Separator Manual

High Speed Separator

P 605

Product No.
Book No.

881099-06-02/0
577460-02 Rev. 1

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax:
+46 8 530 310 40

Alfa Laval Tumba AB 08 June 2005

This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.

Contents
1

Safety Instructions

1.1 Warning signs in text

12

1.2 Environmental issues

13

1.3 Requirements of personnel

14

Read this first & Separator Basics

15

2.1 Read This First

16

2.2 Design and function

18

2.3 Definitions

26

Service Instructions

27

3.1 Periodic maintenance

28

3.2 Maintenance Logs

31

3.3 Check points at Intermediate Service

36

3.4 Check points at Major Service

48

3.5 3-year service

51

3.6 Lifting instructions

52

3.7 Cleaning

53

3.8 Oil change

56

3.9 Vibration

58

3.10 General directions

60

Dismantling/Assembly

65

4.1 Inlet/outlet and bowl

68

4.2 Bowl spindle and frame

86

4.3 Friction coupling

100

4.4 Flat belt and tightener

107

4.5 Oil filling device

112

4.6 Water tank

113

4.7 Brake

113

4.8 Frame feet

115

Technical Reference

117

5.1 Product description

118

5.2 Technical data

119

5.3 Connection list

120

5.4 Basic size drawing

122

5.5 Interface description

124

5.6 Water quality

132

5.7 Lubricants

133

5.8 Drawings

140

5.9 Storage and installation

151

5.10 Protection and storage of goods

152

Operating

161

6.1 Operating routine

162

6.2 Before first Start

162

6.3 Start after a service

164

6.4 After Safety Stop

171

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 Safety Instructions

Kinetic energy is high

Great forces are generated

Stopping time is long

G0010421

The centrifuge includes parts that rotate at high

speed. This means that:

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.

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.

S0151211

The following basic safety instructions therefore

apply:

1 Safety Instructions

When power cables are connected,

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

If excessive vibration occurs, stop

separator and keep bowl filled with
liquid during rundown.

Use the separator only for the purpose

and parameter range specified by
Alfa Laval.

Check that the gear ratio is correct for

power frequency used. If incorrect,
subsequent overspeed may result in a
serious break down.

Welding or heating of parts that rotate

can seriously affect material strength.

Wear on the large lock ring thread must

not exceed safety limit. -mark on lock
ring 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.
S01512H1

S01512G1

S0151241

S01512L1

S01512P1

S01512N1

S01512F1

Disintegration hazards

1 Safety Instructions

Entrapment hazards

Make sure that rotating parts have come

to a complete standstill before starting
any dismantling work.

To avoid accidental start, switch off and

lock power supply before starting any
dismantling work.
Assemble the machine completely
before start. All covers and guards must
be in place.

S0151261

S01512O1

Follow local regulations for electrical

installation and earthing (grounding).

To avoid accidental start, switch off and

lock power supply before starting any
dismantling work.

S0151271

Electrical hazard

Crush hazards

S01512M1

Use correct lifting tools and follow lifting

instructions.

Do not work under a hanging load.

S01512Y1

1 Safety Instructions

Noise hazards

Use ear protection in noisy

environments.
S0151291

Burn hazards

Lubrication oil and various machine

surfaces can be hot and cause burns.
S01512A1

When using chemical cleaning agents,

make sure you follow the general rules
and suppliers recommendation
regarding ventilation, personnel
protection etc.

Use of lubricants in various situations.

10

S01512D1

Skin irritation hazards

1 Safety Instructions

Cut hazards

Sharp edges on bowl discs and threads

can cause cuts.
S01512B1

Flying objects

Risk for accidental release of snap rings

and springs when dismantling and
assembly.
S01512C1

Health hazard

Risk for unhealthy dust when handling

friction blocks/pads. Use a dust mask to
make sure not to inhale any dust.
S01512V1

11

1 Safety Instructions

1.1

Warning signs in text

Pay attention to the safety instructions in this

manual. Below are definitions of the three grades
of warning signs used in the text where there is a
risk for injury to personnel.

R
DANGE

DANGER indicates an imminently

hazardous situation which, if not avoided,
will result in death or serious injury.

ING
WARN

WARNING indicates a potentially

hazardous situation which, if not avoided,
could result in death or serious injury.

ON
CAUTI

CAUTION indicates a potentially

hazardous situation which, if not avoided,
may result in minor or moderate injury.

NOTE

NOTE indicates a potentially hazardous

situation which, if not avoided, may result
in property damage.

12

1 Safety Instructions

1.2

Environmental issues

Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused,
recycled or used for energy recovery.
Plastics should be recycled or burnt at a licensed
waste incineration plant.
Metal straps should be sent for material recycling.

Maintenance
During maintenance oil and wear parts in the
machine are replaced.
Oil must be taken care of in agreement with local
regulations.
Rubber and plastics should be burnt at a licensed
waste incineration plant. If not available they
should be disposed to a suitable licensed land fill
site.
Bearings and other metal parts should be sent to
a licensed handler for material recycling.
Seal rings and friction linings should be disposed
to a licensed land fill site. Check your local
regulations.
Worn out or defected electronic parts should be
sent to a licensed handler for material recycling.

13

1 Safety Instructions

1.3

Requirements of
personnel

Only skilled or instructed persons are allowed to

operate the machine, e.g. operating and
maintenance staff.

Skilled person: A person with technical

knowledge or sufficient experience to enable
him or her to perceive risks and to avoid
hazards which electricity/mechanics can
create.

Instructed person: A person adequately

advised or supervised by a skilled person to
enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.

In some cases special skilled personnel may

need to be hired, like electricians and others. In
some of these cases the personnel has to be
certified according to local regulations with
experience of similar types of work.

14

2 Read this first & Separator Basics

Contents
2.1 Read This First

16

2.2 Design and function

18

2.2.1

Application

18

2.2.2

Design

19

2.2.3

Outline of function

19

2.2.4

Separating function

20

2.2.5

Sludge discharge function

22

2.2.6

Power transmission

24

2.2.7

Sensors and indicators

25

2.3 Definitions

26

15

2.1 Read This First

2.1 Read This First

This manual is designed for operators,
maintenance personnel and service
engineers working with the Alfa Laval S
300 separator.
If the separator has been delivered and
installed by Alfa Laval as a part of a
processing system, this manual should be
viewed as part of the System
Documentation. Study carefully all
instructions in any System Documentation.
In addition to this Separator Manual a
Spare Parts Catalogue, SPC is supplied.
The Separator Manual consists of:

Safety Instructions

Pay special attention to the safety instructions

for the separator. Accidents causing damage to
equipment and/or serious injury to persons or
personnel can result if the safety instructions
are not followed.

Basic Principles of Separation

This chapter describes the purpose of

separation and separation principles.

Design and function

This chapter contains a description of the

separator.

Operating Instructions

This chapter contains operating instructions

for the separator only.

16

2 Read this first & Separator Basics

2 Read this first & Separator Basics

2.1 Read This First

Service, Dismantling, Assembly

This chapter gives instructions for the

maintenance procedures. It also contains stepby-step instructions for dismantling and
assembly of the separator for service and
repair.

Fault Finding

Refer to this chapter if the separator functions

abnormally.
If the separator has been installed as a part of a
processing system, always refer to the troubletracing instructions, in the System
Documentation.

Technical Reference

This chapter contains technical data

concerning the separator and drawings.

Installation

This chapter contains specifications and

recommendations concerning separator
installation.

NOTE
A complete reading of this manual by personnel in
contact with the machine is essential to safety.
Do not allow personnel to clean, assemble, operate
or maintain the separator until they have read and
fully understood this manual.
Ensure that all personnel who operate and service
the separator are well-trained and knowledgeable
concerning the machine and the work to be carried
out.

17

2.2 Design and function

2 Read this first & Separator Basics

2.2 Design and function

2.2.1 Application
The P 605 is a high-speed centrifugal separator
intended for marine and land applications. It is
specifically designed for cleaning of mineral oils
from water and solid particles (sludge). The
cleaned oil is discharged continuously, while the
sludge is discharged at intervals.

Distillate, viscosity 1,5 - 5,5 cSt/40 C

Marine diesel oil, viscosity 13 cSt/40 C

Intermediate fuel oil and heavy fuel oil

(viscosity 30-380 cSt/50 C)

Lubricating oil of R & O type, detergent or

steam turbine.

The separator can be operated either as a

purifier or as a clarifier. When operated as a
purifier the separator discharges the separated
water continuously.
When the oil contains only small amounts of
water the separator is operated as a clarifier,
discharging the water together with the solid
particles.
The separator has to be installed together with
devices for control of its operation.

ING
WARN

Disintegration hazards
Use the separator only for the purpose and
parameters (type of liquid, rotational speed,
temperature, density etc.) specified in chapter
5 Technical Reference, page 117 and in the Purchase
Order documents.
Consult your Alfa Laval representative before any
changes outside these parameters are made.

18

G0464881

The separator handles the following types of

lubricating oils and low viscosity fuel oils:

The P 605 separator.

2 Read this first & Separator Basics

2.2 Design and function

2.2.2 Design
The P 605 separator comprises a frame
consisting of the frame lower part, the
intermediate part and the frame top part with a
frame hood.
The separator bowl (C) is driven by an electric
motor (A) via a flat-belt power transmission (D)
and bowl spindle (B). The motor drive is
equipped with a friction coupling to prevent
overload.

The main inlets and outlets are shown with their

connection numbers in the illustration. The
connections are listed in chapter 5 Technical
Reference, page 117, where also the basic size
drawing can be found.

2.2.3 Outline of function

The separation process takes place in the
rotating bowl. Unseparated oil is fed into the
bowl through the inlet (201). The oil is cleaned in
the bowl and leaves the separator through the
outlet (220) via a paring chamber.
Impurities heavier than the oil are collected in
the sludge space at the bowl periphery and
removed automatically at regular intervals.

G0739541

The bowl is of disc type and hydraulically

operated at sludge discharges. The hollow bowl
spindle (B) features an impeller which pumps
closing water from a built-in tank to the
operating system for sludge discharge.

Sectional view
Main parts, inlets and outlets
A
B
C
D
E
F

Electric motor
Bowl spindle
Bowl
Flat belt
Closing water tank
Brake handle

201 Oil inlet

220 Oil outlet
221, 222 Water/sludge outlet
372 Opening water inlet
373 Bowl closing water
377 Overflow
462 Drain
463 Drain

Permissible pressures and operating conditions

are specified in chapter 5 Technical Reference,
page 117.
The processing parts of the separator are shown
in the illustration on next page.
There are no contacting surfaces between
process rotating parts (the bowl) and stationary
parts (inlet, outlet, feed devices), and the
interfacing surfaces are not sealed. As the
separation process is carefully balanced
regarding pressures and fluid levels, any
leakages will not occur as long as the correct
running conditions are maintained.

19

2.2 Design and function

2 Read this first & Separator Basics

2.2.4 Separating function

Liquid flow

Separation takes place in the separator bowl to

which unseparated oil is fed through the inlet
pipe (201). The oil is led by the distributor (T)
towards the periphery of the bowl.
When the unseparated oil reaches the slots of
the distributor, it will rise through the channels
formed by the disc stack (G) where it is evenly
distributed into the disc stack.
The oil is continuously separated from water and
sludge as it will flow towards the center of the
bowl. When the cleaned oil leaves the disc stack
it rises upwards and enters the paring chamber.
From there it is pumped by the paring disc (F)
and leaves the bowl through the outlet (220).
Separated sludge and water move towards the
bowl periphery. In purification separated water
rises along the outside of the disc stack, passes
from the top disc channels over the edge of the
gravity disc (K) and leaves the bowl into the
common sludge and water outlet (221) of the
separator.

G0112361

Heavier impurities are collected in the sludge

space (H) outside the disc stack and are
discharged at intervals through the sludge ports
(L).

F
G
H
I
K
L
R
S
T
U

20

Paring disc
Disc stack
Sludge space
Top disc
Gravity disc
Sludge ports
Bowl body
Bowl hood
Distributor
Paring chamber cover

201 Oil inlet

206 Water seal and
displacement water
inlet
220 Oil outlet
221 Water outlet
372 Opening water inlet
373 Bowl closing water
377 Overflow

2 Read this first & Separator Basics

2.2 Design and function

Water seal in purification

To prevent the oil from passing the outer edge of

the top disc (I) and escaping through the water
outlet (221), a water seal must be provided in the
bowl. This is done by filling the bowl with water
through the water inlet (206), before
unseparated oil is supplied. When oil feed is
turned on the oil will force the water towards the
bowl periphery and an interface (X) is formed
between the water and the oil. The position of
the interface is determined by the size of gravity
disc (K).

G0112371

Displacement of oil

To avoid oil losses at sludge discharge,

displacement water is fed to the bowl.
Prior to a discharge the oil feed is stopped and
displacement water added through the water
inlet (206). This water changes the balance in
the bowl and the interface (X) moves inwards to
a new position (Y), increasing the water volume
in the sludge space. When the sludge discharge
takes place sludge and water alone are
discharged.
Sludge discharge occurs while the displacement
water is still flowing. A new water seal will
therefore establish immediately afterwards. The
oil feed is then turned on again.

Principle of liquid seal and

displacement water in purification
H
I
K
X
Y

Sludge space
Top disc
Gravity disc
Normal interface position
Interface position just before
discharge

206 Water inlet

221 Water outlet

Gravity disc

In the purification mode, the position of the

interface (X) can be adjusted by replacing the
gravity disc (K) for one of a larger or smaller size.
A gravity disc of a larger size will move the
interface towards the bowl periphery, whereas a
disc of a smaller size will place it closer to the
bowl centre.
The correct gravity disc is selected from a
nomogram, see 5.7.2 Alfa Laval lubricating oil
groups, page 134.
The sizes of the gravity discs are normally
stamped on the discs.

21

2.2 Design and function

2 Read this first & Separator Basics

Clarifier disc

In the clarification mode, the gravity disc is

replaced by a clarifier disc which seals off the
water outlet. In this case no water seal is
required and consequently there is no oil/water
interface in the bowl. The clarifier disc is an
optional disc with a hole diameter of 40 mm.
This disc is not shown in the nomograms.

2.2.5 Sludge discharge function

Sludge is discharged through a number of ports
(L) in the bowl wall. Between discharges these
ports are covered by the sliding bowl bottom (M),
which forms an internal bottom in the
separating space of the bowl. The sliding bowl
bottom is pressed upwards against a sealing ring
(m) by force of the closing water underneath.

The opening and closing only takes a fraction of

a second, therefore the discharge volume is
limited to a certain percentage of the bowl
volume. This action is achieved by the closing
water filling space above the upper distributor
ring and pushing the sliding bowl bottom
upwards. Simultaneously, the water in the
chamber below the operating slide is drained off
through the nozzles in the bowl body.

22

G0112371

The sliding bowl bottom is operated

hydraulically by means of operating water
supplied to the discharge mechanism from an
external freshwater line. Opening water is
supplied directly to the operating system in the
bowl while closing water is supplied to the builtin closing water tank, and pumped to the
operating system through the bowl spindle.

Sludge discharge mechanism

L Sludge ports
M Sliding bowl bottom
m Sealing ring
N Upper distributing ring
O Operating slide
P Lower distributing ring
R Bowl body

2 Read this first & Separator Basics

2.2 Design and function

Bowl opening

The key event to start a sludge discharge is the

downward movement of the operating slide. This
is accomplished by supply of opening water (372)
to the discharge mechanism. Water is drained off
through nozzles (Y) in the bowl body. The sliding
bowl bottom is rapidly pressed downwards by
the force from the liquid in the bowl, opening the
sludge ports.

Bowl closing

G0112521

After the sludge is discharged the sliding bowl

bottom is immediately pressed up and the sludge
ports in the bowl wall are closed.

Supply of opening water and closing water

372 Opening water
B Closing and make-up water through
bowl spindle
Y Nozzles

23

2.2 Design and function

2 Read this first & Separator Basics

2.2.6 Power transmission

Bowl spindle

In addition to its primary role in the power

transmission system, the bowl spindle also
serves as:

pump for the closing water

supply pipe for the closing water

lubricator for spindle ball bearings.

The two spindle bearings are lubricated with oil

mist. An oil pump (b3) creates the oil mist, which
is sucked through the upper ball bearing by a fan
(b1). Oil is supplied via an oil filling device,
which also serves as a level indicator.
Two identical ring-shaped rubber buffers (b2)
support the top bearing housing. The buffers are
held in place by a buffer holder and form
channels through which the recirculated oil
passes.

