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MOPX Separation System

Operating Instructions

Printed
Book No.

Nov 1998
1810106-02 V3

Alfa Laval Marine & Power

Alfa Laval reserve the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:

Alfa Laval Marine & Power AB


S - 147 80 Tumba
Sweden

Copyright Alfa Laval Marine & Power AB 1998.

Study instruction manuals and observe the


warnings before installation, operation,
service and maintenance.

P000272A

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

Scope

Operating

2.1

Start up Check List

2.2

Start up

2.3

Intervals Between Sludge


Discharges

2.3.1

Background

2.3.2

Recommended intervals
between sludge discharges

2.3.3

Fuel oil cleaning

2.3.4

Lubricating oil cleaning

2.3.5

Bowl inspection

2.4

11

Intervals Between Bowl


Cleaning

12

2.5

Operating Check List

14

2.6

Stop

18

2.7

Emergency Stop

20

2.8

After Emergency Stop

20

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1810106-02

Scope

These operating instructions are valid for the


following separation systems:
MOPX 205
MOPX 207
MOPX 309
MOPX 310
MOPX 213
The MOPX separation system is designed for
cleaning of fuel and lubrication oil for marine
and power diesel engines.

1810106-02

1 Scope

MOPX Operating Instructions

1810106-02

Operating

2.1 Start up Check List


Separator
1. Check that the separator is correctly
assembled and connected to power of
correct voltage and frequency.

DANGER

G054742A

Disintegration
hazard
If the separator is not assembled and
connected properly it may lead to
disintegration.
2. Check the oil sump level: it should be no
more than half way up the sight glass and
not less than 1/4 of the sight glass.

G026201A

NOTE
Too much or too little oil can damage
the separator bearings.

Release the brake.

G024632A

3.

Starter

P000025A

4. Power on.

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2 Operating

MOPX Operating Instructions

Control Unit

G001462A

5. Check that the mode selector switch points


to L (local).

6. Power on.
The display reads OFF.

G001461A

7. Close the door.

8. Check the direction of rotation of the bowl


by doing a quick start/stop. The revolution
counter must rotate clockwise.
G013442A

DANGER
Disintegration
hazard
If power cables have been altered
always check the rotation direction. If
the separator rotates in reverse vital
rotating parts could unscrew.
Air Valve Block
9. Check that there is correct air supply by
reading the pressure gauge situated on the
valve block; see System Reference.
Plant set value:

max. ....................

P000081A

min. ....................

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MOPX Operating Instructions

2 Operating

2.2 Start up

G046591A

1. Start the oil feed pump from the pump


starter.

2. Switch on the heater from the control unit.


G001644A

If the heater is not connected to the control


unit it must be switched on independently.

P000022A

3. Start the separator from the starter unit.

4. Listen and observe.


Vibration may occur during start up, when
passing critical speeds.

S005561A

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!
See Separator Manual, chapter
Technical Reference.

DANGER
Disintegration
hazard
Excessive vibration may cause
breakdown.

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2 Operating

MOPX Operating Instructions

5. Ensure that the separator is at full speed.

S000961A

At full speed the starter ammeter reading


has decreased from a high starting value to
a low steady value; the idling value
(slightly lower than the normal operating
value).

G001647A

6. Check the oil feed temperature on the


control unit display by pressing the alarm
reset button.
If the temperature sensor is not linked to
the control unit read the temperature
indicator situated after the heater.

Heavy fuel mode 98 C

Diesel oil mode 40 C

Lube oil

I000731A

7. Wait until the oil feed temperature is


correct:

for cross head engines 85 90C


for trumk piston engines 90 95C
Destillate 20 40C

I000742A

For the further information about


separation temperatures see the
Technical Data in the System
Reference.
8. Start the feed to the system from the
control unit.

G001642A

When the temperature is correct the


operation LED is lit (green).

1810106-02

MOPX Operating Instructions

2 Operating

2.3 Intervals Between


Sludge Discharges
2.3.1 Background
WARNING
Disintegration
hazard
Experience has shown that if
intervals between sludge discharges
are too long, a compact and hard
sludge cake can accumulate. On
discharge, this cake may break up
and be discharged unevenly causing
imbalance in the bowl. If imbalance
is excessive, there is risk for serious
mechanical damage and injury to
personnel.
Recommendations are given regarding initial
intervals between sludge discharges for
different applications. The setting may
subsequently have to be changed after actual
inspection of the bowl.

