Separator Sizes S 851 - S 967

Flex Separation System

Installation System Reference

Printed 11-2011
Book No. 585689–02, rev.6
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 11-2011

Original instructions
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 Technical Data 7
1.1 Demand Specifications Water 7
1.2 Demand Specifications Air 7
1.3 System Data 8

2 Mechanical Drawings 11
2.1 Flow Charts 12
2.1.1 S-separator, Basic and Optional Components 12

2.2 Mounting Drawings 13

2.2.1 S-separator, DIN Mounting Drawing 13
2.2.2 S-separator, JIS Mounting Drawing 14

2.3 Installation Drawings 15

2.3.1 S 851 - S 957 Separator Installation Drawing 15
2.3.2 S 861 - S 967 Separator Installation Drawing 16

2.4 Basic Size Drawings 17

2.4.1 S 851 - S 957 Separator Basic Size Drawing 17
2.4.2 S 861 - S 967 Separator Basic Size Drawing 18

2.5 Foundation Drawings 19

2.5.1 S 851 - S 957 Separator Foundation Drawing 19
2.5.2 S 861 - S 967 Separator Foundation Drawing 20

3
 2.6 Pipe Arrangement 21
2.7 Valve Block Oil Assembly Drawing 22
2.8 Valve Block Oil Assembly Drawing cont. 24
2.9 Valve Block Water Assembly Drawing 25
2.10 Air Distributer Kit 26
2.11 Control Cabinet Dimension Drawing 27
2.12 Control Cabinet Assembly Drawing,
External 28
2.13 Control Cabinet Assembly Drawing,
Internal 30
2.14 Change of EPC 60 Components 31

3 Electrical drawings 35
3.1 Electrical System Layout 36
3.2 Control and Starter Electrical Diagrams 37
3.2.1 Starter cable list 37
3.2.2 Separator Interconnection Diagram 40
3.2.3 Steam Regulating Valve (optional) Interconnection
Diagram 43
3.2.4 Speed Transmitter (optional) Interconnection
Diagram 44
3.2.5 Vibration Transmitter (optional) Interconnection
Diagram 45
3.2.6 Electric Heater (optional) Interconnection Diagram 46
3.2.7 I/O (optional) Interconnection Diagram 47
3.2.8 Heat Tracing (optional) Interconnection Diagram 49
3.2.9 Emergency Shutdown Interconnection Diagram 50
3.2.10 Circuit Diagram 51
3.2.11 Steam Regulating Valve (optional) Circuit Diagram 59
3.2.12 Speed Transmitter (optional) Circuit Diagram 60
3.2.13 Vibration Transmitter (optional) Circuit Diagram 61
3.2.14 Electric Heater (optional) Circuit Diagram 62
3.2.15 I/O (optional) Circuit Diagram 63
3.2.16 Heat Tracing (optional) Circuit Diagram 65
3.2.17 Emergency Shutdown Circuit Diagram 67

4
4 Specifications 69
4.1 Cables 70
4.2 Cable Routing 71
4.3 Oil, Water, Steam, and Condensate
Piping 72
4.4 Ambient Temperature Limitation 72
4.5 Heat Tracing and Insulation of Fuel Oil,
Sludge, and Steam Pipes 73
4.6 More than one Oil Tank 73
4.7 Sludge Removal Kit (Optional
Equipment) 74
4.8 Sludge Tank 76
4.9 Sludge Piping 78

5 Commissioning and Initial Start 79

5.1 Completion Check List 79
5.2 Initial Start-up 80
5.2.1 Calculating Operating Pressure 83

6 Shut-down and Storage 85

6.1 Shut-down after Use 85
6.2 Protection and Storage 86
6.3 Reassembly and Start up 88

5
 1 Technical Data

1.1 Demand Specifications Water

Alfa Laval ref. 574487 Rev. 1

Poor quality of the operating water may with time cause erosion, corrosion and/or operating
problems. The water shall be treated to meet certain demands.

The following requirements are important:

1. Turbidity-free water, solids content <0,001% by volume.
Max. particle size 50 µm.
Deposits shall not be allowed to form in certain areas in the system.
2. 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.
3. Chloride content max. 100 ppm NaCl (equivalent to 60 mg Cl/l). Chloride ions contribute
to corrosion on surfaces in contact with the operating water. Corrosion is a process that is
accelerated by increased separating temperature, low pH, and high chloride ion concentration.
4. 6,5 < pH < 9
Bicarbonate content (HCO3) min. 70mg HCO3 per litre, which corresponds to 3,2 °dKH.
5. Pressure 200 – 800 kPa (2 – 8 bar).

NOTE

Alfa Laval accepts no liability for consequences

arising from unsatisfactorily purified operating water
supplied by the customer.

1.2 Demand Specifications Air

Specific requirements regarding the quality of air
1. Pressure 500 – 800 kPa (5 – 8 bar).
2. Free from oil, and solid particles larger than
0.01 mm.
3. Dry, with dew point min. 10 °C below ambient
temperature.

7
1.3 System Data 1 Technical Data

NOTE

Electrical interconnections must be made by qualified

electricians.
Mechanical interconnections must be made by
qualified mechanical technicians.