G0112721

Closing water is pumped through the hollow

spindle (B) to the discharge mechanism in the
bowl. For this purpose a pump sleeve (b4) is
fitted in the lower end.

Bowl spindle assembly

B
b1
b2
b3
b4

Bowl spindle
Fan
Rubber buffers
Oil pump
Sleeve

Belt drive

Correct tension is set by means of a springloaded belt tightener.

24

G0112821

The bowl spindle is driven by a flat belt.

Adaptation to 50 or 60 Hz power supply is made
by selecting the motor belt pulley with the
appropriate diameter. A longer belt is needed for
the pulley for 50 Hz.
Belt drive

2 Read this first & Separator Basics

2.2 Design and function

Friction coupling

G0112911

The friction coupling on the motor pulley ensures

gentle start-up and prevents overload of the
electric motor. Centrifugal force creates a torque
that acts on the pulley through the friction
elements.
Friction coupling

2.2.7 Sensors and indicators

Sight glass

S0009411

The sight glass shows the oil level in the oil

sump.

Vibration switch (option)

The vibration switch, properly adjusted, trips on

a relative increase in vibration.

G0548421

The vibration switch is sensitive to vibration in a

direction perpendicular to its base. It contains a
vibration detecting mechanism that actuates a
snap-action switch when the selected level of
vibration is exceeded. After the switch has
tripped it must be reset manually by pressing
the button on the switch.
Reset push button on vibration switch

25

2.3 Definitions

2 Read this first & Separator Basics

2.3 Definitions
Back pressure

Pressure in the separator outlet.

Clarification

Liquid/solids separation with the intention of separating

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

Clarifier disc

An optional disc, which replaces the gravity disc in the

separator bowl, in the case of clarifier operation. The disc
seals off the heavy phase outlet in the bowl, thus no liquid
seal exists.

Counter pressure

See Back pressure.

Density

Mass per volume unit. Expressed in kg/m3 at a specified

temperature, normally at 15 C.

Gravity disc

Disc in the bowl hood for positioning the interface between

the disc stack and the outer edge of the top disc. This disc
is only used in purifier mode.

Interface

Boundary layer between the heavy phase (water) and the

light phase (oil) in a separator bowl.

Intermediate
Service (IS)

Overhaul of separator bowl and inlet/outlet. Renewal of

seals in bowl and inlet/outlet.

Major Service (MS)

Overhaul of the complete separator, including bottom part

(and activities included in an Intermediate Service).
Renewal of seals and bearings in bottom part.

Phase

Light phase: the lighter liquid separated, e.g. oil.

Heavy phase: the heavier liquid separated, e.g. water.

Purification

Liquid/liquid/solids separation with the intention of

separating two intermixed and mutually insoluble liquid
phases of different densities. Solids having a higher density
than the liquids can be removed at the same time. The
lighter liquid phase, which is the major part of the mixture,
shall be purified as far as possible.

Sediment (sludge)

Solids separated from a liquid.

Sludge discharge

Ejection of sludge from the separator bowl.

Throughput

The feed of process liquid to the separator per time unit.

Expressed in m3/hour or litres/hour.

Viscosity

Fluid resistance against movement. Normally expressed in

centistoke
(cSt = mm2/s), at a specified temperature.

Water seal

Water in the solids space of the separator bowl to prevent

the light phase (oil) from leaving the bowl through the heavy
phase (water) outlet, in purifier mode.

26

SEPARATOR MANUAL

3 SERVICE INSTRUCTIONS

3 Service Instructions
Contents
3.1 Periodic maintenance
Introduction

28

3.1.2

Maintenance intervals

28

3.1.3

Maintenance procedure

30

3.1.4

Service kits

30

Daily checks

31

3.2.2

Oil change - monthly

31

3.2.3

IS - Intermediate Service

32

3.2.4

MS - Major Service

34

Corrosion

36

3.3.2

Erosion

38

3.3.3

Cracks

39

3.3.4

Discharge mechanism

40

3.3.5

Bowl hood and sliding bowl bottom

40

3.3.6

Spindle top cone and bowl body

nave

43

3.3.7

Threads of inlet pipe, paring disc

43

3.3.8

Threads on bowl hood and bowl

body

44

Priming of bowl parts

46

3.3.10 Disc stack pressure

3.4 Check points at Major Service

Cleaning agents

54

3.7.2

Cleaning of bowl discs

55

3.8 Oil change

3.8.1

Oil change procedure

56
56

3.9 Vibration

58

3.9.1

Vibration analysis

58

3.9.2

Vibration switch (optional)

59

3.10 General directions

60

3.10.1 Ball and roller bearings

60

3.10.2 Before shut-downs

63

36

3.3.1

3.3.9

3.7.1

31

3.2.1

3.3 Check points at Intermediate

Service

53

28

3.1.1

3.2 Maintenance Logs

3.7 Cleaning

47
48

3.4.1

Paring disc height adjustment

48

3.4.2

Radial wobble of bowl spindle

50

3.5 3-year service

51

3.6 Lifting instructions

52

577460-02

27

3.1 Periodic maintenance

3.1 Periodic maintenance

3.1.1 Introduction
Periodic, preventive maintenance reduces the
risk of unexpected stoppages and breakdowns.
Maintenance logs are shown on the following
pages in order to facilitate periodic
maintenance.

ING
WARN

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

3.1.2 Maintenance intervals

The following directions for periodic
maintenance give a brief description of which
parts to clean, check and renew at different
maintenance intervals.
The service logs for each maintenance interval
later in this chapter give detailed enumeration
of the checks that must be done.
Daily checks consist of simple check points to
carry out for detecting abnormal operating
conditions.
Oil change interval is 1500 hours. If the total
number of operating hours is less than 1500
hours change oil at least once every year.
Time of operation between oil changes can be
extended from the normal 1500 hours to 2000
hours if a synthetic oil of group D is used.
In seasonal operation change the oil before a
new period.
IS - Intermediate Service consists of an
overhaul of the separator bowl, inlet and outlet
every 3 months or 2000 operating hours. Seals
in bowl and gaskets in the inlet/outlet device
and operating device are renewed.

28

3 Service Instructions

3 Service Instructions

3.1 Periodic maintenance

MS - Major Service consists of an overhaul of

the complete separator every 12 months or
8000 operating hours. An Intermediate Service
is performed, and the flat belt, friction
elements, seals and bearings in the bottom part
are renewed.
3-year service consists of service of the
coupling bearings, service of frame
intermediate part and renewal of frame feet.
The rubber feet get harder with increased use
and age.

Service schedule
Oil change
Intermediate Service = IS
Major Service = MS
3-year Service
MS
IS

IS

Installation

IS

IS

MS
IS

IS

1st year

IS

IS

MS
IS

2nd year

IS

IS

IS

IS

IS

IS

MS
IS

3-year
Service

Other

Check and prelubricate spindle bearings of

separators which have been out of service for 6
months or longer. See also 3.10.2 Before shutdowns, page 63.
NOTE

Do not interchange bowl parts!

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

29

3.1 Periodic maintenance

3 Service Instructions

3.1.3 Maintenance procedure

At each intermediate and major service, take a
copy of the service log and use it for notations
during the service.
An intermediate and major service should be
carried out in the following manner:

Dismantle the parts as mentioned in the

service log and described in chapter
4 Dismantling/Assembly, page 65.
Place the separator parts on clean, soft
surfaces such as pallets.

Inspect and clean the dismantled separator

parts according to the service log.

Fit all the parts delivered in the service kit

while assembling the separator as described
in chapter 4 Dismantling/Assembly, page 65.
The assembly instructions have references
to check points which should be carried out
during the assembly.

3.1.4 Service kits

Special service kits are available for
Intermediate Service (IS), Major Service (MS)
and 3-year service (3-YSK).

Note that the parts for IS are not included in the

MS kit.
The contents of the service kits are described in
the Spare Parts Catalogue.
NOTE
Always use Alfa Laval genuine parts as otherwise the
warranty will become invalid.
Alfa Laval takes no responsibility for the safe
operation of the equipment if non-genuine spare
parts are used.

30

S0 0 2 1 0 3 1

For other services the spare parts have to be

ordered separately.
Spare parts kits are available for
Intermediate Service and Major Service

3 Service Instructions

3.2 Maintenance Logs

3.2 Maintenance Logs

3.2.1 Daily checks
The following steps should be carried out daily.
Main component and activity

Part

Page

Notes

Inlet and outlet

Check for leakage

Connecting housing

Separator bowl
Check for vibration and noise

Belt transmission
Check for vibration and noise

Oil sump
Check

Oil level

Electrical motor
Check for vibration, heat and noise
See manufacturers instructions

3.2.2 Oil change - monthly

The oil change and check of belt transmission
should be carried out every 1500 hours of
operation.
When using a group D oil, time of operation
between oil changes can be extended from the
normal 1500 hours to 2000 hours.
When the separator is run for short periods, the
lubricating oil must be changed every 12
months even if the total number of operating
hours is less than 1500 hours (less than 2000
hours if a group D oil is used).
See chapter 5.7 Lubricants, page 133 for
further information on oil brands etc.
Main component and activity

Part

Page

Notes

Bowl spindle and transmission

Check

Belt tension

107

Change

Oil in oil sump

56

31

3.2 Maintenance Logs

3 Service Instructions

3.2.3 IS - Intermediate Service

Name of plant:
Separator:

Local identification:
P 605

Manufacture No./Year:

Total running hours:

Product No.:

Date:

Signature:

881099-06-02/0

Renew all parts included in the Intermediate Service kit (IS) and do the following activities.
Main component and activity

Part

Page

Inlet and outlet, frame

Clean and inspect

Threads of inlet pipe

43

Paring disc

43

Housings and frame hood

Separator bowl
Clean and inspect

Check

Bowl hood

44

Top disc

55

Bowl discs

55

Distributor

Nozzles in bowl body

40

Sliding bowl bottom

40

Discharge mechanism

40

Threads on bowl hood and

bowl body

44

Bowl spindle cone and bowl

body nave

43

Disc stack pressure

47

Galling of guide surface

44

Corrosion, erosion, cracks

36 - 38

Power transmission
Check

Belt and belt tension

107

Change

Oil in oil sump

56

Electrical motor
Lubrication (if nipples are fitted)

32

See sign on motor

Notes

3 Service Instructions

Main component and activity

3.2 Maintenance Logs

Part

Page

Notes

Signs and labels on separator

Check attachment and legibility

Safety label on hood

144

Other plates and labels

144

33

3.2 Maintenance Logs

3 Service Instructions

3.2.4 MS - Major Service

Name of plant:
Separator:

Local identification:
P 605

Manufacture No./Year:

Total running hours:

Product No.:

Date:

Signature:

881099-06-02/0

Renew all parts included in the Intermediate and Major Service kits and do the following
activities.
Main component and activity

Part

Page

Inlet and outlet, frame

Clean and inspect

Threads of inlet pipe

43

Paring disc

43

Housings and frame hood

Separator bowl
Clean and inspect

Check

Bowl hood

44

Top disc

55

Bowl discs

55

Distributor

Nozzles in bowl body

40

Sliding bowl bottom

40

Discharge mechanism

40

Threads on bowl hood and

bowl body

44

Bowl spindle cone and bowl

body nave

43

Height of paring disc

48

Disc stack pressure

47

Galling of guide surface

44

Corrosion, erosion, cracks

34

36 - 38

Notes

3 Service Instructions

Main component and activity

3.2 Maintenance Logs

Part

Page

Notes

Vertical driving device

Clean and inspect

Oil mist fan

89

Oil pump

89

Water tank

113

Pump sleeve
Bowl spindle

86

Ball bearing housing

indentations

86

Radial wobble of bowl spindle

50

Clean

Oil sump

56

Change

Oil

56

Clean and inspect

Oil filling device

112

Friction coupling

103

Check
Oil sump

Friction coupling
Clean and inspect
Electrical motor
Replace

Bearings1)

Signs and labels on separator

Check attachment and legibility

1)

Safety label on hood

144

Other signs and labels

144

See manufacturers instructions.

35

3.3 Check points at Intermediate Service

3 Service Instructions

3.3 Check points at

Intermediate Service
3.3.1 Corrosion
Evidence of corrosion attacks should be looked
for and rectified each time the separator is
dismantled. Main bowl parts such as the bowl
body and hood must be inspected with particular
care for corrosion damage.

ING
WARN
G0172111

Disintegration hazard
Inspect regularly for corrosion damage. Inspect
frequently if the process liquid is corrosive.

Always contact your Alfa Laval representative if

you suspect that the largest depth of a corrosion
damage exceeds 1,0 mm or if cracks have been
found. Do not continue to use the separator until
it has been inspected and given clearance for
operation by Alfa Laval.
Cracks or damage forming a line should be
considered as being particularly hazardous.

Non-stainless steel and cast iron parts

Corrosion (rusting) can occur on unprotected

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

36

Main bowl parts to check for corrosion

3 Service Instructions

3.3 Check points at Intermediate Service

Stainless steel

exposed to a stationary solution,

in a crevice,

covered by deposits,

exposed to a solution that has a low pH value.

S0020611

Stainless steel parts corrode when in contact

with either chlorides or acidic solutions. Acidic
solutions cause a general corrosion. The chloride
corrosion is characterised by local damage such
as pitting, grooves or cracks. The risk of chloride
corrosion is higher if the surface is
Example of chloride corrosion in
stainless steel.

Inspect closely for all types of damage by

corrosion and record these observations
carefully.

Polish dark-coloured spots and other

corrosion marks with a fine grain emery cloth.
This may prevent further damage.

S0020511

A corrosion damage caused by chlorides on

stainless steel begins as small dark spots that
can be difficult to detect.

Polish corrosion marks to prevent

further damage.

ING
WARN

Disintegration hazard
Pits and spots forming a line may indicate cracks
beneath the surface.
All forms of cracks are a potential danger and are
totally unacceptable.
Replace the part if corrosion can be suspected of
affecting its strength or function.

Other metal parts

Separator parts made of materials other than

steel, such as brass or other copper alloys, can
also be damaged by corrosion when exposed to
an aggressive environment. Possible corrosion
damage can be in the form of pits and/or cracks.

37

3.3 Check points at Intermediate Service

3 Service Instructions

3.3.2 Erosion
Erosion can occur when particles suspended in
the process liquid slide along or strike against a
surface. Erosion can become intensified locally
by flows of higher velocity.

ING
WARN

Disintegration hazard
Inspect regularly for erosion damage. Inspect
frequently if the process liquid is erosive.

Erosion is characterised by:

Burnished traces in the material.

Dents and pits having a granular and shiny

surface.

Parts of the bowl particularly subjected to

erosion are:

The paring disc.

The top disc.

The underside of the distributor in the vicinity

of the distribution holes and wings.

The sludge ports.

Look carefully for any signs of erosion damage.

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

38

G0205221

Always contact your Alfa Laval representative if

the largest depth of any erosion damage exceeds
1,0 mm. Valuable information as to the nature of
the damage can be recorded using photographs,
plaster impressions or hammered-in lead.
Maximum permitted erosion.

3 Service Instructions

3.3 Check points at Intermediate Service

3.3.3 Cracks
Cracks can initiate on the machine after a
period of operation and propagate with time.

Cracks often initiate in areas exposed to high

cyclic material stresses. These cracks are
called fatigue cracks.

Cracks can also initiate due to corrosion in

an aggressive environment.

Although very unlikely, cracks may also

occur due to the low temperature
embrittlement of certain materials.

The combination of an aggressive environment

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

ING
WARN

Disintegration hazard
All forms of cracks are potentially dangerous as
they reduce the strength and functional ability of
components.
Always replace a part if cracks are present

It is particularly important to inspect for cracks

in rotating parts.
Always contact your Alfa Laval representative
if you suspect that the largest depth of the
damage exceeds 1,0 mm. Do not continue to use
the separator until it has been inspected and
cleared for operation by Alfa Laval.

39

3.3 Check points at Intermediate Service

3 Service Instructions

3.3.4 Discharge mechanism

Dirt and lime deposits in the sludge discharge
mechanism can cause discharge malfunction or
no discharge.

Thoroughly clean and inspect the parts. Pay

special attention to important surfaces (1, 2, 3
and 4). If necessary, polish with steel wool.

Clean nozzles (5) using soft iron wire or

similar. Note that lime deposits can with
advantage be dissolved in a 10% acetic acid
solution.

G0121511

Use Loctite 242 on the threads if the nozzles

have been removed or replaced.

3.3.5 Bowl hood and sliding bowl

bottom

G0071031

Poor sealing between the bowl hood seal ring and

the edge of the sliding bowl bottom will cause a
leakage of process liquid from the bowl.

A Sealing surface in the bowl between bowl

hood and sliding bowl bottom.

