PA Purifier System

Operating Instructions
Printed Jun 2008
Book No. 1810896-02 V 6
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2008.
Contents

1 Operating................................................... 3
1.1 Before Startup ...................................3
1.2 Operator Panel ..................................6
1.3 Startup .................................................7
1.4 During operation .............................10
1.5 Stop.....................................................13
1.6 Emergency Stop .............................15
1.7 After Emergency Stop ..................15
1.8 Intervals Between
Sludge Discharges
(Valid for P 625/635 only) ............17
1.8.1 Background ..........................................17
1.8.2 Recommended intervals between
sludge discharges................................17
1.8.3 Fuel oil cleaning ...................................18
1.8.4 Lubricating oil cleaning ........................18
1.8.5 Bowl inspection ....................................20

1810896-02
 PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

2 1810896-02
PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1 Operating
1.1 Before Startup
The correct gravity disc must be installed in the
separator. See chapter 4.3.3 Selection of gravity
disc in the Separator Manual.

1 Check that the separator is correctly

assembled and connected to power supply of
correct voltage and frequency.

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
!

X0 23 71 4B
Electrical hazard
Follow local regulations for electrical installation and
earthing (grounding).

ING
WARN
!
50 Hz?
60 Hz?
Breakdown hazard
Check that the power frequency is in agreement with
P00 3 99 2A

the machine plate. If incorrect, resulting overspeed

may cause breakdown.

ING
WARN
!

Use the separation system for the purpose, and

within the limits, specified by Alfa Laval. Failure to do
so could cause a violent breakdown.

1810896-02 3
1 OPERATING PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

2 Check the oil sump level and top up if

necessary.

• For P 600, P 605, P 610, and P 615:

The oil level should be slightly above middle
of the sight glass.

NOTE

Too much or too little oil can damage the separator

bearings.

G 08 68 5 43 A
• For P 625/P 635:
Remove the oil pin and make sure that the oil
level is above the lower end of the pin.

G 0 86 8 7K 1

4 1810896-02
PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

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
!

If power cable polarity has been reversed, the

separator will rotate in reverse, and vital rotating

X0 23 71 9B
parts can loosen.

Air Valve Block (PA 600, 610)

Use the pressure gauge situated in the air valve

block to check that the air supply is correct.
See the Installation System Reference booklet.

P0 03 68 3 A

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1 OPERATING PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

1.2 Operator Panel

General principle
The ‘Enter’ button is used to:
– enter into a parameter list
– enter into a parameter
– accept/store a new parameter value.
The ‘+’ or the ‘–’ buttons are used to change the
value flashing in the display window.

Process parameters
Set the process parameters to suit the OP
installation as follows: TT PT PT
HEATER

1 Push ‘Enter’. Parameter no. 1 in the process 16 15 10 SEPARATION

parameter list is displayed. STOP

EPC-50
You have now come to the process parameter DISCHARGE
INFO
list. Go through the list and set parameters. Standst. OP ACTIVE

ENTER

2 When the parameters have been set, ‘End I/O’

P 00 42 16 B
ALARM

(flashing) shows. Push ‘+’. ‘Standst.’ is now

displayed.

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PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.3 Startup
Before startup make sure that all the main
supply valves for air, oil, and water are open.
Open heating media supply valve if applicable.
Switch on the power supplies. Make sure the
control selection switch is in the manual
position.

1 Start the oil feed pump.

G 04 66 02 B
2 If necessary, vent air from the heater through
the relief valve (if applicable). OP
Switch on the heater. (if applicable).
TT PT PT
HEATER

16 15 10 SEPARATION

STOP
EPC-50

DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM

P0 04 2 17 B
3 Press the process start/stop button
OP

TT PT PT
HEATER

16 15 10 SEPARATION

STOP
EPC-50

DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM
P 00 42 18 B

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1 OPERATING PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

4 Start the separator.

G 0 4 66 03 B
5 Listen and observe.
Vibration may occur during start up, when
passing critical speeds.This is normal and
should pass without danger.
If vibration increases, or continues at full

P00 39 9 2A
speed, press the emergency stop button and
stand clear until the vibration stops.
The cause of vibration must be determined
and corrected before starting again!
See the Alarms and Fault Finding booklet.

ING
WARN
!

Breakdown hazard
Always observe the separator during start-up after
assembly. If strong vibration occurs, stop by using
the Emergency Stop button and evacuate the room.

NOTE

If the system is equipped with a vibration sensor, and

has control of heater and feed pump, the Auto Start
can be used.