1.3 System Data

Application
Cleaning of fuel and lubricating oils
Min. density 820 kg/m3 at 15°C
Max. density 1010 Kg/m3 at 15°C
Max. viscosity 55 cSt at 100°C ( 700 cSt at 50°C)
Feed temperature 5°C to 100°C
Ambient temperature 5°C to 55°C
Feed capacity In accordance with the separator size capacity
table

Media inlet/outlet data at separator connections

Pressure
Oil inlet Max. 2 bar at separator inlet
Oil outlet Max. 2.5 bar
Sludge outlet from separator Without pressure
Sludge outlet from sludge pump Max. 5 bar at 6 bar air pressure
Separated water Max. 4 bar ( if not diverted into sludge outlet)
Temperature According to capacity table, depending on oil
viscosity ±2 °C Max. 100 °C

8
1 Technical Data 1.3 System Data

Sludge Removal kits (optional)

The systems can be equipped with their own
sludge tank for collecting the sludge discharge
from the separator.

Sludge Removal Kit tank volume: 29,5 Litres.

Auxiliary systems
Operating water
- Operating water flow SV 10: 5.5 l/m
SV 15: 11.0 l/m
SV 16: 2.8 l/m
For further details see “1.1 Demand Specifications
Water”.
Quality
Pressure 2 – 8 bar
Temperature 5 °C – 55 °C (unheated water)
Air
Quality Instrument air
Pressure 5 – 8 bar (an optional pressure reducer is
available for above 8 bar)
Consumption
Air operated valves 10 N l/h
Sludge pump (pneumatic) 1000 N l/h at max. 1l/s
For further details see “1.2 Demand Specifications
Air on page 7 ”.
Mechanical design part:
Oil and heating media piping
Design pressure Max. 6 bar (for steam / condensate Max. 9 bar)
Test pressure Max. 9 bar (for steam/condensate Max. 14 bar)
Design temperature 5 °C – 180 °C
Flange connections PN 16 DIN 2573/2633
Pipe data Material ; ASTM A 106 gr. B seamless schedule
40 thickness.
Sizes ; from ½” upto 4”
Auxiliary media - Operating water
Design pressure Max. 6 bar
Design temp. 5 °C – 55 °C
Auxiliary media - Air
Design pressure Max 10 bar
Material Nitrile rubber-steel braided hose or PTFE pipes
where possible.
Drip tray volume Max. 28 litres
Drip tray Material Steel sheet laser cut and welded parts
Drip tray Drain connection size 2 x 1” G (internally threaded)
Frame Baseplate Material Steel sheet laser cut and welded parts
Electrical design
Mains supply
Voltage 3x 230 /400V/ 440V / 480V / 575V / 690V ± 10 %

9
1.3 System Data 1 Technical Data

Auxiliary systems
Frequency 50 / 60 Hz
Separator el.motor In accordance with the separator size selected
and related data sheet
Separator el motor power range From 12 kW up to 21 kW
Feed Pump el. Motor In accordance with the pump size selected and
related data sheet
Feed Pump el motor power range from 3 kW up to 5.5 kW
EPC
Voltage 24 V DC (internal)
Control voltage, operating supply 24 V AC ( from internal transformer )
Frequency 50 or 60 Hz ± 5 %
Control cabinet
Enclosure class IP 55
Material Steel sheet
Ambient temp. Max 55 °C

Planned Maintenance Kits (not including wear items)

Hours Period Separa- Module Sludge Feed Control El. heater CBM
tor pump pump cabinet
1000
2000
4000 6 months Inspec-
tion
12000 18 Overhaul Overhaul
months
24000 3 years Overhaul Overhaul Overhaul Overhaul
As necessary CIP Repair Repair CIP
(compon-
ents)
With delivery Inspec-
tion Tools
Backup Support Support

NOTE

The lifespan of wear items, such as friction blocks and

main seal ring, depends on the number of startups, as
well as plant and feed conditions. Check wear items
regularly and change when necessary.

