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System Manual

LOPX 710Separation System

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LOPX 710 Separation System

1 Safety:.2 System Description

• 3 Operating Instructions4 Parameter List

5 Alarms and Fault' Finding

6 System Reference

7 Installation Instructions

'. 8 Separator Manual (incl. fault finding)Spare Parts Catalogue

-- 9 Component Descriptions (incl. fault finding)10 Optional Equipment

Alfa Laval Marine & Power

Printed Dec 1996Book No. 1817176-02

Product No. 1765143-02

Published by:

Alfa Laval reserve the right to make changes at any time withoutprior notice.

Any comments regarding possible errors and omissions orsuggestions for improvement of this publication would begratefully appreciated.

Copies of this publication can be ordered from your local AlfaLaval company.

Alia Laval Separation ABMarine & Power Oil Treatment DivisionS-147 80 TumbaSweden

© Copyright Alfa Laval Separation AB 1996.

•

•

••. ,

Study instruction manuals and observe thewarnings before installation, operation,service and maintenance.

Not following the instructions can result inserious accidents with fatal injuries.

In order to make the information clear only foreseeable conditions havebeen considered. No warnings are given, therefore, for situationsarising from unintended usage of the machine and its tools.

,

•

••

IPrintedBook No.

~~AlfaLavaI

Separation System

Safety

INov 19981810158-02 V4


••

•Alfa Laval reserve the right to make changes at any time without •prior notice.


Copies of this publication can be ordered from your localAlfa Laval company.

Published by: Alfa Laval Marine & Power ABS - 147 80 TumbaSweden

© Copyright Alfa Laval Marine & Power AB 1998.

Contents

••

••

1

1.1

1.2

Safety Instructions

Warning Signs

Specific Factors

1

1

3

1810158-02

~/..J ...•-.. -'••

1 Safety Instructions

1.1 Warning Signs

Pay attention to the safety instructions in thismanual. Below are definitions of the threegrades of warning signs used when there is arisk to personnel.

.DANGER

Ty~e of haz~r(f

Thistypeof.safetyinstructionindicates a situation which, ifnotavoid~d;couldresultin fatal injury,or fatal c\all1ageto health.

Thi stype of safety instructionindicates a situation which, ifl10tavoided,could result in disablinginjury, or disabling damage to health.

••

~.••WARNING

. Type ofhazard

CAUTION

Type of hazard

This. type of safety instructionindicates a situation which, if not·avoided, could result inIightil1jury,or light damage to health.

1810158-02 1

Safety1 Safety Instructions----------------------------'--

The warning sign used when there is a risk toequipment.

NOTE

This type of safety instructionindicates a situation which, if notavoided, could result in damage toequipment.

•The warning sign is also used when there is aneed to stress important information.

NOTE •This sign is used to stress importantinformation, e.g. how to read thissystem manual.

••

2 1810158-02

Safety 1 Safety Instructions

1.2 Specific Factors

••

••

The centrifugal separator includes parts thatrotate at high speed, generate high centrifugalforces, and take a long time to stop rotating.

Materials are carefully chosen and parts aredesigned with extremely fine manufacturingtolerances. Rotating parts are carefully bal-anced to reduce vibration and wear and tearand to withstand stress and fatigue.

The separation system is designed andsupplied for a specific function (type of liquid,rotational speed, temperature, density, etc.)and must be used for this function only, andstrictly within Alfa Laval's specifications.

Incorrect operation or maintenance is likely toresult in an imbalance due to build up ofsediment, reduction of material strength, etc.that could lead to serious injury or damage.

These compulsory safety instructions apply:

• Use the separator only for the purpose andparameter range specified by Alfa Lava!.

• Strictly follow the instructions forinstallation, operation and maintenance.

• Ensure that personnel are fully trained andcompetent in operation, maintenance andemergency procedures.

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

NOTE

If safety instructions and installationinstructions in this manual are notstrictly followed, Alfa Laval can notbe held responsible for anymalfunction or injuries resulting.

1810158-02 3


DANGER

Safety

Disintegrationhazard

Using the separation~ystem,6litsid~',limits specified by Alfa Laval couldcause breakdown.

If power cables have been altered,always check the rotatio~ directionOirthe separator rotates in reverse vitalrotating parts could unscrew.

'Excessive vibration may ,causebreakdown.

Do not enter the room after anemergency stop while the separator isstill rotating.

Do not start the separator after anemergency stop without firstremedying the cause of theemergency.

" After an emergency stop theseparator bowl must be manually

, cleaned before starting up again;

IftheA7- IQ CFOPX)alarm is riotremedied there is a risk forbreakdown.

If th~ A7~ iOj"cLoPx);{iannls not".Temedied there is a risk forbreakdown duet6 insufficient sludgeconditioning.

4

11 'pmHz ..

•

l-- ~=....,!!!=!!!"=~ ~I

1810158-02

••

••

Safety 1 Safety Instructions

DANGER

••

./t>s. ·OiliiritegratiOn·... hazard

. .

. IftheiI1terVal.tJetween sludgedischarges· istoo]ong, there is a riskof heavy sidebh~akdown ...

Operation instand-by mode foraprolonged period of time may causeheavyside breakdown. (FOPX)

Fail~re to follow th~ aboveinstructioIls may l~.~d to heavy sidebreakdown.

Iftheseparator ispm assembled andconnected properly it may lead to

. disintegration.

;

••

" . ", ' )., ." ,::.

Never discharge a vibrating sep.fratoEVibration will increase if only partof .S9lidifi~d sludge is discharged: .

Running a separator build for50 Hzat higher frequency will result inoverspeed and may causedisintegnttion.

1810158-02 5


Do riot be~in maintenancework .\\\'hjJeth~ll1achine is stilI tot~tiJ1g.

Do not switch on without all covers.and guards in place.

,Fire Hazard

.' Excess ofmaximum idling time maycause fire, if a destillate with low'"flashpoint is used.

6

Safety

1810158-02

••

••

Safety

...L1ii .. , .. ',"

-:", .WARNING

N()iSe h~zard


••

••

Excessive noisecanc3use damage to ..hearing if no ear protection is used.

. ..•... -_::-:,_:-:~,\::, -_c.:":::: '::' '," ," ,

WARNING


~....

. Disintegrationhazard

... ,:.:.:..,. .~.

..F~ilur~i!qcle~llthes~p~tor bowI,. includingoperatirlg: system,at

reqllir

••

••

Safety

Processpipes;hibricationoil and~'" vari6us'Iriachine-;~urfacescan be'hot

arid caukebuITls... :".,.' - ::,'

.. "

••

••

b~AlfaLavaI

LOPX Separation System

System Description

Printed Aug 1997Book No. 1810234-02 V3

, Alfa laval Marine & Power

Published by:

••

•Alfa Laval reserve the right to make changes at any time withoutprior notice. •



Alfa Laval Separation ABMarine & Power DivisionS -14780 TumbaSweden

© Copyright Alfa Laval Separation AB 1997.

Contents

1 Scope 1

2 System Overview 3

2.1 System Layout 4

• 2.2 Oil Flow 63 The ALCAP LOPX ProceSS73.1 The ALCAP Principle 7

• 3.2 Low Water Content 83.3 High water content 103.4 Displacement Water

Adjustments 12

3.4.1 Decreasing the Amount ofDisplacement Water 12

3.4.2 Increasing the Amount ofDisplacement Water 12

3.5 Definition of Terms 14

••

1810234-02

•

1 Scope

This system description is valid for thefollowing separation systems:

LOPX705

LOPX707

LOPX709

LOPX71O

• LOPX713

LOPX 714

The LOPX separation systems are designedfor cleaning of lubricating oil for dieselengines in marine and power applications.

••

1810234-02 1

2 System Overview

In the LOPX process, heated lubricating oil isfed through the separator to clean the oil fromsolid particles and water.

An LOPX system comprises:

• • An LOPX separator.

• Ancillary equipment including a controlunit and a water transducer.

• • Optional equipment such as an oil feedpump and an oil heating system.

The LOPX separator operates as a clarifier.Cleaned oil leaves the separator through theoil outlet while free water and separatedsludge accumulate at the periphery of theseparator bowI.

••

The control unit supervises the entireoperation of the separation system andperforms monitoring, control and alarmfunctions.

At normal conditions, characterized by low orno water content and normal sludge content,sludge discharges are initiated by the controlunit at preset intervals. Sludge and water arethen discharged through sludge ports at theperiphery of the bowl.

Water is used in the separation process, andspecific amounts of processing water areadded at different times.

The control uni t adapts the process to changedconditions such as changes in the watercontent of the lube oi I.

1810234-02 3

2 System Overview LOPX System Description

2.1 System Layout

The basic LOPX system layout is illustratedby the following symbol diagram.

••10

9

8

11

14

11

.L-_~5

D~12

4

3

c~

The inlet and outlet arrows indicate thefollowing:

The LOPX system

AB

UA

Unprocessed oil inletCleaned and recirculated oil outlet

CD

Water inletSludge outlet

DB

••

Item Symbol Designation Function

() Displacement pump Feeds unprocessed oil to the separator.1

ElHeater Heats unprocessed oil to separation temperature.