40

3 Service Instructions

3.3 Check points at Intermediate Service

Fit a new bowl hood seal ring at each

Intermediate Service (IS) if the old ring is
damaged or indented more than 0,5 mm.
Fit a new ring as follows:
Press the ring into the groove with a straight
board (1 x 4), placed across the ring.
NOTE
If a new ring is too narrow, put it into hot water,
70 - 80 C for about 5 minutes.

G0071121

If it is too wide it will recover after drying at

80 - 90 C for about 24 hours.

Exchange of seal ring in bowl hood.

41

3.3 Check points at Intermediate Service

3 Service Instructions

Check the sealing edge (a) of the sliding bowl

bottom.

G0071231

Sealing edge on sliding

bowl bottom

G0071221

If damaged through corrosion or erosion or in

other ways it can be rectified by turning in a
lathe. Minimum permissible height of sealing
edge: 4,5 mm.

Removal of seal ring on

sliding bowl bottom.

42

3 Service Instructions

3.3 Check points at Intermediate Service

3.3.6 Spindle top cone and bowl

body nave
Impact marks on the spindle cone or in the bowl
body nave may cause the separator to vibrate
while running.
Corrosion may cause the bowl to stick firmly to
the spindle cone and cause difficulties during the
next dismantling.

Remove any impact marks using a scraper

and/or a whetstone.
Rust can be removed by using a fine-grain
emery cloth (e.g. No. 320).Finish with
polishing paper (e.g. No. 600).
NOTE

G0071611

Always use a scraper with great care. The conicity

must not be marred.

Use whetstone or scraper with great care

3.3.7 Threads of inlet pipe, paring

disc

Examine the threads for damage and rectify if

required.

Examine the paring disc for damage and to

see if the disc walls have parted. If they have,
the inlet pipe has to be replaced with a new
one.
G0113031

Damage to threads or a broken paring disc can

prevent correct tightening of the inlet pipe and
cause the paring disc to scrape against the top
disc, even though the height adjustment of the
paring disc has been made correctly.

43

3.3 Check points at Intermediate Service

3 Service Instructions

3.3.8 Threads on bowl hood and

bowl body
Excessive wear or impact marks on threads and
guide surfaces of the bowl hood or bowl body can
cause seizure damage.
Examine the thread condition by tightening the
bowl hood after removing the disc stack and top
disc from the bowl.

G0071311

When the bowl is new the alignment marks on

the bowl hood and the bowl body should be
aligned. If not, contact an Alfa Laval
representative.

Wear

If thread wear is observed, mark the bowl body

at the new position by punching a new alignment
mark. If the mark on the bowl hood passes the
mark on the bowl body by more than 25, (A in
the illustration) an Alfa Laval representative
should be contacted immediately.

If the marks are illegible, an Alfa Laval

representative should be contacted for
determination and punching of new alignment
marks.

ING
WARN

Disintegration hazards
Wear on threads must not exceed safety limit. f mark
on bowl hood must not pass f mark on bowl body by
more than 25.

44

(MAX 25 )

G0578111

The measure A in millimetres (mm) is obtained

by calculating bowl outside diameter D times
0,2.

3 Service Instructions

3.3 Check points at Intermediate Service

Damage

The position of threads, contact and guide

surfaces are indicated by arrows in the
illustration.

Contact surfaces to inspect on the bowl

Examine for burrs and protrusions caused by

impact.
Clean the threads, contact and guide surfaces
with a suitable degreasing agent.

ON
CAUTI

Cut hazard
The threads have sharp edges which can
cause cuts.

G0071511

If damage is found, rectify by using a whetstone

or fine emery cloth. Recommended grain size:
240.
If the damage is bad, use a fine single-cut file,
followed by a whetstone. After rectifying, the
threads have to be primed with Molykote 1000.

45

3.3 Check points at Intermediate Service

3 Service Instructions

3.3.9 Priming of bowl parts

The instruction refers to contact surfaces (dark
shaded) of both matching parts.

These surfaces should be sprayed with

Molykote D321R after a careful cleaning.

Air cure for 15 minutes.

Polish to an even, homogenous surface.

Spray a second time.

Air cure for 15 minutes.

Polish to a shiny surface, the surface shoud

look like well polished leather when properly
done.

Finish the treatment by lubricating the

surfaces with lubricating paste see 5.7.3
Recommended lubricants, page 135.

46

G0887731

Before assembly:

3 Service Instructions

3.3 Check points at Intermediate Service

3.3.10 Disc stack pressure

The bowl hood exerts a pressure on the disc
stack clamping it in place.
NOTE
Insufficient pressure in the disc stack may affect the
bowl balance, which in turn will cause abnormal
vibration of the separator and shorten the life of ball
bearings.

If the bowl hood can be tightened by hand

without resistance until the marks are in line
with each other, an extra disc must be added
to the top of the disc stack beneath the top
disc.

If one or more discs have been added recheck the disc stack pressure by repeating
the procedure above.

G0071911

Place the bowl hood on the top of the disc

stack and tighten it by hand.
The assembly mark on the bowl hood should
now be positioned at the angle a (see
illustration), 30 - 60 ahead of the
corresponding mark on the bowl body.

1
2
3

Bowl hood
Bowl body
Disc stack. Number of discs
- below wing insert: 42
- above wing insert: at least 41

NOTE
The top disc can stick inside the bowl hood
and fall when the hood is lifted.

G0357651

Angle 30 - 60 between assembly marks

before final tightening

47

3.4 Check points at Major Service

3 Service Instructions

3.4 Check points at Major

Service
3.4.1 Paring disc height adjustment
The height of the paring disc above the frame
hood must be measured if the bowl spindle has
been dismantled or if the bowl has been replaced
with a new one.
NOTE
Incorrect height position can cause the paring disc
(14) to scrape against the paring chamber cover.

Assemble the bowl and frame hood as

described in chapter 4.1.2 Inlet/outlet and
bowl - assembly, page 76.

Measure the distance according to the

illustration above. Adjust the distance by
adding or removing height adjusting rings (7).

Fit the support ring (5) and the inlet/outlet

housing. Tighten the nut with 30 Nm.
Left-hand thread!

48

G00729A1

G0883911

Pay attention to scraping noise at start-up after

service.

Rotate the bowl spindle by hand by means of

the flat belt. If it does not rotate freely or if a
scraping noise is heard, incorrect height
adjustment or incorrect fitting of the inlet pipe
can be the cause. Remove the parts and
readjust.

Finally, fit the safety device.

3.4 Check points at Major Service

G0172951

3 Service Instructions

49

3.4 Check points at Major Service

3 Service Instructions

3.4.2 Radial wobble of bowl spindle

The bowl spindle wobble must be measured if
the bowl spindle has been dismantled or if rough
bowl run (vibration) occurs.
NOTE
Spindle wobble will cause rough bowl run. This leads
to vibration and reduces lifetime of ball bearings.

Check the wobble before removing the bowl

spindle.

Fit a dial indicator in a support and fasten it in

position as illustrated.

Remove the water tank from the frame bottom

part for access to the flat belt. Use the flat belt
to turn the spindle.

Permissible radial wobble: max. 0,04 mm.

If the spindle wobble is more than the
maximum permitted value, contact Alfa Laval
representatives.

Finally fit the water tank to the frame bottom

part.

Incorrect belt tension causes displacement of the

vertical line of the spindle centre, but does not
affect the wobble of the spindle.

50

G0121211

If the bowl spindle has been dismantled check

the wobble before installing the bowl.

3 Service Instructions

3.5 3-year service

3.5 3-year service

Exchange of frame feet

See 4.8.1 Mounting of new frame feet, page 115.

Friction coupling

Exchange of ball bearings, see 4.3 Friction

coupling, page 100.

Frame intermediate part

Replace O-ring and gasket, see 4.2.2 Bowl

spindle and frame - assembly, page 92.

51

3.6 Lifting instructions

3 Service Instructions

3.6 Lifting instructions

1

Remove the inlet/outlet housings, the frame

hood and the bowl according to the
instructions in chapter 4.1.1 Inlet/outlet and
bowl - dismantling, page 71.
A<2 mm
G0507121

NOTE
Make sure to remove the cap nut fixing the bowl to
the bowl spindle.

Before lifting the bowl, check that the bowl hood

has been screwed home into the bowl body. Less
than 2 mm of bowl hood threading must remain
above the bowl body edge. See illustration.

Disconnect the motor cables.

Tighten the frame hood.

Fit the lifting eyes. The two eyebolts must be

fitted in the holes nearest to the electric motor.

Use two endless slings to lift the separator.

Length of each sling: minimum 1,5 metres.
Thread the slings through the lifting eyes and
fit them to the hook of the hoist.

Unscrew the foundation bolts.

When lifting and moving the separator, obey

normal safety precautions for lifting large
heavy objects.

Do not lift the separator unless the bowl has

been removed.

G0820621

When lifting the bowl, use the compression tool

fastened on the distributor.

A Minimum 750 mm distance between lifting eye

and hook.
Use a lifting hook with catch.

NOTE

Remove the lifting eyes afterwards.

Separator without bowl: Use lifting slings for
WLL 300 kg.

ING
WARN

Crush hazards
Use only the two special lifting eyes (M12) for lifting
the machine. They are to be screwed into the special
threaded holes.
Other holes are not dimensioned for lifting the
machine.
A falling separator can cause accidents resulting in
serious injury and damage.

52

Bowl: Use lifting slings for WLL 100 kg.

3 Service Instructions

3.7 Cleaning

3.7 Cleaning
External cleaning

Use a brush and a sponge or cloth when cleaning.

The external cleaning of frame and motor should

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

Many operators believe that these motors are

sealed, and normally they are not.

A water jet played on these motors will

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

Water directed on a hot motor may cause

condensation resulting in short-circuiting and
internal corrosion.

G0615361

Never wash down a separator with a direct

water stream. Totally enclosed motors can be
damaged by direct hosing to the same extent as
open motors and even more than those, because:

Never wash down a separator with a direct

water stream or spray.

G0613661

Be careful even when the motor is equipped with

a protecting hood. Never play a water jet on the
ventilation grill of the hood.

53

3.7 Cleaning

3 Service Instructions

3.7.1 Cleaning agents

When using chemical cleaning agents, make
sure you follow the general rules and suppliers'
recommendations regarding ventilation,
protection of personnel, etc.

For separator bowl, inlet and outlet

For cleaning of lube oil separators the most

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

Fuel oil sludge mainly consists of complex

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

ON
CAUTI

Skin irritation hazard

Read the instructions on the label of the plastic
container before using the cleaning liquid.
Always wear safety goggles, gloves and protective
clothing as the liquid is alkaline and dangerous to
skin and eyes.

54

S0 0 0 8 5 1 1

A chemical cleaning agent must dissolve the

deposits quickly without attacking the material
of the separator parts.

Alfa Laval cleaning liquid for lube oil

and fuel oil separators.

3 Service Instructions

3.7 Cleaning

For parts of the driving devices

Use white spirit, cleaning-grade kerosene or

diesel oil.

Oiling (protect surfaces against corrosion)

Protect cleaned carbon steel parts against

corrosion by oiling. Separator parts that are not
assembled after cleaning must be wiped and
coated with a thin layer of clean oil and
protected from dust and dirt.

3.7.2 Cleaning of bowl discs

Bowl discs

Handle the bowl discs carefully so as to avoid

damage to the surfaces during cleaning.
NOTE
Mechanical cleaning is likely to scratch the disc
surfaces causing deposits to form quicker and
adhere more firmly.

Remove the bowl discs from the distributor

and lay them down, one by one, in the
cleaning agent.

Let the discs remain in the cleaning agent until

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

G0065831

A mild chemical cleaning is therefore preferable to

mechanical cleaning.

Put the discs one by one into the

cleaning agent.

Finally clean the discs with a soft brush.

ING
WARN
G0065841

Cut hazards
The discs have sharp edges that can cause cuts.

Clean the discs with a soft brush.

55

3.8 Oil change

3 Service Instructions

3.8 Oil change

3.8.1 Oil change procedure
NOTE
Before adding or renewing lubricating oil in the oil
sump, the information concerning different oil
groups, handling of oils, oil change intervals etc.
given in chapter 5.7 Lubricants, page 133 must be
well known.

The separator should be level and at standstill

when oil is filled or the oil level is checked. The
MIN-line on the sight glass refers to the oil
level at standstill.
Place a collecting vessel under the drain hole.

Pull out (A) the oil filling device and turn it half
a turn (B).

Collect the oil in the vessel.

G0068911

ON
CAUTI

The lubricating oil and various machine surfaces can

be sufficiently hot to cause burns.

56

G0173811

Burn hazards

3 Service Instructions

3.8 Oil change

Turn the oil filling device back to its normal

position (A), the drain hole pointing upwards.
NOTE

Fill the oil sump in the frame housing with new

oil. The oil level should be slightly above
middle of the sight glass. Information on
volume see 5.2 Technical data, page 119.

Push in the oil filling device.

G0069211

G0069111

When changing from one group of oil to another, the

frame housing and the spindle parts must be
thorougly cleaned before the new oil is filled.

57

3.9 Vibration

3 Service Instructions

3.9 Vibration
3.9.1 Vibration analysis
A separator normally vibrates and produces a
different sound when passing through its critical
speeds during run-up and run-down.
It also vibrates and sounds to some extent when
running. It is good practice to be acquainted with
these normal conditions.
Excessive vibrations and noise indicate that
something is wrong. Stop the separator and
identify the cause.

The level of vibration of the separator should not

exceed 9 mm/s.

ING
WARN

Disintegration hazards
When excessive vibration occurs, keep bowl filled
and stop separator.
The cause of the vibration must be identified and
corrected before the separator is restarted.
Excessive vibration can be due to incorrect
assembly or poor cleaning of the bowl.

58

G0075251

Use vibration analysis equipment to periodically

check and record the level of vibration.

3 Service Instructions

3.9 Vibration

3.9.2 Vibration switch (optional)

Adjustment of setpoint

Back-off the setpoint adjusting screw counterclockwise (A) two or three turns. Press the
reset button. If the armature does not remain
in the reset position, turn the adjusting screw
another turn or two until the armature stays in
position when the reset button is pressed.

Now turn the adjusting screw slowly clockwise

until the armature rocks. Mark this position
with a line immediately in front-of the adjusting
screw pointer (2).

Back-off the adjusting screw counterclockwise a three-quarter turn. Press the reset
button. If the armature now rocks, turn the
adjusting screw counter-clockwise another
quarter turn and so on until the armature
remains in the reset position.
Refit the cap and fasten with the screws.
NOTE

G0546521

The vibration switch is adjusted with the

separator in operation. The cover must be
removed to gain access to the setpoint adjusting
screw (1).

Setpoint adjustment
1. Adjusting screw
2. Pointer
A. Direction of increased checkpoint
(admit higher vibration)

Further adjustment may become necessary if alarm

occurs due to vibration from surrounding equipment.

59

3.10 General directions

3 Service Instructions

3.10 General directions

3.10.1Ball and roller bearings
Specially designed bearings for the bowl
spindle

G0587321

The bearings used for the bowl spindle are

special to withstand the speed, vibration,
temperature and load characteristics of highspeed separators.
Only Alfa Laval genuine spare parts should be
used.
A bearing that in appearance looks equivalent to
the correct may be considerably different in
various respects: inside clearances, design and
tolerances of the cage and races as well as
material and heat treatment.

1.
2.
3.
4.

Outer race
Ball/roller
Inner race
Cage

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

Dismantling

The puller should be accurately centered during

dismantling; otherwise it is easy to damage the
seating.
NOTE
Do not hit with a hammer directly on the bearing.

60

For bearings where no driving-off sleeve

is included in the tool kit, use a puller
when removing bearings.

G0587411

Remove the bearing from its seat by using a

puller. If possible, let the puller engage the inner
ring, then remove the bearing with a steady force
until the bearing bore completely clears the
entire length of the cylindrical seat.

3 Service Instructions

3.10 General directions

Cleaning and inspection

Check shaft (spindle) end and/or bearing seat

in the housing for damage indicating that the
bearing has rotated on the shaft (spindle) and/
or in the housing respectively. Replace the
damaged part, if the faults cannot be remedied
by polishing or in some other way.
Assembly

Leave new bearings in original wrapping until

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

Use the greatest cleanliness when handling

the bearings.

Clean and smear the bearing seating

before assembly.

G0587511

To facilitate assembly and also reduce the risk of

damage, first clean and then lightly smear the
bearing seating on shaft (spindle) or
alternatively in housing, with a thin oil.

