set P21 to while the diesel engine has been 60 Hz. and press the reset button, The running. alarm will disappear. In order to have a reasonable starting — — point the table below shows ‘The installation parameters must be set before recommended initial discharge the initial start-up and before process para~ intervals and operating time to first meters are set. The parameters rarely need to inspection, be adjusted again, Main lubricating oll system 7 NOTE Initial discharge Time to first bow! inspection| for trunk piston engines Recommended interval 1 hour 1 week for cross head engines Stuffing box oil 5 minutes After one batch Recommended interval 0.5 hour 2 days P2— Purifier/clarifier mode ‘The MMPX separator can be defined as a clarifier or as a purifier. It can operate as a single separator or in parallel or series. This is defined by the parameters P2, P3 and P23, See P3 for the relationship between these parameters. If a separator operates in series when the mode is changed the parameter P3 has to be changed accordingly. 16 Alfa Laval can not be held responsible for injuries and damage caused by use of parameter values not recommended by Alfa Laval Factory set value] Plant Parameter Description or unit Range Purter | curt | P20 _| Separator type 1.2= MMPX ra-21 | 12 12 | 12 | P21 | Power frequency Hz 50 or 60 50 50 Check that the frequency is cor- rect, see label on the separator. P22__| Not used on 231 | EPC-41 address 41 = Single unit or the ‘st linked 1-8 1 1 control unit 2 = The 2nd linked control unit = The 3rd linked control unit 4-8= Not used Up to 3 control units can be linked together, Peg For remote communication with 48 48 P25 Profibus protocol 2 2 1et014t-02 1810141-023 Installation Parameters MMPX Parameter List Factory set value | Plant Parameter Description or unit Range 7 T P26! | Tank drain action (0 = Drain during time P60 after | 0 or 1 ° ° discharge Drain during time P60 after discharge when level LSI 4 is indicated P27 to| Not used - - P32 P33 | Emergency stop function, 0 = Emergency stoponly "| ort ° ° 1 = Mechanical vibration switch P34" | Alarm delay time ‘Seconds 15 15 P35! | Low temperature alarm | Seconds 1-999 18 16 delay after MV1 change over P36" | Remote control No remote control 0-30-13) 0 | 0 | Remote switches Remote computer Not applicable No remote control, alarm ‘A4- cancelled | 11 = Remote switch, alarm Ad-1 | cancelled 12 = Remote computer, alarm Aé-1 cancelled 19 = Not applicable P37! | Heater type © = Noorcommon heater with | 0-2 o | 0 separate controller 1 = Heatpac EHS-62 controlled by EPC-41 Heater with control valve, controlled by EPC-41 { P38 | Size of Heatpacheater | kW eee eee If P97 = 1 then P38 is set to 16, otherwise P38 = "~~ P39 | Run time of steam con- | Seconds oo | oe trol valve if PQ7 = 2then P99 is set to 120, | otherwise P39 = * ~~ P40! | Temperature reading c= Corr c c Par Pat! | Max. start time for heater] Minutes 0-999 15 15 | P42 | Not used co a3! | Extra alarm function © = Alarm indication on display. | 0 or 1 o ° z No action, 1 = Alarm indication on dispiay. Oil feed off during separa~ tion sequence P44 to| Not used see | ee Pag 1. For more information, see"Additional Parameter Information” on page 15. 6 ta1otat-02 6 Addi ional Parameter Information 6.1 Process Parameters PL Max time between sludge discharge Long intervals between sludge discharges can cause the sludge to accumulate and solidify. The sludge may then break up at sludge discharge and create imbalance in the bowl. A NB. WARNING Disintegration hazard If the interval between sludge discharges is too long, there is risk of heavy side breakdown, ‘As many factors influence the sludge discharge interval, the choice of interval must be based on experience. When the bow! is opened for routine cleaning, the sludge space should be inspected and, if necessary, the interval between discharges changed accordingly. Clean sludge space: the interval may be prolonged. “Clean sludge space” means that no noticeable amount of solidified sludge remains in the sludge space. Dirty sludge space: the interval must be shortened. “Dirty sludge space” means that some solidified sludge has accumulated in the sludge space. 1810141-02 The only way to get a clean sludge space is to make appropriate adjustment of the interval based on regular inspection. Alfa Laval assumes no responsibility for the actual choice of discharge interval times, as these depend entirely on local feed characteristics. Fuel oil cleaning Conditions may change completely when bunkers are changed. Therefore, great care must be given to the discharge interval setting for each new bunker. In case the current discharge interval exceeds the recommended initial value, the interval setting has to be reduced according to table on next page, when a new, unknown bunker is to be separated. Use of unstable fuel or mixing of incompatible fuel oils may cause precipitation of sludge and overloading of the separator. WARNING Disintegration hazard Each new bunker requires review of the discharge time setting. 155 Service Mode Parameters 90, 94, and 95 MMPX Parameter List 14 1810141-02 4 Timer Sequence Parameters The timer sequence parameters control the operation of the system; i. start, separation, sludge discharge and stop functions. Factory set value | Plant Parameter Description or unit Range set Purifier | Clarifier Vaiue Starting sequence P50" | Sludge discharge | Seconds 0-999 1 1 s P51 | Notused - if - P52! | Bowl closing water | Seconds 0-999 40 40 P53' | Bow! sealing water | Seconds 0-999 30 - P54‘ | Oil feed on during | Seconds 0-999 30 30 stabilizing period PSBto | Not used cee ee P59 ‘Separation sequence P60" | Tank drain Seconds 0-999 40 40 P61" | Time between sludge | Minutes 0-999 30 30 discharges P61 =P1 Changing of P61 automatically changes Pt P62 to] Not used cee fee Peo Sludge discharge sequence P70" | Displacement water. | Seconds 0-999 10 10 Oil feed off P71 | Notused os - P72' | Sludge discharge ‘Seconds 0-99.9 1.0 10 P73 to] Not used so fose P77 P78' | Bowl sealing water | Seconds 0-999 10 10 P79 | Oil feed on 0-999 10 10 1810141-02 ti4 Timer Sequence Parameters MMPxX Parameter List Factory set value | Plant Bowi closing water off P87 to] Not in use Peg Parameter Description or unit Range set Purifier | Clarifier! value ‘Stopping sequence P80 to] Not in use pe Paz P83 | Tank drain Seconds 0-999 40 40 Psa" | Purification: Seconds 0-999 5 Displacement water Clarification: Seconds o- 999 10 | on. Cil feed off P85 | Not in use - P86! | Separator motor off | Seconds. 0-999 180 180 1. For more information, see"Additional Parameter information” on page 15. r910141-02 MMPX Parameter List 5 Service Mode Parameters 90, 94, and 95. 5.3 Timer function By setting P94 to >0.0 a count down timer is activated. It is intended as a reminder of service to be made after the elapsed running hours, If e.g, P94 is set to 2.70 it means 2700 hours, Each 0.1 indicates 100 hours, When 2700 hours of operation have elapsed, an alarm will be released and 3h - - - is indicated in the front window. The alarm is repeated at each start of the EPC. To avoid this the P94 timer has to be started or set to 0. When P94 is >0 the actual count down value is displayed when P95 is activated. P95 is just an indication of the elapsed time in P94. It can not be set. To restart the timer, go to P94. Push third button once (display flashes). Push button one once, The timer is now restarted with the same value, When the display is flashing, a new value can be entered. 