2

@Temperature transmitter Measures the oil temperature.

3

4 1810234-02

LOPX System Description 2 System Overview

••

••

Item Symbol Designation Function

~Pneumatically controlled Leads the unprocessed oil to the separator or back

4change over valve to the tank (recirculation).

2SSeparator Cleans the oil by removing water and solid

5 particles.

@Water transducer Measures the changes of water content in the

6 separated oil.

@-Flow indicator Displays the oil flow rate,

7

@High pressure switch Senses high pressure in the oil outlet.

8

@Low pressure switch Senses low pressu re in the oil outlet.

9

®Pressure gauge Displays the pressure in the oil outlet.

10"

~Manually controlled Regulates the clean oil back pressure.

11 regulating valve.

Non-return valve Stops reverse oil flow..,

12 ~

~Solenoid valve block, water Distributes separator opening and closing water,

13 conditioning water, and displacement water.

11 11

Control unit Supervises the separator system.

14

1810234-02 5

2 System Overview

2.2 Oil Flow

The unprocessed oil is fed through a strainerby a positive displacement pump, operating atconstant flow.

After the heater the change over valve directsthe oi I to the separator. The separated oilpasses the manually operated back-pressureregulating valve back to the lubricating oiltank.

The oil can also be directed back to the oiltank, bypassing the separator. This is the casewhen the oil temperature is outside the presetrange, during separator start and stopprocedures, and during alarm conditions.

6

LOPX System Description

1810234-02

••

••

3 The ALCAP LOPX Process

The terms used in this process description areexplained in section "3.5 Definition ofTerms" on page 14.

• 3.1 The ALCAP Principle

During the separation process sludge andwater accumulate at the periphery of the

• separator bowl.

Normally, sludge and water are discharged atpreset time intervals.

••

Should the build up of separated water andsludge increase, water may approach the discstack. In that case traces of water start toescape with the cleaned oil. This smallincrease of water content is immediatelydetected by the water transducer, installed inthe oil outlet.

The signal from the water transducer iscontinuously transmitted to the control unit,where a reference value is stored.

The control unit continually compares thetransducer signal with the reference value.Should a deviation from the reference valueoccur, a sludge discharge is initiated to keepthe system at optimum separation efficiency.

1810234-02

,

7


3.2 Low Water Content

Nonnally the lube oil contains little or nowater. In this case sludge discharges will betimer initiated.

s


I I 1 I I-.- 8- 11 - - -1- - - - - - - - - - - - - - - - 1- - - 1- -I I 1 I II I 1 I I

A~,lL~1---L¥I I ~;! I I

~~ 1 ~ II~:; F 1 I~:; G I

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I I II 0 I E I

• I • I

••

I I

Transducersigna~normalcondmons

s Transducer signal Et Time FA Trigger range GB Trigger valueC Reference time 1D Preset time between discharge sequences 2

The water transducer signal reflects thenonnal condition where the oil contains nowater. The preset time between sludgedischarges is set in the control unit as a timerfunction.

8

Displacement of oilAddition of conditioning waterAddition of displacement water

Storing of reference valueSludge discharge

1810234-02

••

LOPX System Description 3 The ALCAP LOPX Process

Process Cycle

I. Conditioning water is added to theseparator bowl. The conditioning watersoftens the sludge in order to accomplish agood discharge.

2. A new reference value is stored by thecontrol unit.

3. When the preset time between sludge

• discharges has elapsed, displacementwater is added to the separator bowI. Thedisplacement water eliminates the risk ofoil loss at the following sludge discharge.

• Initially, water is continuously admitted.4. After that, a number of short pulses add aminor amount of water. The interface,""!:•.

between oil and water moves toward butnever into the disc stack. This means thatthere is no risk of water contaminated oilleaving the separator.

.-5. The sludge discharge is initiated after a

predetermined number of water pulses.The actual number of pulses is calculatedby the control unit, and is adapted tochanging conditions.

• 6. After the sludge discharge a new processcycle starts with the adding of• conditioning water. A new reference valueis then stored.

1810234-02 9

3 The ALCAP LOPX Process LOPX System Description

3.3 High water content

When the water content is high, the transducersignal will reach the trigger value after theminimum time between discharge sequencesbut before the maximum time.

s

I Storing of reference value2 Sludge discharge

o Preset time between discharge sequencesF Addition of conditioning water

Process cycle. high water content

••

••

tc ..C 1"I

1 0~I--------~=--------------------.-I

s Transducer signalt TimeA Trigger rangeB Trigger valueC Reference time

Process Cycle

I. After the sludge discharge a new cyclestarts with the adding of conditioningwater.

2. A new reference value is stored.

10 1810234-02

••

••


3. Separated water will fill out the sludgespace of the bowI before the preset timebetween discharge sequences has elapsed.

4. Water escaping with the cleaned oil isimmediately detected by the watertransducer, and a sludge discharge isinitiated. No displacement water is addedin this case.

Alarm

Should five consecutive sludge discharges beinitiated by the transducer signal, the alarm forhigh water content is activated.

This alarm indicates that a water leakage hasoccurred somewhere in the lube oil system.

Resuming the Normal Process

When the water content in the lube oil isreduced, the preset time will elapse without atransducer initiated discharge.

The control unit then starts to add anappropriate amount of displacement water.The amount is adapted to the decreasing watercontent in the unprocessed oil.

After a few process cycles the system resumesits normal operating mode.

1810234-02


11


3.4 Displacement WaterAdjustments

The ALCAP LOPX process is automaticallyadjusting the amount of displacement water tosuit changing conditions, such as changedwater content in the oi I or scaling in the waterline.

3.4.1 Decreasing the Amount ofDisplacement Water

If the water content of the unprocessed oil islow, displacement water is added prior to thesludge discharge.

Should a sludge discharge be initiated by thetransducer signal during addition ofdisplacement water, too much water has beenadded. Less displacement water will then beused at the next sludge discharge cycle.

3.4.2 Increasing the Amount ofDisplacement Water

Every fourth sludge discharge the amount ofdisplacement water is checked to ensure thatan accurate amount of water is added.

A minor amount of extra water is then addedwith the displacement water.

An increased transducer signal confirms thatthe amount of displacement water wassufficient.

. Should the transducer notrespond to theadditional water, the amount of displacementwater is increased at the next sludge dischargecycle.

12


1810234-02

••

••


Alarm


If the amount of displacement water isincreased two times with no transducerresponse, the A7-11 alarm is activated.

This alarm indicates that the displacementwater supply is insufficient and must bechecked.

••

••

" '

1"~

1810234-02

DANGER

[)isir'ltegratiOn hazard

,

13


3.5 Definition of Terms

Transducer signal

Reference value

Reference time interval(Parameter value)

Trigger range(Parameter value)

Trigger value

Preset time between sludge dischargesequences(Parameter value)

Conditioning water

Displacement water

14


The analog signal from the water transducer.The transducer signal is monitored by thecontrol unit to detect minor changes of watercontent in the outlet oil from the separator.

The lowest achievable transducer value for theoil that is being processed.The reference value is determined during thereference time interval. The value is stored inthe control unit.The reference values differ for different lubeoils.

The time period after each sludge discharge,after which the actual transducer signal isstored as a reference value.

The allowed deviation of the water transducersignal, compared with the reference value.The trigger range lower limit is the referencevalue, and the range is normally set to 0.2% ofthe reference value.

Trigger range upper limit. When the transducersignal reaches the trigger value, water must bedischarged from the separator.

When this time has elapsed, a sludge dischargeis initiated.

Water, added to the separator bowl to soften thesludge.

Water, added to the separator bowl to displacethe oil and ensure there is no loss of oil atsludge discharge.

1810234-02

••

••

••

•'.

b~AlfaLavaI


Operating Instructions

Printed Nov 1998Book No. 1810020-02 V4


Alia Laval reserve the right to make changes at any time withoutprior notice.


Copies of this publication can be ordered from your localAlia Laval company.

Published by: Alia Laval Marine & Power ABS - 147 BD TumbaSweden

© Copyright Alia Laval Marine & Power AB 199B.

.',•

••

••

••

Study instruction manuals and observe the

warnings before installation, operation,

service and maintenance.

Not following the instructions can result in

serious accidents with fatal injuries.

In order to make the information clear only foreseeable conditions have

been considered. No warnings are given, therefore, for situations

arising from unintended usage of the machine and its tools.

A summary of the safety information is found in the Safety chapter

under divider 1.

Contents

1 Scope 1

2 Operating 3

2.1 Start up Check List 3

• 2.2 Start up 52.3 Intervals Between SludgeDischarges 72.3.1 Background 7

• 2.3.2 Lubricating oil cleaning 82.3.3 Bowl inspection 102.4 Intervals Between Bowl

Cleaning 11

2.5 Operating Check List 13

2.6 Stop 17

2.7 Emergency Stop 19

2.8 After Emergency Stop 19

••

1810020-02

•

1 Scope

These operating instructions are valid for the

following separation systems:

LOPX705

LOPX 707

LOPX 709

LOPX710

• LOPX713

LOPX 714

The LOPX separation system is designed for

cleaning of lubrication oil for marine and

power diesel engines.