10
2 Mechanical Drawings

11
2.1 Flow Charts 2 Mechanical Drawings

2.1 Flow Charts

2.1.1 S-separator, Basic and Optional Components

Alfa Laval ref. 584767 Rev. 2

12 584767#2_00
2 Mechanical Drawings 2.2 Mounting Drawings

2.2 Mounting Drawings

2.2.1 S-separator, DIN Mounting Drawing

Alfa Laval ref. 584354 Rev. 5

584354#5_00 13
2.2 Mounting Drawings 2 Mechanical Drawings

2.2.2 S-separator, JIS Mounting Drawing

Alfa Laval ref. 584355 Rev. 5

584355#5_00

14
2 Mechanical Drawings 2.3 Installation Drawings

2.3 Installation Drawings

2.3.1 S 851 - S 957 Separator Installation Drawing

Alfa Laval ref. 585172 Rev. 3

585172#3_00 15
2.3 Installation Drawings 2 Mechanical Drawings

2.3.2 S 861 - S 967 Separator Installation Drawing

Alfa Laval ref. 585173 Rev. 3

585173#3_00

16
2 Mechanical Drawings 2.4 Basic Size Drawings

2.4 Basic Size Drawings

2.4.1 S 851 - S 957 Separator Basic Size Drawing

Alfa Laval ref. 562820 Rev. 3

562820 v3_00 17
2.4 Basic Size Drawings 2 Mechanical Drawings

2.4.2 S 861 - S 967 Separator Basic Size Drawing

Alfa Laval ref. 563510 Rev. 1

563510 v1_00

18
2 Mechanical Drawings 2.5 Foundation Drawings

2.5 Foundation Drawings

2.5.1 S 851 - S 957 Separator Foundation Drawing

Alfa Laval ref. 562822 Rev. 0

562822 v0_00 19
2.5 Foundation Drawings 2 Mechanical Drawings

2.5.2 S 861 - S 967 Separator Foundation Drawing

Alfa Laval ref. 563761 Rev. 1

563761 v1_00

20
2 Mechanical Drawings 2.6 Pipe Arrangement

2.6 Pipe Arrangement

Alfa Laval ref. 585382 Rev. 2

585382#2_00
21
2.7 Valve Block Oil Assembly Drawing 2 Mechanical Drawings

2.7 Valve Block Oil Assembly Drawing

Alfa Laval ref. 583476 Rev. 2

Alt. S 831- S 987

Flexible hose kit

Valid only with Flow
Regulating System Alt. S 805 - S 927

Regulating valve
Throttle
washer
block
Alt. P 605, P 615
Flow control valve P 625/623, P 635/636

Throttle
See 583403 washer
Nipple Rectangular
ring
Coppar
washer Pressure
transmitter block
(Option)

Connection
S 805,
flange
S 815
Coupling nut
Nipple Rectangular
ring

S-separator

P-separator

G091041A

22
2 Mechanical Drawings 2.7 Valve Block Oil Assembly Drawing

Throttle washers
Oil type Hole diam. (mm)
S 851 — S 957 LOTP, LOXH, HFO180, 12.5
HFO380, HFO460, HFO600,
HFO700
S 861 — S 967 LOTP, LOXH, HFO180, 14.5
HFO380, HFO460, HFO600,
HFO700

23
2.8 Valve Block Oil Assembly Drawing cont. 2 Mechanical Drawings

2.8 Valve Block Oil Assembly Drawing cont.

Alfa Laval ref. 583403 Rev. 2

G091051A

24
2 Mechanical Drawings 2.9 Valve Block Water Assembly Drawing

2.9 Valve Block Water Assembly Drawing

Alfa Laval ref. 583410 Rev. 1

G091061A

25
2.10 Air Distributer Kit 2 Mechanical Drawings

2.10 Air Distributer Kit

Alfa Laval ref. 582806 Rev. 3

G091071A

26
2 Mechanical Drawings 2.11 Control Cabinet Dimension Drawing

2.11 Control Cabinet Dimension Drawing

Alfa Laval ref. 580903 Rev. 1

580903#1_00

27
2.12 Control Cabinet Assembly Drawing, 2 Mechanical Drawings
External

2.12 Control Cabinet Assembly Drawing, External

Alfa Laval ref. 580904 Rev. 5

580904#5_00

28
2 Mechanical Drawings 2.12 Control Cabinet Assembly Draw-
ing, External

Alfa Laval ref. 580904 Rev. 5

580904#5_01

29
2.13 Control Cabinet Assembly Drawing, 2 Mechanical Drawings
Internal

2.13 Control Cabinet Assembly Drawing, Internal

Alfa Laval ref. 581002 Rev. 6

Front view

OP1

Internal view

Speed transmitter kit(optional) Extra I/O board kit(optional)

Steam heater kit(optional) Vibration transmitter Electrical heater kit(optional)

kit(optional) Relay kit(optional)
Cover interlock kit(optional)
K112
K21
K20

GA1
Q7

PLC
A1-A8 Slots A9-A15

Terminals
X9-X20
X401

X501
X500
X400

TR1
X4
X1
X2
X3

X024902D

30
2 Mechanical Drawings 2.14 Change of EPC 60 Components

2.14 Change of EPC 60 Components

Operating Panel
• Switch power off.
• Remove the connections on the reverse side
of the panel.
• Unscrew the four screws holding the panel and
remove the panel.
• Mount the new panel and connect in reverse
order.
I/O-Board
• Switch power off.
• Hold down the plastic clip on the top of the cable
terminal and pivot the cable terminal towards
you.

X025001A

X025002A

31
2.14 Change of EPC 60 Components 2 Mechanical Drawings

• Pull away the cable terminal.

X025008A

• Hold down the triangle on the top of the I/O

board and loosen the board.

X025003A

• Pull the board straight out (otherwise it can

fasten in one of its guides)

X025004A

• Compare the part number of the new I/O board

to the old board to make sure it is correct.
• If changing more than one board at a time,
check with the electrical diagram to ensure that
the boards are mounted in the right places.

32
2 Mechanical Drawings 2.14 Change of EPC 60 Components

• Mount the new I/O board by pressing it straight

into place. Make sure the board is firmly in
place otherwise it will be impossible to mount
the cable terminal.

X025005A

• Remount the cable terminal. Make sure that

the clip on the bottom of the terminal fastens
properly in place on the axel on the bus holder.

X025007A

• Pivot the terminal on the axel until the clip on the

terminal top fastens into place in the I/O board.