1g10141-02 13,5 Service Mode Parameters 90, 94, and 95 MMPX Parameter List 5 Service Mode Parameters 90, 94, and 95 If the accumulated time becomes more than 999.5 hours it will the first time be indicated by capital “H” and 1000 is subtracted from the displayed value, @) The second time it happens, another 1000 is subtracted from the displayed value etc. With aid of the service mode parameters information can be requested and displayed, for instance the countdown of timer sequences can be displayed while they are running. aay a " Factory set value | Plant i it Re Parameter Description or unit ange Purtor | clrtr| 2,9 7 Ms C3 Between these two alarms 10 hours have elapsed (H 5.0 = 1005.0 hours) P90 | Service mode 0 1 No service mode 0, 1,2, 50 ° 0 Countdown of timers P50 ~ P89. 12 = Power frequency 50 = Alarm log, including self ro- setting alarms P91 For remote 0 0 t fi S 5 P94 =| Count down timer 0.0- 10.0 0.0 0.0 a P95 | Indication of P94 timer | Hours: 0.0 - 10.0 sat PL | 1310] : poste) natene P99 * This indicates the end of the log. 5.1 Countdown of Timers P50 — P89 6 By setting P90 to 1, the mode selector in position L and then by pushing the alarm reset, button, a countdown of each activated timer (P50 — P89) can be displayed during ‘operation. Timer P61 shows that itis 32 seconds left to next sludge discharge. 12 1a10141-02 1810141-02 95 Service Mode Parameters 90, 94, and 95. MMPX Parameter List 5.2 Alarm Log By setting P90 to 50, the mode selector in position L and then by pushing the alarm reset button, the 32 latest alarms can be displayed, including self resetting alarms. Each logged alarm consists of three consecutive groups of information: 1. The accumulated alarm log time, which shows how long the EPC has been in ‘operation since the previous alarm, If the interval between two alarms is greater than 999.5 hours (= 41 days) the whole alarm log will be reset to 0. 2. The alarm is indicated in the same way as when it occurred, except for the alarms starting with an E: + alarm code starting with an A. * LED and an alarm code, for instance ‘High or low oil temperature”, + LED indications only. + “alarm” code starting with an E (events with no alarm released) ‘There is only one event for EPC-41, which is a self resetting function; E2 = low pressure 3. The actual value of parameter P1 (maximum time between sludge discharges). 10 1810141-02 MMPX Parameter List 5 Service Mode Parameters 90, 94, and 95 5.2.1. Examples of Logged Alarms © The capital “H” indicates that this is the latest alarm which has been logged. The EPC had been in operation 48 hours and 20-29 minutes since the previous alarm. Every tenth minute is displayed, but several alarms can be logged within this period. ‘The alarm was a “Power failure”, P1 (maximum time between sludge discharges) was set to 30 minutes. Between these two alarms 10 hours and 0-9 minutes had elapsed (58.2 - 48.2). ‘© This event occurred 58 hours and 20 - 29 minutes ago. ‘The event was a “Low pressure”. P1 indicated 30 minutes. © 106 operating hours and 30-39 minutes ago the first logged alarm occurred, ‘The alarm was a “Low temperature”, (Which is indicated by the LED and the figures on the display). P1 setting was 30 minutes. 1910141-02 "1ky: Alfa Laval MMPxX Separation System Alarms and Fault Finding Printed Nov 1998 Book No. 1810142-02 V4 Alfa Laval Marine & PowerAlfa Laval reserve the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated Copies of this publication can be ordered from your local ‘Alfa Laval company. Published by: Alfa Laval Marine & Power AB $- 147 80 Tumba Sweden © Copyright Alfa Laval Marine & Powe AB1998.5 Test Program MMPX Alarms and Fault Finding se10142-02 Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents with tatal injuries. In order to make the information clear only foreseeable conditions have been considered. No wamings are given, therefore, for situations arising from unintended usage of the machine and its tools ‘A Summary of the safety information is found in the Safety chapter under divider 1.MMPX Alarms and Fault Finding 9. Serial communication 5 Test Program a Circuit correct Measure -10 to -12V DC on X14:1-4 (Circuit correct). Circuit fault Function Terminal | Unit 9.1 Not applicable X14: (The display will show an E). 92 RS2920x14 cara NB, Disconnect the communication cable and put a jumper between X13:2-4 before the test is carried out. N.B. In cases where connections X2 and X3 are bridged, a transistor may blow. After the test, remove the terminal jumpers and connect communication cables. N.B, Stop the test program by switching power off-on. 1810142-02 315 Test Program MMPxX Alarms and Fault Finding 7. Notin use 8. Analog inputs To simulate the temperature sensor elements (Pt 100) in 8.1 and 8.2, a resistor can be used. Separate plug connectors with appropriate resistors are included in the test module kit. [Resistor Reference temp. Display reading TOk 25°C (77 F) 0 T402 | 104°C (219 F) a5 The normal value on the display for function 8.1 and 8.2 should be 60 — 215. Outside the range 42 — 233 indicates a fault. 000 (or a very low value) or 255 indicates a serious fault. A normal value for function 8.3, Reference 4V should be 195-215. This table shows how to find the fault: Hy X10, X11 =n “Temperature sensor error”: alarm code “EEE” Possible causes, Funetion Terminal | Unit Fuse A1:F2| A/D conver- | input blown Input short sion faulty | open | circuit 8.1 Temperature sensor for control | X10: 1-3 | TT2 000 (000 255 (000 8.2 Temperature sensor for alarm | X11:1-3 | TTt (000 (000 255 000 83 Reference 4V 000) 000 195-215 | 195-215 8.4 Notinuse Function Terminal_| Unit Displayed value 8.5 Calibration x10 112 0= OK E = Error 8.6 Calibration xt TT 0=OK E = Error For instance, if the display shows “000” for function 8.1, 8.2 and 8.3, it must be either a blown fuse or A/D converter fault. Check it in this order: 1. If the fuse is blown, replace it. 2. If the fuse is correct, replace the control module. 