Service and Maintenance Manual AFPX 513

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AFPX 513XGD-14/74CG

Service & Maintenance manual

High Speed Separator

Product No. 881135-21-01/5

Book No. 1271468-02 Rev. 3


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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 02 May 2006

This publication or any part there of may not bereproduced or transmitted by any process ormeans without prior written permission ofAlfa Laval Tumba AB.


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Contents

3

1 Safety Instructions 9

1.1 Warning signs in text 14

1.2 Environmental issues 15

1.3 Requirements of personnel 16

2 Maintenance Directions 17

2.1 Periodic maintenance 17

2.1.1 Introduction 17

2.1.2 Maintenance intervals 17

2.1.3 Maintenance procedure 19

2.1.4 Service kits 20

2.2 Maintenance Logs 21

2.2.1 Daily checks 21

2.2.2 Lubrication of electric motor 21

2.2.3 Oil change 21

2.2.4 Intermediate Service (IS) 22

2.2.5 Major Service (MS) 24

2.2.6 3-year Service (3S) 26

2.3 Cleaning 27

2.3.1 Cleaning agents 27

2.3.2 External cleaning 28

2.3.3 Cleaning of bowl discs 29

2.4 When changing oil 30

2.4.1 Worm wheel and worm; wear of teeth 30

2.4.2 Oil change procedure 33

2.5 Lubricants 34

2.5.1 Lubrication chart, general 34

2.5.2 Recommended lubricating oils 36

2.5.3 Recommended oil brands 37

2.5.4 Recommended lubricants 38

2.6 Vibration 42


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2.6.1 Vibration analysis 42

2.7 Common maintenance directions 43

2.7.1 Ball and roller bearings 43

2.7.2 Before shutdowns 47

3 Dismantling/Assembly 49

3.1 Introduction 49

3.1.1 General directions 49

3.1.2 References to checkpoints 50

3.1.3 Tools 50

3.1.4 Tightening of screws 50

3.2 Intermediate Service (IS), dismantling 51

3.2.1 Inlet/outlet and frame hood 51

3.2.2 Bowl hood and disc stack 56

3.2.3 Bowl body and operating mechanism 62

3.2.4 Operating liquid device (IS) 66

3.3 Intermediate Service (IS), checkpoints 70


3.3.2 Bowl hood seal ring 703.3.3 Bowl spindle cone and bowl body nave 71

3.3.4 Corrosion 72

3.3.5 Cracks 74

3.3.6 Dosing ring 75

3.3.7 Erosion and wear liners 75

3.3.8 Guide surfaces 79

3.3.9 Inlet pipe threads and paring disc 81

3.3.10 Lock ring; wear and damage 82

3.3.11 Operating mechanism 83

3.3.12 Operating slide 84

3.3.13 Springs for operating mechanism 84

3.3.14 Sliding bowl bottom 85

3.3.15 Worm wheel and worm; wear of teeth 85

3.3.16 Speed sensor 86

3.3.17 Vibration sensor 863.3.18 Cover interlocking switch (option) 87


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3.3.19 Limits switch 87

3.4 Intermediate Service (IS), assembly 88


3.4.2 Lubrication 883.4.3 Operating liquid device 89

3.4.4 Bowl body and operating mechanism 93

3.4.5 Bowl hood and disc stack 96

3.4.6 Inlet/outlet and frame hood 103

3.5 Major Service (MS), dismantling 107


3.5.2 Horizontal driving device 118

3.6 Major Service (MS), checkpoints 122


3.6.2 Lock ring; priming 122

3.6.3 Brake 124

3.6.4 Buffer springs and ball bearing housing 126

3.7 Major Service (MS), assembly 127


3.7.2 Horizontal driving device 128

3.7.3 Vertical driving device 133

Index 145


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7

Read and understand 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 conditionshave been considered. No warnings are given, therefore, forsituations arising from the unintended usage of the machine and itstools.


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1 Safety Instructions

The centrifuge includes parts that rotate at highspeed. This means that:

• Kinetic energy is high

• Great forces are generated

• Stopping time is long

Manufacturing tolerances are extremely fine.Rotating parts are carefully balanced to reduceundesired vibrations that can cause a breakdown.Material properties have been consideredcarefully during design to withstand stress andfatigue.

The separator is designed and supplied for aspecific separation duty (type of liquid, rotationalspeed, temperature, density etc.) and must not beused for any other purpose.

Incorrect operation and maintenance can result inunbalance due to build-up of sediment, reductionof material strength, etc., that subsequently couldlead to serious damage and/or injury.

The following basic safety instructions thereforeapply:

• Use the separator only for the purposeand parameter range specified byAlfa Laval.

• Strictly follow the instructions for

installation, operation and maintenance.

• Ensure that personnel are competent andhave sufficient knowledge of maintenanceand operation, especially concerningemergency stopping procedures.

• Use only Alfa Laval genuine spare partsand the special tools supplied.

G 0 0 1 0 4 2 1

S 0 1 5 1 2 1 1


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Disintegration hazards

• When power cables are connected,always check direction of motor rotation.If incorrect, vital rotating parts couldunscrew.

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

• Use the separator only for the purposeand parameter range specified byAlfa Laval.

• Check that the gear ratio is correct forpower frequency used. If incorrect,subsequent overspeed may result in a

serious break down.

• Since the separator is equipped with afrequency controlled motor, it isextremely important to ensure that themotor speed does not exceed theallowed maximum speed. A seriousbreak down may be the consequence.

• Welding or heating of parts that rotatecan seriously affect material strength.

• Wear on the large lock ring thread mustnot exceed safety limit. φ-mark on lockring must not pass opposite φ-mark bymore than specified distance.

• Inspect regularly for corrosion anderosion damage. Inspect frequently ifprocess liquid is corrosive or erosive.

S 0 1 5 1 2 F 1

S 0 1 5 1 2 N

1

S 0 1 5 1 2 P 1

S 0 1 5 1 2 L 1

S 0 1 5 1 2 4 1

S 0 1 5 1 2 G 1

S 0 1 5 1 2 H 1


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Entrapment hazards

• Make sure that rotating parts have cometo a complete standstill before startingany 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 mustbe in place.

Electrical hazard

• Follow local regulations for electricalinstallation and earthing (grounding).

• To avoid accidental start, switch off andlock power supply before starting any dismantling work.

Crush hazards

• Use correct lifting tools and follow liftinginstructions.

Do not work under a hanging load.

S 0 1 5 1 2 O 1

S 0 1 5 1 2 6 1

S 0 1 5 1 2 7 1

S 0 1 5 1 2 M 1

S 0 1 5 1 2 Y 1


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Noise hazards

• Use ear protection in noisyenvironments.

Burn hazards

• Lubrication oil and various machinesurfaces can be hot and cause burns.

Skin irritation hazards

• When using chemical cleaning agents,make sure you follow the general rulesand suppliers recommendationregarding ventilation, personnelprotection etc.

• Use of lubricants in various situations.

S 0 1 5 1 2 9 1

S 0 1 5 1 2 A 1

S 0 1 5 1 2 D 1


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Cut hazards

• Sharp edges on bowl discs and threadscan cause cuts.

Flying objects

• Risk for accidental release of snap ringsand springs when dismantling andassembly.

Health hazard

• Risk for unhealthy dust when handlingfriction blocks/pads. Use a dust mask tomake sure not to inhale any dust

S 0 1 5 1 2 B 1

S 0 1 5 1 2 C 1

S 0 1 5 1 2 V 1


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1.1 Warning signs in text

Pay attention to the safety instructions in thismanual. Below are definitions of the three gradesof warning signs used in the text where there is arisk for injury to personnel.

