LOPX Separation System

Operating Instructions

Printed Nov 1998

Book No. 1810020-02 V4

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.

Not following the instructions can result in

serious accidents with fatal injuries.

P000272A
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 5

2.3 Intervals Between Sludge

Discharges 7
2.3.1 Background 7
2.3.2 Lubricating oil cleaning 8
2.3.3 Bowl inspection 10

2.4 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
1810020-02
1 Scope

These operating instructions are valid for the

following separation systems:

LOPX 705
LOPX 707

LOPX 709
LOPX 710

LOPX 713

LOPX 714

The LOPX separation system is designed for

cleaning of lubrication oil for marine and
power diesel engines.

1810020-02 1
1 Scope LOPX Operating Instructions

2 1810020-02
2 Operating

2.1 Start up Check List

Separator
1. Check that the separator is assembled and
connected correctly.

DANGER

Disintegration
hazard

If the separator is not assembled and

connected properly it may lead to
disintegration.

G054741A
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.

G024632A

Starter
4. Power on.
P000025A

1810020-02 3
2 Operating LOPX Operating Instructions

Control Unit
5. Check that the mode selector switch points
to L (local).

G001462A
6. Power on.
The display reads OFF.

7. Close the door.

G001461A
8. Check the direction of rotation of the bowl
by doing a quick start/stop. The revolution
counter must rotate clockwise.

DANGER

G013442A
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:

min. .................... max. ....................

P000081A

4 1810020-02
LOPX Operating Instructions 2 Operating

2.2 Start up
1. Start the oil feed pump from the pump
starter.

G046591A
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.

G001644A
3. Start the separator from the starter unit.

P000022A
4. Listen and observe.
Vibration may occur during start up, when
passing critical rpm (revolutions per
minute).
This is normal and should pass without

S005561A
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!

DANGER

Disintegration
hazard

Excessive vibration may cause

breakdown.

1810020-02 5
2 Operating LOPX Operating Instructions

5. Ensure that the separator is at full speed.

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).

S000961A
6. Check the oil feed temperature on the
control unit display by pressing the alarm
reset button.

G001647A
If the temperature sensor is not linked to
the control unit read the temperature
indicator situated after the heater.
7. Wait until the oil feed temperature is

I000741A
correct:
for cross head engines 80 90 C
for trunk piston engines 85 95 C
8. Start the feed to the system from the
control unit.
When the temperature is correct the

G001642A
operation LED lit (green).

6 1810020-02
LOPX 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.

1810020-02 7
2 Operating LOPX Operating Instructions

2.3.2 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 Type of separator
Initial discharge Time to first bowl in-
spection

Main lubricating oil system 0.5 hours 1 week LOPX

Stuffing box oil 5 min. After each batch LOPX

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
Initial 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 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.

8 1810020-02
LOPX Operating Instructions 2 Operating

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 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 9
2 Operating LOPX Operating Instructions

2.3.3 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.

Sludge space is clean means that no

noticeable amount of hard sludge remains in
the sludge space.

P000961A
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, A. Top disc

B. Bowl hood
the sludge space should always be inspected C. Sludge space
and evaluated. If necessary, the interval D. Disc stack
between discharges should then be changed E. Sliding bowl bottom
accordingly.
N.B. Alfa Laval assumes no responsibility
for the actual choice of discharge
intervals, as these entirely depend on
local conditions.

10 1810020-02
LOPX Operating Instructions 2 Operating

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.
Installation not in accordance with Alfa
Laval specifications and
recommendations.
Poor operating water quality.
Operation without sludge conditioning
water.
Diesel engine condition bad.

Note:
1. 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 manually
cleaned.
3. Intervals between manual cleaning can be
prolonged by the use of the Alfa Laval
CIP System (Cleaning-In-Place).

1810020-02 11
2 Operating LOPX Operating Instructions

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.

12 1810020-02
LOPX Operating Instructions 2 Operating

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
G013441A

Too much or too little oil can damage

the separator bearings.

Check that the starter ammeter reading is the

normal low and steady value.
S000963A

1810020-02 13
2 Operating LOPX Operating Instructions

Observe the control unit front panel

information:
heater operation LED lit (green):
only if the heater is connected to the
control unit.
separator system operation LED lit
(green).
activated valve LED lit (green).

G001541A
During normal operation the trigger value is

I001072A
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
values are always shown to the right):

G001647A
1. the oil feed temperature:
for cross head engines 80 90 C

I000741A
for trunk piston engines 85 95 C
If the temperature sensor is not linked to
the control unit read the temperature
indicator situated after the heater.
2. the oil feed temperature (if a second

I001041A
sensor for heater control is connected).
3. the accumulated operating time1 in hours. I001051A

4. the water transducer value.

I001021A

5. the number of pulses for displacement

I001031A

water.

Continue pressing until the display returns to

I001072A

normal; i.e. the trigger value, and time to next

sludge discharge.

1. 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

14 1810020-02
LOPX Operating Instructions 2 Operating

Check the back pressure:

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

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

P000092A
If excessive vibration occurs press the
emergency stop button and evacuate the room.

DANGER

S005561A
Disintegration
hazard

Never discharge a vibrating separa-

tor. Vibration will increase if only
part of solidified sludge is
discharged.

Check all connections for leakage.

CAUTION
S000981A
Slip hazard

Oil leakage may make the floor

slippery and cause injuries.

1810020-02 15
2 Operating LOPX Operating Instructions

Avoid contact with hot machine surfaces.

CAUTION

S005541A
Burn hazard

Process pipes, lubrication oil and

various machine surfaces can be hot
and cause burns.

Use ear protection if noise levels are high.

WARNING

S005161A
Noise hazard

Excessive noise can cause damage to

hearing if no ear protection is used.

16 1810020-02
LOPX Operating Instructions 2 Operating

2.6 Stop
To stop the system:
1. Stop the system from the control unit:
A sludge discharge is initiated.

G001643A
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.
If the heater is not connected to the control
unit it must be switched off independently.

G001646A
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

G001647A
the control unit read the temperature
indicator situated after the heater.
4. Stop the oil feed pump at the pump starter.

G046592A
5. Wait until the separator is switched off by
the control unit, i.e. when the starter
ammeter reading drops to zero.
S000962A

6. Apply the brake.

G024631A

7. Wait until the separator has come to a

complete stop (4 7 minutes; depends on
separator size; see System Reference).
8. Release the brake.
G024632A

1810020-02 17
2 Operating LOPX Operating Instructions

9. In order to empty the bowl, restart the

separator drive motor from the separator
starter and let it run for about 1 minute.

P000022A

18 1810020-02
LOPX Operating Instructions 2 Operating

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.

S000991A
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.

Consult the Separator Manual and the

S005101A

Alarm List about emergency procedures.

1810020-02 19
2 Operating LOPX Operating Instructions

Dismantling work must not be started before

all rotating parts have come to a complete
standstill.

S005111A
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.

The separator must be reassembled and all

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

S005101A
DANGER

Entrapment hazard

Do not switch on without all covers

and guards in place.

20 1810020-02