1810142-02 Contents 1 Scope 1 2 EPC Signs 3 3 Alarms 7 3.1. Alarm Functions 7 3.2 Alarm Reset 8 3.3. Alarm Survey @ 3.4 LED Alarms and Fault Finding 10 3.4.1 High Oil Pressure 10 3.4.2 Low Oil Pressure ” 3.4.3. Medium Intermediate Tank Level 12 3.4.4 High Intermediate Tank Level12 3.4.5 Emergency Stop 13 3.4.6 Vibrations (Option) 4 3.4.7 Faulty Pressure Switch 15 3.4.8 Heater Fault 18 3.5 LED and Display Alarms and Fault Finding 16 3.5.1 High or Low Oil Temperature (Option) 16 3.5.2 Temperature Sensor Error (Option) 7 3.6 Display Alarms and Fault Finding 18 3.6.1 Communication Error 18 3.6.2 Processor Fault 19 3.6.3 Programming Error 19 3.6.4 Power Failure 20 3.6.5 Temperature Deviation 21 3.6.6 Other Alarms 22 3.6.7 Countdown Timer Alarm 22 1810142-02 5.2 5.3 5.4 Alarm Tests Test Program How to Start the Test Program Lamp Test How to Activate Different Parts of the Test Program Functions in the Test Program 23 25 25 26MMPX Alarms and Fault Finding 5 Test Program 5. Digital outputs Use push-button 3 to activate or deactivate each output (see “How to Activate Different Parts of the Test Program” on page 26). N.B. Corresponding green LED is not lit, Function Terminal | Unit 5.1 Oil feed X4:4-XD | MVTVT O} § 52 Tankarain XEtXD | MVEIVE 5.3 Displacement or sealing water. | X5:2XD | MV10, Circuit deactive supply 1] ¢ [BA _Spenina water X63xD_ | MVI5 5155 Closing water X6:4-xD | MVI6 Reece 5.6 Steam shutoff valve or Heatpac | X6:1-XD | - fixed load 57 Steam valve decrease or Heatpac | X6:2-XD | - fixed load 5.8 Steam valve increase or Heatpac | X6:3-XD_ fixed load 6. Digital outputs Use button 3 to activate or deactivate each output (see ‘How to Activate Different Parts of the Test Program” on page 26). N.B. Corresponding green LED is not lit. : | Function Terminal [Unit 6.1 Heatpac variable load X6:4-XD_ OQ] < [a2 Tieaipac alarm blocking during | Xa2XD | Kis in start power Circuit deactive unit 63 Notinuse LI t | G4 Separator stop Xie Cheuit active «| 65 Netinuse 6.6 Remote/common alarm X2:1-2, 6.7 Blocking vibration switch X2:3-4 XS1 181014202 1810142-02 295 Test Program MMPxX Alarms and Fault Finding 1 Scope 3. Digital inputs Function Terminal | Unit 31 Alarm acknowiedge or Reset | X8:4XC [Remote | 0 al; switch i J The alarms, alarm tests and the test program 3.2 Heater fault XOS-XC 1 are valid for the MMPX separation systems, Grout open: 3.3 Sludge discharge X92XC | Remote | 0 including the EPC-41 control unit with ‘; 7 switch PROM: 31830-6213-L i Circuit closed Mode selector Function 4.17 Remote (R) position 4.1 Local (L) position 44 Program (P) position bloc: R Local position L Pirlo i | P Program position 1. 4.1 has three positions: R, L, and P. 28 1810142-02 1810142-021 Scope MMPX Alarms and Fault Finding MMPX Alarms and Fault Finding 5.4 Functions in the Test 5 Test Program Program 1. Memory Function 11 PROM 1.2 Intermal RAM 1.3 Extemal RAM 14 EEPROM 2. Digital inputs Funetion Terminal | Unit — | Correct value 2.1 Low tlow (Low oil pressure) X74-xC | PS42 0 a {| 22 _ High intermediate tank level x73xC | LS4 1 circuit open «28 Mecium intermediate tarklevel | X72XC | LS4 1 1) ; [24 Eelam XTX |= 1 2/25 Emergency stop or Vibration | X8:4KC | xS20r | 1 Circuit closed swaiten xst 26 Notinuse - - 2.7 Start or stop EPC X82xC [Remote | 0 switch 28 Start or stop heater X8:1-XO | Remote [0 switch 2 1810142-02 1810142-02 275 Test Program 5.2 Lamp Test ‘The test program starts with a lamp test. 1. The display lit with power on. 2. There are two ways to check the lamps: + Each LED and display segment individually lit (see the picture). + Bach group of LE segments lit. Push the button 2 (see the figures in the picture below) to switch between the two modes. :s and display 5.3 How to Activate Different Parts of the Test Program Use the push-buttons to activate different parts of the test program (see the figures 1, 2 and 3 in the picture). 1, Push button 1 to step from function 1 to function 2 etc. in the test program. It is not possible to step backwards. Wait until the function is activated before pushing the button again. 2. Push button 2 to step forward within each function in the test program, for instance from function 1.1 to 1.2, 3. Push button 3 to activate or deactivate output terminal (function 5 and 6). 26 MMPX Alarms and Fault Finding a 7 oO 1810142-02 2 EPC Signs ‘The control unit signs for the MMPX separation system are shown in this chapter. Operating symbols 1810142-022 EPC Signs MMPxX Alarms and Fault Finding ‘System without Intermediate Tank i i i 1 MMPX ' i Input signals Input signais, monitoring functions (Options) EPC~41. MMPX i Output signals 4 181014202 5 Test Program The EPC-41 control unit has a test program, for testing of input and output functions, memory etc. This test program should be run during installation and whenever there is a need for it, for instance, during fault finding. 5.1 How to Start the Test Program “NOTE ‘The test program is only to be used when the separator system is out of operation. To run the test program, do as follows: 1. Open the control unit door. 2. Switch the power off and the mode selector in any position (R, L or P). 3. Press the discharge and the alarm push- buttons simultaneously, and keep them pressed. 4, Switch the power on, 5. Release the discharge and alarm push- buttons when the test program has started. 1810142-02 254 Alarm Tests MMPX Alarms and Fault Finding LED alarm | Display alarm | Function Sensor | Actions to provoke an alarm High or low oll tempera-| TT1 ‘A. Remove sensor from pipe and put @ | fc tute (option) into hovooa! aud B. Change alarm jimit parameters (PS = max. temp., PS = min. temo.) For more information see the “Parameter List’ NB. Reset the parameter values after test ‘A/D conversion error | - + | Remove fuse At :F2 (front board). Ale}-| |b Programming error | - Leave the mode selector switch in |Al3 position P for 30 minutes. T Power failure - ‘Switch the power to the EPC off and on. AY-) Power supply frequency | - Set parameter P21 to wrong frequency. ALY] =| [2]| too high (more than + 5%). Temperature deviation | TT1 - TT2 | Remove sensor irom pipe to cool or heat AG up (temp. diff. more than 30 °C/54 °F), ala Extra alarm - ‘A Activate appropriate sensor. ae B. Disconnect cable X7:1 PSé2 faulty at start | PS42__| With the EPC in off mode put a jumper 9} - [2] | (circuit should be open) between XC- X7:4 and push the start button, 24 1910142-02 MMPX Alarms and Fault Finding 2 EPC Signs System with Intermediate Tank Input signals © £2 6 Mt 1 1 1 ee ! I i 1 7 1 1 ' ' 1 I 1 ' Input signals, monitoring functions (Options) 7 T lige Tay | tMvio T I I i 1 i 1 i ' I L “6, MMPX Output signals 1810142-02 52 EPC Signs MMPX Alarms and Fault Finding 1810142-02 4 Alarm Tests Use the following guide for testing alarm functions by activating them. Alarms are provoked by one or more actions (A, B and so on) as shown in the right column, however, certain alarm functions can not be tested without being disconnected. NB. If the alarm functions are to be disconnected in the control unit, be careful to avoid a short-circuit. The recommendation is to test the alarms every 3 months. LED alarm | Display alarm | Function ‘Sensor ‘Actions to provoke an alarm Low oilpressure (low | PS42 (2) tow ‘A. Stop oil feed pump. B. Change MV1 position by reducing air pressure. C. Reduce the back pressure, High intermediate tank | LS4 Remove the level indicator from the level tank. Lift the float of the high level switch through the opening. Emergency stop x82 Press the emergency stop button. Vibrations (option) xsi ‘Tap the vibration switch until the alarm is released, Faulty pressure switch | PS 4. Bridge terminal X7:4 and XC. 2. Initiate a sludge discharge. ki] ®)@|@] © Heater fault - 1. Start the heater 2, Disconnect cable to X9:3. 