DANGER

Type of hazard

DANGER indicates an imminentlyhazardous situation which, if not avoided,will result in death or serious injury.

WARNING

Type of hazard

WARNING indicates a potentiallyhazardous situation which, if not avoided,could result in death or serious injury.

CAUTION

Type of hazard

CAUTION indicates a potentiallyhazardous situation which, if not avoided,may result in minor or moderate injury.

NOTE

NOTE indicates a potentially hazardoussituation which, if not avoided, may resultin property damage.


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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 licensedwaste incineration plant.

Metal straps should be sent for material recycling.

Maintenance

During maintenance oil and wear parts in themachine are replaced.

Oil must be taken care of in agreement with localregulations.

Rubber and plastics should be burnt at a licensedwaste incineration plant. If not available theyshould be disposed to a suitable licensed land fillsite.

Bearings and other metal parts should be sent toa licensed handler for material recycling.

Seal rings and friction linings should be disposedto a licensed land fill site. Check your localregulations.

Worn out or defected electronic parts should besent to a licensed handler for material recycling.


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1.3 Requirements of

personnelOnly skilled or instructed persons are allowed tooperate the machine, e.g. operating andmaintenance staff.

• Skilled person: A person with technicalknowledge or sufficient experience to enablehim or her to perceive risks and to avoidhazards which electricity/mechanics cancreate.

• Instructed person: A person adequatelyadvised or supervised by a skilled person toenable him or her to perceive risks and toavoid hazards which electricity/mechanicscan create.

In some cases special skilled personnel mayneed to be hired, like electricians and others. Insome of these cases the personnel has to becertified according to local regulations withexperience of similar types of work.


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2 Maintenance Directions

2.1 Periodic maintenance

2.1.1 Introduction

Periodic (preventive) maintenance reduces therisk of unexpected stoppages and breakdowns.Follow the maintenance logs on the followingpages in order to facilitate the periodicmaintenance.

2.1.2 Maintenance intervals

The following directions for periodic maintenancegive a brief description of which parts to becleaned, checked and renewed at differentmaintenance intervals.

The maintenance logs for each maintenanceinterval later in this chapter give detailed

enumeration of the check points that must bedone.

Daily checks consist of minor check points tocarry out for detecting abnormal operatingconditions.

Oil change

The oil change interval is every 1000-1500 hours or at least once every year if the total number of

operating hours is less than 1000-1500 hours.

WARNING


Separator parts that are either worn beyondtheir safe limits or incorrectly assembled maycause severe damage or fatal injury.


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2.1 Periodic maintenance 2 Maintenance Directions

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Intermediate Service (IS)

Intermediate Service consists of an overhaul ofthe separator bowl, inlet/outlet and operatingdevice every 3 months or 2000 operating hours.

Seals in bowl and gaskets in inlet/outlet deviceare renewed.

Major Service (MS)

Major Service consists of an overhaul of thecomplete separator and includes an IntermediateService every 12 months or 8000 operatinghours. Seals and bearings in the bottom part arerenewed.

3-year Service (3S)

3-year Service consists of renewing the framefeet. The feet get harder with increased use andage.

2nd year

Oil change

I ntermediate S ervice = IS

M ajor S ervice = MS

Periodic maintenance schedule

Installation 1st year

MS MS

3rd year

MS

IS IS IS IS IS IS IS IS IS IS IS IS

3 -year S ervice = 3S 3S


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2 Maintenance Directions 2.1 Periodic maintenance

2.1.3 Maintenance procedure

At each Intermediate and Major Service, take acopy of the maintenance log and use it fornotations during the service.

An Intermediate and Major Service should becarried out in the following manner:

1. Dismantle the parts as mentioned in themaintenance log and described in chapter ‘‘3Dismantling/Assembly” on page 49.

Place the separator parts on clean, softsurfaces such as pallets.

2. Inspect and clean the dismantled separatorparts according to the maintenance log.

3. Fit all the parts delivered in the service kitwhile assembling the separator as describedin chapter ‘‘3 Dismantling/Assembly” on page45. The assembly instructions havereferences to check points which should becarried out before and during the assembly.

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2.1 Periodic maintenance 2 Maintenance Directions

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2.1.4 Service kits

Special service kits are available for IntermediateService (IS) and Major Service (MS), as well asfor servicing the frame feet (3S).

For other services the spare parts have to beordered separately.

Note that the parts for IS are not included in theMS kit and parts for IS and MS are not includedin the 3S kit.

The contents of the service kits are described inthe Spare Parts Catalogue .

NOTE

Always use Alfa Laval genuine parts asotherwise the warranty will become invalid.

Alfa Laval takes no responsibility for the safeoperation of the equipment if non-genuinespare parts are used.

WARNING


Use of imitation parts may cause severedamage.

S 0 0 2 1 0 2 1

Kits are available for Intermediate Service, MajorService and for servicing the frame feet


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2 Maintenance Directions 2.2 Maintenance Logs

2.2 Maintenance Logs

2.2.1 Daily checksThe necessary daily checks to be carried out for asafe operation are enumerated in chapterRunning in the Operator´s Manual.

2.2.2 Lubrication of electric motor

The bearings of the electric motor shall begreased with intervals that is dependent of themotor speed (50 or 60 Hz), ambient temperature

and if the bearing is located on the driving end ornon driving end.

The recommended interval can vary from 250 upto 5000 operating hours.

Correct lubrication interval and recommendedtype of grease can be found on a plate fixed onthe motor. The information can also be found inchapter Motor specifications in the InstallationManual.

2.2.3 Oil change

The oil change and check of worm gear should becarried out every 1000-1500 hours of operation.

Note: In a new installation, or after replacementof gear, change the oil after 200 operating hours and clean the gear housing.

When the separator is running for short periods, thelubricating oil must be changed every 12 months evenif the total number of operating hours is less than1000-1500 hours (2000 h).

a) See chapter ‘‘2.5 Lubricants” on page 34 for

further information.

Main component and activity Part Page Notes

Horizontal driving device

Worm wheel shaft and gear housing

Check Worm wheel and worm 30

Renew Oila) in gear housing 33


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2.2 Maintenance Logs 2 Maintenance Directions

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2.2.4 Intermediate Service (IS)

Name of plant: Local identification:

Separator: AFPX 513XGD-14/74CG Manufacture No./Year:

Total running hours: Product No: 881135-21-01/4

Date: Signature:


Inlet and outlet

Clean and inspect Connecting housing –

Threads of inlet pipe 77

Paring disc -

Separator bowl

Clean and check Lock ring 78

Bowl hood 66

Bowl discs 29

Distributor –

Distributing cone –

Sliding bowl bottom 81

Bowl body –

Guide surfaces 75

Bowl spindle cone and bowlbody nave

67

Operating mechanism 71, 79,80, 80,

Paring chamber

Check Corrosion 68

Cracks 70Erosion and wear liners 71

Galling of guide surface 76

Disc stack pressure 97

Renew O-rings and sealings –

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Operating liquid device

Clean and check Operating liquid device –

Renew O-rings –




Renew Oil in gear housing 33

Electrical motor

Lubrication (if nipples are fitted) See sign on motor –

Signs and labels on separator

Check attachment and legibility Safety label on hood -

Direction of rotation arrow -

Power supply frequency -

Monitoring equipment

Function check Vibration sensor 82

Speed sensor 82

Cover interlocking switch(option)

83

Note: Renew all parts included in the Intermediate Service kit (IS).