2.3.2 Recommended intervals


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

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2 Operating

MOPX Operating Instructions

2.3.3 Fuel oil cleaning


Recommendations
Type of fuel

Distillate (1.5 6 cSt/40 C)


Marine Diesel Oil (max. 14 cSt/40 C
Heavy Fuel Oil

Initial intervals between discharges

Time to first bowl inspection

4 hours
2 hours
0.5 hours

1 week
1 week
2 days

Conditions may change completely when


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

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MOPX Operating Instructions

2 Operating

2.3.4 Lubricating oil cleaning

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

Main lubricating oil system


Main lubricating oil system
Stuffing box oil

Type of separator
Initial discharge

Time to first bowl inspection

1 hour
0.5 hours
5 min.

1 week
1 week
After each batch

MOPX
MMPX
MMPX

When separating stuffing box oil, the


specialised MMPX Box Oil Cleaning
Plant is primarily recommended. Please
note that the recommended initial
discharge interval is 5 minutes and that it
must never exceed three times this value.
Recommended intervals for Trunk
engines
Type of oil

Main lubricating oil system

Initial discharge

Time to first bowl inspection

0.5 hours

2 days

If separator has been out of operation:


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

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2 Operating

MOPX Operating Instructions

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 24
auxiliary engines switching after
maximum 24 hours of cleaning.
Discharge interval:

Engine has been in operation without cleaning of the system oil

Engine has not been in operation


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

10

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MOPX Operating Instructions

2 Operating

2.3.5 Bowl inspection


To check if the initially selected interval is
appropriate, the bowl should be inspected
after a short test period shown in the previous
tables.
If sludge space is clean:
Interval may be prolonged with steps of 15
minutes, but it must not exceed three times the
recommended initial interval.

P000961A

Sludge space is clean means that no


noticeable amount of hard sludge remains in
the sludge space.
If sludge space is dirty:
Interval has to be shortened.

Sludge space in bowl. Parts to be inspected:

When the bowl is opened for routine cleaning,


the sludge space should always be inspected
and evaluated. If necessary, the interval
between discharges should then be changed
accordingly.

A.
B.
C.
D.
E.

Top disc
Bowl hood
Sludge space
Disc stack
Sliding bowl bottom

N.B. Alfa Laval assumes no responsibility


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

1810106-02

11

2 Operating

MOPX Operating Instructions

2.4 Intervals Between


Bowl 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.
General:

Installation not in accordance with Alfa


Laval specifications and
recommendations.

Poor operating water quality.

For fuel oil separators:

HFO with excessive or extraneous


contaminants.

Separation of fuel containing stuffing box


oil, spent lubricating oil or recovered from
sludge tanks.

For lubricating oil separators:

Diesel engine condition bad.

Separation of piston rod stuffing box oil in


the case of crosshead diesel engines.

Inadequately cleaned piston rod stuffing


box oil recycled to system oil.

12

1810106-02

MOPX Operating Instructions

2 Operating

Note:
1. A low pressure/low flow 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 productwetted parts of the bowl are manually
cleaned.
3. Intervals between manual cleaning can be
prolonged by the use of the Alfa Laval
CIP System (Cleaning-In-Place). Note
this does not apply to MOPX 207.
4. In cases where an uneven sludge cake
remains in the bowl after a discharge, this
induces a particularly heavy imbalance
when not covered by liquid. This may
occur in total discharge type separators
and when starting separators without
previous cleaning.
Therefore, always after each stop, inspect
the bowl for cleanliness from sludge, and
if required clean it before restart. This
should be done when the separator has
been in operation for 24 hours or more
after the last inspection or cleaning.

WARNING
Disintegration
hazard
Failure to clean the separator bowl,
including operating system, at
required intervals or after alarms and
stop of bowl may cause imbalance
with risk of injury to personnel.

1810106-02

13

2 Operating

MOPX Operating Instructions

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 components 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.
For further information see the Separator
Manual.
The level should be no more than half way up
the sight glass.

NOTE
Neglecting or delaying an oil change
may result in damage to separator
bearings.
3. Tighten all connections.
During operation:

G013441A

Check visually that there is oil in the sump.


The level should be no more than half way up
the sight glass, see fig.1.

NOTE
Fig.1. Oil level in the separator oil sump.