1810142.02 233 Alarms MMPxX Alarms and Fault Finding 3.6.6 Other Alarms ‘Alarm codes Causes Corrective actions Extra alarm, 1. Ghack the connecied external Ri-| | function, 2. Chook the jumper at torminal XC-X7:1 (When extra alarm not used) ¢ | Lowpressure signal (PS42) | Check the pressure switch A\9}-| \el E faulty at start, Circuit should be open. ‘Automatic actions at alarm ‘Automatic actions after alarm reset Main alarm flashes. Main alarm off. Display flashes. Display normal. ‘Only valid for alarm At Oil feed on. Paget then oil feed off. ‘Only valid for alarm AS-2: The start of the timer sequences is blocked. 3.6.7 Countdown Timer Alarm ‘Alarm codes ‘Causes Corrective actions % _| The count down timer has Restart the timer after relevant actions are 3h] =|] £ | reached zero. completed (Parameter 94}. ‘Automatic actions at alarm ‘Automatic actions after alarm reset Main alarm flashes. Display flashes. Main alarm off. Display normal. 1810142.02 3. Alarms 3.1 Alarm Functions The alarm system is designed to ensure that the separation system always remains in a safe state. There are two different types of alarm functions: * Sensor-related alarm functions are indicated by light emitting diodes (LEDs) on the EPC-41. © Display-related alarm functions are indicated on the EPC-41 display. When any of the displayed alarm functions are activated the left digits start flashing and the right digits are steadily lit. If there is more than one alarm at the same time, the EPC-41 will display the alarm with the highest priority first and then the next alarm, and so on in priority order. An activated alarm condition is identified either by an alarm LED (to the left in the picture) or an alarm code on the display together with the main alarm LED (to the right in the picture). 1910142-023 Alarms MMPxX Alarms and Fault Finding 3.2 Alarm Reset 1. Acknowledge the alarm signal by pressing the alarm push-button. The flashing light then changes to steady. 2. Remedy the cause. 3. Reset the alarm function by pressing the alarm push-button a second time. The LED will tum off. It is possible to reset the system without remedying the cause, but the alarm signal will be repeated, NOTE Never return to the EPC-41 control unit to acknowledge or reset an alarm if it by any means can be hazardous, p WARNING Disintegration hazard Never reset an alarm without first finding and remedying the cause. e21Q — ag 1910142-02 MMPxX Alarms and Fault Finding 3 Alarms 3.6.5 Temperature Deviation more than 30 °C/54 °F). ee Alarm code Cause Corrective actions 3 _| Temperature deviation alarm (dif-| At commissioning: AS | ference between TT1 and TT2 is Check if the distance between sensors is too great, System in operation: Check the temperature sensors. N.B. Push the alarm reset button to find the appropriate process 26 (2F} = TT2. For more information, see “Operating Instru value reading 1C (1F) = TT1, tions” ‘Automatic actions at alarm ‘Automatic actions after alarm reset Main alarm flashes. Display flashes, Main alarm off Display normal 1a10142-02 213 Alarms MMPX Alarms and Fault Finding 3.6.4 Power Failure Fl ‘Alarm codes Causes Corrective actions aly 7 i | Powertaiure, 1. Check the power supply. 5 2. Ifthe power has been off more than about 10 minutes the separator bow! must be stopped and manually cleaned before restart. 3. Restart the heater, separator and EPC program, =| Power supply frequency too high | 1. Check the power supply. ATT-[ 12] 2 | more than + 5%)" 2. Ifthe power has been off more than about 10 minutes the separator bow! must be stopped and manually ‘leaned before restart. 3. Restart the heater, separator and EPC program. 20 ‘Automatic actions at alarm ‘Automatic actions after alarm reset All outputs are off, Oniy valid for alarm A4-1: Main alarm diode and display start to flash when power returns. Only valid for alarm Aa-t; Main alarm off, Display indicates “OFF”. Only valid for alarm A4-2: Main alarm flashes. Display flashes. (Only valid for alarm A4-2: Main alarm off Display normal “The frequency deviation must be continuous or repeated during the alarm delay time before an alarm is activated 1810142-02 MMPxX Alarms and Fault Finding 3.3 Alarm Survey LED alarms. ®@HOO®O®OO® 1810142-02 Display alarms ‘Alarm function High Oi Pressure Low Oil Pressure Medium Intermediate Tank Level High Intermediate Tank Level Emergency Stop Vibrations (Option) Faulty Pressure Switch, low Heater Fault High or Low Oil Temperature (Op- tion) {Le IE] Temperature Sencor Error (Op- tion) [A ¢ Communication Error Processor Fault Programming Error Power Failure Temperature Deviation Other Alarms Countdown Timer Alarm Page 10 "1 13 14 18 19 19 20 at 22 22 3 Alarms,3 Alarms 3.4 LED Alarms and Fault Finding 3.4.1 High Oil Pressure MMPxX Alarms and Fault Finding Causes Corrective actions Valve RV4 or other valve downstream throttled! closed. ‘Open or regulate RV4, or other valves, to correct back pressure, normally about 1.5 bar (150 kPa) ‘Automatic actions at alarm ‘Automatic actions after alarm reset Main alarm flashes. Main alarm off. ‘Alarm diode (PS41) flashes. ‘Alarm diode of. ‘Change over valve (V1) is set for oil recirculation, V1 is set for oil feed to separator. 10 se10142-02 MMPX Alarms and Fault Finding 3 Alarms 3.6.2 Processor Fault ei | ‘Alarm codes: l Causes l Corrective actions: = Internal RAM error Replace control module. Ale|-| 14) = 6 External RAM error. Replace control module. > a ap ESRAW enor Replace control module. Ale]-[ [3] | (Ale "7 i Program error. Replace control module. 7 Mode swatch enor. Check that the mode selector isin the oor Ale]-| 15] rect postion, ¢ A/D (Analog/Digital) conversion Check the fuse A1:F2 (front board) Rel-[ lb] § etror It the fuse is correct, replace the control module. i Calibration error. ‘Ask for service or replace the control mod- Ael-[ 1 | ule ‘Automatic actions at alarm Main alarm flashes. Main alarm off Display flashes. Display normal. 3.6.3 Programming Error ‘Automatic actions after alarm reset Programming during this time). return tothe *P" (Programming) position and continue with programming aj Alarm code Cause Corrective action |_| In programming mode too long | Change the mode selector to the a3) £ | (more than 30 minutes without | *L” (Local) position and, when appropriate, ‘Automatic actions at alarm ‘Automatic actions after alarm reset ‘Main alarm flashes. Display flashes. 1810142-02 Main alarm off. Display normal 193 Alarms MMPxX Alarms and Fault Finding 3.6 Display Alarms and Fault Finding MMPX Alarms and Fault Finding 3 Alarms 3.4.2 Low Oil Pressure 3.6.1 Communication Error Ai F Alarm code Cause Corrective actions {Communication error with exter- | 1, Check external and internal AL A-[ Ta] 2 nal computer connections. 2. Itinternal communication error, replace the contral module. {| Communication error with tne 2%] 1. Check external and internal Al =| |e a EPC-41 control unit, connections. 2. Ifinternal communication error, teplace the control module. | Communication error with the 3" | 1. Check external and internal At El EPC-41 control unit. connections. 2. Ifinternal communication error, replace the control module. Automatic action at alarm Automatic actions atter alarm reset Main alarm flashes. Main alarm of Display flashes. Display normal. 