When assembling ball bearings, the bearings

must be heated in oil to maximum 125 C.
NOTE
Heat the bearing in a clean container with a cover.
Use only clean oil with a flash point above 250 C.
The bearing must be well covered by the oil and not
be in direct contact with the sides or the bottom of
the container. Place the bearing on some kind of
support or suspended in the oil bath.

G0587611

The bearing must not be in direct contact

with the container.

61

3.10 General directions

3 Service Instructions

There are several basic rules for assembling

cylindrical bore bearings:
Never directly strike a bearings rings, cage
or rolling elements while assembling. A ring
may crack or metal fragments break off.
Never apply pressure to one ring in order to
assemble the other.

Make sure the bearing is assembled at a

right angle to the shaft (spindle).

G0587711

Use an ordinary hammer. Hammers with

soft metal heads are unsuitable as
fragments of the metal may break off and
enter the bearing.
Use a driving-on sleeve for bearings that are not
heated.

If necessary use a driving-on sleeve that

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

Always fit single-row angular contact ball

bearings with the wide shoulder of the inner race
facing the axial load (upwards on a bowl
spindle).

62

G0587211

Angular contact ball bearings

The wide shoulder of the inner race must

face the axial load.

3 Service Instructions

3.10 General directions

3.10.2Before shut-downs
Before the separator is shut-down for a period of
time, the following must be carried out:

Remove the bowl, according to instructions in

chapter 4 Dismantling/Assembly, page 65.

Protect parts in contact with process liquid

from corrosion by applying a thin layer of oil.

Remove the O-rings.

Protect cleaned carbon steel parts against

corrosion by oiling. Separator parts that are not
assembled after cleaning must be wiped and
protected against dust and dirt.
NOTE
The bowl must not be left on the spindle during
standstill for more than one week.

G0466851

Vibration in foundations can be transmitted to the

bowl and produce one-sided loading of the bearings.
The resultant indentations in the ball bearing races
can cause premature bearing failure.

If the separator has been shut-down for more

than 3 months but less than 12 months, an
Intermediate Service (IS) has to be made before
the separator is put into operation again.

Remove the bowl if the separator is left at

standstill for more than one week.

If the shut-down period has been longer than 12

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

63

3.10 General directions

64

3 Service Instructions

4 Dismantling/Assembly

Contents
4.1 Inlet/outlet and bowl

68

4.1.1

Inlet/outlet and bowl dismantling

71

4.1.2

Inlet/outlet and bowl assembly

76

4.2 Bowl spindle and frame

86

4.2.1

Bowl spindle and frame dismantling86

4.2.2

Bowl spindle and frame assembly 92

4.3 Friction coupling

100

4.3.1

Friction coupling dismantling

101

4.3.2

Friction coupling assembly

103

4.4 Flat belt and tightener

4.4.1

Belt replacement and tightening

4.5 Oil filling device

4.5.1

Dismantling/assembly

107
107
112
112

4.6 Water tank

113

4.7 Brake

113

4.7.1

Exploded view

113

4.7.2

Checking of friction element

114

4.8 Frame feet

4.8.1

Mounting of new frame feet

115
115

65

4 Dismantling/Assembly

References to check points

In the text you will find references to the check

point instructions in chapter 5. The references
appear in the text as in the following example:

Check point

S0 0 5 1 0 1 1

3.3.10 Disc stack pressure, page 47.

In this example, look up check point Disc stack
pressure for further instructions.

Switch off and lock power supply before starting any

dismantling work.

Tools

Special tools from the tool kit must be used for

dismantling and assembly. The special tools are
specified in the Spare Parts Catalogue.
Additional tools needed for dismantling but not
included in the tool kit are shown here.
For bowl and bowl spindle
Screwdriver

Torque wrench (50 Nm) with socket 16 mm

Pliers for internal snap ring

Ball bearing puller

Screw vice with copper liners

Adjustable wrench, length approx. 400 mm

Adjustable wrench or spanner, width of jaws

24 mm

Two lifting slings, working load limit (WLL):

>300 kg are also needed.

66

6, 7
G0278821

4 Dismantling/Assembly

For friction coupling and flat belt

Pliers for internal snap ring

Pliers for external snap ring

T-handle, extension rod and socket 16 mm

Adjustable wrench or spanner, width of jaws

36 mm

Hammer

G0278921

67

4.1 Inlet/outlet and bowl

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

ING
WARN

1. Safety device
2. Nut
6. Insert

Interlocking switch (optional)

Entrapment hazard
The support ring is removed
from the frame hood top, at
paring disc adjustment (Major
Service).

To avoid accidental start,

switch off and lock power
supply before starting any
dismantling work.

3. Inlet/outlet housing
5. Support ring
7. Height adjusting ring

8. Frame hood

9. Lock ring

11. Gravity disc/Clarifier disc

13. Paring chamber cover

IS Intermediate service kit
MS Major service kit

G0073751

14. Inlet pipe with paring disc

68

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

15. Bowl hood

16. Top disc

17. Bowl discs

18. Wing insert

19. Bowl discs

20. Distributor

21. Sliding bowl bottom

G0887751

IS Intermediate service kit

MS Major service kit

69

4.1 Inlet/outlet and bowl

4 Dismantling/Assembly

22. Cap nut

Left-hand thread

23. Upper distributing ring

24. Valve plug

25. Operating slide

26. Lower distributing ring

IS Intermediate service kit

28. Nozzle

70

G0074251

27. Bowl body

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

4.1.1 Inlet/outlet and bowl

dismantling
The frame hood and the heavy bowl parts must
be lifted by means of a hoist. Position the hoist
exactly above the bowl centre. Use an endless
sling and a lifting hook with catch.
The parts must be handled carefully. Dont
place parts directly on the floor, but on a clean
rubber mat, fibreboard or a suitable pallet.

Remove safety device and look through the

slot in the frame hood to see if the bowl still
rotates.

ING
WARN

Entrapment hazard

G0819751

Make sure that rotating parts have come to a

complete standstill before starting any dismantling
work.

G0467361

The bowl parts can remain very hot for a

considerable time after the bowl has come to a
standstill.

Unscrew nut clockwise and lift off inlet- outlet

housing together with the connecting hoses.
When removing the connecting hoses, do not
drop the washer.
Left-hand thread!

G0821531

71

4.1 Inlet/outlet and bowl

Remove the bolts and lift off frame hood (8).

Unscrew lock ring (9) clockwise by using the

special tool; spanner for lock ring.

4 Dismantling/Assembly

G0070021

Left-hand thread!

Lift off gravity disc (clarifier disc) (11).

Carefully prise loose paring chamber cover

(13) by using a screwdriver. Lift off the paring
chamber cover.
NOTE

G0070131

If the gravity disc has to be replaced owing to

changed operating conditions, see 5.8.2 Gravity disc
nomogram, page 141.

72

4 Dismantling/Assembly

Lift out inlet pipe (14) with the paring disc.

Preparations for unscrewing of bowl hood

(15):

G0070221

4.1 Inlet/outlet and bowl

Fit the spanner to the bowl hood and secure

it with the bolt (a).
Fit the compression tool and screw down
the central screw (b) until it stops
G0167121

Compress the disc stack by tightening the

nut (c) firmly.
NOTE
Use the compression tool as instructed.
Use of substitute tools can damage the equipment.

Unscrew bowl hood (15) clockwise by using a

tin hammer.
Left-hand thread!

10 Lift off the bowl hood with the spanner still

15

G0357411

attached.

73

4.1 Inlet/outlet and bowl

4 Dismantling/Assembly

11 Lift out the top disc, the bowl discs with wing

G0357521

insert and the distributor.

Screw the nut of the compression tool up
against the eye bolt, turn the unit with the tool
still attached upside down and hit it against a
firm base. This will facilitate loosening of the
top disc.

12 Lift out sliding bowl bottom (21) using the

G0072031

special tool.
Ease the sliding bowl bottom off with the
central screw of the tool. If necessary, knock
on the handle.

13 Unscrew cap nut (22).

Left-hand thread!

14 Remove upper distributing ring (23) using the

special tool.
Detach the distributing ring either:

G0070631

by jerking, or
by tightening the nuts equally

74

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

15 Lift out operating slide (25) using the special

G0070721

tool: lifting bolts for operating slide.

G0070821

16 Lift out lower distributing ring (26).

17 Lift out bowl body (27) using the special tool.

18 Ease the bowl body off with the central screw
of the tool. If necessary, knock on the handle.

19 Soak and clean all parts thoroughly in suitable

G0070922

cleaning agent, see 3.7.1 Cleaning agents,

page 54.

20 Clean nozzles (28) in bowl body (27) using

soft iron wire of maximum 1,2 mm diameter,
see 3.3.4 Discharge mechanism, page 40.
NOTE
Dirt and lime deposits in the sludge discharge
mechanism can cause discharge malfunction or
failing discharge.

21 Remove O-rings and replace them with spares

from the intermediate service kit (IS).

75

4.1 Inlet/outlet and bowl

4.1.2 Inlet/outlet and bowl

assembly
Make sure that the following check points are
carried out before and during assembly of the
separator bowl.

Check point
3.3.1 Corrosion, page 36,
3.3.2 Erosion, page 38,
3.3.3 Cracks, page 39,
3.3.4 Discharge mechanism, page 40,
3.3.6 Spindle top cone and bowl body nave,
page 43,
3.3.7 Threads of inlet pipe, paring disc, page
43,
3.3.8 Threads on bowl hood and bowl body,
page 44,
3.3.10 Disc stack pressure, page 47,
3.4.1 Paring disc height adjustment, page 48.

76

4 Dismantling/Assembly

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

22. Cap nut

Left-hand thread

23. Upper distributing ring

24. Valve plug

25. Operating slide

26. Lower distributing ring

27. Bowl body

G0074251

IS Intermediate service kit

28. Nozzle

77

4.1 Inlet/outlet and bowl

4 Dismantling/Assembly

IS Intermediate service kit

MS Major service kit

15. Bowl hood

16. Top disc

17. Bowl discs

18. Wing insert

19. Bowl discs

20. Distributor

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

G0887751

21. Sliding bowl bottom

78

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

1. Safety device
2. Nut
6. Insert
IS Intermediate service kit
MS Major service kit

Interlocking switch (optional)

The support ring is removed
from the frame hood top, at
paring disc adjustment (Major
Service).

3. Inlet/outlet housing
5. Support ring
7. Height adjusting ring

8. Frame hood

9. Lock ring

11. Gravity disc/Clarifier disc

13. Paring chamber cover

NOTE
Be sure bowl parts are not
interchanged.

14. Inlet pipe with paring disc

G0073751

Out of balance vibration

will reduce ball bearing
life.

79

Clean the hollow part (b) of the spindle top

and the radial hole (a). Wipe clean the spindle
top and nave bore in the bowl body. Apply oil
to the tapered end of the spindle, smear the oil
over the surface and wipe off surplus with a
clean cloth.
Clean the nozzles in the bowl body, see 3.3.4
Discharge mechanism, page 40.

Check point

4 Dismantling/Assembly

Oil

G0071721

4.1 Inlet/outlet and bowl

3.3.6 Spindle top cone and bowl body nave,

page 43 and 3.3.9 Priming of bowl parts, page
46.

Fit the bowl body (27) on the spindle.

Avoid damaging the spindle cone.

Screw down the central screw of the tool,

then lower the bowl body until the screw
rests on the spindle top.
Screw up the central screw and the bowl
body will sink down on the spindle cone.

G0071831

Attach the special lifting tool to the bowl

body nave.

Place the lower distributing ring (26) in the

bowl body.
Using the lifting bolts fit the operating slide
(25).
Make sure that the seal rings lie concentrically
in their grooves.

G0071841

If replacing valve plugs (24), use a rubber

mallet.

80

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

Fit the upper distributing ring so that drill mark

(a) is in line with hole (c) on the distributing
ring.
When the distributing ring is in correct position
the guide pin (b) will enter hole (c).
NOTE
The two guide pin (b) in the distributing ring have to
be fitted properly in the hole (c).

G0378031

Check the distance A. If the play is larger than 2

mm the guide pins have not entered the holeproperly.
a. Drill mark
b. Guide pin
c. Guide pin

Screw cap nut (22) counter-clockwise onto the

spindle.
Tighten firmly.

G0378111

Left-hand thread!

Fit sliding bowl bottom (21).

Make sure that the square seal ring lies
concentrically in its groove.
Press the sliding bowl bottom down on the
upper distributing ring.

G0072031

81

4.1 Inlet/outlet and bowl

4 Dismantling/Assembly

Check point
Before assembling the bowl discs, check the
threads of the bowl hood and bowl body, see
3.3.8 Threads on bowl hood and bowl body,
page 44.

Assemble the bowl discs with wing insert and

top disc on the distributor. Note the angular
positioning (six options).
Ensure that the pins in the distributor fit
properly into the holes of the top disc.

Preparations for lifting in the disc stack

a

Fit the compression tool and screw down

the central screw (a) until it stops
Tighten the compression nut by hand

10 Fit the disc stack assembly in the bowl body.

G0357561

Make sure that the cuts in the wings on the

underside of the distributor fit properly in the
corresponding lugs of the bowl.

11 Fit bowl hood (15):

Apply a thin layer of Molykote Paste 1000 to
threads and on contact and locating
surfaces.

Molykote
Paste1000

Fit the spanner for the bowl hood and

secure it with the bolt (a).

Left-hand thread!

82

G0072231

Screw on the bowl hood by hand.

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

12 Fit the compressing tool and screw down the

central screw (a) until it stops.

Compress the disc stack by tightening the nut
(b) firmly.
NOTE

Use the compression tool as instructed.

Use of substitute tools can damage the equipment.

Check point
G0072361

3.3.10 Disc stack pressure, page 47.

13 Attach the spanner and tighten the bowl hood

by using a tin hammer.
Strike the spanner handle until the bowl hood
lies tightly against the bowl body. In a new
bowl, the assembly marks now will be in line
with each other.

ING
WARN

Disintegration hazard
G0357711

The assembly mark on the bowl hood must never

pass the mark on the bowl body by more than 25.

See also 3.3.8 Threads on bowl hood and bowl

body, page 44.

14 Place inlet pipe (14) in the bowl.

Check point

G0072721

3.3.7 Threads of inlet pipe, paring disc, page

43.

83

4.1 Inlet/outlet and bowl

4 Dismantling/Assembly

15 Fit paring chamber cover (13) by pressing it

down gently.

G0073341

16 Assemble gravity disc/ clarifier disc (11).

17 Fit lock ring (9).

Apply a thin layer of Molykote Paste 1000 to
the threads and on contact and locating
surfaces.
Left-hand thread!

G0074331

Molykote
paste 1000

18 Fit frame hood (8).

The two eye-bolts must be fitted in the holes
nearest to the electric motor.
In case of Major Service remove the
connecting housing and fit a new O-ring on
the insert (2).

3.4.1 Paring disc height adjustment, page 48.

To be performed at Major Service and if the
bowl spindle has been dismantled.

84

G0073581

Check point

4 Dismantling/Assembly

4.1 Inlet/outlet and bowl

19 Fit inlet/outlet housing.

Tighten nut.
Left-hand thread!

20 Then rotate the bowl by means of the flat belt.

G0172951

If the bowl does not rotate freely or a scraping

noise is heard, incorrect bowl assembly or
incorrect height adjustment of the paring disc
can be the cause.
NOTE
To avoid damage on the inlet pipe the tightening
torque must not exceed 30 Nm.

21 Make sure that the gasket on the safety device

is in position. If not, glue with Loctite 407.
Fit and secure safety device.

22 Fit the connecting hoses if they have been

removed. Make sure to fit their gasket rings.

23 Fit the water tank on the frame bottom part if it

has been removed.

85

4.2 Bowl spindle and frame

4 Dismantling/Assembly

4.2 Bowl spindle and

frame
4.2.1 Bowl spindle and frame
dismantling
Before dismantling the bowl spindle, the inlet
and outlet housing, frame hood and bowl as
well as the flat belt must be removed.
Before dismantling, in the case of Major
Service, or if the separator vibrates while
running, see

Check point
3.4.2 Radial wobble of bowl spindle, page 50.
1. Lip seal ring

3YSK Parts to be renewed at

Three year service

2. Screen
3. Gasket

G01132A1

4. Frame, top part

86

4 Dismantling/Assembly

4.2 Bowl spindle and frame

5. Deflector ring
6. Top bearing cover
7. Gasket
8. Fan

MS Parts to be renewed at
Major Service

9. Buffer holder
10. Rubber buffer

11. Bowl spindle

12. Ball bearing holder

13. Ball bearing
14. Snap ring
15. Ball bearing
16. Oil pump
17. Belt pulley

18. Pump sleeve

19. Rubber buffer

20. O-ring

G01131A1

21. Frame, intermediate

22. O-ring

87

4.2 Bowl spindle and frame

Loosen but do not remove the motor adapter

screws.