••

1810020-021

Separator

1. Check that the separator is assembled and

connected correctly.••

2 Operating

2.1 Start up Check List

.................. DANGER.· ......~ .

. Disl~tegration..hazard

.If the separator is not assembled and

connected properly itmay lead todisintegration; ..•.•.••.....

. ..... .... ... ......

.

1~ __ _._ ~~ •.,.. Y'-...:........ ' .......... .............. .:..~._;:,~--~

......~

2 ....__._..._-~-~~~~

••

2. Check the oil sump level: it should be no

more than half way up the sight glass.

NOTE

Too much or too little oil can damage

the separator bearings.

3. Release the brake.

Starter

4. Poweron.

1810020-02

'- --,- ----'0

3

2 Operating LOPX Operating Instructions

Control Unit

5. Check that the mode selector switch pointsto L (local). mm~- , .. ....

L~

6. Power on.

The display reads "OFF".

7. Close the door.

~cm

ITi~ ;m

- u~ ..

IOJMEJI••8. Check the direction of rotation of the bowl

by doing a quick start/stop. The revolutioncounter must rotate clockwise.

DANGER

DI~integration.hazard

. Ifpowereables have bee~alteredalways check the rotation direction.If the separato~rotates in reverse vital ..rotaWlg parts.~o~d u~c:rew. ................••.... •

•Air Valve Block9. Check that there is correct air supply by

reading the pressure gauge situated on thevalve block; see "System Reference".

Plant set value:

t?t---+

<

IL- ~=~ ____I;max.....................mm.

4 1810020-02

LOPX Operating Instructions2 Operating

2.2 Start up

1. Start the oil feed pump from the pump

starter.

•

I~-------==---------'

•2. Switch the heater on from the control unit.

If the heater is not connected to the control

unit it must be switched on independently.

• 3. Start the separator from the starter unit. 0[i] °E1l....~@

0

DANGER·

.. Disintegration··hazard

4. Listen and observe.

Vibration may occur during start up, when

passing critical rpm (revolutions per

minute).

This is normal and should pass without

danger.

If vibration increases, or continues at full

speed, press the emergency stop button.

The cause of vibration must be determined

and corrected before starting again!••

'., .' .

.• EJ{c~s~i~e vibratio~ Ill.ily cause .breakdown. . .

1810020-025


5. Ensure that the separator is at full speed.

[Z]]At full speed the starter ammeter readinghas decreased from a high starting value toa low steady value; the idling value •(slightly lower than the normal operatingvalue). [&]

6. Check the oil feed temperature on the

~ ~control unit display by pressing the alarm 0reset button.

~ •If the temperature sensor is not linked to ~0the control unit read the temperatureindicator situated after the heater.

7. Wait until the oil feed temperature is~

• •correct: j• for cross head engines 80 - 90°C

• for trunk piston engines 85 - 95°C

8. Start the feed to the system from the

-Wcontrol unit. ,',

~-.-

When the temperature is correct the"I'

~0 ~operation LED lit (green). ••0

••

6 181002~2

••

••

LOPX Operating Instructions

2.3 Intervals BetweenSludge Discharges

2.3.1 Background

WARNING


. . .

.. Experience has shown thatif

intervals between sludge discharges

are too long, a compact and hard

sludg~cake can accumulate.· On· .

. discharge, this cake may break up

and be discharged unevenly causing

imbalance in the bowl. If imbalance

is excessive, there is risk for serious

mechanical damage and injury toPerSonnel. .. . .

Recommendations are given regarding initial

intervals between sludge discharges for

different applications. The setting may

subsequently have to be changed after actual

inspection of the bowl.

1810020-02

2 Operating

7

2 Operating

2.3.2 Lubricating oil cleaning


• Continuous operation:

In a new lubricating oil system the oil isinitially clean but as it gets dirtier theinterval between discharges will have tobe shortened until a "steady state" isreached. Following information refers tosystems in "steady state".

Recommended Intervals for Crossheadengines

Type of 011 Type of separatorInitial discharge Time to first bowl in-

spection

Main lubricating oil system 0.5 hours 1 week LOPXSluHing box oil 5min. After each batch LOPX

When separating stuffing box oil, thespecialised "MMPX Box Oil CleaningPlant" is primarily recommended. Pleasenote that the recommended initialdischarge interval is 5 minutes and that itmust never exceed three times this value.

Recommended Intervals for Trunkengines

Type of 011Initial discharge Time to first bowl in-

spection

Main lubricating oil system 0.5 hours 2 days

• If separator has been out of operation:

If the separator has been out of service for24 hours or longer, while the engine hasbeen running, the interval betweendischarges has to be shortened.In this case the recommendation is:

• Discharge interval 5 minutes until thewhole oil volume has passed twicethrough the separator.

• After that resume normal dischargeinterval.

••

••

8 1810020-02

••

••


• Intermittent operation:

For installations where one separator

serves one engine which is temporarily

stopped the following recommendations

apply:

If the engine is to be stopped for 24 hours

or less:

• Operate the separator continuously.

If the engine is to be stopped for more than

24 hours:

• Keep the separator in operation for 8

hours after the engine is stopped.

• Start the separator 8 hours before the

engine is started again.

Doing so most of the suspended particles

and condensed water will be removed

from the system and not settle in the sump

tank.

For installations where one separator

serves more than one engine the following

recommendations apply:

• Continuous use of the separator

whenever possible.

• Frequent switches between the engine

systems to be cleaned. In a typical case

with one separator serving 2-4

auxiliary engines switching after

maximum 24 hours of cleaning.

• Discharge interval:

Engine has been in operation with- Engine has not been in operation

out cleaning of the system oil since last cleaning of system oil

Discharge interval 5 min. Normal discharge interval

Duration until the whole oil volume

has passed twice through the

separator

After that resume to normal

discharge interval

1810020-02

2 Operating

9

2 Operating

2.3.3 Bowl inspection

To check if the initially selected interval isappropriate, the bowl should be inspectedafter a short test period shown in the previoustables.

If sludge space is clean:

Interval may be prolonged with steps of 15minutes, but it must not exceed three times therecommended initial interval.

"Sludge space is clean" means that nonoticeable amount of hard sludge remains inthe sludge space.

If sludge space is dirty:

Interval has to be shortened.

When the bowl is opened for routine cleaning,the sludge space should always be inspectedand evaluated. If necessary, the intervalbetween discharges should then be changedaccordingly.

N.B. Alfa Laval assumes no responsibilityfor the actual choice of dischargeintervals, as these entirely depend onlocal conditions.

10


Sludge space in bowl. Parts to be inspected:

A. Top discB. BowlhoodC. Sludge spaceD. Disc stackE. Sliding bowl bottom

1810020-02

••

••

••

••


2.4 Intervals BetweenBowl Cleaning

Suitable intervals between cleaning vary

according to the process parameters and

installation. The intervals can only be

determined by bowl inspections at actual

operating conditions. Indicated below are

some of the conditions, where experience has

shown that the interval between cleaning has

to be closely monitored and possibly

shortened.

• Installation not in accordance with Alfa

Laval specifications andrecommendations.

• Poor operating water quality.

• Operation without sludge conditioning

water.

• Diesel engine condition bad.

Note:

I. A low pressure/low flow or no discharge

alarm with no apparent external cause

(incorrect flow, temperature etc.) is a sign

that the bowl needs immediate cleaning.

Never neglect to investigate and remedy

the cause of such alarms.

2. Cleaning of the operating system is

normally required whenever product-

wetted parts of the bowl are manuaUy

cleaned.

3. Intervals between manual cleaning can be

prolonged by the use of the "Alfa Laval

CIP System"'(Cleaning-In-Place).

1810020-02

2 Operating

11


4. In cases where an uneven sludge cakeremains in the bowl after a discharge, thisinduces a particularly heavy imbalancewhen not covered by liquid. This mayoccur in total discharge type separatorsand when starting separators withoutprevious cleaning.Therefore, always after each stop, inspectthe bowl for cleanliness from sludge, andif required clean it before restart. Thisshould be done when the separator hasbeen in operation for 24 hours or moreafter the last inspection or cleaning.

...•/f\....l..U

WARNING

. Disintegrationhazard

••

Failure to c1eanthe separator bowl,including operating system, at .required intervals Or after alarms and ..stop of bowl may cause imbalancewith risk of injury to perscmnel.

12 181002~2

••

••

••


2.5 Operating Check List

Compulsory 200 hour Service

A compulsory service must be carried out

when the system has completed 200 hours of

operation after installation or after a gear has

been replaced.

1. Check that all units are in good condition

and function correctly.

2. Change the oil in the separator oil sump.

Clean the oil sump before filling with new

oil.

Consult the "Separator Manual".

The level should be no more than half way up

the sight glass.

NOTE

Neglecting an oil change will result in

damage to separator bearings.