18 1810142-02 @ Causes Corrective actions Broken water seal: + Strainer in operating water high pressure side | * Clean the strainer. Make sure that the water clogged or water pressure too low. pressute is 200 ~ 600 kPa (2-6 bar). ‘© Seal ring in operating slide detective. + Install a new seal ring, + MV165 not opening. ‘+ Examine the electrical system and correct the fault (open circuit, low or high voltage or ditt) Too low oil feed Check the oil feed pump. Adjust the cil low. Strainer before the oil feed pump is clogged Clean the strainer. Oil feed pump has stopped. Hose between MV1 and the separator is twisted. Change over valve (V1) is in recirculation position. | 4. Check the air supply to the solenoid valve block air ‘Check the oil feed pump. Check the hose is installed with no kinks or sharp bends. (Mv1), 2. Check MV4. 3. Check V1. Too low back pressure. Inctease the back pressure with regulating valve RV4. ‘The correct back pressure is normally about 1.5 bar (150 kPa). ‘Check the opening water valve (MV15) for leakage. See "Separator Manual” Bow! opened accidentally during operation. Leakage from bowl. ‘See “Separator Manual”. ‘Automatic actions at alarm ‘Automatic actions after alarm reset Main alarm flashes. Main alarm off. ‘Alarm diode (PS42) flashes. ‘Alarm diode off. Oil feed (MV1) of. 1. MVton. 2. Sealing water valve (MV10) on, in case of purification mode, NB. Inpurifier mode when the control unit receives a low flow signal the oll fead is recirculated and water Is fed into the bow! to keep the water seal intact. The alarm diode only it. Oils again fed to the separator. Ifthe signal persists or repeats within the same separation sequence, the alarm function is activated. 1810142-02 "13 Alarms 3.4.3 Medium Intermediate Tank Level MMPxX Alarms and Fault Finding Causes Corrective actions Tank drain function faulty. Drain the tank manually and check function after dis- charge (See “Parameter List’, P26). Feed pump does not stop. ‘Check pump function. ‘Sensor function faulty. ‘Check the sensor function, ‘Automatic acti ‘Automatic action after draining tank ‘Alarm diode is it ‘Alarm diode off 3.4.4 High Intermediate Tank Level @ Causes Corrective actions Tank drain function faulty. Drain the tank manually and check function after dis- charge (See “Parameter List’, P26). Feed pump does not stop. ‘Check pump function. ‘Sensor function faulty. ‘Check the sensor function. ‘Automatic actions at alarm ‘Automatic actions ater alarm reset Main alarm flashes. Main alarm of, ‘Alarm diode flashes. ‘Alarm diode off. Oil feed (MV1) off. MVT on, 12 181014202 MMPX Alarms and Fault Finding 3.5.2 Temperature Sensor Error (Option) @ (cL IEIE[E 3 Alarms N.B. Also applicable to TT2 temperature sensor, if fitted. Causes Corrective actions Temperature sensor is incorrectly connected. ‘Check the temperature sensor by the test program, $08 “analog inputs” on page 30 in the chapter Test Program, Temperature sensor loop is open or short-circuit. Check the connections. Temperature sensor cables are too close to power ca- bies. Check the cables between the temperature sensor and EPC-41. N.B. Push the alarm reset button to find appropriate process value reading 1€ (1F) = TT1, 2C (2F) = TT2. If both temperature sensors are fitted, alarm A6 is also activated. ‘Automatic actions at alarm ‘Automatic actions after alarm reset Main alarm flashes. Main alarm off ‘Alarm diode and displayed value flashes. ‘Alarm diode off and display returned to normal. Oll feed (MV1) off. MV1 on. Heater switched off at high temperature (if controlled by EPC-41). Heater switched on when temperature is below set point {if heater is controlled by EPC-41). 1810142-02 173 Alarms MMPxX Alarms and Fault Finding 3.5 LED and Display Alarms and Fault Finding 3.5.1 High or Low Oil Temperature (Option) @) E= N.B. Also applicable to TT2 temperature sensor, if fitted. Causes Corrective actions Low temperature alarm when: ~ clogged heater - insufficient steam supply - faulty steam trap - faulty steam supply valve ~ electtical fault (tripped fuse) Investigate the reason and remedy it. High temperature alarm when: faulty steam supply valve - electrical control system out of action Investigate the reason and remedy it. Set point (P7) changed or the alarm limits are too close to the set point. 1. Adjust the parameters, P5 = max. temp P6 = min. temp P7 = set point See “Parameter List" 2. Check the temperature control loop. ‘Steam control valve (SRV1) too far open or closed. 1. Check and adjust the SRV1 function. 2. Check the EPC output functions. Low temperature alarm when the temperature in- creases too slowly, during start-up. Check the heater and parameter P41, See “Parameter List”. Pt 100 temperature signal faulty. Check the Pt 100 temperature sensor. N.B. The current temperature is indicated when the alarm is acknowledged. To find the appropriate temperature sensor reading, push the alarm reset button twice 16 (1F) = TT1, 26 (2F) = TT2, For more information, see “Operating Instructions”. ‘Automatic actions at alarm ‘Automatic actions after alarm reset Main alarm flashes. Main alarm off ‘Alarm diode and displayed value flashes. ‘Alarm diode off and display returned to normal. Oil feed (MV1) off. MV1 on, Heater switched off at high temperature (if controlled by EPC-41). Heater switched on when temperature Is below set point (it heater is controlled by EPC-41). 16 181014202 MMPxX Alarms and Fault Finding 3 Alarms 3.4.5 Emergency Stop i Cause Corrective actions Emergency stop button has been pushed. 1. Remedy the cause for the emergency stop. 2. Reset the alarm by switching the power off and on. 3. Restart the separator. 4. Restart the EPC program. ‘Automatic actions at alarm ‘Automatic action after alarm reset Main alarm flashes. ‘Alarm diode flashes. NB. This alarm function ean not be reset by pushing the alarm reset button. See above. ‘The separator is stopped and the heater tumed off il feed through the heater and separator stays on for 8 minutes. Bow! closing water supplied for 3 minutes. ) DANGER Disintegration hazard The separator bow! must be manually cleaned before starting up again 181014202 133 Alarms 3.4.6 Vibrations (Option) ® MMPxX Alarms and Fault Finding ‘Cause Corrective actions Vibration switch activated: separator bowl out of bal- ance. 1. Remedy the cause. See “Separator Manual’. Check the vibration switch setting Reset the alarm by switching the power off and on. Restart the separator. Restart the EPC program, ‘Automatic actions at alarm ‘Automatic action after alarm reset Main alarm flashes. ‘Alarm diode flashes. N.B. This alarm function can not be reset by pushing the alarm reset button, See above. ‘The separator is stopped and the heater tured off. Oilfeed through the heater and separator stays on for 3 minutes. Bow! closing water supplied for 3 minutes. i DANGER Disintegration hazard ‘The separator bowl must be manually cleaned before starting up again 14 1810142-02 MMPX Alarms and Fault Finding 3.4.7 Faulty Pressure Switch & 3 Alarms Cause Corrective actions The EPC did not get a signal for open switch during discharge cycle ‘Check the pressure switch function ‘Automatic