Remove the water tank.

Remove the brake.

Remove the flat belt.

Remove the screws and lift off frame top part

(4). Lip seal ring (1) must be removed in the
case of 3-year service, or if found damaged.

G0113461

G 0 1 1 3 3 E1

4 Dismantling/Assembly

88

4 Dismantling/Assembly

Clean the bowl spindle cone in place and

remove deflector ring (5).

Remove, in the following sequence:

G0113521

4.2 Bowl spindle and frame

Top bearing cover (6)

Gasket (7)
Fan (8)
Buffer holder (9)
Rubber buffer (10).
NOTE

G0113621

Be very careful not to damage the wings of

the buffer holder.

89

4.2 Bowl spindle and frame

4 Dismantling/Assembly

Screw the cap nut counter-clockwise (lefthand thread) onto the spindle top to protect
the top and bore.

Left-hand thread

Lift out spindle assembly (11), rubber buffer

(10) and O-ring (20).

G0076132

Remove snap ring (14) by using a pair of

pliers and pull off ball bearing holder (12).

Clamp the bowl spindle (11) in a screw vice.

Remove the pump sleeve (18). When turning
the spindle upside down there is a risk that the
vane in the pump sleeve can slide down partly
or entirely into the spindle. Therefore, after
unscrewing the sleeve, check that the vane
has not been damaged.

10 Remove the belt pulley (17). If the pulley has

stuck proceed with point 10.

11 Lubricate the mounting/dismantling tool.

Fit the mounting/dismantling tool and screw it
down as far as it will go (A).
Use a long spanner (450 - 650 mm) to press
the belt pulley off the spindle (B).
Oil

Molykote paste 1000

90

G0076251

Remove the oil pump (16) by hand, do not

loos the flat key.

4 Dismantling/Assembly

4.2 Bowl spindle and frame

12 Pull off ball bearing (15) using a puller and

thrust washer.

Thrust washer
Puller

Pull off bearing (13) using the special

mounting tool and a hammer.
NOTE
Always discard a used bearing.

G0076321

Special mounting tool

In case of 3-year-service

13 Loosen the screws and lift off the frame

intermediate part (21).

14 Discard the O-ring (22).This O-ring is not

G0093791

included in any service kit, but must be

ordered separately.

91

4.2 Bowl spindle and frame

4 Dismantling/Assembly

15 Remove the screen (2) from the frame top part

(4).

G0113771

Discard the gasket (3). This gasket is not

included in any service kit, but must be
ordered separately.

16 Clean the oil sump.

17 Clean all dismantled parts thoroughly in a
degreasing agent and check for damage and
corrosion.
Replace all parts supplied in the spare parts
kits.

4.2.2 Bowl spindle and frame

assembly
The bowl spindle and frame is assembled in
reverse sequence to dismantling.

1. Lip seal ring

3-YSK parts to be renewed at

3-years service kit

2. Screen
3. Gasket

G01132A1

4. Frame, top part

92

4 Dismantling/Assembly

4.2 Bowl spindle and frame

Molykote 1000 paste

(thin layer to be rubbed into surface)

5. Deflector ring

6. Top bearing cover

7. Gasket

Silicone grease (thin layer)

MS Major service kit

8. Fan
9. Buffer holder
10. Rubber buffer
Silicone grease (thin layer)

11. Bowl spindle

12. Ball bearing holder

13. Ball bearing
14. Snap ring
15. Ball bearing
16. Oil pump
17. Belt pulley

18. Pump sleeve

19. Rubber buffer

Silicone grease (thin layer)
20. O-ring
21. Frame, intermediate

G01131B1

Loctite 242

22. O-ring

93

4.2 Bowl spindle and frame

4 Dismantling/Assembly

In case of 3-year-service

Fit a new O-ring (22) and assemble the frame

intermediate part (21).
Use a torque wrench and tighten the screws
lightly crosswise at first. Then tighten all
around to 45 Nm.
Loctite 242

G0093781

Secure the screws with Loctite 242.

Fit a new gasket (3).

G0113761

Fit the screen (2).

Clear the spindle bore from dirt and lime

deposits with the special reamer

G0076341

94

4 Dismantling/Assembly

4.2 Bowl spindle and frame

Inspect the tapered end and the hollow part of

the bowl spindle for wear and clean if
necessary. Assemble ball bearings (13 and
15).

Mounting tool

Heat the new ball bearings in oil to maximum

125 C. Use the special mounting tool from the
tool kit.
NOTE
Always fit new bearings.

G0113831

If in doubt how to install roller bearings in a correct

way, please see the detailed description in
3.10.1 Ball and roller bearings, page 60.

Fit oil pump, flat key and belt pulley. Make

sure that the recess in the belt pulley fits over
the guide pin in the oil pump.

Oil

Molykote 1000 paste

(Thin layer to be
rubbed into surface)

G0113941

95

4.2 Bowl spindle and frame

Check that the radial hole ( 1 mm) in the

pump sleeve is clean, and fit the pump.

Fit ball bearing holder (12) and secure it with

snap ring (14).

G0114341

4 Dismantling/Assembly

Fit O-ring (20) and rubber buffer (19).

G0076122

Lower spindle assembly (11) carefully into the

separator intermediate frame.

96

4 Dismantling/Assembly

4.2 Bowl spindle and frame

Assemble, in the following sequence:

Rubber buffer (10)
Buffer holder (9)
Fan (8)
Gasket (7)
Top bearing cover (6)
Make sure that the 3 mm hole in fan (8) is
clean and the lugs in the fan enter the
recesses in the bowl spindle.
Before tightening, make sure that there is
some play (a) between top bearing cover
(6) and the frame. The play will disappear
when the screws are tightened.

G0114421

Tighten the screws sequentially (not

crosswise) in order to successively
compress the rubber buffers.

Push down deflector ring (5) till it stops.

Silicone grease
(thin layer)

G0114521

97

4.2 Bowl spindle and frame

10 Assemble frame top part (4). If lip seal ring (1)

has been removed, fit a new one before the
frame top part is put in place.

4 Dismantling/Assembly

Silicone grease
(thin layer)

Make sure the lip seal is turned the correct

way. See illustration.

G0114661

Silicone grease
(thin layer)

11 Tighten the screws of the top frame using a

torque wrench (width across flats 16 mm).
Tighten the screws slightly crosswise at first.
Then tighten all around to 45 Nm.
Loctite 242

G0114751

Secure the screws with Loctite 242.

98

4 Dismantling/Assembly

4.2 Bowl spindle and frame

12 Fit and adjust the flat belt, see 4.4.1 Belt

replacement and tightening, page 107.

Check point
3.4.2 Radial wobble of bowl spindle, page 50.

G01133A1

13 Fit the water tank and tighten the screws.

99

4.3 Friction coupling

4 Dismantling/Assembly

4.3 Friction coupling

If the separator does not attain full speed
within about 2 minutes, the friction elements
or the coupling may be worn or greasy. The
friction elements must then be replaced with
new ones or be thoroughly cleaned from grease.

ING
WARN

Entrapment hazards
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work.

1. Snap ring
2. Snap ring
3. Ball bearings

5. Belt pulley

5. Belt pulley

6. Coupling hub
7. Friction element

G0372121

8. Cover
9. Snap ring
10. Washer
11. Spring washer
12. Screw
(MS) = Set of friction elements
included in the Major service Kit for
50 Hz or 60 Hz

100

4 Dismantling/Assembly

4.3 Friction coupling

4.3.1 Friction coupling dismantling

1

Check that the belt tightener is in backward

position.

Remove the motor adapter screws.

Remove the water tank and the flat belt.

Note that the tank must be lowered past
spindle end (A) before it can be withdrawn
(B).
Remove the flat belt.

Remove the electric motor complete with the

friction coupling and motor adapter.

G0113391

G0077331

Weight of motor including adapter and friction

coupling is not more than 35 kg.

Remove snap ring (9), cover (8) and friction

elements (7).
If the friction elements are worn, fit new ones.
Replace all friction elements even if only one
is worn.
If the friction elements are only greasy:
Clean the friction elements and the inside of
belt pulley (5) with a degreasing agent.

G0170841

101

4.3 Friction coupling

4 Dismantling/Assembly

Remove the screw (12), spring washer (11)

and washer (10) from the friction coupling.

Complete dismantling of the friction

coupling

Lubricate and fit the special mounting and

dismantling tool.
Ease off the coupling.
Oil

Molykote 1000 Paste

(thin layer to be rubbed into
surface)

G0171021

Mounting tool

Remove snap rings (1 and 2) and drive off

coupling hub (6). Turn the coupling, i.e. belt
pulley (5) with bearings (3), the other way
round and drive off the ball bearings and
washer by using a tube.

10 Clean all parts in a degreasing agent and

replace parts supplied in the spare parts kits.
NOTE

G0171131

Always discard a used bearing.

102

4 Dismantling/Assembly

4.3 Friction coupling

4.3.2 Friction coupling assembly

Before the friction coupling is assembled,
examine all parts thoroughly for wear and
corrosion.
Assemble the new ball bearings in belt pulley
(5) by using a tube and a hammer.
Apply Loctite 641 on the outer surfaces of ball
bearings (3).
Knock down the bearings carefully (do not
forget washer 4) by using the tube which must
rest on the outer race of the bearing.
The new bearings must not be heated as they
are packed with grease and sealed with
plastic membranes.

Loctite 641

After the assembly of the bearings, fit snap

ring (2).
NOTE
G0171231

Do not refit used bearings.

103

4.3 Friction coupling

Apply Loctite 641 on the coupling hub (6) and

knock it down into the belt pulley by using a
hammer.

Fit snap ring (1).

4 Dismantling/Assembly

G0171321

Loctite 641

Wipe clean the motor shaft and apply a thin oil

film on it. Fit the special mounting and
dismantling tool to the motor shaft (by means
of the small screw on one end of the tool) and
press the friction coupling onto the shaft.

Oil

104

G0171021

Mounting tool
Molykote 1000 Paste
(thin layer to be rubbed into
surface)

4 Dismantling/Assembly

Fit the screw (12) with the washer (11) and

spring washer (10) to secure the friction
coupling.

G0170921

4.3 Friction coupling

Assembly of friction elements

Fit new friction elements (7), cover (8) and

snap ring (9).
A coupling with two friction elements is
used for 60 Hz installations.
A coupling with four friction elements is
used for 50 Hz installations.
G0170831

105

4.3 Friction coupling

4 Dismantling/Assembly

Degrease and clean the contact surfaces of

frame and motor adapter. Lubricate the
contact surfaces with Molykote 1000 paste.
Then fit the electric motor with adapter and
friction coupling in position.

G0077341

Also lubricate the threads of the belt tightener

with Molykote 1000 paste or similar.

Fit and tighten the flat belt, see 4.4.1 Belt

replacement and tightening, page 107.

Install the water tank and the cover.

NOTE
The belt must be re-tightened before starting the
separator, see next page.

106

4 Dismantling/Assembly

4.4 Flat belt and tightener

4.4 Flat belt and tightener

The flat belt must be removed before
dismantling of the bowl spindle or the friction
coupling. The procedure is the same when
replacing the belt at a Major Service.
A new belt must be re-tightened twice:

30 minutes after the belt has been installed.

The separator must not be started until the
re-tightening has been done.

after approximately 24 hours of operation.

NOTE
Do not start the separator unless the flat belt has
been re-tightened after 30 minutes. If started, the
belt may slip and be damaged.

4.4.1 Belt replacement and

tightening
If only tightening of flat belt should be done,
only steps 3 and 7-11 have to be performed.

ING
WARN

Entrapment hazards
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work.

Remove the water tank and brake.

Note that the tank must be lowered past
spindle end (A) before it can be withdrawn
(B).

G0884721

G0467361

Look into the slot in the frame hood to see if

separator parts are rotating or not.

107

4.4 Flat belt and tightener

4 Dismantling/Assembly

Check that the belt tightener is in backward

position.
NOTE

Loosen but do not remove the motor adapter

screws.

G0076622

G0473911

Pay attention to the air gap A between the cup

springs and the threaded sleeve.
The distance A must not exceed 0,5 mm.
Otherwise a correct belt tightening will be
impossible.

NOTE

Molykote 1000 Paste

Knock out the tubular spring pin and separate

the parts, lubricate and assemble the parts.

G0885711

To guarantee a proper function of the belt tightener it

is advisable to protect the surfaces

Remove the existing belt and clean the

raceways of the bowl spindle and the friction
coupling by using a degreasing agent. Wipe
the raceways with a clean rag after cleaning.

G0171531

Exercise the greatest possible cleanliness.

There must be no dirt, oil or grease on the
raceways.

108

4 Dismantling/Assembly

Remove the motor adapter screws. Lift the

motor together with adapter and friction
coupling and check that there is a sufficient
film of Molykote 1000 Paste, or an equivalent
lubricating paste, between the adapter and
the frame surface. Lower the motor after
checking. Fit the motor adapter screws but do
not tighten them.

4.4 Flat belt and tightener

Molykote 1000 Paste

The weight of motor including adapter and

friction coupling is not more than 35 kg.

G0077341

The threads of the belt tightener should be

lubricated with a thin layer of Molykote 1000
Paste.
(to be rubbed into surface)

Fit a new belt. Start on the motor side.

Tighten the belt by moving the motor
backwards by hand.
Pull the belt around a few turns by hand.

Rotate the belt tightener by rotating the shaft

until it makes contact with the frame pad.

G0489821

G0171661

109

4.4 Flat belt and tightener

Tighten the shaft (1) further until the threaded

sleeve (2) and dog (3) are disengaged.
Shake the motor by hand several times
during this operation in order to overcome the
friction between the motor adapter and the
frame.

Tighten the motor adapter screws.

G0076622

G0477111

4 Dismantling/Assembly

10 Loosen the belt tightener by rotating the

G0477211

threaded sleeve (2) backwards.

110

4 Dismantling/Assembly

4.4 Flat belt and tightener

11 Rotate the shaft (1) relative to the threaded

sleeve (2) until the sleeve (2) and dog (3) are
engaged again with a clicking sound.
NOTE

G0477311

If the springs (4) are not decompressed they will

loose their tension and correct tightening of belt will
be impossible.

12 Let the belt stay in this position for at least 30

minutes without starting the separator.
Then repeat steps 3 and 7-11 above. After this
proceed to step 13.
G0474021

NOTE
Do not start the separator unless the flat belt has
been re-tightened after 30 minutes.
If started, the belt may slip and be damaged.

13 Fit the water tank and brake.

14 The separator may now be started.
NOTE
The belt must be re-tightened when the separator has
been in operation approximately 24 hours after the
belt change: Repeat steps 3 and 7-11.

111

4.5 Oil filling device

4 Dismantling/Assembly

4.5 Oil filling device

4.5.1 Dismantling/assembly
Drain off the oil, see 3.8 Oil change, page 56.
Unscrew nipple (4) and pull off the oil filling
device. Then unbend the round safety wire (6)
and pull off nipple (4).

If plate (8) is to be replaced, wipe the sight glass (7) with a degreasing agent.

Fit the new plate on the outside of the sight glass. The plate is self-adhesive.

Mark the position of the plate relative to the recess in sleeve (1).

G0155811

Assemble the oil filling device and fit it into the frame. Note that the mark on sleeve (1) must be
positioned opposite the mark on the frame. Fill the sump with new oil.

6. Round safety wire

5. Sealing ring
4. Nipple
2. O-ring
1. Sleeve for oil filling
7. Sight glass

Silicone grease (thin layer)

112

8. Plate
G0155911

3. O-ring

4 Dismantling/Assembly

4.6 Water tank

4.6 Water tank

Remove the water tank (1).
Note that the tank must be lowered past the
spindle end (A) before it can be withdrawn (B).
Check the tank interior and clean out if
necessary.

Check that the pipes are not defective.

Replace if necessary.

G0884711

2. Elbow

If the parts fitted on the tank have been

removed, it is necessary to fit the parts properly
together at assembly.

1. Water container
2. Elbow

Seal the water inlet pipe with Loctite 573.

4.7 Brake
4.7.1 Exploded view

5. Split pin

1. Spindle with friction element

2. Spring

6. Brake handle
G0171731

3. Bracket
4. Cylindrical pin with hole

113

4.7 Brake

4 Dismantling/Assembly

4.7.2 Checking of friction element

A worn or oily friction element will lengthen the
stopping time. Remove bracket with the brake.
Examine the friction element.
If the friction element is worn; Fit a new
complete spindle (includes friction element).