8 1810896-02
PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

6 Ensure that the separator is at full speed (see

ammeter on starter). ‘Start.’ is shown on the OP
display.
TT PT PT
HEATER

16 15 10 SEPARATION

STOP
EPC-50

DISCHARGE
INFO

OP A CTIVE

ENTER

7 Check the oil feed temperature by pressing ALARM

the ‘+’ button twice.

8 Wait until the oil feed temperature is correct:

Heavy fuel mode 98 °C

P0 0 42 19 B
Lube oil mode 95 °C (trunk engines), or 90 °C
(cross-head engines)
Diesel oil mode 40 °C

9 When ‘Standby’ is shown on the display, and

the oil is at the correct temperature, press the OP
process start/stop button on the operator
TT PT PT

panel to start the separation process. HEATER

16 15 10 SEPARATION

STOP
EPC-50

DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM

P 00 42 18 B

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1 OPERATING PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

1.4 During operation

Operator panel information

Observe the operator panel information:

• Heater operation LED lit (green)
• Separator system operation LED lit (green)
• Activated valve LED lit (green)

During normal operation, the time to next sludge

discharge is shown on the right hand side of the
display.
Any alarm is indicated on the display. For
further information see the Alarms and Fault
Finding booklet.

NOTE

Regularly check connections. Tighten if necessary.

10 1810896-02
PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

NOTE OP
The values displayed in the examples below are not TT PT PT
HEATER
recommendations.
16 15 10 SEPARATION

STOP

More operational information may be read as EPC-50

DISCHARGE
INFO
required, by pressing the ‘+’ button repeatedly. OP A CTIVE

ENTER

ALARM

To return to normal display, i.e. the trigger

value, and time to next sludge discharge,

P0 0 42 21 B
continue pressing the ‘+’ button.

1 Oil feed temperature. For the correct

P 00 36 1R A
separation temperature see the Installation
System Reference booklet.
TT1 98 °C
2 Oil pressure, oil inlet

P00 36 1 Q A
PT1 1.4
3 Oil pressure, oil outlet

P00 3 61 PA
PT4 1.4

4 Accumulated operating time in hours P0 03 6 25 A

Run time 5 hours

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1 OPERATING PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

ING
WARN
!

Noise hazard
Use ear protection if noise levels are high.

ING
WARN
!

Breakdown hazard
Never reset an alarm without first finding and
remedying the cause.

ON
CAUTI
!

X 02 37 16 A
Burn hazard
Avoid contact with hot surfaces. Process pipes,
various machine surfaces, and processed liquid
can be hot and cause burns.

ON
CAUTI
!

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

ING
WARN
!

Burn hazard
To prevent hot water, oil or steam from splashing,
make sure that the inspection plug on the
X0 24 47 1 A

discharge pipe is in place.

Use safety goggles when removing the plug.

NOTE

Make sure that the hose clamps are fully tightened.

12 1810896-02
PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.5 Stop

To stop the system:

1 Stop the system by pushing the process start/

stop button button on the operator panel.
OP
A sludge discharge is initiated. TT PT PT
HEATER

The yellow LED for separator stop sequence 16 15 10 SEPARATION

starts to flash. EPC-50

STOP

DISCHARGE

The stop sequence LED changes to steady INFO

OP A CTIVE
yellow, and the green LED for separation ENTER

system operation goes out, when the sludge ALARM

discharge is completed.

P0 04 21 CB
2 If an external heater is used, stop the heater
on the operator panel. OP

Close the heating medium supply and outlet TT PT PT

HEATER

valves (if applicable). 16 15 10 SEPARATION

STOP
EPC-50

DISCHARGE
INFO

OP A CTIVE

ENTER

ALARM

P0 04 2 17 B
3 Wait until the oil feed temperature starts to
drop. Read the temperature by pressing the
‘+’ button.

4 When the oil feed temperature has started to

drop, the feed pump will be stopped
automatically if controlled from the control unit.
If the pump starter is independently
controlled, stop manually.

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1 OPERATING PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

5 When the separator motor has stopped, apply

the brake, if any.

G 02 4 63 1A
6 Wait until the separator has come to a
complete standstill (after about 20 minutes).

ON
CAUTI
!

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

ON
CAUTI
!

Never attempt to clean the bowl by manual discharge

in connection with stop.

7 Release the brake, if any.

G 02 46 3 2A

14 1810896-02
PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.6 Emergency Stop

If an emergency situation occurs, press the

emergency stop button and evacuate the room.
Do not return until the separator has come to a
complete standstill.

G 04 6 60 8B
ING
WARN
!