actions at alarm ‘Automatic action after alarm reset ‘Main alarm flashes. Main alarm off Alarm diode flashes. Alarm diode off. Oil feed (MV1) off. MV on. 3.4.8 Heater Fault ( N.B. Heater fault is only activated if the heater is controlled by the EPC-41 Cause Corrective action Oil flow stopped or temperature switch tripped in an installed Heatpac heater Troll flow stopped, investigate the cause. ‘See corrective actions for PS42. Check the flow switch on the Heatpac heater. If temperature switch tripped, investigate the tempera- ture switch setting. If OK check that the heater is clean, Clogged heater. Clean heater. Safety switch for other type of electric heater or steam heater tripped. Remedy the cause. ‘Automatic actions at alarm ‘Automatic actions after alarm reset Main alarm flashes. Main alarm off. Alarm diode flashes. ‘Alarm diode off ‘Change over valve (V1) is set for oll recirculation, V1 Is set for oil feed to separator. Heater switched off. Heater switched on 1810142-08 15ky Alfa Laval MMPX 403 Separation System System Reference Product No. 1765592-01 Printed Dec 2000 Book No. 1810446-02 V3 CME Ee aceAlfa Laval reserves the right to make changes at any time without, prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local Alfa Laval company. Published by: Alfa Laval Marine & Power AB SE - 147 80 Tumba ‘Sweden © Copyright Alfa Laval Marine & Power AB 2000.Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents with fatal injuries. In order to make the information clear only foreseeable conditions have been considered, No warnings are given, therefore, for situations arising from unintended usage of the machine and its tools. A summary of the safety information is found in the Safety chapter under divider 1.2 Drawings MMPX 403 System Reference NOTE * Terminal X13:2 in Master is connected to term, X13:4 in Slave and X13:4 (Master) to X13:2 (Slave) © Straight parallel connection between Slaves ‘¢ When change of Master interconnections must be changed too © For Master/Slave coding see operators service manual IMPORTANT Minimum distance 0,3 m between screened signal cables and power cables parallel to each other, For more information see “Electrical System” in the “Installation Instruction”. 22 1810446-02 Contents 11 1.2 24 22 Technical Data Separation System Separator Drawings Assembly Drawings 244 242 ‘Assembly Drawing, System without Sludge Tank Assembly Drawing, System with Sludge Tank Interconnection and Circult Diagrams 224 222 223 224 2.25 226 227 228 229 2.2.10 22.11 1810446-02 Cable List ‘Separator Starter Interconnection Diagram; 4-125 Amp Separator Starter Circuit Diagram; 4- 12.5 Amp Combined Separator and Pump Starter Interconn. Diag; 412.5 Amp. Combined Separator and Pump Starter Circuit Diag.; 4— 12.5 Amp Standard Equipment interconnection Diagram Standard Equipment Interconnection Diagram (Cont.) Optional Equipment Interconnection Diagram Optional Equipment Heatpac Control Interconnection Diagram Optional Equipment Steam Heater Control Interconnection Diagram Master/Slave Connection of Control Unit EPC-41 Interconn. Diag. 10 10 12 13 14 15 16 7 18 20 241810446-02 MMPX 403 System Reference 2 Drawings 2.2.11 Master/Slave Connection of Control Unit EPC-41 Interconn. Diag. so —s1 Ff 50-4 |—s-2F ses. | —s-3F 502 Le si-4~F < Non-return valve Stops reverse cil flow. Solenoid valve biock, air Distributes compressed air to the pneumatically controled shut-of valve 1" Dal Air line Solenoid valve block, water | Distributes operating water, conditioning water, and ia bd displacement water to the separator. 13 | A | Flexible hose, water Leads the operating water to the separator. ‘Control unit ‘Suporvises the separation eystem. 14 Starter unit Starts the separator and/or the pump. 15 Emergency stop button Initiates a controlied switch off sequence. 16 Oo 17 | CAR FR | Flexible hose, oi Leads the oil. 4 1810449-02MMPxX Installation Instructions 2 System Layout tem | Symbol Designation Function Intermediate sludge tank | Collects sludge and water from the separator. 18 (According to order) A Preumatically controlled | Discharges sludge and drain water from the 19 shut-off valve lermediate tank | Water ine, drain water and | Leads the drain water and sludge to the sludge sludge tank ‘Sludge tank Gollects sludge and water from the intermediate 20 qi a tank. Flow indicator Displays the oll flow rate «| @ 22 | ———— | Inspection pipe Used for manual check of the discharge system, (According to order) 1810449-022 System Layout MMPX Installation Instructions 2.1.2 Series Operation e A Oil feed B_ Cleaned oil outlet, C Oilrecirculation ‘Numbers in brackets refer to units not included in the standard delivery. 1810449-02MMPx Installation Instructions 2 System Layout 2.2 Lubricating Oil System 3 14 (15)_ 16 ° Cc A Oil feed D_ Operating water G Water drain outlet C Cleaned and recirculated E Compressed air H_ Bowl casing drain oil outlet F Sludge outlet () Numbers in brackets refer to units not included in the standard delivery. 1810449-02 72 System Layout MMPx Installation instructions 8 810800.023 Separator 8 14 (15) 16 See the storage and installation instructions and descriptions in “Technical Reference” and “Dismantling/Assembly” in the “Separator Manual”, 1810449-02 93 Separator MMPxX Installation Instructions 10 1810449-024 Sludge and Water Drain System 8 14 (15) 16 bd (20) o6 months ‘See description in ‘Action Separator | Ancillaries | Separator | Ancillaries Protect from dust, this chapter. dirt, water, etc. x x x x “Storage and installation” in “Technical reference” in “Separator Manual’ Protect with anti-rust this chapter. oil x x “Before shutdowns” in "Common maintenance instructions” in “Separator Manual” Intermediate Service) x x “Service instructions” (S) after storage in “Separator Manual": ‘Major Service (MS) x “Service instructions” after storage in “Separator Manual’ 1810449-02 3710 Shut-down and Storage MMPX Installation Instructions 10.2 Shut-down after Use If the separation system is going to be shut- down for a period of time these safeguards must be performed: ‘Shut-down period) <3 months 3-12 months > 12 months (stand-by) ‘See description in ‘ction Separa. | Anita | Separa. | Ancilar | Sparat. | Anca. L Remove bow x x x “Dismanting/Assembly™ in “Separator Manual”: Protect from dust, this chapter. din, water, ete. x | x x x x x Protect with anti- this chapter. rust oll x x x x | "Before shutdowns” in "Common maintenance instructions” in | “Separator Manual”. Intermediate Serv- “Service instructions” ice (IS) before start x x in “Separator Manual”: vp | | Major Service (MS) | | “Service instructions” before start up x in “Separator Manual 38 1810449-02MMPX Installation Instructions 10 Shut-down and Storage 10.3 Protection and Storage All system equipment, both the separator and the ancillary equipment, must be stored indoors at 5 ~ 55°C, if not delivered in water- resistant box for outdoor storage. If there is a risk for condensation of water, the equipment must be protected by ventilation and heating above dew point. The following protection products are recommended: * Anti-rust oil (Dinitrol 112 or