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2.2.5 Major Service (MS)

Name of plant: Local identification:

Separator: AFPX 513XGD-14/74CG Manufacture No./Year:

Total running hours: Product No: 881135-21-01/4

Date: Signature:


Inlet and outlet

Clean and inspect Connecting housing –

Threads of inlet pipe 77

Paring disc -

Separator bowl

Clean and check Lock ring 78

Bowl hood 66

Bowl discs 29

Distributor –

Distributing cone –

Sliding bowl bottom 81

Bowl body –

Guide surfaces 75

Bowl spindle cone and bowlbody nave

67

Operating mechanism 71, 79,80, 80,

Paring chamber

Check Corrosion 68

Cracks 70

Erosion and wear liners 71

Galling of guide surface 76

Disc stack pressure 97

Height position of outletparing disc

101

Renew O-rings and sealings –

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Operating liquid device

Clean and check Operating liquid device –

Check Height position 88

Renew O-rings –

Vertical driving device

Clean and check Bowl spindle –

Buffer springs and ballbearing housing

122

Check Radial wobble of bowl spindle 135

Renew Spindle bearings, sealings

and rubber buffers

129




Radial wobble of worm wheelshaft

128

Renew Bearings, O-rings andsealings

114

Oil in gear housing 33

Brake

Clean and check Spring and brake shoe 121

Renew Friction pad 120

Flexible coupling

Check Axial play of elastic plates 126

Electrical motor

Lubrication (if nipples are fitted) See sign on motor –

Signs and labels on separator

Check attachment and legibility Safety label on hood -

Direction of rotation arrow -

Power supply frequency -

Monitoring equipment

Function check Vibration sensor 82

Speed sensor 82

Cover interlocking switch(option)

83

Note: Renew all parts included in the Intermediate Service kit (IS) and Major Service kit (MS).


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2.2.6 3-year Service (3S)

Renew the frame feet as described below. The 3-year service should be carried out in conjunctionwith a Major Service (MS). The extent of the 3-year

service is the same as for a major service plusrenewing the parts included in the 3-year Service kit(3S).

Frame feet, renewal

1. Disconnect pipes, hoses and cables connectedto the separator.

2. Remove the nuts (1, 2).

3. Lift the separator.

4. Renew the vibration dampers (3, 4).

5. Lower the frame. Check that the bolts do notpress against the edges of the holes.

6. Tighten the nut (2) to 20 Nm.

7. Hold the nut (2) firmly and secure with the locknut (1).

8. Connect the previously disconnected pipes,hoses and cables.

.

NOTE

When lifting a separator it must always hangsecurely. See separate instruction in chapterLifting instructions in the Installation Manual .

G 0 2 5 8 9 2 1

1. Lock nut 2. Nut 3. Vibration damper, upper 4. Vibration damper, lower


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2 Maintenance Directions 2.3 Cleaning

2.3 Cleaning

2.3.1 Cleaning agentsWhen using chemical cleaning agents, make sureyou follow the general rules and suppliers’recommendations regarding ventilation,protection of personnel, etc.

For separator bowl, inlet and outlet

A chemical cleaning agent must dissolve thedeposits quickly without attacking the material of

the separator parts.

For operating mechanism

Use 10% acetic acid solution to dissolve limedeposits. The acid should be heated to 80 °C.

For parts of the driving devices

Use white spirit, cleaning-grade kerosene ordiesel oil.

Oiling (protect surfaces against corrosion)

Protect cleaned carbon steel parts againstcorrosion by oiling. Separator parts that are notassembled after cleaning must be wiped and

coated with a thin layer of clean oil and protectedfrom dust and dirt.

CAUTION

Skin irritation hazard

Read the instructions on the label of thecontainer before using the chemical cleaningagent.

Always wear safety goggles, gloves andprotective clothing as the liquid is alkalineand dangerous to skin and eyes.


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2.3.2 External cleaning

The external cleaning of the frame and motorshould be restricted to brushing, sponging orwiping while the motor is running or is still hot.

Never wash down a separator with a direct waterstream. Totally enclosed motors can be damagedby direct hosing to the same extent as openmotors and even more than those, because:

• Many operators believe that these motors aresealed, and normally they are not.

• A water jet played on these motors willproduce an internal vacuum, which will suckthe water between the metal-to-metal contact

surfaces into the windings, and this watercannot escape.

• Water directed on a hot motor may causecondensation resulting in short-circuiting andinternal corrosion.

Be careful even when the motor is equipped witha protecting hood. Never play a water jet on theventilation grill of the hood (if any).

G 0 5 4 5 1 2 1

Never wash down a separator with a direct waterstream or playing a water jet on the motor

G 0 5 4 5 1 3 1

Use a sponge or cloth and a brush when cleaning


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2 Maintenance Directions 2.3 Cleaning

2.3.3 Cleaning of bowl discs

Handle the bowl discs carefully so as to avoiddamage to the surfaces during cleaning.

1. Remove the bowl discs from the distributor

and lay them down, one by one, in thecleaning agent.

2. Let the discs remain in the cleaning agentuntil the deposits have been dissolved. Thiswill normally take between two and fourhours.

3. Finally clean the discs with a soft brush.

NOTE

Mechanical cleaning is likely to scratch thedisc surfaces causing deposits to formquicker and adhere more firmly.

A gentle chemical cleaning is thereforepreferable to mechanical cleaning.

CAUTION

Cut hazard

Sharp edges on the separator discs maycause cuts.

G 0 0 6 5 8 3 1

Put the discs one by one into the cleaning agent

G 0 0 6 5 8 4 1

Clean the discs with a soft brush


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2.4 When changing oil 2 Maintenance Directions

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2.4 When changing oil

2.4.1 Worm wheel and worm;wear of teeth

To check at each oil change

Check the teeth of both the worm wheel andworm for wear. Examine the contact surfaces andcompare the tooth profiles with the ‘‘ Toothappearance examples” on page 32. The gear mayoperate satisfactorily even when worn to somedegree.

• Replace both worm wheel and worm at thesame time, even if only one of them is worn.

• To avoid damaging the teeth when lifting thebowl spindle: push the worm wheel to oneside first.

Position the spindle in correct place beforefitting the worm wheel.

When replacing the gear, always make sure thatthe new worm wheel and worm have the samenumber of teeth as the old ones. See chapter

Technical data in the Installation Manual forcorrect number of teeth.

WARNING


Check that gear ratio is correct for powerfrequency used. If incorrect, subsequentoverspeed may result in a serious

breakdown.

NOTE

Presence of metal chips in the oil bath is anindication that the gear is wearingabnormally.

G 0 2 0 5 3 1 1

1 Worm 2 Worm wheel

G 0 2 0 5 4 1 1

Check the gear ratio (number of teeth) when replacingthe gear


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2 Maintenance Directions 2.4 When changing oil

Important!

When using mineral-type oil in the worm gearhousing, the presence of black deposits on thespindle parts is an indication that the oil base has

deteriorated seriously or that some of the oiladditives have precipitated. If pitting is found onthe worm gear, the cause could be that theadditives are not suitable for this purpose.

In all these cases it is imperative to change to ahigh-temperature oil.

For further information, see chapter ‘‘2.5Lubricants” on page 34.


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2.4 When changing oil 2 Maintenance Directions

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Tooth appearance examples

Satisfactory teeth:

Uniform wear of contact surfaces. Surfaces aresmooth.