3. Tighten all connections.

During operation:

Check visually that there is oil in the sump.

NOTE

Too much or too little oil can damage

the separator bearings.

Check that the starter ammeter reading is the

normal low and steady value.

181002(}-()2

2 Operating

I~13


Observe the control unit front panelinformation: ,1/

heater operation LED lit (green):-e- rsl• / I ', /

1fonly if the heater is connected to the I -e-o-e-o / , 'control unit.0 ~/ , '

separator system operation LED lit..•

I i*(green). Ij:• activated valve LED lit (green). j~'

During normal operation the trigger value is

~ •shown on the left, and the time to next sludge ~discharge is shown on the right of the display. ~

More information may be read, as required, by •~~pressing the alarm reset button repeatedly (the 0values are always shown to the right): ~;;I. the oil feed temperature: g• for cross head engines 80 - 90 cc

~ ~• for trunk piston engines 85 - 95 °C iIf the temperature sensor is not linked tothe control unit read the temperatureindicator situated after the heater.

2. the oil feed temperature (if a second OOIIJ •sensor for heater control is connected). ; •athe accumulated operating time l in hours. 0illIJ3. •!~4. the water transducer value. [ilIIJ •5. the number of pulses for displacement [ll[[]water.Continue pressing until the display returns to

~normal; Le. the trigger value, and time to nextsludge discharge.

I. How to interpret the displayed figures ashours:000 - 999 a actual value in hours1.00 - 9.99 - 1000 - 9990 hours10.0 - 99.9 - 10000 - 99900 hours100. - 999. - 100000 - 999000 hours

14 1810020-02

••

••


Check the back pressure:

read the pressure gauge situated by the low

pressure switch on the clean oil outlet line.

Plant set value:

If excessive vibration occurs press the

emergency stop"button and evacuate the room.

DANGER

Disintegrationhazard .

Neverdischarge a vibrating separa-

tor. Vibration will increase ifonly

part ofsOlidified sludge is.'. dischMged'·· .

Check all connections for leakage.

I!\ .. CAUTION.Sliphazard •

Oilleakagema~1lllikethefloorslippeIYaIldcailseinjuries.. "

1810020-02

2 Operating

i'-------'=-------------"~

~

l--_--=,""""".!=!!!.l.=r=--_---.l1

6

15

2 Operating

Avoid contact with hot machine surfaces.

CAUTION

Burn hazard

Process pipes, lubrication oil andI •. vanous machinesilrfaces can be hot

and cause burns..

Use ear protection if noise levels are high.

WARNING

Noise hazard·

Excessive noise can cause damage tohearing if no ear protection is used.

... . . .

16


\\\

1810020-02

••

••


2.6 Stop

To stop the system:

1. Stop the system from the control unit: 0 1f~'- I / ~A sludge discharge is initiated. -.-


•I"'7\'l~

@@

• iL-- ~__--.-J

9. In order to empty the bowl. restart theseparator drive motor from the separatorstarter and let it run for about I minute.

••

••

18 1810020-02


2.7 Emergency Stop

If an emergency situation occurs press the

emergency stop button and evacuate the room.

Do not return until the separator has come to a

complete stop. •IL- ---',

DANGERif··. Disintegrationhazard.

Do not enter the room after an

emergencystop while the separator is

. still.rotating.

••

2.8 After Emergency Stop

••

The cause of the emergency must be remedied

before attempting to restart the separator.

If the cause is not found a major service must

be performed and all moving parts thoroughly

checked.

. •. ~.·.·."· .• DANGER

LU Disintegration···hazard .

. .' ;-- . . .

Do nots~th~~~£~torafte~~•..emergency stopwitho~tf1rst . ..

.. reIl1edyiIlgtl1ecauseofthe.·

eIl1ergency

To avoid accidental start, switch off and lock

the power supply before dismantling.

Consult the "Separator Manual" and the

"Alarm List" about emergency procedures.

1810020-0219

2 Operating

Dismantling work must not be started beforeall rotating parts have come to a completestandstill.

DANGER.

Entrapment hazard

Do not begin maintenance workwhile the machine is still rotating.

DANGER


After an emergency stop theseparator bowl must be manually

. cleaned before starting up again...

The separator must be reassembled and allcovers and guards in place before unlocking.the power supply and starting the system.

DANGER

Entrapment hazard

Do not switch on without all coversand guaTds in place.

20


t~. .

1810020-02

•

.'•

••

••

List No.:

PrintedBook No.

31830-6181-5

Sep 19971810138-02 V5

AlfaLaval


Parameter List

I - , . -. ' Alfa Laval Marine & Power_ . - '.':-. .

Alfa Laval reserve the right to make changes at any lime withoutprior notice.


Copies of this publication can be ordered from your localAlia Laval company.

Published by: Alfa Laval Separation ABMarine & Power DivisionS - 147 80 TumbaSweden

© Copyright Alia Laval Separation AB 1997.

••

••

••

••




A summary of the safety information is found in the Safety chapterunder divider 1.

Contents

1 Scope 1

2 Process Parameters 3

3 Installation Parameters 5

• 4 Timer SequenceParameters 75 Service Mode Par~meter

• 90,94 and 95 95.1 Countdown of TimersP50 - P89 95.2 Alarm Log 10

5.2.1 Examples of Logged Alarms 11

5.3 Timer function 13

6 Additional ParameterInformation 15

6.1 Process Parameters 15

6.2 Installation Parameters 18

• 6.3 Timer Sequence Parameters 196.3.1 Starting Sequence 196.3.2 Separation Sequence 20

• 6.3.3 Sludge Discharge Sequence 206.3.4 Stopping Sequence 207 Sequence Diagram 21

1810138-02

•

1 Scope

The parameter list is valid for the followingseparation systems:

LOPX705

LOPX 707

LOPX709

LOPX 710

• LOPX7l3

LOPX 714

Including the EPC-400 control unit withPROM (memory chips):

PROM (front circuit board): 31830-6210-1PROM (rear circuit board): 31830-6132-1

••

1810138-02 1

••

••

2 Process Parameters

The EPC-400 control unit is used within aseparation system for control of the separationprocess. The control unit can be programmedfor different separator systems and fordifferent conditions within the system. Theprogramming is made by setting parameters.

The process parameters can be adjusted easilyand as often as required to meet changes in theoperating conditions, e.g. time between sludgedischarges, oil temperature and alarm points.

DANGER


If the interval between sludgedischarges is too long, there is risk ofheavy side breakdown.

Parameter Description or unit RangeFactory Plantset value set value

P1 1 Max. time between Minutes 0-999 30 .....sludge discharges P1 ~ P60 + P61

Changing of P1 automaticallychanges P61.

P21 Clarifier mode C C

P3 Not in use - - -P4

PS1 High temperature DC or OF 0-115°Cor 0 .....alarm 0- 255 of

P61 Low temperature DC or OF 0- 115°C or - - - .....alarm 0- 255 of

P71 Temperature set point °C or of 0-110°Cor - - - .....0- 240 of

1810138-02 3

2 Process Parameters LOPX Parameter List

Parameter Description or unit Range FactoryPlant

set value set value

PS' P-band % 10 - 500 - - - .....P9' I-time Minutes 0.1 -10.0 - - - .....P10' Stand-by/On mode o ~ Stand-by o or 1 1 .....

1 ~ OnP10 = 0 must only be used duringtest operation or if high watercontent in oil.

P11 Not applicable 0-999 0

P12 Conditioning water Number of pulses 0-999 5. . ....

P13 Displacement water Number of pulses 0-999 10 .....

P14 Min. number of Min. number of pulses of 0-999 2 .....separate pulses additional displacement water.

P15to Not in use - - -P1S

P19 Factory test constant 1

1. For more information, see "Additional Parameter Information" on page 15.

••

••

4 181013&-02

••

••

3 Installation Parameters

NOTE

EPC-400 parameter P2l is factory setto 50 Hz. If connected to a 60 Hzsupply an alarm will occur. Set P2 I to60 Hz and press the reset button. The

i alarm will disappear.

The installation parameters must be set beforethe initial start-up and before processparameters are set. The parameters rarely needto be adjusted again.


P201 Separator type 5.1 ~ LOPX 705, 707, 709, 710, 4.1 - 5.2 5.1 5.1 or 5.3713

5.3 ~ LOPX 714

P21 Power frequency Hz 50 or 60 50 .....Check that the frequency iscorrect, see label on theseparator.

P22 Not in use - - -P231 EPC-400 address 1 ~ EPC-400 1- 8 1 1

2-8 ~ Not in use

P24 For remote communication with 48 .....P25 COMLI protocol 2 .....