X025006A

33
2.14 Change of EPC 60 Components 2 Mechanical Drawings
3 Electrical drawings

35
3.1 Electrical System Layout 3 Electrical drawings

3.1 Electrical System Layout

Alfa Laval ref. 580907 Rev. 4

580907#4_00

36
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2 Control and Starter Electrical Diagrams

3.2.1 Starter cable list

Alfa Laval ref. 580881 Rev. 7

No. Type Connection Instruc- Connection Remarks

point A tion point B
Basic design (currents according to order)
1 MPRXCX 3x4 Mains supply Starter 1) Fuse 20 A
1 MPRXCX 3x10 Mains supply Starter 1) Fuse 35A
1 MPRXCX 3x16 Mains supply Starter 1) Fuse 50 A

1 MPRXCX 3x25 Mains supply Starter 1) Fuse 63 A

1 MPRXCX 3x35 Mains supply Starter 1) Fuse 80 A

2 MPRXCX 2x2m5 Supply Starter 1) Fuse 16 A

3 MPRXCX 3x1,5 Starter Marked 3A Separator 4,0 – 6,3 A

motor
3 MPRXCX 3x2,5 Starter Marked 3B Separator 6,3 – 16 A
motor
3 MPRXCX 3x4 Starter Marked 3C Separator 16 – 20 A
motor
3 MPRXCX 3x6 Starter Marked 3D Separator 20 – 25 A
motor
3 MPRXCX 3x10 Starter Marked 3E Separator 25 – 32 A
motor
3 MPRXCX 3x16 Starter Marked 3F Separator 32 – 45 A
motor
3 MPRXCX 3x25 Starter Marked 3G Separator 45 – 63 A
motor
Optional or customer’s own feed pump (as ordered)
4 3x25 Feed pump 2)
MPRXCX Starter
Optional sludge handling (as ordered)
35 RFE-HF 1x4x0,75 Starter GS, Valve
switch
36 RFE-HF 1x2x0,75 Starter LS, Sludge
level
37 RFE-HF 1x2x0,75 Starter SV6, Solenoid For pneumatic
valve sludge pump
73 RFE-HF 2x0,75 Starter Heatpac on Included
tank in heater
element
Optional space heating (as ordered)
71 MPRXCX 2x1,5 Starter Separator
pump
73 2x1,5 Feed pump 2)
MPRXCX Starter
Optional heat tracing (as ordered)
74 MPRXCX 2x1,5 Starter Thermostat
75 3x1,5 Starter Heating cable

37
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

1) Cable not included in Alfa Laval delivery.

2) Cable not included in Alfa Laval delivery
except when feed pump ordered as part of a
Module including Pumping and Heating Unit.

No. Type Connection Instruc- Connection Remarks

point A tion point B
Signal cables (currents according to order)
11 RFE–HF 1x2x0,75 EPC 60 SV1
12 RFE–HF 1x2x0,75 EPC 60 SV4
13 RFE–HF 1x2x0,75 EPC 60 SV5 S-type only
14 RFE–HF 1x2x0,75 EPC 60 SV10
14A RFE–HF 1x2x0,75 EPC 60 SV10A Lube oil only
15 RFE–HF 1x2x0,75 EPC 60 SV15
16 RFE–HF 1x2x0,75 EPC 60 SV16
17 RFE–HF 1x2x0,75 PT1 1)
EPC 60
18 RFE–HF 1x2x0,75 EPC 60 PT4
19 RFE–HF 1x4x0,75 EPC 60 MT S-type only
20 RFE–HF 4x2x0,75 EPC 60 ST, (YT, SS) Not for P605,
P615, S805,
S815
21 RFE–HF 1x2x0,75 EPC 60 PT5 S-type only
22 RFE–HF 1x2x0,75 2)
EPC 60 Common
alarm
23 RFE–HF 4x2x0,75 3)
EPC 60 TT1/TT2
Options (as ordered)
25 RFE-HF 1x4x0,75 EPC 60 SS 2) Only for
P605, P615,
S805, S815
30 RFE-HF 1x4x0,75 EPC 60 YS 2) Only for
P605, P615,
S805, S815
38 4x1,5 2) 4)
MPRXCX EPC 60 Syst.
Emergency
100 4x1,5 2) 4)
MPRXCX EPC 60 Sep.
Emergency
stop
Optional Electric Heater (as ordered)
40 RFE-HF 4x2x0,75 Starter Power unit
45 RFE-HF 1x2x0,75 Starter Power unit
Optional heat tracing (as ordered)
41 RFE-HF 1x4x0,75 EPC 60 Steam reg.
valve
44 RFE-HF 1x2x0,75 EPC 60 Shut-off valve
50 RJ45 2)
EPC 60 CPU Client remote
data commu-
nication

38
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

1) Cable only included in the Alfa Laval delivery

when PT1 is delivered mounted on Module.
2) Cable not included in Alfa Laval delivery
3 )Cable only included in the Alfa Laval delivery
when Electric Heater is delivered mounted on
Module.
4) This cable cannot be longer than 25 m to
avoid voltage drop.

Other equivalent and approved cables may be

used.

Cable areas are calculated with correction factor

0.7.

Cables used are Shipboard Cables, designed

according to IEC 60092-3.

Flame retardant according to IEC 60332-1-2

and IEC 60332-3-22.

Halogen-free according to IEC 60754 series.

Smoke emission according to IEC 61034 series.

All power cables should be Signal Shielded

Cables with the shield properly connected to
earth as shown in the electrical drawings.

For armoured power cables, the armour

must be connected to earth, as shown in the
electrical drawings, and must give sufficient EMI
protection. Copper wire armouring is normally
used.

