Professional Documents
Culture Documents
Mar 2010
Book No.
EPS002-E-1 V 3
Alfa Laval reserves the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by:
Contents
1
Installation ....................................................................... .5
1.1
1.1.1
1.1.2
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.3
1.3.1
1.4
1.4.1
1.4.2
1.4.3
1.5
1.5.1
1.6
1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
Introduction .............................................................. 31
Separation by gravity .................................................... 31
Continuous separation .......................................... 32
How a disc stack centrifuge works ............................... 35
Disc stack centrifuge sections. ..................................... 36
Fuel and lubricating oils ....................................... 40
Running the separator........................................... 45
Conventional separators, Purifier/Clarifier. .................... 45
Separation results with purifiers .................................... 46
Cleaning intervals.......................................................... 49
Basic operation........................................................ 51
Purifier/ Clarifier limitations ............................................ 53
How to find the right Gravity disc .................................. 55
Operation on off-spec fuel. .................................. 56
Normal operation........................................................... 56
High density oil.............................................................. 57
High catfines oil ............................................................. 58
Alcap technology .................................................... 59
2.7.1
2.7.2
2.7.3
2.7.4
2.7.5
2.7.6
2.7.7
2.7.8
1 INSTALLATION
1 Installation
1.1 Settling Tanks
Suction to separator
Transfer pump
I0 01 00 7 2
Drain
1 INSTALLATION
1 INSTALLATION
1.1.2 Recommendations
If there has been an incident with high catfines on board we recommend cleaning the
tank as soon as possible after the incident.
1 INSTALLATION
PI
S0 01 01 2 A
PI
constant temperature
1 INSTALLATION
1 INSTALLATION
I 00 11 1 0B
10
I0 01 1 10 A
1 INSTALLATION
1.2.4 Strainer
To protect the pump from coarse particles,
there must be a strainer in front of the
pump. The diameter of the holes in the
screen should be 0.5-0.8 mm. The strainer
free-flow area must be at least 35% of the
total filter area. It is a good idea to check
that a screen is actually installed.
1.2.5 Recommendations
NOTE
The return pipe from the three-way valve in front of
the separator should lead back to the settling tank,
and not to the suction side of the pump. The latter
case will lead to operational problems.
11
1 INSTALLATION
PS
PI
Mt4
PI
S0 01 01 0C
PI
Conventional separators;
12
1 INSTALLATION
ALCAP separators;
13
1 INSTALLATION
14
PI
I0 0 10 69
PI
1 INSTALLATION
15
1 INSTALLATION
16
1 INSTALLATION
17
1 INSTALLATION
OP
TT
Temperature accuracy 1C
MT
PT
PT
10
SEPARATION
STOP
DISCHARGE
OP ACTIVE
ENTER
ALARM
.
The HEATPAC electric heater comprises a
heating element bundle inserted in a pressure
vessel. Mineral oil is fed continuously to the
heater. A baffle plate inside the vessel divides the
flow into two passes.
18
15
INFO
PT
HEATER
16
EPC-50
1 INSTALLATION
Steam trap
P0 0 11 50 B
Installation
OP
TT
PT
MT
PT
HEATER
PT
16
15
10
SEPARATION
STOP
EPC-50
DISCHARGE
INFO
OP ACTIVE
ENTER
ALARM
I 00 1 03 8H
19
1 INSTALLATION
Drain
20
I 00 1 00 71
1 INSTALLATION
21
1 INSTALLATION
22
1 INSTALLATION
I 00 10 10 A
23
1 INSTALLATION
I 00 1 01 0E
24
1 INSTALLATION
I 00 1 01 0E
1.6.2 ULSMDO/GO
1 INSTALLATION
I 00 1 01 0H
Recommendation
26
1 INSTALLATION
Pumps:
Check that the return pipe from the threeway valve is led back to the settling tank
and is not in front of the pump. If it is in the
front of the pump, change it.
1 INSTALLATION
Separators
28
1 INSTALLATION
1.6.5 Conclusions
Experience and future trends indicate that there
is an increasing need for efficient and reliable
fuel and lube oil treatment on board ships whether existing operational ships or projected
new buildings.
There are numerous factors that must be
considered and various actions that can be taken
to upgrade existing installations or designs.
Our basic recommendations can be summarized
as follows:
29
1 INSTALLATION
30
2 SEPARATION
2 Separation
2.1 Introduction
The purpose of separation can be:
31
2 SEPARATION
I0 0 10 68 A
I0 01 06 8 B
32
2 SEPARATION
Centrifugal separation
0 68 C
Types of centrifuge
33
2 SEPARATION
34
2 SEPARATION
35
2 SEPARATION
Inlet zone
36
0,5 - 0,8 mm
I0 0 10 59
2 SEPARATION
I0 01 06 7
37
2 SEPARATION
38
2 SEPARATION
Separator system
39
2 SEPARATION
Fuel oil
40
2 SEPARATION
Catalytic fines;
2 SEPARATION
Lubricating oil
Trunk engines
42
2 SEPARATION
Cross-head engines
43
2 SEPARATION
An essential application
44
2 SEPARATION
45
2 SEPARATION
I 00 10 63 A
46
2 SEPARATION
I0 0 10 63 C
47
2 SEPARATION
I 00 1 06 3B
48
2 SEPARATION
49
2 SEPARATION
Oil losses
50
2 SEPARATION
2 SEPARATION
52
2 SEPARATION
NOTE
53
2 SEPARATION
54
2 SEPARATION
kg/m
O (mm)
1,00
1000
991
45,8
47,3
48,7
50,1
51,5
I
950
0,95
Max.