If the friction element is oily; Clean the element

and its surface in contact with the belt pulley
with a suitable degreasing agent.
G0171821

Checking of bracket, spindle and spring

Rust can form on the brake parts and cause the

brake to jam.

A = Coupling surface
Molykote 1000 Paste

Checking the brake

After the brake assembly has been fitted,

release the brake and rotate the bowl slowly by
hand. If a scraping noise is heard, the friction
element is probably touching the coupling
pulley surface (A). If so, it is necessary to adjust
the position of the motor adapter and retighten the flat belt, see 4.4 Flat belt and
tightener, page 107.

114

G0171931

Remove rust from the spindle and the

corresponding guide surface on the bracket. Rub
the surface of the spindle with a thin layer of
lubricating paste. Replace the spring with a new
one if it has lost its stiffness. Oil the spring when
assembling.

Oil

4 Dismantling/Assembly

4.8 Frame feet

4.8 Frame feet

4.8.1 Mounting of new frame feet
When replacing the frame feet, the separator
must be lifted.
Remove the bowl before lifting the separator.

Loosen the foundation bolts and lift the

separator.

Remove the existing frame feet.

Mount the new feet.

Place the separator in its original position and

fasten the foundation bolts.

Remove the two lifting eye bolts.

Assemble the separator bowl, see 4.1.2 Inlet/

outlet and bowl - assembly, page 76.

G0358351

Follow 3.6 Lifting instructions, page 52.

115

4.8 Frame feet

116

4 Dismantling/Assembly

SEPARATOR MANUAL

5 TECHNICAL REFERENCE

5 Technical Reference
Contents

5.8.6
5.8.7

5.1 Product description

118
5.8.8

5.2 Technical data

Operating water interface

(Clarifier)

147

Performance data,
in- and outlet device

148

Interconnection diagram

150

119

5.9 Storage and installation

5.3 Connection list

120

5.4 Basic size drawing

122

5.4.1

Dimensions of connections

5.5 Interface description

5.9.1

Introduction

151
151

5.10 Protection and storage of goods 152

123
124

5.10.1 Storage at out of operation

153

5.10.2

Before start-up

153

5.10.3

Connections to surrounding
equipment

154

5.5.1

Scope

124

5.10.4

Reassembly and Start up

155

5.5.2

References

124

5.10.5

Storage and transport of goods

155

5.5.3

Definitions

124

5.10.6 Planning of installation

158

5.5.4

Goal

125

5.10.7 Foundations

160

5.5.5

Description of separator modes.

126

5.5.6

Handling of connection interfaces. 127

5.5.7

Fluid connections.

128

5.6 Water quality

132

5.7 Lubricants

133

5.7.1

Lubrication chart.

133

5.7.2

Alfa Laval lubricating oil groups

134

5.7.3

Recommended lubricants

135

5.7.4

Recommended lubricating oils

137

5.7.5

Recommended oil brands

138

5.8 Drawings

140

5.8.1

Foundation plan

140

5.8.2

Gravity disc nomogram

141

5.8.3

Electric motor

142

5.8.4

Machine plates and safety labels

144

5.8.5

Operating water interface

(Purifier)

146

577460-02

117

5.1 Product description

5 Technical Reference

5.1 Product description

Alfa Laval ref. 570871, rev. 0

Product number: 881099-06-02/0

Separator type: P 605
Application: Mineral oil
Technical design:
Purifier (clarifier as option) with partial discharge.
Machine bottom part for belt drive
Intended for marine and land applications.
Colour of finish painting of painted parts according to order.
Quality of painting according to specifications on drawings.
Sealings available in Nitrile.
Designed in accordance with directives and standards:
98/37/EC
91/368 EEC
93/44 EEC

Directive of the European

Parliament and the Council
relating to machinery.

ISO 3744

Acostics - determination of sound

power levels of noise sources
using sound pressure.

EN 292-2

Safety of machines. Use of the

machine in applications subject
to hygienic demands require a
well adapted cleaning program.

Operational limits:
Max. Allowed speed 9510 r/minute
Discharge interwall: 2 - 60 minutes
Feed temperature: 0 C to + 100 C
Ambient temperature: + 5 C to + 55 C
Not to be used for liquids with flashpoint below 60 C
Maximum allowed density of operating liquid: 1000 kg/m3

118

5 Technical Reference

5.2 Technical data

5.2 Technical data

Alfa Laval ref. 561687, rev. 1,

Maximum density

feed
sediment

1100 kg/m3
2631 kg/m3

Power consumption

idling

0,8 kW

running (at max. capacity)

1,8 kW

max. power consumption

2,8 kW (at starting-up)

Bowl speed

9510/9305

max. rev/min. 50Hz/60Hz

Speed motor shaft

3000/3600

max. rev/min. 50Hz/60Hz

Gear ratio (pulleys)

130:41 (50 Hz)

106:41 (60 Hz)

Starting time

1,8 - 2,3 minutes

Stopping time

Running down without brake

average 14 minutes

With brake

min. 3, max. 4 minutes

Maximum running time without

flow

Empty bowl

180 minutes

Filled bowl

180 minutes

Sludge volume total/efficient

0,6 / 0,2 litres

Bowl volume

1,5 litre

Discharge volume

1 litre (nominal) fixed

Required water quality

See 5.6 Water quality, page 132

Lubrication

See 5.7 Lubricants, page 133

Lubricating oil volume

0,5 litre

Sound pressure level

69 dB(A)

Vibration level

New separator

Max. 5,6 mm/sec

Separator in use

Max. 9 mm/sec

Separator without motor

Net weight approx. 191 kg

Motor

16 kg

Complete bowl

35 kg

Weight

Overhead hoist for 300 kp is required

Motor power

2,2 Kw

Bowl material

AL 111 2377-02

stainless steel

NOTE
The separator is a component operating in an
integrated system including a monitoring system. If
the technical data in the system description does
not agree with the technical data in this instruction
manual, the data in the system description is the
valid one.

119

5.3 Connection list

5 Technical Reference

5.3 Connection list

Alfa Laval ref. 561658, rev. 1

Connection
No.

Description

201

Inlet for process liquid.

- Flow:
- Pressure:

206

220

Requirements/limits

See 5.8.7 Performance data,

in- and outlet device, page
148

Inlet for liquid seal and displacement liquid.

- Quality requirements:

See 5.6 Water quality, page

132

- Flow, set value:

8 litres/minute

Outlet for light phase, clarified liquid.

- Counter pressure:
- Capacity:

(221)

Outlet for heavy phase (water).

222

Outlet for solid phase.

- Discharge volume:

See 5.8.7 Performance data,

in- and outlet device, page
148
Should be possible to drain
liquids by gravity.

See 5.2 Technical data, page

119
The outlet after the separator
should be installed in such a
way that you can not fill the
frame top part with sludge.
(Guidance of sludge pump or
open outlet)

372

120

Inlet for discharge liquid.

- Flow , set value:

18 litres/minute

- Quality requirements:

See 5.6 Water quality, page

132

5 Technical Reference

Connection
No.

Description

373

Inlet for make-up liquid.

5.3 Connection list

Requirements/limits

- Flow, set value:

0,9 litres per minute

- Quality requirements:

See 5.6 Water quality, page

132

- Consumption:

0,9 litres per discharge

377

Outlet for operating liquid.

Should be possible to drain

liquids by gravity.

462

Drain of frame top part, lower.

Should be possible to drain

liquids by gravity.

463

Drain of frame top part, upper.

Should be possible to drain

liquids by gravity.

701

Motor for separator

Allowed deviation from nominal frequency
(momentarily during maximum 5 seconds):

753

5%
(10%)

Unbalance sensors, vibration

- Type:

Mechanical switch

- Frequency range:

< 300 Hz

- Vibration measurement range:

< 4,5 g

- Internal impedance:

4 k 5%

- Reset coil voltage:

48 V DC

- Reset coil power:

Max. 14 W

- Switch rating, resistive load max

2 A @ 24 V DC

Location of connections on the separator, see

5.4 Basic size drawing, page 122, and 5.4.1
Dimensions of connections, page 123.

121

5.4 Basic size drawing

5 Technical Reference

5.4 Basic size drawing

G0922911

Alfa Laval ref. 565297, rev. 1

Connections 201 and 220 are turnable 90.

A Maximum horizontal displacement during operation 20 mm
B Maximum vertical displacement during operation 10 mm

122

5 Technical Reference

5.4 Basic size drawing

5.4.1 Dimensions of connections

G0922921

Alfa Laval ref. 565297 rev. 1

All dimensions are nominal.

Reservation for individuall deviations due to tolerance.
All connections to be installed non-loaded and flexible.
Data for connections see 5.3 Connection list, page 120

123

5.5 Interface description

5.5 Interface description

Alfa Laval ref. 565810, rev. 0

5.5.1 Scope
This document gives information, requirements
and recommendations about operational
procedures and signal processing for safe and
reliable operation of the separator. It is
intended to for designing auxiliary equipment
and control system for the separator.

5.5.2 References
This Interface Description is one
complementary document to the separator.
Other such documents that contain necessary
information and are referred to here are:

Interconnection diagram

Connection List

Technical Data

Operating Water Interface

Standards referred to are:

EN 418 Safety of machinery - Emergency

stop equipment, functional aspects Principles of design

EN 1037 Safety of machinery - Prevention of

unexpected start-up

5.5.3 Definitions
For the purpose of this document, the following
definitions apply:

Synchronous speed: The speed the machine

will attain when it is driven by a three-phase
squirrel-cage induction motor and there is no
slip in the motor and the drive system.

Full speed: The synchronous speed minus

normal slip.

124

5 Technical Reference

5 Technical Reference

5.5 Interface description

5.5.4 Goal
To eliminate situations that can cause harm,
i.e. injury, damage to health or property and
unsatisfactory process result are e.g.:

Situation

Effect

Unbalance caused by uneven sediment

accumulation in the bowl.

Too high stress on bowl and bearing

system which might cause harm.

Too high bowl speed.

Too high stress on bowl which might

cause harm.

Access to moving parts.

Can cause injury to person who

accidentally touches these parts.

Insufficient cleaning of separator.

Unsatisfactory product quality.

Bowl leakage.

Product losses.

Information and instructions given in this

document aim at preventing these situations.
Control and supervision can be more or less
comprehensive depending on the type of used
control equipment. When a simple control unit
is used it would be impossible or too expensive
to include many of the functions specified here
while these functions could be included at
nearly no extra cost when a more advanced
control unit is used. For this reasons functions
that are indispensable or needed for safety
reasons to protect the machine and/or
personnel are denoted with shall while other
functions are denoted with should.

125

5.5 Interface description

5.5.5 Description of separator

modes.
For control purposes the operation of the
separator should be divided into different
modes.
The normally used modes are described below
but other modes might exist.
It is assumed that:

The separator is correctly assembled.

All connections are made according to

Connection List, Interconnection
Diagram and Interface Description.

The separator control system is activated.

If above conditions are not fulfilled the

separator is unready for operation.
STAND STILL means:

The power to the separator motor is off.

The bowl is not rotating.

STARTING means:

The power to the separator motor is on.

The bowl is rotating and accelerating.

RUNNING means:

The power to the separator motor is on.

The bowl is rotating at full speed.

RUNNING is a collective denomination for

a
number of sub modes which e.g. can be:
STAND BY: Separator is in a waiting mode
and not producing.
PRODUCTION: Separator is fed with
product and producing.
CLEANING: Separator is fed with cleaning
liquids with the intention to clean the
separator.

126

5 Technical Reference

5 Technical Reference

5.5 Interface description

STOPPING means:

The power to the separator motor is off.

The bowl is rotating and decelerating.

STOPPING is a collective denomination for
a number of sub modes which e.g. can be:
NORMAL STOP: A manually or
automatically initiated stop.
SAFETY STOP: An automatically initiated
stop triggered by too high vibrations.
EMERGENCY STOP: A manually initiated
stop at emergency situations. This stop
will be in effect until it is manually reset.

5.5.6 Handling of connection

interfaces.

Electrical connections.

701 Separator motor.

The separator is equipped with a 3-phase DOL

(Direct On Line) started motor.
There shall be an emergency stop circuit
designed according to EN 418 and a power
isolation device according to EN 1037.
There shall be a start button close to the
separator that shall be used for first start after
assembly of the separator.
There should be a counter to count number of
running hours.
There should be a current transformer to give
an analogue signal to the control unit about the
motor current.

127

5.5 Interface description

753 Unbalance sensor.

For indication of any abnormal unbalance and

to be able to perform appropriate
countermeasures, the separator may be
equipped with a vibration initiated mechanical
switch on the separator frame.
The vibration monitor shall include a self-check
function to be performed at least at initiation of
STARTING.
If to high vibrations occur the separator shall
be stopped the quickest way possible and it
shall not be restarted until the reasons for the
vibrations have been found and measures to
remove them have been taken.
Signal processing in STARTING:

If to high vibrations occur the separator shall

be stopped automatically by SAFETY STOP.

If the self-check system triggers, an alarm

shall be given and an automatic stop by
NORMAL STOP shall be initiated.

Signal processing in RUNNING:

If to high vibrations occur the separator shall

be stopped automatically by SAFETY STOP.

If the self-check system triggers, an alarm

shall be given.

Signal processing in STOPPING:

If the self-check system triggers, an alarm

shall be given.

Signal processing in NORMAL STOP:

If to high vibrations occur the system shall

turn over automatically to SAFETY STOP.

5.5.7 Fluid connections.

Complementary information is given in 5.3
Connection list, page 120.

128

5 Technical Reference

5 Technical Reference

5.5 Interface description

201 Inlet for process liquids (feed).

Processing in STAND STILL:

Shall be closed.

Processing in STARTING:

Should be closed. Bowl will be open and

empty or closed and filled depending on if
start is done from STAND STILL or
STOPPING.

Processing in RUNNING:

Could be closed or open.

Shall be closed before a discharge. See

5.8.5 Operating water interface (Purifier),
page 146 or 5.8.6 Operating water interface
(Clarifier), page 147.

Processing in NORMAL STOP or

EMERGENCY STOP:

Could be closed or open but the bowl should

be filled unless the stop is initiated in
STARTING.

Processing in SAFETY STOP:

Could be closed or open but the bowl shall

be filled unless the stop is initiated in
STARTING.

206 Inlet to liquid seal.

Processing in STAND STILL:

Shall be closed.

Processing in STARTING:

Shall be closed.

Processing in RUNNING:

Supplying a liquid seal prior to opening the

feed: See 5.8.5 Operating water interface
(Purifier), page 146 or 5.8.6 Operating water
interface (Clarifier), page 147.

Displacing (the interface) before a

discharge: See 5.8.5 Operating water
interface (Purifier), page 146 or 5.8.6
Operating water interface (Clarifier), page
147.

129

5.5 Interface description

220 and 221 Outlets

Processing in STAND STILL:

Could be closed or open.

Processing in other modes:

Shall be open.

372 Inlet for discharge liquid.

Processing in STAND STILL:

Shall be closed.

Processing in STARTING:

Shall be closed.

Processing in RUNNING:

A discharge is initiated according to

procedure in Operating Water Interface.

After a discharge has been triggered the

motor current or bowl speed should be
monitored to indicate if there comes a
current peak or a sudden drop in speed. The
absence of such a signal indicates that the
discharge has failed and corrective action
should be taken (e.g. trigger a new
discharge). Absence of a discharge may
result in problems due to solidification of the
sediment.
That the current returns to original value after
discharge could also be supervised. If
current is much higher after the discharge
this might be an indication that the bowl has
not closed properly after the discharge.

For service purposes there should be a

counter to count number of discharges.

130

5 Technical Reference

5 Technical Reference

5.5 Interface description

373 Inlet for make-up liquid.

Processing in STAND STILL:

Shall be closed.

Processing in STARTING:

Shall be closed.

Processing in RUNNING:

The separator bowl is closed according to

procedure in
Operating Water Interface.

The separator bowl is closed in a discharge

sequence according to procedure in
Operating Water Interface.

131

5.6 Water quality

5.6 Water quality

Alfa Laval ref. 553406, rev. 5

Quality requirements for operating water

Operating water is used in the separator for several

different functions: e.g. to operate the discharge
mechanism, to lubricate and cool mechanical seals, etc.
Poor quality of the operating water may with time
cause erosion, corrosion and/or operating problem in
the separator and must therefore be treated to meet
certain demands.

The following requirements are of fundamental

importance

Turbidity-free water, solids content <0,001% by volume.

Deposits must not be allowed to form in certain areas in
the separator.