39
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

3.2.2 Separator Interconnection Diagram

Alfa Laval ref. 580906 Rev. 6

580906#6_00

40
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

Alfa Laval ref. 580906 Rev. 6

580906#6_01

41
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

Alfa Laval ref. 580906 Rev. 6

580906#6_02

42
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.3 Steam Regulating Valve (optional) Interconnection Diagram

Alfa Laval ref. 580886 Rev. 1

580886 v1_00

43
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

3.2.4 Speed Transmitter (optional) Interconnection Diagram

Alfa Laval ref. 580888 Rev. 3

580888#3_00

44
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.5 Vibration Transmitter (optional) Interconnection Diagram

Alfa Laval ref. 580890 Rev. 1

580890 v1_00

45
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

3.2.6 Electric Heater (optional) Interconnection Diagram

Alfa Laval ref. 580896 Rev. 1

580896 v1_00

46
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.7 I/O (optional) Interconnection Diagram

Alfa Laval ref. 580894 Rev. 3

580894#3_00

47
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

Alfa Laval ref. 580894 Rev. 3

580894#3_01

48
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.8 Heat Tracing (optional) Interconnection Diagram

Alfa Laval ref. 580884 Rev. 0

580884 v0_00

49
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

3.2.9 Emergency Shutdown Interconnection Diagram

Alfa Laval ref. 580898 Rev. 0

580898 v0_00

50
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.10 Circuit Diagram

Alfa Laval ref. 580905 Rev. 5

580905#5_00

51
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

Alfa Laval ref. 580905 Rev. 5

580905#5_01

52
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

Alfa Laval ref. 580905 Rev. 5

580905#5_02

53
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

Alfa Laval ref. 580905 Rev. 5

580905#5_03

54
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

Alfa Laval ref. 580905 Rev. 5

580905#5_04

55
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

Alfa Laval ref. 580905 Rev. 5

580905#5_05

56
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

Alfa Laval ref. 580905 Rev. 5

580905#5_06

57
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

Alfa Laval ref. 580905 Rev. 5

580905#5_07

58
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.11 Steam Regulating Valve (optional) Circuit Diagram

Alfa Laval ref. 580885 Rev. 2

580885#2_00

59
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

3.2.12 Speed Transmitter (optional) Circuit Diagram

Alfa Laval ref. 580887 Rev. 2

580887#2_00

60
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.13 Vibration Transmitter (optional) Circuit Diagram

Alfa Laval ref. 580889 Rev. 2

580889#2_00

61
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

3.2.14 Electric Heater (optional) Circuit Diagram

Alfa Laval ref. 580895 Rev. 2

580895#2_00

62
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.15 I/O (optional) Circuit Diagram

Alfa Laval ref. 580893 Rev. 2

580893#2_00

63
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

Alfa Laval ref. 580893 Rev. 2

580893#2_01

64
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.16 Heat Tracing (optional) Circuit Diagram

Alfa Laval ref. 580883 Rev. 1

580883#1_00

65
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings

Alfa Laval ref. 580883 Rev. 1

580883#1_01

66
3 Electrical drawings 3.2 Control and Starter Electrical Diagrams

3.2.17 Emergency Shutdown Circuit Diagram

Alfa Laval ref. 580897 Rev. 1

580897#1_00

67
3.2 Control and Starter Electrical Diagrams 3 Electrical drawings
 4 Specifications

• Only qualified personnel are allowed to work

with lifting of the module.
• Use only the lifting lugs as shown in the
illustrations.
• Slings or wires used for lifting the Module must
be adjusted so that the beam is located above
the centre of gravity.
• Slings or wires used for lifting the Double Module
must be of the same length to avoid instability.
• Slings/wires must be dimensioned locally
depending on equipment used.
• For information on how to lift the separator, see
the Separator Manual booklet.

NG
WARNI
!
Crush hazard
When lifting the Module, use only the lifting eyes
specifically for this purpose. Always use a lifting
beam.

69
4.1 Cables 4 Specifications

4.1 Cables
Cable Identification
All cables are marked to simplify identification
and fault finding.

Specifications
The following specifications apply to cables
connected to and from Alfa Laval equipment.
Follow the instructions given in the cable list.
Examples of cable types that can be used:

• Steel armoured cable.

G032224A

• Copper armoured cable with a separate earth

core.

G032244A

• Steel armoured and shielded signal cable; pair

twisted or parallel.

G032214A

• Shielded signal cable; pair twisted or parallel.

G032234A

70
4 Specifications 4.2 Cable Routing

4.2 Cable Routing

Recommendations
Power cables carry the power supply to motors,
heaters, etc.
Any distance between signal and power cables
reduces electrical noise transfer.

Examples of recommended routing of various

cable types.

• Power cables and signal cables routed on a

cable rack should be separated.
• Sattbus cables should be routed away from
power cables.

G032273A

Left: Power Cables / Right: Signal cable

If the space is limited, cables can be routed in

tubes.

71
4.4 Ambient Temperature Limitation 4 Specifications

4.3 Oil, Water, Steam, and Condensate Piping

For piping to and from Alfa Laval equipment,
see the specifications below.