equivalent) with long lasting effective treatment for external surfaces. The oil should prevent corrosion attacks and give a waxy surface. © Anti-rust oil (Dinitrol 40 or equivalent) thin and lubricating for inside protection. It gives a lubricating transparent oil film. * Solvent, e.g. white spirit, to remove the anti-rust oil after the shut-down, If the storage time exceeds 12 months, the equipment must be inspected every 6 months and, if necessary, the protection be renewed. Separator The separator must be dismantled and protected. See the “Service Instructions” in the “Separator Manual”. Electrical Equipment See “EPC-41 Control Unit” in the “Component Descriptions”. Solenoid Valve Block, Water See the “Component Description 1910449-02 3910 Shut-down and Storage MMPxX Installation Instructions: Valves, Pipes and Similar Equipment ‘© Components like valves need to be cleaned with solvent and treated with anti-rust oil (type 112). © Water pipes should be drained and treated with anti-rust oil (type 112). * Articles made of rubber or plastics (e.g. seals) must nor be treated with anti-rust oil. Electric Heater © Fill the heater with a non-corrosive lubricating oil. * Place a number of bags of silica gel inside the connection box to absorb humidity. Steam Heater ‘* Drain the condensed water from the steam valve and the steam trap. ‘© Drain all condensed water from the heater. Fill the oil part of the heater with a non-corrosive lubricating oil. Pump © Clean the pump housing outside from oil and grease with solvent, © Protect the pump by filling it with non- corrosive lubricating oil. Apply anti-rust oil on the pump housing outside. 40 1810449-02MMPxX Instailation Instructions 10 Shut-down and Storage Module © Clean unpainted stee! parts with solvent and treat with anti-rust oil (type 112). © Ifnecessary, clean other equipment on the module with solvent. © Treat the equipment with anti-rust oil by following the description above accordingly. © Bolts, nuts and other steel components should be treated with anti-rust oil (type 112). Rubber Parts © Gaskets, O-rings and other rubber parts should not be stored for more than two years. After this time, they should be replaced. 10.4 Reassembly and Start up © Clean away the anti-rust oil spirit. ‘ith white © Remove the silica gel bags from all units. * Follow all relevant instructions in the “Separator Manual”, the “Installation. Instructions” and the “Component Descriptions” respectively. * Before operating the heater: * Check by lifting the safety valve handle that it functions correctly. + Follow the start-up check list for the heater in the manufacturer’s tructions. + For plate heat exchangers: check the bolt connections to ensure that all gaskets are tight. 1810449-02 4ky: Alfa Laval MMPxX Separation System Installation Instructions Printed Book No. Mar 1998 1810449-02 V1 rVieRe Ci euiieeom eileAlfa Laval reserve the right to make changes at any time without prior notice. Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated. Copies of this publication can be ordered from your local ‘Alfa Laval company. Published by: Alfa Laval Separation AB Marine & Power Division S$ - 147 80 Tumba ‘Sweden © Copyright Alfa Laval Separation AB 1998.10 Shut-down and Storage MMPx installation Instructions 42 1810449-02ALFA LAVAL MMPX 403SGP-11 Separator Manual Book No. 1271082-02 V6 SFAlfa Laval Separation AB Separator Manuals, dept. SKEL 8-147 80 Tumba, Sweden Telephone: +46 8 53 06 50 00 Telefax: +46 8 5303 10 40 Printed in Sweden, 00-10 © Alfa Laval Separation AB 2000 This publication or any part thereof may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Separation AB.Contents Safety Instructions Separator Basics 3.1. Basic principles of separation 3.2. Design and function 3.3. Definitions Operating Instructions 4.1 Operating routine Service Instructions 5.1. Periodic maintenance 5.2 Maintenance Logs 5.3. Check points at Intermediate Service 5.4 Check points at Major Service 5.5 3-year service 5.6 Lifting instructions 5.7 Cleaning 5.8 Oil change 5.9 Vibration 5.10 General directions Dismantling/Assembly 6.1 Inlet/outlet and bow! 6.2 Bowl spindle and frame 6.3. Friction coupling 6.4 Flat belt and tightener 6.5 Oil filling device 6.6 Water tank 81 102 114 120 125 12667 68 Brake Frame feet 7 Trouble-tracing 7A 7.2 7.3 74 75 Trouble-tracing procedure Mechanical function Purification and clarification faults Purification faults Clarification faults 8 Technical Reference 8.1 8.2 83 84 85 8.6 87 8.8 Index Technical data Connection list Basic size drawing Interface description Water quality Lubricants Drawings Storage and installation 126 128 129 131 131 137 139 141 143 144 146 148 150 157 158 166 17 187Study instruction manuals and observe the warnings before installation, operation, service and maintenance. Not following the instructions can result in serious accidents. In order to make the information clear only foreseeable conditions have been considered. No warnings are given, therefore, for situations arising from the unintended usage of the machine and its, tools.1 Read this first This manual is designed for operators and service engineers working with the Alfa Laval separator MMPX 403SGP-11 For information concerning the function of the separator, see chapter “3 Separator Basics” on page 15, and chapter “8 Technical Reference” on page 143. If the separator has been delivered and installed by Alfa Laval as part of a processing system, this manual is a part of the system documentation. In this case, study carefully all the instructions in the system documentation. In addition to this separator manual a Spare Parts Catalogue, SPCis supplied. This separator manual consists of. Safety Instrue Pay special attention 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. ns Separator Basics Read this chapter if you are not familiar with this, type of separator. This chapter contains the technical description and function description. Operating Instructions This chapter contains operating instructions for the separator only. ‘Separator Manual and Spare Parts Catalogue1 Read this first Service Instructions This chapter gives instructions for daily checks, cleaning, oil changes, servicing and check points. Dismantling / 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. Ifthe separator has been installed as part of a processing system always refer to the trouble- tracing part of the system documentation first. Technical Reference This chapter contains technical data and drawings concerning the separator. Index This chapter contains an alphabetical list of subjects, with page references.2 Safety Instructions ‘The centrifugal separator includes parts that rotate at high speed, This means that: * Kinetic energy is high * Great forces are generated ‘© Stopping time is long Manufacturing tolerances are extremely fine. Rotating parts are carefully balanced to reduce undesired vibrations that can cause a breakdown. Material properties have been considered carefully during design to withstand stress and fatigue. The separator is designed and supplied for a specific separation duty (type of liquid, rotational