Too much or too little oil can damage


the separator bearings.

14

S000963A

Check that the starter ammeter reading is the


normal low and steady value.

1810106-02

MOPX Operating Instructions

2 Operating

Observe the control unit front panel


information:

heater operation LED lit (green):

separator system operation LED lit


(green).

activated valve LED lit (green).

G001541A

only if the heater is connected to the


control unit.

I001071A

During normal operation the time to next


sludge discharge is shown on the right of the
display.

G001647A

More information may be read, as required, by


pressing the alarm reset button repeatedly (the
values are always shown to the right):

I000731A

1. oil feed temperature. For the correct


separation temperature see the Technical
Data in the System Reference.
If the temperature sensor is not linked to
the control unit read the temperature
indicator situated after the heater.

I001421A

2. oil feed temperature (if a second sensor for


heater control is connected).

I001431A

3. accumulated operating time1 in hours.

N.B. The values displayed in the pictures to


the right are examples and not
recommendations.

1.

I001071A

Continue pressing until the display returns to


normal; i.e. the time to next sludge discharge.

How to interpret the displayed figures as


hours:
000 999 = actual value in hours
1.00 9.99 = 1000 9990 hours
10.0 99.9 = 10000 99900 hours
100. 999. = 100000 999000 hours

1810106-02

15

2 Operating

MOPX Operating Instructions

Check the back pressure:


read the pressure gauge situated by the low
pressure switch on the clean oil outlet line.

P000092A

Plant set value: ...........................

If excessive vibration occurs press the


emergency stop button and evacuate the room.

S005561A

DANGER
Disintegration
hazard
Do not discharge a vibrating separator. Vibration can increase if only part
of solidified sludge is discharged.

Check all connections for leakage.

S000981A

CAUTION
Slip hazard
Oil leakage may make the floor
slippery and cause injuries.

16

1810106-02

MOPX Operating Instructions

2 Operating

Avoid contact with hot machine surfaces.

S005541A

CAUTION
Burn hazard
Process pipes, lubrication oil and
various machine surfaces can be hot
and cause burns.

Use ear protection if noise levels are high.

S005161A

WARNING
Noise hazard
Excessive noise can cause damage to
hearing if no ear protection is used.

1810106-02

17

2 Operating

MOPX Operating Instructions

2.6 Stop
To stop the system:
1. Stop the system from the control unit:
G001643A

A sludge discharge is initiated.


Separator stop sequence operation LED
flashes (yellow).
The LED changes to steady when the
sludge discharge is completed.
2. Stop the heater from the control unit.

G001646A

If the heater is not connected to the control


unit it must be switched off independently.

G001647A

3. Wait until the oil feed temperature starts to


drop, read the temperature on the control
unit display by pressing the alarm reset
button.
If the temperature sensor is not linked to
the control unit read the temperature
indicator situated after the heater.

G046592A

4. Stop the oil feed pump at the pump starter.

S000962A

5. Wait until the separator is switched off by


the control unit, i.e. when the starter
ammeter reading drops to zero.

G024631A

6. Apply the brake after the EPC 41 display


shows OFF.
7. Wait until the separator has come to a
complete stop (4 7 minutes; depends on
separator size; see System Reference).

G024632A

8. Release the brake.

18

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MOPX Operating Instructions

2 Operating

P000022A

9. In order to empty the bowl, restart the


separator drive motor from the starter unit
and let it run for about 25 seconds.

1810106-02

19

2 Operating

MOPX Operating Instructions

2.7 Emergency Stop

S000991A

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.

DANGER
Disintegration
hazard
Do not enter the room after an
emergency stop 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
Disintegration
hazard
Do not start the separator after an
emergency stop without first
remedying the cause of the
emergency.
To avoid accidental start, switch off and lock
the power supply before dismantling.

20

S005101A

Consult the Separator Manual and the


Alarm List about emergency procedures.

1810106-02

MOPX Operating Instructions

2 Operating

S005111A

Dismantling work must not be started before


all rotating parts have come to a complete
standstill.

DANGER
Entrapment hazard
Do not begin maintenance work
while the machine is still rotating.

DANGER
Disintegration
hazard
After an emergency stop the
separator bowl must be manually
cleaned before starting up again.

S005101A

The separator must be fully reassembled with


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

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

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21

2 Operating

22

MOPX Operating Instructions

1810106-02