Specifications
• The correct pipe size must be used in the oil
system.
• The number of bends in the oil pipes must be
minimized.
• The suction height must be as low as possible.
• The oil feed pump must be of positive
displacement type.
• The pump must be positioned close to the oil
tank.
• The heater must be installed close to the
separation module to maintain correct feed oil
temperature.
• The recirculation line should be connected
either directly to the settling tank (HFO) or to the
oil outlet line from the separator (LO).
• The oil outlet line from the separator must be
connected to the system tank for lube oil, or the
service tank for fuel oil.
4.4 Ambient Temperature Limitation
Specification
Leading classification societies state in their
regulations for engine room equipment that the
maximum ambient temperature permissible is
+55 °C. To meet this regulation, it is essential
that electrical and electronic components have
good ventilation, and temperature control.

X024675A

72
4 Specifications 4.6 More than one Oil Tank

4.5 Heat Tracing and Insulation of Fuel Oil, Sludge, and

Steam Pipes
Alfa Laval can, on request, supply modules
which are heat traced and insulated, as optional
equipment.

4.6 More than one Oil Tank

Recommendation
When one separator serves more than one oil A B
tank, both the suction and the outlet lines should
be fitted with change-over valves. To avoid oil
transfer from one tank to another, these valves
must be interlinked. C

C
D

P000062B

A. Unprocessed oil
B. Clean oil
C. Change over valve
D. Interlink

73
4.7 Sludge Removal Kit (Optional Equipment) 4 Specifications

4.7 Sludge Removal Kit (Optional Equipment)

If you have a Sludge Removal Kit, this must be
connected to a ventilation pipe.

NOTE

The sludge removal pump must be set to the correct

speed – circa 60 strokes/min, otherwise the lifetime
of the diaphragm, valve balls, and air motor will be
severely shortened.

NG
WARNI
!
Health Risk
Oil mist and vaporized oil constituents from hot oily
sludge may be dangerous to health and must not be
inhaled.

A pipe or hose must be drawn from the flange to

the nearest oil tank ventilation pipe.

The pipe/hose must have the same diameter

as the flange opening.

The pipe/hose must be as straight as possible,

with a steady upward incline.

The connection to the oil tank ventilation pipe

must point upwards as shown.

NOTE B
For HFO separation, it is not recommended to make
the connection to the separator room ventilation
system.
For LO separation, connection to the separator
room ventilation system should be made only if
the separator room ventilation is adequate. Use the
optional connection hose (part no. 568023-80, -81, or
A
-82) for this purpose. This hose is designed to entrap
oil drops in the vent hose, and lead the oil back to the
Sludge Removal Kit tank.
P000063B

A. ~5 mm
B. Oil tank ventilation pipe

74
4 Specifications 4.7 Sludge Removal Kit (Optional Equipment)

NOTE

Impurities gather in the Sludge Removal Kit tank.

Regularly check the tank and level switch.
See instructions below.

Proceed as follows:

• From the Control Panel, run the sludge pump

manually for a few seconds.
• Undo the four screws connecting the sludge
pump to the sludge tank and remove the sludge
pump.
• If necessary, clean the level switch and the
inside of the tank using diesel oil.
• Check the seals and gaskets, and change if
necessary.
• Loosen the hose clip and check the inside of the
ventilation hose. Clean if necessary.
To avoid breakdown of the Sludge Removal
system, the sludge pump must be regularly
overhauled as follows using spare parts kit
specified in the spare parts catalogue.

• Replace the diaphragms and the O-rings with

those delivered in the spare parts kit.
• Perform a 4000 hour Inspection Service.
For Service and Overhaul intervals, see 1.3
System Data on page 8 .

75
4.8 Sludge Tank 4 Specifications

4.8 Sludge Tank

It is not necessary to have a sludge tank
together with a Separation Module with sludge
removal kit (for lube oil). If a sludge tank is
required, follow the recommendations below:

Recommendations
• Sludge tank volume per Separation Module
should cover approximately up to 2 days storage
at a discharge interval of 2 hours (for discharge C
volumes see technical data).
• A manhole should be installed for inspection B
and cleaning.
• The tank should be fitted with a sounding pipe.
• The tank floor, or most of it, should have a slope
(B) of minimum 15°. D
• The sludge outlet pump connection should be
A
positioned in the lowest part of the tank.
• A high level alarm switch, connected to the E
sludge pump, should be installed.
G004273B

• A heating coil should be used to keep the sludge

A. Sludge outlet pump connection
warm and fluid while being pumped out.
B. Sludge pipe connection
• Tank ventilation must follow the classification C. Ventilation pipe
rules for evacuation of gases. D. Min. height 400 mm
E. Min. slope 15°
• There should be a ventilation pipe to fresh air.
• The ventilation pipe should be straight. If this is
not possible, any bends must be gradual.
• The ventilation pipe must not extend below the
tank top. A B C D
• A sludge tank with partition walls must have
ventilation pipes in all compartments, or cutouts
in the upper edge, to allow vapours to travel
E
through the tank.

G004270B

A. Bowl casing drain connection

B. Manhole
C. Water drain connection
D. High level alarm switch
E. Heating coil

In retrofit applications, where an Alfa Laval

Separation Module will share a common
separator sludge tank with existing separators, it
is recommended to install a Sludge Removal Kit.

76
4 Specifications 4.8 Sludge Tank

The number of ventilation pipes, and their

minimum dimension, depend on the size and
number of separators connected to the same
tank. See table below.