Good contact surfaces will form on the teeth whenthe gear is subjected to only moderate loadduring its running-in period.

Worn teeth:

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

• the wear is uniform over the whole of the flankof a tooth

• and all teeth are worn in the same way.

Spalling:

Small bits of the teeth have broken off, so-calledspalling. This is generally caused by excessiveload or improper lubrication. Damage of this type

may not necessitate immediate replacement, butcareful checking at short intervals is of imperativeimportance.

Pitting:

Small cavities in the teeth, so-called pitting, canoccur through excessive load or improperlubrication. Damage of this type need notnecessitate immediate replacement, but careful

check at short intervals is of imperativeimportance.

G 0 5 3 8 7 1 1

Satisfactory teeth

G 0 5 3 8 8 1 1

Worn teeth

G 0 5 3 8 9 1 1

Spalling

G 0

5 3 9 0 1 1

Pitting


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2 Maintenance Directions 2.4 When changing oil

2.4.2 Oil change procedure

1. Place a collecting tray under the drain hole,remove the drain plug (3) and then drain offthe oil.

2. Fill new oil in the worm gear housing. The oillevel should be slightly above middle of thesight glass.

Oil volume: approx. 8 litres.

Suitable oil brands can be found in ‘‘2.5.3Recommended oil brands” on page 37.

NOTE

Before adding or renewing lubricating oil inthe worm gear housing, the informationconcerning different oil groups, handling ofoils, oil change intervals etc. given in chapter‘‘2.5 Lubricants” on page 34 must be wellknown.

CAUTION

Burn hazards

Lubricating oil and various machine surfacescan be sufficiently hot to cause burns.

NOTE

During operation the oil level must be slightlybelow the middle of the sight glass.

If the oil level is too high, the lifetime of therolling bearings will be reduced due to hightemperature.

G 0 1 3 4 4 1 1

1. Cover 2. Sight glass

3. Oil drain plug

G 0 0 3 5 9 2 1

Burn hazards: The drained oil may be hot

G 0 2 6 2 0 1 1

The oil level must not be above the middle of the sightglass


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2.5 Lubricants 2 Maintenance Directions

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2.5 Lubricants

2.5.1 Lubrication chart, generalAlfa Laval ref. 553216-01, rev. 6

Lubricating points Lubricants

Bowl spindle ball bearings and buffers arelubricated by oil mist.

Lubricating oil as specified in ‘‘2.5.2Recommended lubricating oils” on page 36.

Bowl spindle taper. Lubricating oil (only a few drops for rustprotection).

Metal buffers of bowl spindle. Lubricating oil.

Bowl:

Sliding contact surfaces and pressure loadedsurfaces such as lock rings, threads of lock rings,bowl hood, and cap nut.

Pastes as specified in ‘‘2.5.4 Recommendedlubricants” on page 38.

Rubber seal rings. Grease as specified in ‘‘2.5.4 Recommendedlubricants” on page 38.

Friction coupling ball bearings. The bearings are packed with grease andsealed and need no extra lubrication.

Electric motor (if nipples are fitted). Follow manufacturer’s instructions.

NOTE

The Lubrication chart, general can be complemented with more detailed charts, showing thelubrication points in detail and what type of lubricant to use.

Instructions related to a specific design of the machine, refer to the general assembly drawings.

Some application processes demand special lubrication.

If not specified otherwise, follow the supplier’s recommendation about method of application.


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2 Maintenance Directions 2.5 Lubricants

Alfa Laval Lubricating Oil Groups

• 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 operatingtemperatures.

• Group E oil: Characteristics as a group D-oil but suitable at a higheroperation 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 afew drops of motor oil mixed into a synthetic oil may result in severefoaming.

Any presence of black deposits in a mineral type oil is an indication thatthe oil base has deteriorated seriously or that some of the oil additiveshave precipitated. Always investigate why black deposits occurs.

• If it is necessary to change from one group of oil brand to another it isrecommended to do this in connection with an overhaul of theseparator. Clean the gear housing and the spindle parts thoroughlyand remove all deposits before filling the new oil.

• It is of utmost importance to use the lubricants recommended in ourdocumentation.

This does not exclude, however, the use of other brands, provided theyhave equivalently high quality properties as the brands recommended.The use of oil brands and other lubricants than recommended, is doneon the exclusive responsibility of the user or oil supplier.

Applying, handling and storing of lubricants

• Always be sure to follow lubricants manufacturer's instructions.

NOTEAlways clean and dry parts (also tools) before lubricantsare applied.

CAUTION

Check the oil level before start. Top upwhen necessary.

Oil volume = see “Technical Data”.


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36

2.5.2 Recommended lubricating oils

Alfa Laval ref. 553219-08, rev. 0

Type of frame X 10 with motor 25-45 kW.

One group of lubricating oil is approved for this separator. It isdesignated as lubricating oil group B.

The numerical value after the letter states the viscosity grade.

The corresponding commercial oil brands are found in chapter ‘‘2.5.3Recommended oil brands” on page 37.

Note:

• In a new installation or after change of gear transmission,change oil after 200 operating hours.

• When the separator is operated for short periods, lubricating oilmust be changed every 12 months even if the total number ofoperating hours is less than stated in the recommendationsabove.

• 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.

Ambient temperature (°C) Alfa Laval lubricating oilgroup

Time in operationOil change interval

between +5 and +45 B/320 1 500 h


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2.5.3 Recommended oil brands

Paraffinic mineral lubricating oil, category

(ISO-L-) CKE 320.

Alfa Laval ref. 553218-07, rev. 3

* These oils must be used when the frame

temperature is above 80 °C.

If the temperature can't be measured, a roughestimate is that 80 C is when onecan touch the surface of lower part of frameonly for a short time.

The list of recommended oil brands are notcomplete. Other oil brands may be used as longas they have equivalently quality as the brandsrecommended. The oil must have the sameviscosity class and shall follow the requirementsin one of the standards below. The oil must alsobe endorsed for worm gear with brass wormwheel. The use of other lubricants than therecommended is done on the exclusiveresponsibility of the user or oil supplier.

NOTE

The following is a list of recommended oil brands.Trade names and designations might vary from country to country.Please contact your local oil supplier for more information.

Alfa Laval lubrication oil group B

Viscosity grade VG (ISO 3448/3104)Viscosity index VI (ISO 2909)

VG 320VI >90

Manufacturer Designation

ChevronTexaco Texaco/Caltex Meropa 320

Shell Omala 320(Omala RL 320) * Synthetic

Standard Designation

ISO 12925-1, (ISO 6743/6) ISO-L-CKC/CKD/CKE/CKT 320

DIN 51517 part 3 DIN 51517 - CLP 320


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2.5.4 Recommended lubricants

553217-01, rev. 10

Pastes for non-food applications:

Bonded coatings:

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. Please contact your localsupplier for more information.

Brands with Alfa Laval article number are approved and recommended for use.