speed, temperature, density etc.) and must not be used for any other purpose: Incorrect operation and maintenance can result in unbalance due to build-up of sediment, reduction of material strength, etc., that subsequently could lead to serious damage and/or injury. The following basic safety instructions therefore apply: * Use the separator only for the purpose and parameter range specified by Alfa Laval. * Strictly follow the instructions for installation, operation and maintenance. * Ensure that personnel are competent and have sufficient knowledge of maintenance and operation, especially concerning emergency stopping procedures. * Use only Alfa Laval genuine spare parts and the special tools supplied.2 Safety Instructions DANGER ZN Disintegration hazards Use the separator only for the purpose and parameter range specified by ag Alfa Laval. vot e If excessive vibration occurs, stop [7 separator and keep bowl filled with east liquid during rundown, When power cables are connected, always check direction of motor rotation. IFincorrect, vital rotating parts could unscrew. a Check that the gear ratio is correct for y N power frequency used. If incorrect, a! subsequent overspeed may result in a ) ( serious break down. Welding or heating of parts that rotate can seriously affect material strength. Wear on bowl and bow! hood threads. must not exceed safety limit. ¢-mark on bowl hood must not pass opposite ¢-mark by more than specified distance, Inspect regularly for corrosion and erosion damage. inspect frequently if process liquid is corrosive or erosive. 102 Safety Instructions DANGER AN Entrapment hazards Make sure that rotating parts have come toa complete standstill before starting any dismantling work. To avoid accidental start, switch off and lock power supply before starting any dismantling work. ‘Assemble the machine completely before start. All covers and guards must be in place. Electrical hazards Follow local regulations for electrical installation and earthing (grounding). "12 Safety Instructions WARNING AN Crush hazards t © Use correct lifting tools and follow lifting i instructions. * Do not work under @ hanging load. Noise hazards * Use ear protection in noisy environments. CAUTION a ‘¢ Lubrication oil and various machine surfaces can be hot and cause bums. i Cut hazards «Sharp edges on separator bow! disos and threads can cause cuts. 122 Safety Instructions Warning Pay attention to the safety instructions in this of warning signs used in the text where there is a risk for injury to personnel. DANGER Ase This type of safety instruction indicates a situation which, if not avoided, could result in fatal injury or fatal damage to health. WARNING TA a ae This type of safety instruction indicates a situation which, if not avoided, could result in disabling injury or disabling damage to health. CAUTION ae | This type of safety instruction indicates a ituation which, if not avoided, could result in light injury or light damage to health. NOTE This type of instruction indicates a situation which, if not avoided, could result in damage to the equipment 132 Satety Instructions3 Separator Basics Contents 3.1 Basic principles of separation B44 B12 3.13 Factors influencing the separation result Purification Clarification (optional) 3.2. Design and function 324 3.22 323 3.24 3.25 326 327 Application Design Outline of function Separating function Sludge discharge function Power transmission Sonsors and indicators 3.3. Definitions 7 18 20 22 24 24 25 25 26 28 3 153. Separator Basics3 Separator Basics 3.1 Basic principles of separation 3.1. Basic principles of separation The purpose of separation can be: + to free a liquid of solid particles, » to separate two mutually insoluble liquids with different densities while removing any solids presents at the same time, + to separate and concentrate solid particles from a liquid. Separation by gravity A liquid mixture in a stationary bow! will clear slowly as the heavy particles in the liquid mixture sink to the bottom under the influence of gravity. A lighter liquid rises while a heavier liquid and solids sink. Continuous separation and sedimentation can be achieved in a settling tank having outlets arranged according to the difference in density of the liquids. Heavier particles in the liquid mixture will settle and form a sediment layer on the tank bottom. Centrifugal separation In a rapidly rotating bowl, the force of gravity is replaced by centrifugal force, which can be thousands of times greater. Separation and sedimentation is continuous and happens very quickly. The centrifugal force in the separator bowl can achieve in a few seconds what takes many hours in a tank under influence of gravity. ‘The separation efficiency is influenced by changes in the viscosity (separating temperature) and in the throughput. © ‘@ ‘Sedimentation by gravity ‘Sedimentation in a settling tank, with outlets making it possible to separate the lighter liquid parts from the heavier The centrifugal solution 73.1 Basic principles of separation 3.1.1 Factors influencing the separation result Separating temperatures For some types of process liquids (e.g. mineral olls) a high separating temperature will normally increase the separation capacity. The temperature influences oil viscosity and density and should be kept constant throughout the separation. Viscosity Low viscosity facilitates separation. Viscosity can be reduced by heating. Density difference The greater the density difference between the two liquids, the easier the separation. The density difference can be increased by heating. 18 3 Separator Basics High viscosity (with low temperature) Low viscosity (with high temperature) High density (with low temperature) Low density (with high temperature)3. Separator Basics 3.1 Basie principles of separation Phase proportions An increased quantity of water in a oil will influence the separating result through the optimum transporting capacity of the disc stack. ‘An increased water content in the oil can be compensated for by reducing the throughput in order to restore the optimum separating efficiency. Size and shape of particles ‘The round and smooth particle (A) is more easily separated out than the irregular one (B). 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 it they have the same density. The throughput 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. Sludge space - sludge content ‘The sediment accumulates along the bowl wall. If the sludge is allowed to fill up the space outside the discs the flow in the bowl is influenced, and the separating efficiency is reduced. In such cases the time between discharge of sediment should be reduced to prevent this effect. Disc stack Aneglected disc stack containing deformed discs or discs coated with deposits will impair the 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. ‘Sludge accumulation 193.1 Basic principles of separation 3.1.2 Purification 3 Separator Basics 20 Centrifugal force Process liquid Heavy liquid phase Light liquid phase Sediment (solids) —o._, De, D, Diameter of inner outlet. D. Hole diameter of gravity disc. D3 Diameter of interface.