Max particle size 50 m.

Total hardness less than 180 mg CaCO3 per litre, which

corresponds to 10 dH or 12,5 E.Hard water may with
time form deposits in the operating mechanism. The
precipitation rate is accelerated with increased operating
temperature and low discharge frequency. These effects
become more severe the harder the water is.

Chloride content max 100 ppm NaCl (equivalent to 60 mg

Cl/l).
Chloride ions contribute to corrosion on the separator
surfaces in contact with the operating water, including the
spindle. Corrosion is a process that is accelerated by
increased separating temperature, low pH, and high
chloride ion concentration. A chloride concentration
above 60 mg/l is not recommended.

pH>6
Increased acidity (lower pH) increases the risk for
corrosion; this is accelerated by increased temperature
and high chloride ion content.
NOTE
Alfa Laval accepts no liability for consequences
arising from unsatisfactorily purified operating
water supplied by the customer

132

5 Technical Reference

5 Technical Reference

5.7 Lubricants

5.7 Lubricants

G0112122

Alfa Laval ref. 553216-01 rev. 6

5.7.1 Lubrication chart.

Lubricating points

Lubricants

Bowl spindle ball bearings and buffers are lubricated by

oil mist.

Lubricating oil as specified in 5.7.5 Recommended oil

brands, page 138.

Bowl spindle taper.

Lubricating oil, only a few drops for rust protection.

Metal buffers of bowl spindle.

Lubricating oil.

Bowl: Sliding contact surfaces and pressure-loaded

surfaces such as lock rings, threads of lock rings, bowl
hood and cap nut.

Pastes as specified in 5.7.3 Recommended lubricants,

page 135.

Rubber seal rings.

Grease as specified in 5.7.3 Recommended lubricants,

page 135.

Friction coupling ball bearings.

The bearings are packed with grease and sealed, they

need no extra lubrication.

Electric motor.

Follow the manufacturers instructions.

133

5.7 Lubricants

5 Technical Reference

5.7.2 Alfa Laval lubricating oil

groups
Alfa Laval ref. 553216-01 rev. 6

Group A oil: a high quality gear oil on paraffin base with stable AW (anti wear)
additives.

Group B oil: a high quality gear oil on paraffin base with stable EP (extreme pressure)
additives.

Group D oil: a synthetic base oil with additives stable at high operating temperatures.

Group E oil: Characteristics as a group D-oil but suitable at a higher operation power
(55 kW)

Do not mix different oil brands or oils from different oil groups.
Always use clean vessels when handling lubricating oil.
Great attention must be paid not to contaminate the lubricating oil. Of particular
importance is to avoid mixing of different types of oil. Even a few drops of motor oil
mixed into a synthetic oil may result in severe foaming.
Any presence of black deposits in a mineral type oil is an indication that the oil base
has deteriorated seriously or that some of the oil additives have precipitated. Always
investigate why black deposits occurs.
If it is necessary to change from one group of oil brand to another it is recommended to
do this in connection with an overhaul of the separator. Clean the gear housing and
the spindle parts thoroughly and remove all deposits before filling the new oil.
NOTE
Always clean and dry parts (also tools) before
lubricants are applied.

ON
CAUTI
Check the oil level before start. Top up when
necessary.
Oil volume = see 5.2 Technical data, page 119.

It is of utmost importance to use the lubricants recommended in our

documentation.
This does not exclude, however, the use of other brands, provided they have
equivalently high quality properties as the brands recommended. The use of
oilbrands and other lubricants than recommended, is done on the exclusive
responsibility of the user or oil supplier.
Applying, handling and storing of lubricants
Always be sure to follow lubricants manufacturer's instructions.

134

5 Technical Reference

5.7 Lubricants

5.7.3 Recommended lubricants

Alfa Laval ref. 553217-01 rev. 8

Pastes for non-food applications:

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

Manufacturer Designation
Fuchs Lubritech

Gleitmo 805 K
Gleitmo 705 K

Dow Corning

Molykote 1000 (Paste)

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

Rocol

Antiscuffing (ASP) (Paste)

Kluber

Wolfracoat C (Paste)

Alfa Laval No.

537086-02(1000 g)
537086-03 (100 g)
537086-04 (50 g)

Bonded coatings
Manufacturer Designation

Alfa Laval No.

Fuchs Lubritech

Gleitmo 900 (Varnish or

spray)

Dow Corning

Molykote D321R (Spray)

535586-01 (300 ml)
Molykote D321R (Varnish) 535586-02 (60 ml)

135

5.7 Lubricants

5 Technical Reference

Silicone grease for rubber rings

Manufacturer Designation

Alfa Laval No.

Dow Corning

Molykote 111 (Compound)

Molykote 111 (Compound)

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

Fuchs Lubritech

Gleitmo 750

Kluber

Unisilkon L 250 L

Wacker

Silicone P (Paste)

Greases for ball and roller bearings:

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

Manufacturer

Designation

BP

Energrease MM-EP2
Energrease LS2

Castrol

APS 2 Grease
EPL 2

Chevron

Duralith grease EP2

Elf

Epexa 2

Esso/Exxon

Beacon EP2
Unirex N2

Fina

Marson EPL 2A

Mobil

Mobilith SHC 460

Mobilux EP2

Gulf

Gulflex MP2

Q8/Kuwait Petroleum

Rembrandt EP2

Shell

Albida Grease EP2

Alvania EP Grease 2

SKF

LGEP2 or LGMT2

Texaco

Multifak AFB 2

136

5 Technical Reference

5.7 Lubricants

5.7.4 Recommended lubricating oils

Alfa Laval ref. 553219-09 rev. 0

Two different groups of lubricating oils are

approved. They are designated as Alfa Laval
lubricating oil groups A and D which are
described in 5.7.2 Alfa Laval lubricating oil
groups, page 134.
The numerical value after the letter in the
table states the viscosity grade..
Ambient temperature

Alfa Laval lubricating oil

group

Time in operation

between +15 and +45 C

A/150

1500 h

between +2 and +65 C

D/220

2000 h

Oil change interval

The corresponding commercial oil brands are

listed on next page.
NOTE

When the separator is operated for short

periods, lubricating oil must be changed
every 12 months even if the total number of
operating hours is less than stated in the
recommendations above.

Check and prelubricate spindle bearings on

separators which have been out of service
for 6 months or longer.

In seasonal operation: change oil before

every operating period.

Alfa Laval do not accept responsibility for any

damage caused by the use of lubricants which
deviate from the recommended lubricants
listed in this manual.

137

5.7 Lubricants

5 Technical Reference

5.7.5 Recommended oil brands

Alfa Laval lubricating oil group A/150

Alfa Laval ref. 553218-04 rev. 2

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

Alfa Laval lubrication oil group A

Viscosity grade VG (ISO 3448/3104)

150

Viscosity index VI (ISO 2909)

>95

Manufacturer

Designation

Alfa Laval

546098-80(20 litres)
546098-81(4 litres)
546098-82(208 litres)
546098-83(1 litre )

BP

Bartran 150

Castrol

Alpha ZN 150

Esso/Exxon

Nuto 10
Teresso 150
Terrestic 150

Mobil

DTE oil Extra Heavy

Q8/Kuwait Petroleum

Haydn 150

Shell

Morlina 150
Tellus 150

Texaco/Caltex

Regal Oil 150

Paper Machine Oil Premium 150

138

5 Technical Reference

5.7 Lubricants

Alfa Laval lubricating oil group D/220

Alfa Laval ref. 553218-08 rev. 3

Specification: Synthetic lubricating oil,

category PAO (ISO-L-) CKE 220
NOTE
The data in below tables is based on supplier
information in regards to lubrication properties.
Trade names and designations might vary from
country to country, contact your local supplier for
more information.
Brands with Alfa Laval article number are approved
and recommended for use.

Alfa Laval lubrication oil group D

Viscosity grade VG (ISO 3448/3104)

220

Manufacturer

Designation

Alfa Laval

542690-80(20 litres)
542690-81(4 litres)
542690-82(208 litres)

BP

Enersyn HTX 220

Castrol

Alphasyn EP 220
Alphasyn HG 220

Chevron

Tegra 220

ELF

Epona SA 220

Esso/Exxon

Terrestic SHP 220

Teresso SHP 220

Mobil

SHC 630

Q8/Kuwait Petroleum

Schumann 220

Shell

Paolina 220
Omala RL 220

The lists of recommended oil brands are not complete. Other oil brands may
be used as long as they have equivalently quality as the brands
recommended. The oil must have the same viscosity class and ought to follow
the ISO standard 12925-1, category ISO-L-CKE (ISO 6743-6) or DIN 51517,
part 3 CLP, but shall have a synthetic base oil of polyalphaolefin type (PAO)
instead of mineral base oil. The oil must be endorsed for worm gear with
brass worm wheel. The use of other lubricants than recommended is done on
the exclusive responsibility of the user or oil supplier.

139

5.8 Drawings

5 Technical Reference

5.8 Drawings
5.8.1 Foundation plan

G0645721

Alfa Laval ref. 548711, rev. 2

A
B
C
D
E
F

Center of separator bowl

Center of motor
8 holes for foundation bolt
Foundation bolt
Service side
Max. height of largest component incl. lifting tool

Vertical force not exceeding 5 kN/foot

Horizontal force not exceeding 7 kN/foot

Service area

140

5 Technical Reference

5.8 Drawings

5.8.2 Gravity disc nomogram

G0931711

Alfa Laval ref. 565798 rev. 0

Oil density, kg/m3 at 15 oC

Oil temperature, C, F

Gravity disc hole diameter, mm

Throughput, m3/h

The nomogram is based on the properties of

fresh water.
Example I in nomogram

Example II in nomogram

Reference in graph:

Reference in graph:

Oil density

965 kg/m3
at 15 C (60 F)

Oil density

875 kg/m3
at 15 C (60 F)

Separation
temperature

70 C (158 F)

Separation
temperature

60 C (140 F)

Throughput

0,7 m3/h

Throughput

1 m3/h

From the graphs (heavy line), the correct

gravity disc has a hole diameter of 54 mm.

From the graphs (broken line), the correct

gravity disc has a hole diameter of 66 mm.

141

5.8 Drawings

5 Technical Reference

5.8.3 Electric motor

Alfa Laval ref. 552807, rev. 4

G0606231

The rotor balanced with half key.

Maximum vibration velocity 1,8 mm/s (rms) acc. to IEC
34-14.

A Knock out openings for cable glands on both sides 2 x 23

B Sheet-steel fan hood
C 4 holes 12

NOTE
The motor bearings are permanent lubricated.

Manufacturer

ABB Motors

Manufacturers drawing CAT. BA/Marine motors GB 98-05

Standards

IEC 34-series, 72, 79 and 85

Size

90L

Type

M2AA 90L

Weight

16 kg

Poles

Insulation class

Bearings

D-end 6305-2Z/C3, N-end 62042Z/C3

Method of cooling

IC 411 (IEC 34-6)

Specification

Totaly enclosed three-phase motor

for marine service3)

142

Type of mounting
IEC 34-7

Degree of protection
IEC 34-5

IM 1001

IM 3001
IP 55
IM 3011

IM 3031

5 Technical Reference

5.8 Drawings

Article No. Output Speed Freq. Voltage

Hz
kW
RPM
V
552807-01
2,2
2870
50
220D
552807-01

552807-01

2,5

2,2

3460

3435

60

60

Current
A
8,1

Power
Ist / |(1 Termist.
C(2
factor Cos. j
0,87
6,6

380Y
220D

4,7
8,0

0,90

5,9

255D

8,1

0,87

6,8

440Y
220D

4,7
8,0

0,90

5,9

255D

8,1

0,87

6,8

Note

552807-02
552807-03
552807-04
552807-05

2,2
2,2
2,2
2,5

2870
2870
2870
3460

50
50
50
60

440Y
415Y
440 Y
200Y
240Y

4,7
4,3
4,1
8,9
4,7

0,87
0,87
0,87
0,87

6,6
6,6
6,6
6,8

Y-ser.

552807-06

2,5

3460

60

220Y
460Y

9,4
4,5

0,87

6,8

Y-par.
Y-ser.

552807-07
552807-09
552807-10
552807-11
552807-12
552807-13
552807-14
552807-15
552807-16
552807-17
552807-18
552807-19
552807-20
552807-21

2,5
2,2
2,2
2,2
2,2
2,2
2,5
2,5
2,5
2,5
2,5
2,5
2,5
2,5

3460
2870
2870
2870
2870
2870
3460
3460
3460
3460
3460
3460
3460
3460

60
50
50
50
50
50
60
60
60
60
60
60
60
60

230Y
575Y
400Y
230D
500Y
660Y
690Y
440Y
460Y
480Y
690Y
230D
220D
200D
380Y

9,0
3,6
4,5
7,8
3,6
2,7
2,6
4,7
4,5
4,3
3,0
9,0
9,4
10,3
5,4

0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87
0,87

6,8
6,6
6,6
6,6
6,6
6,6
6,8
6,8
6,8
6,8
6,8
6,8
6,8
6,8

1)

lst /l=starting current /rated current at direction on line starting.

2)

Thermistors tripping temperature if applicable.

3)

The motors can be designed to fulfil requirements of following

Classification Societies (Essential Service, if required).

Y-par.
CSA-plated

Lloyds Register of Shipping (LRS)

Nippon Kaiyi Kyokai (NK)

Det Norske Veritas (DnV)

Korean Register of Shipping (KR)

Germanischer Lloyd (GL)

Polski Rejester Statkow (PRS)

Bureau Veritas (BV)

China Classification Societies (CCS)

American Bureau of Shipping (ABS)

Indian Register of Shipping (IRS)

Registro Italiano Navale (RINA)

Maritime Register of shipping (RMS)

Required classification society must always be specified when ordering.

Factory test certificate to be enclosed at the delivery.
Rated output (kW) valid for temp-rise max. 90 C.
The motors can be provided with space heaters for 110 V or 220 V, 25 W as option.
State supply voltage when ordering.
Connection to separate terminal board in the main terminal box acc. to attached connection diagram.

143

5.8 Drawings

5 Technical Reference

G0635141

5.8.4 Machine plates and safety

labels

Location of machine plates and safety lables

Separator

P 605

Manufacturing serial No / Year

XXXX

Product No

881099-06-02/0

Inlet and outlet

561312-01

Bowl

561123-01

Machine bottom part

565390-01

Max. speed (bowl)

9512 r/min (50 Hz), 9307 r/min (60 Hz)

Direction of rotation (bowl)

Speed motor shaft

3000 r/min (50 Hz), 3600 r/min (60 Hz)

El. current frequency

50/60 Hz

Recommended motor power

2,2 kW (50 Hz), 2,2 kW (60 Hz)

Max. density of feed

1100 kg/m3

Max. density of sediment

2631 kg/m3

Process temperature min./max. 0/+100 C

144

S0061411

1. Machine plate

5 Technical Reference

5.8 Drawings

3. Safety label

! WA R N I N G

WARNING
Read the instruction manuals before
installation, operation and maintenance.
Consider inspection intervals.

XXXXXXXXXXXXXXXXX
XXXX XXXX XXXX
XXXXXXXXXXXX XXX
XXXXXXX XXXXX XX
XXXXX XXXXXXX
XXXXXXXXX.

XXX XXX X XXX XX XXXX

XXXX XX X X XXXXX XXX
X XXX XXXX XXX XX XX X
X XXX X XXX.

XX X XXXXX XX X XXXX
XXX XXX X XXXXXX
XXX XXX XXX X XXXXX
XXX X XXXX .

XXXXX XXX XXXX XXX

XXXXX XXXX X XXXX XXX XXXXX X XXXXX XX X
XXX XX XXX XXX XX X.
XX.
XXXXXXX/XX,X XX

S0 0 6 9 0 N 1

Text on label:

Failure to strictly follow instructions can lead

to fatal injury.
If excessive vibration occurs, stop separator
and keep bowl filled with liquid during
rundown.
Out of balance vibration will become worse if
bowl is not full.
Separator must stop rotating before any
dismantling work is started.

S0 0 6 3 2 1 1

4. Name plate

S0 0 6 3 1 1 1

6. Power supply frequency

7. Label
Text on label:

S0 0 6 9 1 1 1

Read the instruction manual before lifting.

A. Space for label indicating

representative

145

5.8 Drawings

5 Technical Reference

5.8.5 Operating water interface

(Purifier)
Alfa Laval ref. 565819, rev. 0

Proposed operation of operating water interface for purifier execution.

Closing the bowl and supplying liquid seal:

Initialise by opening connection 372 for 1 second.

Close the bowl by opening connection 373 for 40 seconds.