Manufacturer Designation Alfa Laval No

Fuchs Lubritech Gleitmo 805KGleitmo 705

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

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

Rocol Dry Moly Paste MT-LM

Klüber Wolfracoat C (Paste)


Fuchs Lubritech Gleitmo 900 (Varnish or spray)

Dow Corning Molykote D321R (Spray)Molykote D321R (Varnish)Molykote D321R (Paste)

535586-01 (400 ml)535586-02 (60 ml)535586-80 (25 ml)


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Pastes for hygienic applications (NSFregistered H1 is prefered):

Manufacturer Designation Hygienic Comment Alfa Laval No

Fuchs Lubritech Gleitmo 805 DVGW (KTW) approvalfor drinking water(TZW prüfzeugnis)

Geralyn 2 NSF Registered H1(3 sep 2004)

561764-01 (50 g)

Bremer &Leguil, FuchsLubritech

Rivolta F.L.A NSF Registered H1(15 Feb 2003) German §5 Absatz 1LMBG approved

Dow Corning Molykote TP 42Molykote D

Molykote P1900 NSF Registered H1(7 Jan 2004)

Klüber Klüberpaste 46 MR 401 White; contains nolead, cadmium, nickel,sulphur nor halogens.

Klüberpaste UH1 96-402 NSF Registered H1(25 Feb 2004)

Rocol Foodlube Multi Paste NSF Registered H1(13 Apr 2001)


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Silicone grease for rubber rings:

Manufacturer Designation Follows according. toManufacturer

Alfa Laval No

Dow Corning Molykote 111(Compound)Molykote 111(Compound)

Conform to the FDAregulations (21 CFR178.3570) for occasionalfood contact. Certified:National Water Council UKand WRC, UK. Certified:food industry as perChemical Testing LaboratoryDr. Böhm, Munich.

539474-02 (100 g)

539474-03 (25 g)

Molykote FoodslipSR grease

Former USDA H1 approved. 569415-01 (50 g)

FuchsLubritech

Chemplex 750 DVGW approved accordingto the German KTW-recomendations for drinkingwater.

Bremer & LeguilRivolta F.L.G MD2

NSF Registered H1(15 Feb 2003)

Klüber Unisilkon L 250 L Complies with GermanEnvironmental Agency onhygiene requirements for tapwater. Certified by DVGW-KTW, WRC, AS4020, ACS.

Paraliq GTE 703 NSF Registered H1 (25 Feb2004) Complies with LMBGand the European standardEN 1672, part2.

Bel-Ray No-Tox Siliconevalve seal

NSF Registered H1(19 June 2002)

MMCC ALCO 220 NSF Registered H1(25 March 2002)

Rocol Foodlube Hi-Temp NSF Registered H1

(18 April 2001)


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Greases for ball and roller bearings:

NOTE

Always follow the specific recommendation for lubrication as advised by themanufacturer.


BP Energrease MP-MG2Energrease LS2Energrease LS-EP2

Castrol APS 2

Spheerol EPL 2

Chevron Texaco Chevron Dura-Lith Grease EP2Texaco Multifak AFB 2

Dow Corning Molykote G-0101Molykote Multilub

ExxonMobil Beacon EP2Unirex N2Mobilith SHC 460Mobilux EP2

Fuchs Lubritech Lagermeister EP2

Q8/KuwaitPetroleum

Rembrandt EP2

Shell Alvania EP 2Albida EP2

SKF LGEP 2LGMT 2

Total Multis EP2


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2.6 Vibration 2 Maintenance Directions

42

2.6 Vibration

2.6.1 Vibration analysis

Excessive vibration or noise indicates a malfunction.Stop the separator and identify the cause.

Use vibration analysis instrument to periodicallycheck and record the level of vibration. See theillustration where to take measurements.

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 formore information.

Brands with Alfa Laval article number are approved and recommended for use.

NOTE

The level of vibration should not exceed9,0 mm/s at full speed.

WARNING


If excessive vibration occurs, keep bowlfilled and stop separator.

The cause of the vibration must be identified

and corrected before the separator isrestarted. Excessive vibration can be due toincorrect assembly or poor cleaning of thebowl.

G 0 1 2 0 4 3 1

Measuring points for vibration analysis


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2 Maintenance Directions 2.7 Common maintenance directions

2.7 Common

maintenance

directions

2.7.1 Ball and roller bearings

Special-design bearings for the bowl spindle

The bearings used for the bowl spindle arespecified to withstand the speed, vibration,temperature and load characteristics of high-speed separators.

Only Alfa Laval genuine spare parts should beused.

A bearing that appears equivalent to the genuinemay differ considerably in various respects: insideclearances, design and tolerances of the cageand races as well as material and heat treatment.

Dismantling

For bearings where no driving-off sleeve isincluded in the tool kit, remove the bearing fromits seat by using a puller. If possible, let the pullerengage the inner ring, then remove the bearingwith a steady force until the bearing borecompletely clears the entire length of thecylindrical seat.

The puller should be accurately centred duringdismantling; otherwise, it is easy to damage theseating.

NOTE

Using an incorrect bearing can cause aserious breakdown with damage to

equipment as a result.

Do not re-fit a used bearing. Always replaceit with a new.

NOTE

Do not strike with a hammer directly on the

bearing.

G 0 5

8 7 3 2 1

1 Outer race 2 Ball/roller 3 Inner race 4 Cage

G 0 5 8 7 4 1 1

For bearings where no driving-off sleeve is included inthe tool kit, use a puller when removing bearings


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2.7 Common maintenance directions 2 Maintenance Directions

44

Cleaning and inspection

Check shaft (spindle) end and/or bearing seat inthe housing for damage indicating that thebearing has rotated on the shaft (spindle) and/or

in the housing respectively. Replace the damagedpart(s), if the faults cannot be remedied bypolishing.

Assembly

• Leave new bearings in original wrapping untilready to fit. The anti-rust agent protecting anew bearing should not be removed beforeuse.

• Maintain the greatest cleanliness whenhandling the bearings.

• To facilitate assembly and also reduce therisk of damage, first clean and then lightly oilthe bearing seating on shaft (spindle) oralternatively in housing, with a thin oil.

• When assembling ball bearings, the bearingsmust be heated in oil to max. 125 °C.

NOTE

Heat the bearing in a clean container.

Use only clean oil with a flash point above250 °C.

The bearing must be well covered by the oiland not be in direct contact with the sides orthe bottom of the container. The bearingshould be supported or suspended in the oilbath.

G 0 5 8 7 5 1 1

Clean and oil the bearing seating before assembly

G 0 5 8 7 6 1 1

The bearing must not be in direct contact with thecontainer


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45


• There are several basic rules for assemblingcylindrical bore bearings:

− Never directly strike a bearing’s rings,cage or rolling elements whileassembling. A ring may crack or metalfragments break off.

− Never apply pressure to one ring in orderto assemble the other.

− Use an ordinary hammer. Hammers withsoft metal heads are unsuitable asfragments of the metal may break off andenter the bearing.

− Make sure the bearing is assembled at aright angle to the shaft (spindle).

• If necessary use a driving-on sleeve that

abuts the ring which is to be assembled withan interference fit, otherwise there is a riskthat the rolling elements and raceways maybe damaged and premature failure mayfollow.

Angular contact ball bearings

Always fit single-row angular contact ball bearingswith the wide shoulder of the inner race facing theaxial load (upwards on a bowl spindle).

WARNING

Burn hazards

Use protective gloves when handling theheated bearings.

G 0 5 8 7 7 1 1

Use a driving-on sleeve for bearings that are not

heated

G 0 5 8 7 2 1 1

The wide shoulder of the inner race must face theaxial load


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Lubrication

NOTE

Since roller bearings are normally treated

only with rust protection oil from the factory,an initial lubrication of new bearings mustalways be performed whenever bearings arereplaced.

The initial lubrication implies adding a fewdrops of lube oil to the bearings. Use thesame oil type as in the separator worm gearhousing.


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2.7.2 Before shutdowns

Before the separator is shut-down for a period oftime, the following must be carried out:

• Remove the bowl, according to instructions inchapter ‘‘3 Dismantling/Assembly” on page45.