P26 to Nolin use - - -P32

P33 Emergency stop o = Emergency stop only o or 1 0 .....function 1 = Mechanical vibration switch

P341 Alarm delay time Seconds 1 -30 15 .....P351 Low temperature Seconds 1 -999 15 .....

alarm delay, after MV1change over

1810138-02 5

3 Installation Parameters LOPX Parameter List


P36' Remote control 0= No remote control 0-3,10-13 0 .....1 = Remote switches2 ~ Remote computer3 = Not used

10 = No remote control, alarmA4-1 cancelled

11 ~ Remote switch, alarm A4-1cancelled

12 ~ Remote computer, alarmA4-1 cancelled

13 = Not used

P37' Heater type o = No or common heater with 0-2 0 .....separate controller

1 = Heatpac EHS-62 controlledby EPC-400

2 = Heater with control valve,controlled by EPC-400

P38 Size of Heatpac kW 0,7,8,14,16,22, - - - .....heater If P37 = 1 then P38 is set to 16, 24,36,40,50,56,

otherwise P38 = "- - -". 65,72

P39 Run time of control Seconds 0-999 - - - .....valve If P37 ~ 2 then P39 is set to 120,

otherwise P39 ~ "- - -".

P40' Temperature reading C ~ °C Cor F C .....F = OF

P41' Max. start tim e for Minutes 0-999 15 .....heater

P42 Not in use - - -P43' Extra alarm function o = Alarm in dication on display. 0-1 0 .....

No action.1 = Alarm indication on display.

Oil feed off during separa-tion sequence.

P44 Displacement water Number of times the displacement 0-999 2 .....pulses water is increased by two pulses

. before alarm (A7-11 ).

P45to Not in use -- -P49


6 1810138-02

••

••

••

••

4 Timer Sequence Parameters

The timer sequence parameters control theoperation of the separation system, i.e. start,separation, sludge discharge and stopfunctions.


Starting sequence

PS01 Bowl closing water Seconds 0-999 15 .....PS1 Not in use - - -PS21 Conditioning water Seconds 0- 999 30 See table

Automatically set to belowP52= P12 x P70

PS31 Reference time, oil Seconds 0-999 120 .....feed on

PS4to Notin use - - -PS9

Separation sequence

P601 Time to first discharge Minutes 0- 999 10 .....after start-up (for P60 + P61 = P1calibration)

P61 1 Time between sludge Minutes 0-999 20 .....discharges P60 + P61 = P1

Changing of P1 automaticallychanges P61.

P62 Pre-discharge interval Seconds 0-999 60 .....P63 to Not in use - - -P69

1810138-02 7

4 Timer Sequence Parameters LOPX Parameter List


Sludge discharge sequence

P701 Displacement water Seconds 0-999 6 See tablebelow

P71 Pause Seconds 0-99.9 30 .....P721 Sludge discharge Seconds 0-99.9 3.0 .....

P73to Not in use - - -P75

P761 Conditioning water Seconds 0-999 30 See tableAutomatically set to belowP76 = P12 x P70

P77 Not in use - - -P781 Reference time Seconds 0-999 60 .....P79 Not in use - - -

Stopping sequence

P80to Not in use - - -P83

P841 Displacement water. Seconds 0-999 70 .....Oil feed off

P85 Not in use - - -P861 Separator motor off Seconds 0-999 180 .....P87to Not in use - - -P89


LOPX 705 LOPX 707/709/ LOPX 713/714710

P12 5 5 5

P70 6 10 15

P52 and P76 30 50 75=P12xP70

••

••

8 1810138-02

5 Service Mode Parameter 90, 94 and 95

Factory PlantParameter Description or unit Range set set

value value

P90 Service mode o = No service mode 0,1,50 0 .....1 = Countdown of timers

P50 - P8950 = Alarm log, including self

resetting alarms

P91 For remote 0P92 communication with 19,2P93 Profibus protocol 60

P94 Count down timer 0.0 - 10.0 0.0

P95 Indication of P94 timerHours

0.0 - 10.0 -- - .....actual value

P96 to Not in use -- -P99

••

••

With aid of the service mode parametersinformation can be requested and displayed,for instance the countdown of timer sequencescan be displayed while they are running.

5.1 Countdown of TimersP50 - P89

By setting P90 to 1, the mode selector inposition L and then by pushing the alarm resetbutton, a countdown of each activated timer(P50 - P89) can be displayed duringoperation.

1810138-02

I I· IIIGI/~aI31211"~J·'(Q) I

Io )X iO~I(Q)I~

L --===='-! ----.:I~

Timer P61 shows that it is 32 seconds/eff to nextsludge discharge.

9


5.2 Alarm Log

Set P90 to 50, the mode selector back to Landpush the alarm reset button; the 32 latestalarms are displayed, including self resettingalarms. Each logged alarm consists of threeconsecutive groups of information:

I. The accumulated alarm log time, whichshows how long the EPC has been inoperation since the alarm in question.Max. time between two alarms is 999.5hours'" 41 days. If this time is exceededthe whole alarm log will be reset to O.

2. The alarm is indicated in the same way aswhen it occurred (except for the "alarms"starting with an E):

• Alarm code starting with an A

• LED and an alarm code, for instance"High or low oil temperature"

• LED indications only

• "Alarm" code starting with an E (eventswith no alarm released). E I is a selfresetting function

El'" no signal for discharge

E4 = ALCAP functions in stand-bymode

E5 = ALCAP functions back tooperation mode again.

3. The value of parameter PI (maximumtime between sludge discharges).

10

LOPX Parameter List

1810138-02

••

••

••

LOPX Parameter List

5.2.1 Examples of Logged Alarms

• The capital "H" indicates that this is thelatest alarm which has been logged. TheEPe has been in operation 48 hours and20 - 29 minutes since the alaffil inquestion. Every tenth minute is displayed,but several alarms can be logged withinthis period.

The latest alaffil was a "Power failure"

PI (maximum time between sludgedischarges) was set to 30 minutes.

Between these two alaffils 10 hours and 0 - 10minutes have elapsed (58.2 - 48.2).


~I

~I

• 58 hours and 20 - 29 minutes ago the ~ ·event below occurred. •~The event was a ;;No signal for discharge". [ill[IIJNo alarm was given, as the next discharge ~

"attempt was succesful. •P I setting was 30 minutes. ~• • 106 operating hours and 30 - 39 minutes

Ihl/~olb.131• ago another alarm occurred.The alarm was a ;;Water transducer fault". S(Which is indicated by the LED and not onthe display) DJI]]JPI setting was 30 minutes.

~

1810138-02 11

5 Service Mode Parameter 90. 94 and 95

• If the accumulated time becomes morethan 999.5 hours it will the first time beindicated by capital "H" and 1000 issubtracted from the displayed value.

The second time it happens, another 1000is subtracted from the displayed value etc.

Between these two alarms 10 hours haveelapsed (H 5.0 = 1005.0 hours)

• This indicates the end of the log.

12

LOPX Parameter List

mmJQ]@

~

~

1810138-02

••

••

••

••

LOPX Parameter List

5.3 Timer function

By setting P94 to >0.0 a count down timer isactivated. It is intended as a reminder ofservice to be made after the elapsed runninghours. If e.g. P94 is set to 2.70 it means 2700hours. Each 0.1 indicates 100 hours. When2700 hours of operation have elapsed, analarm will be released and 3h - - - is indicatedin the front window. The alarm is repeated ateach start of the EPe. To avoid this the P94timer has to be started or set to O.

When P94 is >0 the actual count down valueis displayed when P95 is activated. P95 is justan indication of the elapsed time in P94. It cannot be set.

To restart the timer, go to P94. Push thirdbutton once (display flashes). Push button oneonce. The timer is now restarted with the samevalue. When the display is flashing, a newval ue can be entered.

1810138-02


13

6 Additional Parameter Information

••

••

6.1 Process ParametersPI Max time between sludge discharge

Long intervals between sludgedischarge can cause sludgeaccumulation and solidity in the bowl.The sludge may then break up atsludge discharge and create heavyimbalance in the bowl.

DANGER


If the interval between sludgedischarges is too long, there is risk ofheavy side breakdown.

As many factors influence the sludgedischarge interval, the choice ofinterval must be based on experience.

When the bowl is opened for routinecleaning, the sludge space should beinspected and, if necessary, the intervalbetween discharges changedaccordingly.Clean sludge space: the interval maybe prolonged. "Clean sludge space"means that no noticeable amount ofsolidified sludge remains in the sludgespace.Dirty sludge space: the interval mustbe shortened. "Dirty sludge space"means that some solidified sludge hasaccumulated in the sludge space.

1810138-02

The only way to get a clean sludgespace is to make appropriateadjustment of the interval based onregular inspection.

N.B. Alfa Laval assumes no responsibilityfor the actual choice of dischargeinterval times, as these depend entirelyupon local feed characteristics.

15

6 Additional Parameter Information LOPX Parameter List

Main lubricating oil system

Initial discharge Time to first bowl inspection

Recommended interval 1 hour 1 weekfor cross head engines

Recommended interval 0.5 hour 2 daysfor trunk piston engines

P2 Clarifier modeThe LOPX separator is a clarifier •which can handle water.PS High temperature alarmShould be set sufficiently above the •temperature set point P7.(Recommendation 5 - IO °C, or10- 20 OF, higher than P7).If P5 = 0 (no monitoring temperaturesensor, Pt 100, is connected)then P6 = P7 = "- - -".