Type 1 module 2/3 modules 4 modules

S851–S967 1 x Ø 75 mm 1 x Ø 100 mm 1 x Ø 140 mm

The Module generates almost no air during

operation. At any discharge, the maximum
volume of air produced is the same as the bowl
volume (see technical data).

77
4.9 Sludge Piping 4 Specifications

4.9 Sludge Piping

Specification
• The sludge pipe from the separator to the
sludge tank should be vertical.
If a vertical pipe is not possible, the deviation (A)
from the vertical line must not exceed 30°.

G004401A

• The sludge pipe must not extend below the tank

top.

NOTE

An extended sludge pipe will obstruct ventilation

and create back pressure that could cause separator
problems.

G004316A

Recommendation
In cases where sludge tank ventilation is
not adequate, and more than one separator
is connected to the same sludge tank, we
recommend that a butterfly valve is installed in
each sludge pipe.

NOTE

If a butterfly valve is not used, the bowl and the

operating system may be affected by corrosive fumes
and sludge from the sludge tank.

• If a butterfly valve is used, it should be equipped

with an interlocking switch (connected to the
separator starter) to prevent the separator from
being started when the valve is not fully open. G004411A

78
 5 Commissioning and Initial Start

5.1 Completion Check List

It is essential before starting up the separation
system that all modules are in good operating
condition and that all pipelines and control
equipment are properly connected to assure
correct operation.

Use this check list as a guide for completing the

system installation:

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

1. Check that transport seals are removed from

all pipes.

2. Use flushing filters to prevent pipe work debris

from being pumped into the separation module.

NOTE

The flushing filters must be removed after initial

flushing.

3. Check that all separators are in proper

working condition. Follow the manufacturer’s
instructions.

4. Make sure that separators are lubricated in

accordance with instructions.

NOTE

Make sure that the spindle bearings are prelubricated

g08687t1

Drop some frame oil onto the bearings

79
5.2 Initial Start-up 5 Commissioning and Initial Start

5. Separators are delivered without oil in the oil

sump. For information on oil filling and oil type,
see the Separator Manual booklet.

NOTE

Too much, or too little oil may result in damage to

separator bearings.
Neglecting an oil change may result in damage to
separator bearings.

6. Power on.

7. Check that the separator rotation direction

corresponds with the arrow on the frame by
doing a quick start/stop (1–2 seconds.) and
looking at the motor fan rotation.

ON
CAUTI
!
If power cables have been installed incorrectly, the
separator will rotate in reverse, and vital rotating parts
can unscrew.

8. Check the pump function and direction.

9. If a Sludge Removal Kit is used, check that

the sludge pump speed is set to circa 60
strokes/min.If necessary, adjust the throttling
valve (positioned after solenoid valve SV 6).

5.2 Initial Start-up

NOTE

After every start the separator must always be run

continuously for a minimum of 1 hour to ensure proper
lubrication.

Use this check list for initial system start up:

1. Check that there is oil in the feed oil tank.

2. Check water and air supply. See 1.3 System

Data.

3. Check power supplies to the control unit and

that the voltage is in accordance with data in
1.3 System Data.

80
5 Commissioning and Initial Start 5.2 Initial Start-up

4. Check all parameter settings in the control unit.

See Installation Parameters in the Parameter
List booklet.

5. Check the separator.

NOTE

Always lubricate the bearings before start-up.

NOTE

The Separation module is supplied with standard

configuration parameters. You may have to make
some changes to suit your installation.

6. Start the separation system as described in the

Operating Instructions booklet.

7. Start up step by step, checking that the machine

and module function properly.

8. Establish system pressures. The delivery height

pressure is the pressure in the oil pipe work
down stream from the separation module, due
to the pipe bends and the height (head) to
the cleaned oil tank. If the cleaned oil tank is
below the separation module the delivery height
pressure may be very low. The oil paring disc
pressure will have to be greater than the delivery
height pressure for any oil to flow.
Proceed as follows:

• Ensure the valves in the oil system are in the

correct positions.
• The oil should be at separation temperature.
For S-type separators:

• The paring tube should be able to move freely.

• Ensure that V5 is closed.
• Fully open the back pressure regulating valve
RV4.
• The shut off valve V4 should be open.
• Open SV15 for 3 seconds to prime the operating
slide.
• Open SV16 for 15 seconds to close the bowl.
• Open SV10 for 1 minute to put water into the
bowl.
• Feed oil to the separator at the normal flow rate
by opening SV1.

81
5.2 Initial Start-up 5 Commissioning and Initial Start

• Note the pressure in the oil outlet PT4, both on

the pressure gauge and in the EPC 60 display.
This pressure is P min.
• Gradually close the back pressure regulating
valve RV4. The pressure on PT4 will increase.
The water pressure (PT5) decreases slightly
as the paring tube moves inwards. The water
pressure will suddenly drop when oil passes
from the oil paring chamber to the water paring
chamber. Note the pressure of PT4 both on the
pressure gauge and in the EPC 60 display.
This pressure is P max.
• Open RV4.
• Stop the oil feed to the separator and note the
pressure in the oil outlet. This is the delivery
height pressure P del.
• Stop the heater.
• Stop the separator.
• Stop the feed pump when the heater has cooled.
For P-type separators:

• Fully open the back pressure regulating valve

RV4.
• Open SV15 for 5 seconds to prime the operating
slide.
• Open SV16 for 15 seconds to close the bowl.
• Open SV10 for 5 seconds to put water into the
bowl.
• Feed oil to the separator at the normal flow rate
by opening SV1.
• Note the pressure in the oil outlet PT4, both on
the pressure gauge and in the EPC 60 display.
This pressure is P min.
• Gradually close the back pressure regulating
valve RV4. The pressure on PT4 will increase.
The oil pressure will suddenly drop when oil
passes over to the water outlet. Note the
pressure of PT4 both on the pressure gauge
and in the EPC 60 display.
This pressure is P max.
• Open RV4.
• Stop the oil feed to the separator and note the
pressure in the oil outlet. This is the delivery
height pressure P del.
• Stop the heater.
• Stop the separator.
• Stop the feed pump when the heater has cooled.