• Protect cleaned carbon steel parts againstcorrosion by oiling. Separator parts that arenot assembled after cleaning must be wipedand protected against dust and dirt.

• If the separator has been shut-down for more

than 3 months but less than 12 months, anIntermediate Service (IS) has to be made. Ifthe shut-down period has been longer than12 months, a Major Service (MS) should becarried out.

NOTE

The bowl must not be left on the spindleduring standstill for more than one week.

Vibration in foundations can be transmitted tothe bowl and produce one-sided loading ofthe bearings. The resultant indentations inthe ball bearing races can cause prematurebearing failure.

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3 Dismantling/Assembly

3.1 Introduction

3.1.1 General directions

The separator must be dismantled regularly forcleaning and inspection.

The recommended intervals are stated in chapter

‘‘2.1.2 Maintenance intervals” on page 17.

The frame hood and heavy bowl parts must belifted by hoist. Position the hoist directly above thebowl centre. Use an endless sling and a liftinghook with catch.

These parts must be handled carefully.

Do not place parts directly on the floor, but on a

clean rubber mat, fibreboard or a suitable pallet.

WARNING

Entrapment hazard

Make sure that rotating parts have come to acomplete standstill before starting any dismantling work.

The revolution counter and the motor fanindicate if separator parts are rotating or not.

NOTE

Never interchange bowl parts

To prevent mixing of parts, e.g. in aninstallation comprising several machines ofthe same type, the major bowl parts carry themachine manufacturing number or its lastthree digits.

G 0 2 4 6 2 2 1

The revolution counter indicates if the separator still isrotating

http://02012.pdf/http://02012.pdf/


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3.1 Introduction 3 Dismantling/Assembly

50

3.1.2 References to checkpoints

In the beginning of each sub-chapter describingthe assembly you will find references to the checkpoint instructions included in separate chapters.

The references appear in the text as in thefollowing example:

✔ Check point

‘‘3.3.2 Bowl hood seal ring” on page 70

It is assumed that these check points are donebefore starting the assembly.

3.1.3 Tools

Special tools from the tool kit must be used fordismantling and assembly. The special tools arespecified in the Spare Parts Catalogue and areshown as illustrations together with thedismantling/assembly instructions.

3.1.4 Tightening of screws

When tightening screws, use the torques stated inthe table below unless otherwise stated. Thefigures apply to oiled, stainless screws tightenedwith a torque wrench.

NOTE

When lifting parts without weightspecifications, always use lifting straps with

the capacity of at least 500 kg.

METRIC THREAD

Thread

Torque(stainless steel)

Nm

M6 7

M8 18

M10 35

M12 64

M16 157

M20 304

M24 500


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3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

3.2 Intermediate Service

(IS), dismantling

3.2.1 Inlet/outlet and frame hood

1. Nipple 9. Rectangular ring

2. Rectangular ring 10. Diaphragm

3. Inlet pipe 11. Pressure gauge

4. O-ring 12. Discharge cover

5. Cap nut 13. Screw

6. Washer 14. Guide ring

7. Coupling nut 15. Height adjusting rings

8. Connecting sleeve 16. Frame hood

G 0 8 0 8 7 2 1


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3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

52

1. Unscrew the coupling nuts for inlet hose andoutlet hose. Disconnect the in- and outletpipes.

2. Remove the rectangular rings.

3. Loosen the paring disc from the dischargecover by turning the inlet pipe.

Left-hand thread!

4. Remove the inlet pipe.

G 0 8 0 6 0 1 1

G 0 8 0 6 1 1 1

S 0 0 7 2 8 2 1

G 0 8 0 6 2 1 1


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5. Unscrew the nuts holding the dischargehousing and remove it from the frame hood.

6. Unscrew the hook screws holding the framehood.

7. Lift the frame hood with lifting straps attachedto the handles.

Remove the O-ring.

G 0 8

0 7 5 1 1

G 0 8 0 6 9 2 1

G 0 8 0 7 0 2

1


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In case of major service.

8. Unscrew the hook screws holding the framering.

9. Lift off the frame ring.

10. Remove the O-ring.

G 0 8 0 7 1 2 1

G 0 8 0 7 3 2 1


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3.2.2 Bowl hood and disc stack

G 0 9 2 3 6 9 1


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1. Small lock ring

2. Paring chamber top part

3. O-ring

4. Gasket

5. Paring disc complete (2 pieces)

6. Gravity disc

7. O-ring

8. Paring chamber, lower part

9. O-rings

10. Lock ring

11. O-ring

12. Bowl hood

13. Seal ring

14. O-ring

15. Top disc

16. Bowl discs (thinner caulks than other discs in the disc stack)

17. Bowl discs

18. Wing insert

19. Bottom bowl disc (caulks on both sides)

20. Distributor

A. Purifier, Bowl no: 558927-02, -09

B. Purifier, Bowl no: 558927-05, -12

C. Purifier, Bowl no: 558927-04, -11

D. Concentrator, Bowl no: 558927-03, -10

E. Concentrator, Bowl no: 558927-01, -08

F. Concentrator, Bowl no: 558927-06, -07, -13, -14

H. Concentrator, Bowl no: 558927-16


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1. Unscrew and remove the lock ring using thespanner.

Left-hand thread!

2. Remove

− paring chamber top part,

− paring disc top and bottom part,

− gravity disc,

− paring chamber lower part,

− Remove all O-rings.

3. Apply the brake.

G 0 8 0 9 4 2 1

S 0 1 0 3 1 1 1

G 0 8 0 7 8 3 1

G

0 5 2 0 1 2 1


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4. Compress the disc stack

a. Fit (1) the lifting tool on the bowl hood.

b. Fit the compressing tool on the lifting tool.

Use the lever arm to screw (2) thethreaded pillar of the tool into thedistributor. The switch on thecompressing tool should be in position 0.

c. Turn the switch (3) to position 1 forcompression.

d. Compress the disc stack by pumping (4)with the lever arm.

The compressing tool is hydraulic and is fittedwith a relief valve.

5. Unscrew the large lock ring using the spannerand tin hammer.

Left-hand threads!

6. Remove the compressing tool

a. Release the pressure in the compressingtool. Turn the switch (1) to position 0.

b. Loosen the compressing tool from thebowl hood. Use the lever arm to screw (2)the threaded pillar of the tool out of thedistributor.

NOTEThe large lock ring must be placed resting ona flat and horizontal surface to avoiddistortion.

Only slight distortion can make it impossibleto refit.

G 0 5 8 1 9 1 1

G 0 5 8 2 3 2 1

G 0 5 8 1

9 2 1


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7. Fit the lifting eyes and remove the large lockring with a hoist.

8. Lift off the bowl hood with a hoist. Be carefulnot to scratch the bowl hood seal ring.

9. Remove the O-ring and seal ring on the bowlhood.

10. Remove the top disc.

NOTEThe large lock ring must be placed resting ona flat and horizontal surface to avoiddistortion.Only a slight distortion can make it

impossible to refit.

CAUTION

Crush hazard

If the top disc is stuck into the bowl hood,remove it now before it accidentally falls out.

G 0 5 3 1 5 2 1

S 0 0 7 8 2 1 1

G 0 4 9 7 0 3 1


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11. Fit the lifting tool into the distributor and liftthe distributor with disc stack out of the bowlbody with a hoist.

CAUTION

Cut hazard

Sharp edges on separator discs may causecuts.