Supply liquid seal by opening connection 206 for 12 seconds.

Open the feed (connection 201).

G0931751

Starting sequence illustrated graphically:

Performing a discharge:

Close the feed (connection 201).

Open connection 373 and perform a displacement (of the interface) by opening
connection 206.

After 8 seconds open connection 372 during 1 second.

After another 12 seconds close connections 206 and 373.

Open the feed (connection 201).

G0931761

Discharge sequence illustrated graphically:

During the separating process the make-up

water supply volume is maintained by opening
connection 373 for 2 seconds every 15 minutes.

146

5 Technical Reference

5.8 Drawings

5.8.6 Operating water interface

(Clarifier)
Alfa Laval ref. 565849, rev. 0

Proposed operation of operating water interface

for clarifier execution.
Closing the bowl:

Initialise by opening connection 372 for 1

second.

Close the bowl by opening connection 373

for 40 seconds.

Open the feed (connection 201).

G0931771

Starting sequence illustrated graphically:

Performing a discharge:

Close the feed (connection 201).

Open connection 373.

After 12 seconds open connection 372

during 1 second.

After another 15 seconds close connection

373.

Open the feed (connection 201).

G0931781

Discharge sequence illustrated graphically:

During the separating process the make-up

water supply volume is maintained by opening
connection 373 for 2 seconds every 15 minutes.

147

5.8 Drawings

5 Technical Reference

5.8.7 Performance data,

in- and outlet device
Alfa Laval ref. 565805, rev. 0

G0931721

Maximum light phase counter pressure as a

function of throughput and viscosity:

A.
B.

Max. light phase counter pressure, kPa

Light phase throughput, m3/h

10 cSt

30 cSt
48 cSt

148

5 Technical Reference

5.8 Drawings

G0931731

Inlet pressure as a function of throughput

and viscosity

A.
B.

Pressure kPa
Throughput m3/h

149

5.8 Drawings

5 Technical Reference

G0931741

Maximum heavy capacity as a function of

gravity disc:

A.
B.

litres/hour
Gravity disc

5.8.8 Interconnection diagram

1
2

Reset Coil

NO

Common

NC

6
7
8

Heater

G0931791

Alfa Laval ref. 561723, rev. 0

Vibration sensor (mechanical switch)

150

5 Technical Reference

5.9 Storage and installation

5.9 Storage and

installation
5.9.1 Introduction
These installation specifications are valid
for the S 300 separator.
The installation instructions are specifications,
which are compulsory requirements.
Any specific requirements from classification
societies or other local authorities must be
followed.
NOTE
If the specifications are not followed, Alfa Laval can
not be held responsible for any malfunctions related
to the installation.

151

5.10 Protection and storage of goods

5 Technical Reference

5.10 Protection and

storage of goods
a The separator must be stored indoors at 5 55 C, if not delivered in a water-resistant
box, designated for outdoor storage.

The following protection products are

recommended:

c If the storage time exceeds 12 months, the

equipment must be inspected every 6
months and, if necessary, the protection be
renewed.

G0873611

1 Anti-rust oil (Dinitrol 112 or equivalent) with long

lasting effective treatment for external surfaces.
The oil should prevent corrosion attacks and
leaves a waxy surface.
2 Anti-rust oil (Dinitrol 40 or equivalent) is a thin
lubricant for inside protection. It gives a
lubricating transparent oil film.
3 Solvent, e.g. white spirit, to remove the anti-rust
oil after the storage period.
4 Moist remover to be packed together with the
separator equipment.

b If there is a risk for water condensation, the

equipment must stand well ventilated and at
a temperature above dew point.

152

5 Technical Reference

5.10 Protection and storage of goods

5.10.1Storage at out of operation

If the separator is out of operation for more
than 1 month:

Lift out the bowl.

Protect the spindle taper from corrosion by

lubricating it with oil.

Keep the separator and bowl well stored, dry

and protected from mechanical damage.

For details see 5.10 Protection and storage of

goods, page 152

5.10.2 Before start-up

If the separator has been out of operation for:
1 months or longer

Pre-lubricate the spindle bearings.

6 months or longer

Perform an Inspection service i i and make

sure to pre-lubricate the spindle bearings.

Change the oil before starting.

Perform an Overhaul service o and make

sure to pre-lubricate the spindle bearings.

Change the oil before starting.

G0464881

18 months or longer

153

5.10 Protection and storage of goods

5 Technical Reference

5.10.3 Connections to surrounding

equipment

If the local safety regulations prescribe that the

installation has to be inspected and approved by
responsible authorities before the plant is put
into service, consult with such authorities before
installing the equipment and have the projected
plant design approved by them.

G0873911

Local safety regulations

Service media

G0874021

Ensure that all service media (electric power,

operating and safety liquids etc.) required for the
separator have the correct quality and capacity.

Sludge discharge tank

If the sediment from the separator is discharged

into a tank, this tank must be sufficiently
ventilated. The connection between the
separator and the tank must be of the size and
configuration specified.

G0874311

If the solids are discharged from the separator

bowl casing into a closed system, ensure that
this system cannot be overfilled or closed in such
a way that the solids cannot leave the bowl
casing. This could cause a hazardous situation.

154

5 Technical Reference

5.10 Protection and storage of goods

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 not be treated with anti-rust
oil.

5.10.4 Reassembly and Start up

Clean away the anti-rust oil with white spirit.

Remove the silica gel bags from all units.

Follow all relevant instructions in the Service

Manual and Operating Instructions.

5.10.5 Storage and transport of

goods

Storage

Specification
Upon arrival to the store, check all
components and keep them:

Well stored and protected from mechanical

damage.

Dry an protected from rain and humidity.

Organized in the store in such a way that the

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

155

5.10 Protection and storage of goods

5 Technical Reference

A separator can be delivered with different

types of protection:

Fixed on a pallet.

G0057111

The separator must be stored in a dry storage

room, protected from rain and humidity. It
must be well protected from mechanical
damage.

Fixed on a pallet

In a wooden box which is not water tight.

G0057211

The separator must be stored in a dry storage

room, protected from rain and humidity.

In a wooden box which is not water tight

In a special water-resistant box for outdoor

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

G0057311

The packaging for outdoor storage is only to

special order.

In a special water-resistant box for outdoor storage

156

5 Technical Reference

5.10 Protection and storage of goods

Transport

Specification
During transport of the separator, the bowl
must always be removed from the machine
and transported separately.

When lifting a separator it must always be

hung securely. See details in chapter 3.6
Lifting instructions, page 52.

ING
WARN

Crush hazard
Use correct lifting tools and follow lifting
instructions.

During erection, all inlets and outlets to

separators and accessories must be
covered to be protected from dust and dirt.
G0057581

H = minimum 750 mm

157

5.10 Protection and storage of goods

5 Technical Reference

5.10.6Planning of installation

Introduction

G0020611

The space required for one or more separators

can be calculated by consulting 5.4 Basic size
drawing, page 122, and instructions for
ancillary equipment, electrical and electronic
equipment and cables.

Check the drawings when planning the installation

Important measurements

Plan your installation with sufficient room for

the controls and operation so that instruments
are easily visible. Valves and controls must be
within convenient reach. Pay attention to space
requirements for maintenance work, work
benches, dismantled machine parts or for a
service trolley.

Space for separator

The separator shall be placed in such a way

that suitable space for maintenance and repair
is obtained.
Specification
See the 5.8.1 Foundation plan, page 140 for the
service space required with the separator
installed.
Recommendation
The spanner for the bowl hood should have
sufficient space to make a complete turn
without touching any of the ancillary
equipment surrounding the separator.

158

G0020721

Important measurements are the minimum

lifting height for lifting tackle, shortest
distance between driving motor and wall, free
passage for dismantling and assembly,
maintenance and operation.

Suitable space must be obtained for the maintenance

work

5 Technical Reference

5.10 Protection and storage of goods

Lifting height for transport of bowl

Specification
A minimum height is required to lift the bowl,
bowl parts and the bowl spindle, see the
drawing 5.8.1 Foundation plan, page 140.
Recommendation
When two or more separators are installed, the
lifting height may have to be increased to
enable parts from one separator to be lifted and
moved over an adjoining assembled separator.

Space for oil changing

Specification
The oil filling device must not be blocked by
floor plate arrangement, etc.
Recommendation
It should be possible to place a portable
collecting tray under the oil filling device drain
hole.

159

5.10 Protection and storage of goods

5.10.7Foundations
NOTE
When lifting a separator it must always be hung
securely. see separate lifting instructions in this
book.

See 5.8.1 Foundation plan, page 140.

The separator must be installed on a strong

and rigid foundation to reduce the influence
of vibrations from adjacent machinery.

The foundation should be provided with a

cofferdam.

Fit the separator frame on the foundation as

follows:
Check that the bolts do not press against
the edges of the holes, otherwise the
elasticity of the mounting of the separator
frame will be impeded.
Fit height adjusting washers required.
Check that the separator frame is
horizontal and that all feet rest on the
foundation.
Tighten the screws.

160

5 Technical Reference

SEPARATOR MANUAL

6 OPERATING

6 Operating
Contents
6.1 Operating routine

162

6.2 Before first Start

162

6.2.1

Selection of gravity disc

6.3 Start after a service

163
164

6.3.1

Before normal start

6.3.2

Starting and running-up procedure 167

6.3.3

Separation

168

6.3.4

Stopping procedure

169

6.3.5

Safety stop

170

6.4 After Safety Stop

164

171

577460-02

161

6.1 Operating routine

6 Operating

6.1 Operating routine

These operating instructions describe routine
procedures to follow before and during the
start, running and stopping sequences of the
separator.
If system documentation is available always
follow the operating instructions of this. If
there is no system documentation the
instructions below are to be followed.

6.2 Before first Start

Technical demands for connections and logical
limitations for separator are listed in chapter
Technical Reference on page 117.

Ensure that the separator is correctly installed and

that feed lines and drains have been flushed clean.

ING
WARN

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

ING
WARN

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

ING
WARN

P003595B

Breakdown hazard
Check that the power frequency is in agreement with the
machine plate. If incorrect, resulting overspeed may cause
breakdown.

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

162

50 Hz?
60 Hz?

P003992A

ING
WARN

6 Operating

Check the oil sump level.Top up if necessary.

The oil level should be slightly above middle

of the sight glass.

6.2 Before first Start

NOTE

G0868543

Too much or too little oil can damage the separator

bearings.

6.2.1 Selection of gravity disc

The separator is delivered with a set of gravity
discs with different diameters for purification
operation. The hole diameter of the gravity disc
sets the position of the oil/water interface in the
separator, see page 21. The separation
efficiency can be optimized by selection of the
correct diameter for each oil quality.
As a guide the 5.8.2 Gravity disc nomogram,
page 141 can be used. The size of the first
gravity disc to be tried can be read directly
from the nomogram.
The best separation results are obtained by
using a gravity disc with as large size as
possible, which will not cause a broken water
seal in the bowl or an emulsification in the
water outlet.
The presence of salt water in the oil may
demand the use of a gravity disc with bigger
hole than indicated in the nomogram. The
nomogram is based on the properties of fresh
water in the oil.
For operating the separator as a clarifier the
diameter of the disc should be 40 mm.

163

6.3 Start after a service

6 Operating

6.3 Start after a service

Pay special attention to unusual conditions
when starting the separator after a service.

6.3.1 Before normal start

Check these points before every start.
1. Make sure that the bowl is clean and that
the separator is properly assembled.

G0465431

2. Make sure that the bolts of the outlet cover

and the frame hood are fully tightened.

Check assembly and tightenings

3. Make sure that all couplings and

connections are securely tightened to
prevent leakage.
N
CAUTIO
S0009821

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

4. Make sure that the inlet pipe is tightened.

164

Check for leakages (not admitted)

6 Operating

6.3 Start after a service

5. Read the oil level. The line in the middle of

the sight glass shows the minimum level.
Refill if necessary.

S0009411

For grade and quality of oil see 5.7

Lubricants, page 133.

Check the oil level

Rotation Direction

Check the rotation of the bowl by doing a quick

start/stop. The motor fan must rotate in a clockwise
direction.

ON
CAUTI

P0 0 3 5 9 6 B

If power cable polarity has been reversed, the

separator will rotate in reverse, and vital rotating
parts can loosen.

ING
WARN

Disintegration hazards
After change of feed the sludge discharge interval
must be adjusted.
Too long intervals between discharges can result in
breakdown.

165

6.3 Start after a service

6 Operating

ON
CAUTI

Avoid contact with hot surfaces. Process pipes,

various machine surfaces, and processed liquid can
be hot and cause burns.

166

P004073C

Burn hazard

6 Operating

6.3 Start after a service

6.3.2 Starting and running-up

procedure

4
3

1. Open the water supply valve(s). Make sure

that the water supply is on 150-600 kPa
(1,5-6 bar).

6
7
8

1
10

S0009121

2. Start the separator.

Water supply

3. Be alert for unusual noises and conditions.

4. Note the normal occurrence of critical
speed periods. Some vibrations occur for
short periods during the starting cycle,
when the separator passes through its
critical speeds. This is normal and passes
over without danger. Try to learn the
vibration characteristics of the critical
speed pattern.

ING
WARN

Disintegration hazards
When excessive vibration occurs, keep bowl filled
and stop separator.
The cause of the vibration must be identified and
rectified before the separator is restarted.
Excessive vibration may be due to incorrect
assembly or insufficient cleaning of the bowl.

167

6.3 Start after a service

6 Operating

5. Check the current to the separator motor to

ensure that the separator has reached full
speed:
During start, the current reaches a peak and
then slowly drops to a low and stable value.
S0009621

For normal length of the start-up period see

5.2 Technical data, page 119.
Current increases during start...

6. For purification:
a. Supply water to form the water-seal.
The water should have the same
temperature as the process liquid.

c.

Start the oil feed slowly to avoid

breaking the water seal.

7. For clarification:
a. Start the oil feed with full flow.
8. For both purification and clarification
modes:
Check the separator inlet and outlet
pressures. See recommended values in your
system documentation.
9. Adjust to desired throughput.

6.3.3 Separation
Do regular checks on:

oil inlet temperature (if applicable)

water collecting tank level (if applicable)

sound/vibration of the separator

back pressure

motor current.

168

S0009631

b. Close the water feed when water flows

out through the water outlet.
... to decrease to a stable value when full speed has
been reached

6 Operating

6.3 Start after a service

6.3.4 Stopping procedure

1. Turn off the oil feed.
2. Feed displacement water until water flows
out through the water outlet. Then close
this feed.
3. Stop the separator.
4.

Wait until the separator has come to a

complete standstill.
Remove the safety device and look through
the slot in the frame hood to see the
movement of the bowl.

Separator standstill

Dismantling work must not be started before all

rotating parts have come to a complete
standstill.

R
DANGE
Entrapment hazard

I0 0 2 9 3 C B

Make sure that rotating parts have come to a

complete standstill before starting any dismantling
work.

169

6.3 Start after a service

6 Operating

6.3.5 Safety stop

If the separator begins to vibrate excessively
during operation, stop it immediately by
pushing the safety stop. The separator motor
is switched off.
Keep the bowl filled during the run-down
to minimize the excessive vibration.
Evacuate the room. The separator may be
hazardous when passing its critical speeds
during the run-down.

S0055611

Hazard!

ING
WARN

Disintegration hazards

S0009911

Never discharge a vibrating separator.

Push the safety stop!

170

6 Operating

6.4 After Safety Stop

6.4 After Safety Stop

Separator standstill

Dismantling work must not be started before all

rotating parts have come to a complete
standstill.

R
DANGE
Entrapment hazard
I00293CB

Make sure that rotating parts have come to a

complete standstill before starting any dismantling
work.

Avoid accidental start

ING
WARN

Entrapment hazard
To avoid accidental start, switch off and lock power
supply before starting any dismantling work.
Make sure that separator has come to a complete
standstill before starting any dismantling work

Remedy the cause

The cause of the emergency must be remedied

before attempting to restart the separator.
If the cause is not found, an overhaul must be
performed on the separator, and all moving parts
thoroughly checked

ING
WARN

Disintegration hazard
Do not start the separator after an emergency stop
without first remedying the cause of the emergency.
Make sure that the bowl is clean before restart.

171

6.4 After Safety Stop

6 Operating

Separator reassembled

The separator must be fully reassembled with all

covers and guards in place and tightened before
unlocking the power supply and starting the
system.

ING
WARN

Breakdown hazard

P0 0 3 5 9 5 B

Assemble the separator completely before restart. All

couplings, covers, and guards must be in place and
properly tightened. Non compliance may lead to
breakdown.

172