P6 Low temperature alarmShould be set sufficiently below thetemperature set point P7.(Recommendation 5 - IO °C, or10 - 20 OF, lower than P7).

P7 Temperature set point •To be set according to plantapplication. See also P5 and P6.PS P-band (Proportional band)

If P37 = 0 then P8 = "- - -". •If P37 = I or 2 thenP8 is set to 40%.P9 I-time (Integral time)

If P37 = 0 then P9 = "- - " .If P37= I or 2 then P9 is set to 1.2minutes.

16 1810138-02

•

••

••

LOPX Parameter List

How to set PS and P9:If the temperature varies with regularlyrepeated oscillation, setting of theproportional band and integral timewould be necessary.

• Increasing the value of parameterPS (proportional band width) willresult in a slower and more stablecontrol action.

• Increasing the value of parameterP9 (integral time) also results inslower response from the EPC-400.

We recommend you to follow theseguidelines:

I. Set P9 = 10 minutes.

2. Decrease P-band (PS) in steps untilthe process reaches the point whereit starts to oscillate with a constantamplitude. Test the stability aftereach step by introducing a step-change of load or set point.

3. When you have discovered thepoint where the process oscillateswith a constant amplitude note thefollowing figures:

A = The value ofP-band (PS).B = The time for one full period in

seconds.

4. Calculation of optimal parametersettings.


Constant amplitude

[\ [\\J

I

,IB

P-bandPS = 2.2 x A

I-timeP9 = O.S x B

The settings above give a rather goodresult but may be adjusted according toindividual characteristics in differentloops.

1810138-02 17

6 Additional Parameter Information LOPX Parameter List

6.2 Installation Parameters

Failure to follow the aboveinstructions may lead to heavy sidebreakdown.

To remind the operator of stand-bymode, the display will indicate "n.c."(not connected) to the left of thedisplay and the time to next sludgedischarge to the right of the display.The time between sludge dischargeswill automatically be set to 15 minutesand a reminding alarm will occur every24 hours (A7-3).

••

••

DANGER


Only use the stand-by mode whennecessary.Not adding displacement water willlead to loss of oil.Check the addition of conditioningwater regularly while in stand-bymode..

N.B.

P20 Separator typeWhen P20=5.l the specific functionsfor the LOPX are automatically set.

P23 EPC·400 addressIn a LOPX separation system theEPC-400 is always regarded as masterunit, e.g. P23 = I. LOPX can onlyoperate as a single unit and not in aserial separation system.

• No "ALCAP alarms, A7" will bedisplayed.

• No sludge discharges will beinitiated by the transducer duringP61. There will only be a sludgedischarge when P61 has elapsed.

• No addition of displacement waterto the separator bowl.Conditioning water only is added.

• No draining function during P60

Stand-by I On modeIn ihe case of transducer failure ortemporarily abnormal operation withexcessive water content, or during fau Itfinding, the ALCAP functions can beset in stand-by mode (PlO = 0) and theseparator can be operated as aconventional clarifier.In stand-by mode the following apply:

• No transducer value nor deviationfrom reference value wi 11 bedisplayed.

• No alarm function for "Watertransducer fault"

PlO

18 181013&02

LOPX Parameter List 6 Additional Parameter Information

P34 Alarm delay time If a steam heating system is connectedActivation of most alarm functions can to the EPC-400 and if the system isbe delayed up to 30 seconds, except equipped with an optional shut-offfor: valve, and provided P37= 0 or 2, the

• emergency / vibration alarm valve is opened when the heater isstarted. The valve is shut:• high temperature alarm • when the heater is stopped• transducer alarmwhich have a fixed delay time of 2 • at high temperature alarmseconds. • at power failure

• P35 Low temperature alarm delay after • at. EPC stand-by mode.MVl change over P40 Temperature readingWhen the change over oil feed valve Degrees Celsius (0C) or Fahrenheitchanges position the flow rate and thus (OF) temperature readings available.• the oil temperature may be influenced. P5, P6 and P7 have to be set accordingBy delaying the temperature alarm, a to °C or oF.false alarm is avoided as the oiltemperature has time to stabilize. P41 Max. start time for heater

P35 should be set according to plant Sets the maximum allowed start time

application. If a delay time above 120 for the heater. Minimum temperature

seconds is necessary, check the heating limit (P6) must be reached within this

system and the installation layout. time.

P36 Remote control P43 Extra alarm function

Remote control can be applied in form Extra alarm functions can be

of: connected. By setting P43 to I the oil

external switchesfeed to the separator will be stopped

• when the extra alarm occurs.• • external computersP37 Heater type6.3 Timer SequenceThe EPC-400 control unit is designed• for control of: Parameters• Heatpac EHS-62 (P37 =1)

• Heater with heating media control 6.3.1 Starting Sequencevalve (P37=2) P50 Bowl closing water

N.B. If a different type of heater is installed For proper closing of the separator(P37 = 0), only a start/stop signal is bowl during start-up sequence. If moreavailable from the EPC-400 control than 60 seconds is required. it mayunit. indicate a malfunction.

1810138-02 19


P52 Conditioning waterAddition of water to separator bowlduring starting sequence. The water isto soften the sludge, to prevent sludgeremaining after discharge.

P53 Reference time, oil feed onTime to stabilize the transducerreference value during the startingsequence. The transducer referencevalue is stored when this time haselapsed.

6.3.2 Separation Sequence

P60 Time to first discharge after start-u pOnly the first time, after start-up, thereis a discharge after P60 (minimum timebetween sludge discharges). The drainvalve (VS) can only be activatedduring P60. Bowl closing water isintermittently supplied.

P61 Time between sludge dischargesP60 + P61 is the maximum timebetween two consecutive sludgedischarges. See PI.Bowl closing water is intermittentlysupplied.The time within P6l may beinterrupted by a sludge discharge,initiated by the transducer signal.

6.3.3 Sludge Discharge Sequence

P70 Pulse length of displacement waterPulse length during filling ofdisplacement water.

20

LOPX Parameter List

Filling of displacement water to thebowl eliminates the risk of oil loss atthe following sludge discharge.When a transducer signal from thetransducer MT4 is obtained the fillingof displacement water is stopped andP72 starts.

P72 Sludge dischargeSludge discharge initiated by MV 15admitting water to the separator bowl.If more than 4 seconds are requ ired,this may indicate a malfunction.

P76 Conditioning waterAddition of water to the bowl after asludge discharge. The water is to softenthe sludge, to prevent sludge remainingafter discharge.

P78 Reference timeReference time after a sludgedischarge. The transducer referencevalue is stored when this time haselapsed.

6.3.4 Stopping Sequence

P84 Displacement water. Oil feed offBefore the separator is stoppeddisplacement water is added to thebowI to displace the oil and ensurethere is a minimum loss of oil.

P86 Separator motor offThe separator motor is automaticallyswitched off. Restarting is blocked for3 minutes.

181013&-02

••

••

••

••

7 Sequence Diagram

The duration of the monitoring functions and output signals is illustrated in the diagram.

Valve Terminal Activated function Stand· Starting Separation Sludge discharge StoppingRelay by sequence sequence sequence sequenceSensor OFF P50 P52 P53 P60 P61 P62 P70 P71 P72 P76 P78 P84 P86 OFF

15 s 0-755 120 s Omin Omin 60s s 30 S 3.0$ 0-755 60s 70 s 180 s

Mon. functions

- X7:1 Extra alarm

1'541 X7:3 High oil pressure

1'542 X7:4 Low oil pressure

X511X8A

VibrationX52 Emergency stop"

- X9:3 Heater fault

TT1 Xl1:1-3 High oil temperature3

TT1 Xl1:1-3 Low oil temperature3

MT4 XE:1-4Water transducer(signal displayed)

MV151X5:3/X7:4 Discharge failure

1'542

Output signals

- Xl:1-2 Motor starter '-X51 X2:3-4

Blocking vibration -switchMV1 X4A Oil to separator

MV10NX5:1/X5:2

Displacement!~ 10- - -MV10 Conditioning water

MV15 X5:3 Bowl opening water -MV16 X5:4 Bowl closing water4 ~ ••• •••

1. See list after timer sequence parameters on page 4.2. Emergency stop (X52) is normally connected to terminal X8:4. If optional vibration switch (X51) is installed, it

will be connected to terminal X8:4. Emergency stop (X52) will then be connected to the system power supply.If the EpC is in stand-by mode (OFF) and the emergency stop button is pushed, the separator motor will bestopped.

3. With optional sensor TT1 installed 1'50 will not start if the temperature is to low or to high.4. During 1'60 and 1'61 intermittently.

1810138-02 21

7 Sequence Diagram

Separation sequence

Bowl closing water is intermittently suppliedduring the separation sequence (shown in thediagram with a broken line).

Sludge discharge sequence

Within this period of time any trigger signalfrom the transducer MT4 will interrupt theP70 sequence.

Stopping sequence

Before the actual stopping sequenc~ beginsthe separation is completed with a sludgedischarge sequence.