G 0 4 9 7 1 2 1

S 0 0 9 0 3 1 1


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3.2.3 Bowl body and operating

mechanism

1. Cap nut

2. O-ring

3. Distributing cone A. Purifier bowl B. Concentrator bowl

4. Sliding bowl bottom

5. O-ring

6. Screw

7. O-ring

8. Bowl body

9. Wear protection

10. O-ring

11. Rectangular ring

12. Valve plug

13. Operating slide

14. Screw

15. Insert ring

16. Dosing ring

17. Screw

18. Nozzle *)

*) Secured with Loctite 242

G 0 9 2 3 6 5 1


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1. Remove the cap nut using the hook spanner.

Left-hand threads!

2. Fit the lifting tool to the distributing cone andlift it out.

3. Fit the lifting tool to the sliding bowl bottomand lift it out with a hoist.

Remove the rectangular ring by blowingcompressed air through hole on underside ofsliding bowl bottom.

4. Remove the three screws in the bottom of thebowl.

5. Fasten the lifting tool to the bowl body. Screwback the lifting eye to allow the three screwsto be properly screwed down.

Tighten the three screws to the bowl. Ease offthe bowl body from the bowl spindle top bytightening the central screw (lifting eye).

G 0 8 0 7 6 1 1

G 0 8 1 0 0

1 1

G 0 8 1 0 1 1 1

G 0 8 1 0 2 1 1

G 0 8 1 0 3 1 1


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6. Lift out the bowl body using a hoist.

7. Remove the O-ring on the bowl body nave.

Thread a strap through two sludge ports andturn the bowl body upside down with a hoist.

8. Loosen the screws holding the dosing ring iplace.

WARNING

Crush hazards

Support the bowl body when turning toprevent it from rolling.

G 0 8 1 0 4 2 1

G 0 6 1 5 8 2 1

G 0 8 1 0 6 1 1


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9. Fit the lifting eye bolts to the dosing ring andlift it off.

10. Remove the O-rings on the bowl body andoperating slide.

11. Lift off the operating slide.

12. The insert ring should normally not beremoved. But if, loosen the screws holdingthe insert ring and remove the ring.

13. Remove deposits and clean all partsthoroughly in a suitable cleaning agent. Seechapter ‘‘2.3 Cleaning” on page 27.

G 0 8 1 0 7 1 1

S 0 0 7 8 1 1 1

G 0 8 1 0 8 1 1

G 0 8 1 0 9 1 1



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3.2.4 Operating liquid device (IS)

1. Hydraulic piston

2. Rectangular r ing

3. O-ring

4. O-ring

5. Cover

6. Screw

7. Paring disc

8. Gasket

9. O-ring

10. Cover

11. Distributing cover

12. O-ring

G 0 8 7 8 0 3 1


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1. Slacken the screws of the paring disc with ahexagon wrench and unscrew with a suitablescrew driver.

2. Lift out the paring disc device.

3. Loosen and undo the liquid hoses (1) fromthe operating liquid pipes.

G 0 1 3 1 7 2 1

G 0 5 8 8 0 1 1

G 0 6 8 1 2 6 1


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68

4. Unscrew the screws and lift up the distributingcover including the liquid pipes.

Then separate the pipes from the cover.

5. To dismantle the paring disc device turn itupside down and remove the screws.

G 0 5 8 8 1 1 1

G 0 5 8 8 2 1 1


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6. Remove deposits and clean all partsthoroughly in a suitable cleaning agent. Payspecial attention to the channels. See chapter‘‘2.3 Cleaning” on page 27.

7. Check the parts for damage and corrosion.

G 0 5 8 9 2 1 1



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3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

70

3.3 Intermediate Service

(IS), checkpoints

3.3.1 Introduction

This chapter consists of checkpoints that can bedone when the separator has been dismantled forIntermediate Service but before it is assembled. Other checkpoints that can be done only in theconjunction with the assembly are described inthe assembly sections.

3.3.2 Bowl hood seal ring

Poor sealing between the bowl hood seal ring andthe sealing edge of the sliding bowl bottom willcause a leakage of process liquid from the bowl.

Renew the bowl hood seal ring at eachIntermediate Service (IS).

Knock out the old ring by means of a pin insertedin the holes intended for this purpose.

G 0 2 0 6 2 1 1

Max. permitted indentation of the seal ring is 1 mm

G 0 2 0 6 2 1 1

G 0 2 0 6 3 1 1

G 0 2 0 6 3 1 1

Removal of the seal ring


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71

3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

Fit the new ring as follows:

Press the ring into the groove with a straightwooden board placed across the ring..

3.3.3 Bowl spindle cone and bowl

body nave

Impact marks on the spindle cone or in the bowlbody nave may cause poor fit and out-of-balancevibrations.

The bowl spindle and the nave should also bechecked if the bowl spindle has been dismantledor if the bowl runs roughly.

Corrosion may cause the bowl to stick firmly tothe spindle cone and cause difficulties during the

next dismantling.

• Remove any impact marks with a scraperand/or whetstone.

Rust can be removed by using a fine-grain emerycloth (e.g. No. 320).

Finish with polishing paper (e.g. No. 600).

NOTE

If the new ring is too narrow, place it in hotwater (70-80 °C) for about 5 minutes.If it is too wide, it will shrink after drying at80-90 °C for about 24 hours.

NOTE

Always use a scraper with great care. Thecone shape must not be deformed.

G 0 2 0 6 4 1 1

Fitting of the seal ring

G 0 2 0 6 4 1 1

G 0 5 4 7 9 2 1

Remove impact marks from the nave and cone


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72

3.3.4 Corrosion

Evidence of corrosion attack should be looked forand rectified each time the separator isdismantled. Main bowl parts such as the bowl

body, bowl hood and lock ring must be inspectedwith particular care for corrosion damage.

Always contact your Alfa Laval representative ifyou suspect that the largest depth of thecorrosion damage exceeds 1,0 mm or if crackshave been found. Do not continue to use theseparator until it has been inspected and givenclearance for operation by Alfa Laval.

Cracks or damage forming a line should beconsidered as being particularly hazardous.

Non-stainless steel and cast iron parts

Corrosion (rusting) can occur on unprotectedsurfaces of non-stainless steel and cast iron.Frame parts can corrode when exposed to anaggressive environment.

WARNING

Disintegration hazard

Inspect regularly for corrosion damage.Inspect frequently if the process liquid iscorrosive.

G 0 2 0 6 1 1 1

Main bowl parts to check for corrosion

G 0 2 0 6 1 1 1


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Stainless steel

Stainless steel parts corrode when in contact witheither chlorides or acidic solutions. Acidicsolutions cause general corrosion. The chloride

corrosion is characterised by local damage suchas pitting, grooves or cracks. The risk of chloridecorrosion is higher if the surface is:

• Exposed to a stationary solution.

• In a crevice.

• Covered by deposits.

• Exposed to a solution that low pH.

Corrosion damage caused by chlorides on

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

1. Inspect closely for all types of damage bycorrosion and record these observationscarefully.

2. Polish dark-coloured spots and othercorrosion marks with a fine grain emery cloth.This may prevent further damage.

Other metal parts

Separator parts made of materials other thansteel, such as brass or other copper alloys, canalso be damaged by corrosion when exposed toan aggressive environment. Possible corrosiondamage can be in the form of pits and/or cracks.

WARNING


Pits and spots forming a line may indicatecracks beneath the surface.

All forms of cracks are a potential danger andare totally unacceptable.

Renew the part if corrosion can besuspected of affecting its strength or

function.