53,3
55,5
58,2
900
0,90
61,6
II
65,8
850
0,85
70,9
800
77
20
30
40
50
60
70
80
90
100
C
F
o
60
70
80
90
I0 01 06 5
0,80
0,75
0
6
3
Q m /h
100 110 120 130 140 150 160 170 180 190 200 212
55
2 SEPARATION
56
2 SEPARATION
CLARIFIER
CLARIFIER
57
2 SEPARATION
PURIFIER
58
PURIFIER
2 SEPARATION
59
2 SEPARATION
60
2 SEPARATION
2.7.3 Application
The WT 200/MT 50 water transducer is used to
monitor the water content in the processed oil
leaving a separator. The signal from the water
transducer is processed in the EPC program
unit, and appropriate action is initiated,
depending on the status in the separation
system.
2.7.4 Design
The water transducer consists of a housing (2),
a concentric electrode (4), and an electrical
connection box fitted to the housing. The box
contains a test circuit board (1) and
connections. The electrode is insulated (3) from
the housing and forms a circular capacitor. The
transducer is mounted in the oil pipe by flanges
on the outer pipe, and the full oil flow passes
through the capacitor.
4
1
3
I0 01 05 0 D
1
2
3
4
61
2 SEPARATION
Dielectric constant
(Approximate values)
Mineral oil: 2 6
Water: 90 95
62
2 SEPARATION
63
Transducer value
Separation period
64
Ref. time
0,2% increace
in dialectic value
Separation period
I 00 10 61
Ref. Time
Trigger range
100%
2 SEPARATION
2 SEPARATION
Trigger point
V5 opening
100%
V5 closing
Stored reference
Min Sep. period
Separation period
P0 01 0 60 A
Ref. time
Trigger point
V5 opening
100%
V5 closing
Stored reference
Min Sep. period
Separation period
I0 0 10 60 B
Ref. time
65
2 SEPARATION
Trigger point
100%
Sludge
discharge
Ref. time
66
2 SEPARATION
67
2 SEPARATION
68
Ref. time
Trigger range
Transducer value
Separation period
0,2% increace
in dialectic
Discharge
30% increace
in trigger range
Ref. time
I 00 1 06 4A
100%
2 SEPARATION
69
2 SEPARATION
100%
Cond.
Water
Ref. time
Separation period
70
I0 0 10 64 B
Trigger point
2 SEPARATION
71
2 SEPARATION
72
2 SEPARATION
100%
Trigger range
70%
Transducer value
Separation period
Reference time
Separation period
I 00 10 66 H
Reference time
73
2 SEPARATION
74
2 SEPARATION
100%
70%
V5 closing
Reference value
Ref. time
V5 opening
Separation period
75
2 SEPARATION
100%
70%
Reference value
Ref. time
Separation period
76
V5 opening
2 SEPARATION
77
2 SEPARATION
100%
70%
Reference value
New lower ref. value
Ref. time
Separation period
78
3 BOOSTER SYSTEM
3 Booster system
3.1 Purpose of the system
To provide the diesel engine with fuel with the
correct viscosity and flow stipulated by the
engine manufacturer.
All low speed engines and most modern medium
speed engines operate today on heavy fuel oil. To
ensure proper treatment and a good combustion,
a booster system is needed. The principal
purpose of these systems is to ensure proper
conditioning of the heavy fuel oil fed from the
daily service tank to the diesel engines.
The system ensures that the correct flow,
pressure and viscosity of the heavy fuel oil is
maintained.
The booster system is situated between the daily
service tanks and the diesel engines
3.2 Applications
Booster systems are primarily suitable for ships
or power stations using HFO diesel engines.
There are generally two separate conditioning
systems for shipboard applications where HFO
engines are in use, as today, heavy fuel is
commonly used for the auxiliaries (Unifuel
system) as well as for the main engines. For
safety reasons, there is usually one independent
booster system for the main engines and one for
the auxiliaries.
79
3 BOOSTER SYSTEM
80
3 BOOSTER SYSTEM
I0 01 00 5 8B
Service tank
81
3 BOOSTER SYSTEM
Mixing pipe
Flow meter
82
3 BOOSTER SYSTEM
83
3 BOOSTER SYSTEM
Viscosity sensor
84
3 BOOSTER SYSTEM
Automatic filter
85
3 BOOSTER SYSTEM
I0 01 00 58 A
86
3 BOOSTER SYSTEM
Filter upgrading
87
3 BOOSTER SYSTEM
Heater
3 BOOSTER SYSTEM
Viscosity sensor
89
3 BOOSTER SYSTEM
Automation
90
3 BOOSTER SYSTEM
91
3 BOOSTER SYSTEM
Process alarms:
High temperature
Low temperature
High viscosity
Low viscosity
System alarms:
power alarm
communication failure
input signal failure
temperature/flow switch
computer failure
steam valve failure
Following alarms are given to the alarm panel:
Low pump pressure, stand-by pump started
Low dearator tank level
High difference in pressure over automatic
filter
Starter alarm for all pumps (and filter if
applicable). Each pump has an
independent starter activated by low fuel oil
pressure.
All modules are supplied insulated and heat
traced as well as tested and certified to required
class.
92
3 BOOSTER SYSTEM
93
3 BOOSTER SYSTEM
94
3 BOOSTER SYSTEM
95