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

1.7 After Emergency Stop

Separator standstill

Dismantling work must not be started before all

rotating parts have come to a complete
standstill.

R
! DANGE

Entrapment hazard

I 00 2 93 CD
Make sure that rotating parts have come to a
complete standstill before starting any dismantling
work.

1810896-02 15
1 OPERATING PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

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

See the Alarms and Fault Finding booklet for

emergency procedures.
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.

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
X0 2 37 14 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.

16 1810896-02
PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

1.8 Intervals Between

Sludge Discharges
(Valid for P 625/635
only)

1.8.1 Background

ING
WARN
!

Disintegration hazard
Experience has shown that if intervals between
sludge discharges are too long, a compact and hard
sludge cake can accumulate. On discharge, this cake
may break up and be discharged unevenly causing
imbalance in the bowl. If imbalance is excessive,
there is risk for serious mechanical damage and
injury to personnel.

Recommendations are given regarding initial

intervals between sludge discharges for different
applications. The setting may subsequently have
to be changed after actual inspection of the bowl.

1.8.2 Recommended intervals

between sludge discharges
Many factors influence accumulation and
hardening of sludge between the discharges, so
the appropriate interval depends on local
conditions. However, in order to have a
reasonable starting point the following table
shows recommended initial discharge intervals
and operating times to first inspection.

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1 OPERATING PA PURIFIER SYSTEM OPERATING INSTRUCTIONS

1.8.3 Fuel oil cleaning

Type of fuel Recommendations
Initial intervals between discharges Time to first bowl inspection
Distillate (1.5 – 6 cSt/40 °C) 4 hours 1 week
Marine Diesel Oil (max. 14cSt/40 °C) 2 hours 1 week
Heavy Fuel Oil ( Max interval ) 1 hour ( 2 hours ) 2 days

Conditions may change completely when

bunkers are changed. Therefore, great care must
be given to the discharge interval setting for
each new bunker. In case the actually used
discharge interval exceeds the recommended
initial value, the interval setting has to be
reduced, according to the table above, when a
new, unfamiliar bunker is separated. Use of
unstable fuel or mixing of incompatible fuel oils
may give precipitation of sludge and overloading
of the separator.

1.8.4 Lubricating oil cleaning

Continuous operation:
In a new lubricating oil system the oil is initially
clean but as it gets dirtier the interval between
discharges will have to be shortened until a
“steady state” is reached. Following information
refers to systems in “steady state”.

Type of fuel Recommended intervals for Crosshead and Trunk

Initial intervals between Time to first bowl inspection
Main lubricating oil system 1 - 2 hours 1 week

If separator has been out of operation:

If the separator has been out of service for 24
hours or longer, while the engine has been
running, the interval between discharges has to
be shortened. In this case the recommendation
is:
• Discharge interval 5 minutes until the whole oil
volume has passed twice through the
separator.
• After that resume normal discharge interval.

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PA PURIFIER SYSTEM OPERATING INSTRUCTIONS 1 OPERATING

Intermittent operation:
For installations where one separator serves one
engine which is temporarily stopped the
following recommendations apply: If the engine
is to be stopped for 24 hours or less:
• Keep the separator in operation for 8 hours
after the engine is stopped.
• Start the separator 8 hours before the engine
is started again.
Doing so most of the suspended particles and
water condensate will be removed from the
system and not settle in the sump tank. For
installations where one separator serves more
than one engine the following recommendations
apply:
• Continuous use of the separator whenever
possible.
• Frequent switches between the engine
systems to be cleaned. In a typical case with
one separator serving 2–4 auxiliary engines
switching after maximum 24 hours of cleaning.

Discharge interval:
Engine has been in operation Engine has not been in operation
with-out cleaning of the system oil since last cleaning of system oil
Discharge interval 5 min. Normal discharge interval
Duration until the whole oil volume has passed
twice through the separator
After that resume to normal discharge interval

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1.8.5 Bowl inspection

To check if the initially selected interval is
appropriate, the bowl should be inspected after a
short test period shown in the previous tables.
If sludge space is clean:
Interval may be prolonged with steps of 15
minutes, but it must not exceed three times the
recommended initial interval.
“Sludge space is clean” means that no noticeable
amount of hard sludge remains in the sludge
space.
If sludge space is dirty:
Interval has to be shortened.
When the bowl is opened for routine cleaning,
the sludge space should always be inspected and
evaluated. If necessary, the interval between
discharges should then be changed accordingly.

NOTE

Alfa Laval assumes no responsibility for the actual

choice of discharge intervals, as these entirely
depend on local conditions.

20 1810896-02