22

LOPX Parameter List

1810138-02

••

••

••

••

~~AIfa Laval


Alarms and Fault Finding

Printed Nov 2000Book No. 181 0144-02 V6

. Alfa Laval Marine & Power

Alfa Laval reserves the right to make changes at any time withoutprior notice.



Published by: Alfa Laval Marine & Power ABSE - 147 80 TumbaSweden

© Copyright Alfa Laval Marine & Power AB 2000.

••

••

••

••




A summary of the safety information is found in the Safety chapterunder divider I.

Contents

1 Scope 1 4 Alarm Tests 25

2 EPC Signs 3 5 Test Program 27

3 Alarms 5 5.1 How to Start theTest Program 27

3.1 Alarm Functions 5• 5.2 Lamp Test 283.2 Alarm Reset 6 5.3 How to Activate3.3 Alarm Survey 7 Different Parts of the3.4 LED Alarms and Test Program 28• Fault Finding 8 5.4 Functions in the3.4.1 High Oil Pressure 8 Test Program 29

3.4.2 Low Oil Pressure (Low Flow) 9

3.4.3 Sludge Discharge Failure 10

3.4.4 Water Transducer Fault 11

3.4.5 Emergency Stop 12

3.4.6 Vibrations (Option) 13

3.4.7 Heater Fault 14

3.5 LED and Display Alarms andFault Finding 15

3.5.1 High or Low Oil Temperature

• (Option) 153.5.2 Temperature Sensor Error(Option) 163.6 Display Alarms and• Fault Finding 173.6.1 Communication Error 17

3.6.2 Processor Fault 18

3.6.3 Programming Error 18

3.6.4 Power Failure 19

3.6.5 Temperature Deviation 20

3.6.6 ALCAP Alarms 21

3.6.7 Other Alarms 23

3.6.8 Countdown Timer Alarm 23

1810144-02

1 Scope

The alarms, alarm tests and the test programare valid for the following separation systems:

LOPX 705

LOPX 707

• LOPX709

LOPX 710

• LOPX 713

LOPX 714

Including the EPC-400 control unit withPROM (memory chips):

PROM (front circuit board):31830-621 0-1PROM (rear circuit board):31830-6132-1

••

1810144-02 1

••

2 EPC Signs

The control unit signs for the LOPX

separation system are shown in this chapter,

Monitoring functions'

9I1

II1

I

9IIIIII

rI

'I1

III

9 9 ~• ;I..... I II I• ~ I ILOPX 1 II 1 I •

I I I,•

Monitoring functions (options)

1810144-023

2 EPC Signs LOPX Alarms and Fault Finding

I I IVl J MV10 J £ MV10:

...£.;' ..EI ---+~MV16 ..,;;r !nMV15 Q .~~ -D'... (I--....------_ • IEPC-400 I <

'----- "'~ =.:LO"-2p--,X,,----- ---,iOutput signals

.. .1: ~ ..U

Operating symbols

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••

4 1810144-02

3 Alarms

3.1 Alarm Functions

••

The alann system is designed to ensure thatthe separation system always remains in a safestate. There are two different types of alannfunctions:

• Sensor-related alarm functions areindicated by light emitting diodes (LEDs)on the EPC-400.

• Display-related alarm functions areindicated on the EPC-400 display. Whenany of the displayed alann functions areactivated the left digits start flashing andthe right digits are steadily lit.

If there is more than one alarm at the sametilT'e, the EPC-400 will display the alanns inthe order in which they occurred.

IIDJDIJI

• OOl ©O1f ©o'lf0 () ©o )X

@ o /> ©•An activated alarm condition is identified either by an alarm LED (to the left in thepicture) or an alarm code on the display together with the main alarm LED (to theright in the picture).

1810144-02 5

3 Alarms

3.2 Alarm ResetI. Acknowledge the alann signal by pressing

the alann push-button.

The flashing light then changes to steady.

2. Remedy the cause.

3. Reset the alann function by pressing thealann push-button a second time.

The LED will turn off.

It is possible to reset the system withoutremedying the cause, but the alann signal willbe repeated.

NOTE

Never return to the EPC-400 controlunit to acknowledge or reset an alannif it by any means can be hazardous.

WARNING


Never reset an alann without firstfinding and remedying the cause.

6

LOPX Alarms and Fault Finding

o

1810144-02

••

••


3.3 Alarm SurveyLED Display Alarm function Page

alarms alarms

8 High Oil Pressure 88 Low Oil Pressure (Low Flow) 9),)(. Sludge Discharge Failure 10

• (3 Water Transducer Fault 11@ Emergency Stop 12• . @) Vibrations (Option) 13Q Heater Fault 14

8 C High or Low Oil Temperature (Op- 15tion)8 ~ Temperature Sensor Error (Op- 16lion)

IT Communication Error 17~ Processor Fault

18

• ~ Programming Error 18~ Power Failure

19

• ~ Temperature Deviation 20IT ALCAP Alarms 21~ Other Alarms

23

[C Countdown Timer Alarm 23

1810144-02

3 Alarms

7

3 Alarms

3.4 LED Alarms and FaultFinding

3.4.1 High Oil Pressure


Cause Corrective action

Regulating valve, RV4, or other valves, downstream Open or regulate RV4, or other valves, to correct backthrottled or closed. pressure, normally about 1.5 bar (150 kPa).

Automatic actions at alarm Automatic actions after alarm reset

Main alarm flashes. Main alarm off.

Alarm diode (PS41) flashes. Alarm diode off.

Change over valve (V1) is set for oil recirculation. V1 is set for oil feed to separator.

•

••

8 1810144-02


3.4.2 Low Oil Pressure (Low Flow)

3 Alarms

••

••

Causes Corrective actions

Too low oil feed. Check the oil feed pump.Adjust the oil flow.

Strainer before the oil feed pump is clogged. Clean the strainer.

Oil feed pump has stopped. Check the oil feed pump.

Change over valve (V1) is in recirculation position. 1. Check the air supply to the solenoid valve block air(MV1).

2. Check MV1.

3. Check V1.

Too low back pressure. Increase the back pressure with regulating valve RV4.The correct back pressure is normally about 1.5 bar(150 kPa).

Bowl opened accidentally during operation. Check the opening water valve (MV15) for leakage.See "Separator Manual".

Leakage from bowl. See "Separator Manual".



Alarm diode (PS42) flashes. Alarm diode off.

V1 is set for oil recirculation. V1 is set for oil feed to separator.

1810144-02 9

3 Alarms

3.4.3 Sludge Discharge Failure



No or very low opening water supply. Check the water supply system:11 Iitres/min are required for LOPX 70518litres/min are required for LOPX 707,709,710, 713 &714.

Opening water valve (MV15) damaged. Check MV15.

No signal from low oil pressure switch (PS42) at dis- Check PS42.charge.

Separator operating system not working. 1. Check the separator by manually opening MV15 fordischarge.

2. Dismantie and check the operating system. See'"Separator Manual".

Dosing ring tightened too mUCh. Tighten the dosing ring screws with a torque of 7 Nm forLOPX 705Tighten the dosing ring screws with a torque of 20 Nm forLOPX 707,709,710, 713 & 714.

N.B. This alarm is activated after two attempts to discharge, within the same discharge cycle, have failed.



Alarm diode flashes. Alarm diode off.

The stop sequence is initiated. 1. If the power has been off for more than about 10minutes the separator bowl must be stopped andmanually cleaned before restart.

2. The separator and the EPC program have to berestarted.

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••

10 1810144-02


3.4.4 Water Transducer Fault

3 Alarms

••

••


Loose connection between transducer test circuit Check connecUons.board and oscillator.

Faulty oscillator unit or faulty EPC control module. Check supply voltage in the MT4 on terminal 3 - 4 (20 VDC).About every fifth second the voltage at terminal 4 - 5 (20V DC) will drop for approx. 0.5 second:

• If voltage drop: replace the oscillator unit.• If no voltage drop: replace the EPC control module.For more information about the interconnections, see"System Reference".

Automatic actions at alarm Automatic actions after alarm reset -.




1810144-02 11

3 Alarms

3.4.5 Emergency Stop


Cause Corrective actions

Emergency stop button has been pushed. 1. Remedy the cause for the emergency stop.

2. Reset the alarm by switching the power off and on.

3. Restart the separator.

4. Restart the EPC program.

Automatic actions at alarm Automatic action after alarm reset

Main alarm flashes. N.B. This alarm function can not be reset by pushingthe alarm reset button. See above.

Alarm diode flashes.

The separator is stopped and the heater turned off.

Oil feed through the heater and separator stays on formax. 3 minutes, or until FS4 signals no flow. Bowlclosing water supplied for 15 seconds.

DANGER


The separator bowl must be manuallycleaned before starting up again

••

••

12 1810144-02


3.4.6 Vibrations (Option)

3 Alarms

••

••

Cause Corrective actions

Vibration switch activated: separator bowl out of baI- L Remedy the cause. See "Separator Manual".ance. Check the vibration switch setting.