S 0 0 2 0 6 1 1

S 0 0 2 0 6 1 1

Example of chloride corrosion in stainless steel

S 0 0 2 0 5 1 1

Polish corrosion marks to prevent further damage

S 0 0 2 0 5 1 1


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74

3.3.5 Cracks

Cracks can initiate on the machine after a periodof operation and propagate with time.

• Cracks often initiate in an area exposed tohigh cyclic material stresses. These arecalled fatigue cracks.

• Cracks can also initiate due to corrosion in anaggressive environment.

• Although very unlikely, cracks may also occurdue to the low temperature embrittlement ofcertain materials.

The combination of an aggressive environmentand cyclic stresses will speed-up the formation ofcracks. Keeping the machine and its parts cleanand free from deposits will help to preventcorrosion attacks.

It is particularly important to inspect for cracks inrotating parts and especially the pillars betweenthe sludge ports in the bowl wall.

Always contact your Alfa Laval representative ifyou suspect that the largest depth of the damageexceeds 1,0 mm. Do not continue to use theseparator until it has been inspected and clearedfor operation by Alfa Laval.

WARNING


All forms of cracks are potentially dangerousas they reduce the strength and functionalability of components.

Always replace a part if cracks are present.


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3.3.6 Dosing ring

Clean the nozzles (1) with a soft iron wire andpolish the surface (2) with steel wool.

Inspect the surface (3) in contact with theoperating slide. Remove any marks with awhetstone or fine emery cloth (grain size 240).

3.3.7 Erosion and wear liners

Erosion can occur when particles suspended inthe process liquid flow along or strike against asurface. Erosion can become intensified locally byflows of higher velocity.

Always contact your Alfa Laval representative ifthe largest depth of any erosion damage exceeds1,0 mm. Valuable information as to the nature of

the damage can be recorded using photographs,plaster impressions or hammered-in lead.

Erosion is characterised by:

• Burnished traces on the material.

• Dents and pits having a granular and shinysurface.

WARNING


Inspect regularly for erosion damage. Inspectfrequently if the process liquid is erosive.

G 0 5 3 7 0 2 1

1. Nozzles

2. Surface inside the dosing ring 3. Surface in contact with the operating slide

G 0 5 3 7 0 2 1

G 0 2 0 5 2 2 1

G 0 2 0 5 2 2 1

Max. permitted erosion


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Surfaces particularly subjected to erosion are:

1. The outlet paring disc.

2. The top disc.

3. The pillars between the sludge ports in thebowl wall.

4. The sealing edge of the bowl body for theseal ring in the sliding bowl bottom.

5. The underside of the distributor in the vicinityof the distribution holes and wings.

6. The surface of the sliding bowl bottom thatfaces the conical part of the distributor.

7. The sealing edge of the sliding bowl bottom.

Look carefully for any signs of erosion damage.Erosion damage can deepen rapidly andconsequently weaken parts by reducing thethickness of the metal.

WARNING


Erosion damage can weaken parts byreducing the thickness of the metal.

Pay special attention to the pillars betweenthe sludge ports in the bowl wall.

Renew the part if erosion is suspected ofaffecting its strength or function.

G 0 8 0 8 6 4 1

Surfaces particularly subjected to erosion


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Wear liners in the bowl

The wear liners protect both the wall pillars in thebowl body and the sliding bowl bottom. They mustbe replaced before the liners have been

perforated by erosion.

Wear liners in wall pillars

When fitting new liners keep in mind that they willbe subjected to a very high service stress. Forcesup to 10 000 G are not unusual at the bowlperiphery. It is essential, therefore, that the linersare being mounted carefully and in full agreementwith the following instructions:

The wear liners are made of stainless steelaccording to the adjoining illustration.

1. Remove the old liner and place the new linerblank in the wall pillar.

2. Fasten the mounting tool between the wallpillars as shown in the illustration. Clamp thewear liner with the tool.

3. Tighten the tool nut with a spanner until theliner is firmly pressed to its seat.

4. Bend the shank (1) at right angles to theoutside of the bowl wall using a drift.

G 0 2 0 7 6 1 1

S 0 0 3 2 0 1

1

G 0 2 9 8 6 1 1

G 0 2 9 8 7 1 1

G 0 2 9 8 9 2 1


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5. Back off the nut of the tool and remove it.

6. Remove the liner and cut the shank so that itends 0,5-1,5 mm (A) from the bowl wall.

7. Fit the wear liner in the wall pillar and clamp itwith the tool. Knock the shank flat against thewall of the pillar.

8. Remove the tool and check that the wear lineris well attached and that the shank (1) doesnot protrude beyond the bowl periphery. Fitthe other liners as described above.

Wear liner in sliding bowl bottom

When fitting a new wear liner (4) in the slidingbowl bottom (6), dismantle and assemble asillustrated.

The wear liner can preferably be pressed out ofthe sliding bowl bottom by using two screw driversor similar. Normally the wear liner will be

destroyed when removed.When renewing the wear liner also renew theO-rings (3 and 5).

G 0 6 7 0 2 2 1

S 0 0 3 1 8 1 1

G

0 2 9 8 8 2 1

G 0 9 2 3 6 6 1

1. Screw 2. Fixing ring 3. O-ring 4. Wear liner 5. O-ring

6. Sliding bowl bottom


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3.3.8 Guide surfaces

Check surfaces indicated (1 and 2) for burrs orgalling. Rectify when necessary.

Repair of galling on guide surfaces; see followingpages. Before fitting the sliding bowl bottom,clean (do not degrease) the contact surfaces (1).Apply Alfa Laval lubricating paste or Molykote1000 Paste with a well-cleaned brush on surfaces(1 and 2).

Lubricate the O-ring and the seal ring withsilicone grease making sure they are notdamaged and lie properly in their grooves.

NOTE

To avoid the risk of galling, the contactsurfaces (1) should be primed with a slidelacquer at every Major Service (MS).

The slide-lacquered surfaces will bedestroyed if the surfaces are degreased.

1 & 2. Lubricated with Molykote 1000 Paste

G 0 3 7 8 2 8 1

Sliding bowl bottom

G 0 3 7 8 2 9 1

Bowl body

G 0 3 7 8 2 7 1

Operating slide

G 0 3 7 8 2 6 1

Dosing ring


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Repair of galling on guide surfaces

Galling (friction marks) may appear on guidesurfaces in the operating system, the bowl bodyand the sliding bowl bottom. Surfaces subject to

repair are indicated by an arrow.

The example below describes the repair of thelower guide surface of the bowl body nave.

Recommended tools for correction of galling:

- Emery cloth, 240 grade.- Small power drill

- Degreasing agent.- Fibre brush, ∅ 25mm.- Fibre brush, ∅ 50 mm.- Very fine single-cut file.

1. Clean the surface thoroughly with adegreasing agent, i.e. white spirit. This isimportant.

2. If the galling is excessive, first use the finesingle-cut file. The file should be used withcaution so that the damage is not madeworse.

Remove the high spots on the surface. Do not

use rotating files or similar. Remove the highspots only - not the undamaged material.

G 0 2 0 5 5 1 1

Guide surface in the bowl body

G 0 2 0 5 6 1 1

G 0 2 0 5 7 1 1


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3. An emery cloth of 240 grade should be usedto smooth the edges and to remove anyburnt-in foreign matter.

4. Finish off by polishing the damaged spot withthe fibre brushes and brush wax. It isrecommended that

Documents

Service and Maintenance Manual AFPX 513