82
5 Commissioning and Initial Start 5.2 Initial Start-up

5.2.1 Calculating Operating Pressure

• Calculate the normal back pressure level during
operation as follows:
Pmin + Pmax
= Pnormal
2

• Calculate the value for low pressure alarm

setting (Pr 11) as follows:
Pmin + Pnormal
= Plow press.
2

• Calculate the value for high pressure alarm

setting (Pr 10) as follows:
Pnormal + Pmax
= Phigh press.
2

Adjust the back pressure to Pnormal

Set P154 to give alarm at pressure decreasing

below the Plow press. value.

Set P153 to give alarm at pressure increasing

above the Phigh press. value.

83
5.2 Initial Start-up 5 Commissioning and Initial Start
 6 Shut-down and Storage

Storage before Installation

If the separation system is stored before
installation, the following safeguards must be
taken:

Storage period 1 < 6 months ≥6 months See

Action before storage
Protect from dust, dirt, X X This chapter
water, etc.
Protect with anti-rust oil X X This chapter
Action before
installation
Inspection service X Service manual
Overhaul service X Service manual

6.1 Shut-down after Use

If the separation system is going to be shut down
for a period of time, the following safeguards
must be taken:

Shut-down period 1 < 6 months 6 – 18 months > 18 months See

(stand-by)
Action before
storage
Remove bowl X X X Dismantling and
Assembly in the
Service Manual
Protect from dust, X X X This chapter
dirt, water, etc.
Protect with X X X This chapter
anti-rust oil
Inspection service X X Service manual
Overhaul service X Service manual

85
6.2 Protection and Storage 6 Shut-down and Storage

6.2 Protection and Storage

All system equipment, both the separator and
the ancillary equipment, must be stored indoors
at 5 – 55°C, if not delivered in water-resistant
box for outdoor storage.

If there is a risk for condensation of water, the

equipment must be protected by ventilation and
heating above dew point.

The following protection products are

recommended:

• Anti-rust oil with long lasting effective treatment

for external surfaces. The oil should prevent
corrosion attacks and give a waxy surface.
• Anti-rust oil (Dinitrol 40 or equivalent) thin and
lubricating for inside protection. It gives a
lubricating transparent oil film.
• Solvent, e.g. white spirit, to remove the anti-rust
oil after the shut-down.
• Moist remover to be packed together with
separator equipment.
• If the storage time exceeds 12 months, the
equipment must be inspected every 6 months
and, if necessary, the protection be renewed.
Modules
• Clean unpainted steel parts with solvent and
treat external surfaces with anti-rust oil (type
112).
• If necessary, clean other equipment on the
module with solvent.
• Treat the equipment with anti-rust oil by following
the description above accordingly.
• Bolts, nuts and other external steel components
should be treated with anti-rust oil (type 112).
Rubber Parts
• Gaskets, O-rings and other rubber parts should
not be stored for more than two years. After this
time, they should be replaced.
Separator
Dismantle the separator bowl and take out the
O-rings. Clean the bowl with oil and reassemble
without the O-rings. Place in a plastic bag with
silica dessicant bags and seal the plastic bag.

Grease the spindle.

86
6 Shut-down and Storage 6.2 Protection and Storage

Valves, Pipes and Similar Equipment

• Components such as 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.
Electric Heater
• Fill the heater with a non-corrosive lubricating
oil.
• Place a number of bags of silica gel inside
the connection box to absorb humidity. Steam
Heater •Drain the condensed water from the
steam valve and the steam trap.
• Drain all condensed water from the heater.
• Fill the oil part of the heater with a non-corrosive
lubricating oil.
Pump
• Clean the pump housing outside from oil and
grease with solvent.
• Protect the pump by filling it with non-corrosive
lubricating oil.
• Apply anti-rust oil on the pump housing outside.
• Fill the pump screws with lubricating oil to
prevent rust.

87
6.3 Reassembly and Start up 6 Shut-down and Storage

6.3 Reassembly and Start up

• Clean away the anti-rust oil with white spirit.
• Remove the silica gel bags from all modules.
• Pre-lubricate the separator spindle bearings
• If stored for 6 months or longer, perform an
inspection service (including change of oil in the
separator sump).
• Follow all relevant instructions in this booklet
and in the Separator Manual.
• Before operating the heater:

- Check by lifting the safety valve handle that it

functions correctly.
- Follow the start-up check list for the heater in
the manufacturer’s instructions.
- For plate heat exchangers: check the bolt
connections to ensure that all gaskets are tight.

NOTE

Always lubricate the bearings before start-up.

NOTE

After every start the separator must always be run

continuously for a minimum of 1 hour to ensure proper
lubrication.

88