2. Reset the alarm by switching the power off and on.

3. Clean the separator bowl.

4. Restart the separator.

5. Restart the EPC program.

Automatic actions at alarm Automatic action after alarm reset

Main alarm flashes. N.B. This alarm function can not be reset by pushingthe alarm reset button. See above.

Alarm diode flashes.

The separator is stopped and the heater turned off.

Oil feed through the heater and separator stays on formax. 3 minutes. or until FS4 signals no flow. Bowlclosing water supplied for 15 seconds..

DANGER


The separator bowl must be manuallycleaned before starting up again

1810144-02 13

3 Alarms

3.4.7 Heater Fault


N.B. Heater fault is only activated if the heater is controlled by the EPC-400.

Cause Corrective action

Oil flow stopped or temperature switch tripped in an If oil flow stopped. investigate the cause.installed Heatpac heater. See corrective actions for PS42.

Check the flow switch on the Heatpac heater.If temperature switch tripped. investigate the tempera-ture switch setting. If OK check that the heater is clean.

Clogged heater. Clean heater.

Safety switch for other type of electric heater or steam Remedy the cause.heater tripped.





Heater switched off. Heater switched on.

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14 1810144-02

LOPX Alarms and Fault Finding 3 Alarms

3.5 LED and DisplayAlarms and FaultFinding

3.5.1 High or Low Oil Temperature(Option)


Low temperature alarm when: Investigate the reason and remedy it.- clogged heater- insufficient steam supply- faulty steam trap- faulty steam supply valve- electrical fault (tripped fuse)

High temperature alarm when: Investigate the reason and remedy it.- faulty steam supply valve- electrical control system out of action

Set point (P7) changed or the alarm limits are too 1. Adjust the parameters.close to the set point. P5 = max. temp

P6 = min. tempP7 =set point.See "Parameter UsC

2. Check the temperature control loop.

Steam control valve (SRV1) open or closed too much. 1. Check and adjust the SRV1 function.

2. Check the EPC output functions.

Low temperature alarm when the temperature in- Check the heater and parameter P41, See "Parametercreases too slowly, during start-up. Usf'.

Pt 100 temperature signal faulty. Check the Pt 100 temperature sensor.

N.B. The current temperature is indicated when the alarm is acknowledged. To find the appropriatetemperature sensor reading, push the alarm reset button twice 1C (1 F) = IT1, 2C (2F) =TT2.For more information, see "Operating Instructions".

• N. B. Also applicable to IT2 temperature sensor, if fitted.

•

••



Alarm diode and displayed value flash. Alarm diode off and display returned to normal.

Oil feed (MV1) off. MV10n.

Heater switched off at high temperature (if controlled Heater switched on when temperature is below set pointby EPC-400). (if heater is controlled by EPC-400).

1810144-02 15

3 Alarms

3.5.2 Temperature Sensor Error(Option)


•

iN.B. Also applicable to TI2 temperature sensor, if filled.


Temperature sensor is incorrectly connected. Check the temperature sensor by the test program, see"Analog inputs" on page 32 in the chapter Test Program.

Temperature sensor loop is open or short-circuit. Check the connections.

Temperature sensor cables are too close to power ca- Check the cables between the temperature sensor andbles. EPC-400.

N.B. Push the alarm reset bullon to find appropriate process value reading.1C (1 F) = TI1, 2C (2F) = TT2. If both temperature sensors are filled, alarm A6 is also activated.



Alarm diode and displayed value flashes. Alarm diode off and display returned to normal.

Oil feed (MV1) off. MV10n.

Heater switched off at high temperature (if controlled Heater switched on when temperature is below set pointby EPC-400). (if heater is controlled by EPC-400).

••

••

16 1810144-02


3.6 Display Alarms andFault Finding

3.6.1 Communication Error

3 Alarms

••

••

Alarm code Cause Corrective actions

§TIE[]]Communication error with exter- 1. Check extemal and internalnal computer. connections.

2. If internal communication error,replace the control modUle.

§]]EIBJCommunication error between 1. Check by measurement the fusesfront and rear circuit board. A1:F2 (front board), A2:F2 (rear

board).(See "Component Description,EPC-400 Control Unit").

2. Replace the control module.

Automatic action at alarm Automatic actions after alarm reset

Main alarm flashes. Main alarm off.Display flashes. Display normal.

1810144-02 17

3 Alarms

3.6.2 Processor Fault


Alarm codes Causes Corrective actions

~" Internal RAM error. Replace control module.g~

~" External RAM error. Replace control module.~~

M:ITI § E2 RAM error. Replace control module.~Mll] 11 Program error. Replace control module.

~

~ iMode switch error. Check that the mode SE"'3ctor is in the cor-

~rect position.

~~ A I D (Analog I Digital) conversion Check the fuse A1:F2 (front board)~ error. If the fuse is correct, replace the control~

module.

~" Calibration error. Ask for service or replace the control mod-~ ule.8



3.6.3 Programming Error

Alarm code Cause Corrective action

~" In programming mode too long Change the mode selector to the~ (more than 30 minutes without "L" (Local) position and. when appropriate.~

programming during this time). return to the "P" (Programming) positionand continue with programming.



••

••

18 1810144-02


3.6.4 Power Failure

3 Alarms

••

••


HI]] Power failure. 1. Check the power supply.2. If the power has been off more thanabout 10 minutes the separator bowlmust be stopped and manuallycleaned before restart.

3. Restart the heater, separator andEPC program.

~Power supply frequency too high 1. Check the power supply.

(more than + 5%).1 2. If the power has been off more thanabout 10 minutes the separator bowlmust be stopped and manuallycleaned before restart.

3. Restart the heater, separator andEPC program.


All outputs are off.

Only valid for alarm A4-1 : Only valid for alarm A4-1:Main alarm diode and display Main alarm off.start to flash when power returns. Display indicates "OFF".

Only valid for alarm A4-2: Only valid for alarm A4-2:Main alarm flashes. Main alarm off.Display flashes. Display normal.

1. The frequency deviation must be continuous or repeated during the alarm delay time before an alarm is acti-vated.

1810144-02 19

3 Alarms

3.6.5 Temperature Deviation


Alarm code Cause Corrective actions

MJJJ< Temperature deviation alarm (dif- At commissioning:~ ference between n1 and nz is Check if the distance between~

more than 30 'C/54 'F). sensors is too great.System in operation:

Check the temperature sensors.

N.B. Push the alarm reset button to find the appropriate process value reading 1C (1 F) = TT1 ,ZC (ZF) = nz. For more information, see "Operating Instructions".



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••

20 1810144-02


3.6.6 ALCAP Alarms

3 Alarms

••

••

Alarm codes Causes Correctiveactions

@ll]], High water transducer (MT4) val-~

ue (above 400):

• High water content in oil. Check the oil system for water leakage.

• Water transducer dirty. Clean the contact surfaces of water trans-ducer. See "Component Description, Wa-

ter Transducer'.

~~

Low water transducer (MT4) val-

~ue (below 100):

• Open circuit in the MT4. 1. Check connections in control unit andtransducer.

2. Check cables for damage.

• Bad connection between 1. Check the cable connection.oscillator unit and electrode. 2. Tighten oscillator electrode connector

@]£mJ. ALCAP stand-by for more than 1. The reason for stand-by mode must"~

24 hours. be checked!

2. Try to operate the system normally.

~~

PROM and/or RAM fault. Replace control module.

~

~~

Water transducer trigger value 1. System and component check:

~less than 30. • Check that the valve block strainer isInsufficient displacement water. free from deposits.Insufficient conditioning water.

• Check that the displacement waterflow from MV10 is correct.

• Check that the inner water pipe in theseparator inlet pipe is free from

deposits. Clean if necessary.

• Check that the seal ring and sealingsurface on the sliding bowl bottom are

free from any damage.

2. If the alarm still occurs, please check

following parameter settings in EPC

400:

• P12 2: 5 (If this value is below 5, thenset it to 5)

• P70 = according to parameter listsetting for your separator type

• P76 = actual value of P12 x actualvalue of P70.

1810144-0221

3 Alarms LOPX Alarms and Fault Finding


~Water transducer (MT4) trigger- 1. Check for water leakage into lube oiling 5 times in a row. system (e.g. from cooler or engine).

2. Change over to stand-by mode(adjust P10 to 0).


Main alarm flashes. Main alarm off.Display flashes. Display normal.Oil feed off.. Oil feed on.

DANGER

Disintegration hazard

••

If the A7 - 11 alarm is not remediedthere is a risk for breakdown.

22 1810144-02

••


3.6.7 Other Alarms

3 Alarms

••

••


@ill]]. Extra alarm. 1. Check the connected external§ function.~

2. Check the jumper at terminal XC-Xl:1(when extra alarm not used).

~. Low pressure signal (PS42) Check the pressure switch..,

faulty at start. Circuit should be~

open.



Only valid for alarm A9-1: Oil feed on.If P43=1 then oil feed off.

Only valid for alarm A9·2:The start of the timer sequencesis blocked.

3.6.8 Countdown Timer Alarm


@EEtB The count down timer has Restart the timer after relevant actions arereached

alfa laval lopx 710

Engineering

zahid nawaz