MMPX Separation System

Operating Instructions

Printed Nov 2000

Book No. 1810029-02 V6

Marine & Diesel Equipment

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 Tumba AB
Marine & Diesel Equipment
SE - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2005.
 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 Recommended intervals
between sludge discharges 7
2.3.3 Fuel oil cleaning 8
2.3.4 Lubricating oil cleaning 9
2.3.5 Bowl inspection 11

2.4 Intervals Between

Bowl Cleaning 12

2.5 Operating Check List 14

2.6 Check of Gravity Disc Size

During Operation 18

2.7 Stop 19

2.8 Emergency Stop 21

2.9 After Emergency Stop 21

1810029-02
1810029-02
1 Scope

The MMPX separation system is designed for

cleaning of fuel and lubrication oil for marine
and power diesel engines.

1810029-02 1
1 Scope MMPX Operating Instructions

2 1810029-02
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.

G046481A
2. Check the oil sump level: it should be
above the min. line on the sight glass.

NOTE

Too little oil can lead to damage of the

separator bearings.

Starter
3. Power on.
P000025A

1810029-02 3
2 Operating MMPX Operating Instructions

Control Unit
4. Ensure that the mode selector switch
points to L (local).

G001462A
5. Power on.
The display reads “OFF”.

G001461A
6. Close the door.
7. Check that the direction of rotation of the
bowl corresponds with the sign on the
frame; do a quick start/stop and look at the
motor fan rotation.

P000022A
DANGER

Disintegration
hazard

If power cables have been altered

G006141A
always check the rotation direction.
If the separator rotates in reverse vital
rotating parts could unscrew.

Air Valve Block

8. Ensure that there is correct air supply by
reading the pressure gauge situated on the
valve block; see “System Reference”.

Plant set value:

P000081A

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

4 1810029-02
MMPX 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.

1810029-02 5
2 Operating MMPX 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
correct:
• lube oil;
• for cross head engines 90°C

I000741A
• for trunk piston engines 95 °C
• fuel oil;
• for the correct separation temperature

I001081A
see the “Technical Data” in the “System
Reference”.
8. Start up the system from the control unit.
Operation LED lit (green). G001642A

6 1810029-02
MMPX 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.

1810029-02 7
2 Operating MMPX Operating Instructions

2.3.3 Fuel oil cleaning

Recommendations
Type of fuel Initial intervals be- Time to first bowl in-
tween discharges spection

Distillate (1.5 – 6 cSt/40 °C) 4 hours 1 week

Marine Diesel Oil (max. 14 cSt/40 °C 2 hours 1 week
Heavy Fuel Oil 0.5 hours 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.

8 1810029-02
MMPX 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 Type of separator
Initial discharge Time to first bowl in-
spection

Main lubricating oil system 1 hour 1 week MOPX

Main lubricating oil system 0.5 hours 1 week MMPX
Stuffing box oil 5 min. After each batch 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
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.

1810029-02 9
2 Operating MMPX 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 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

10 1810029-02
MMPX 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.

“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.
1% Alfa Laval assumes no responsibility
for the actual choice of discharge
intervals, as these entirely depend on
local conditions.

1810029-02 11
2 Operating MMPX 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 1810029-02
MMPX 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 product-
wetted parts of the bowl are manually
cleaned.
3. 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.

1810029-02 13
2 Operating MMPX 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 units are in good condition
and function correctly.
2. Change the oil in the separator oil sump.
Consult the “Separator Manual”.
The level should be above the min. line on
the sight glass.

NOTE

Neglecting or delaying an oil change

may result in damage to separator
bearings.

3. Tighten all connections.

During operation:

Check visually that there is oil in the sump.

NOTE
G047021A

Too little oil can lead to damage of the

separator bearings.

Check that the starter ammeter reading is the

normal low and steady value.
S000963A

14 1810029-02
MMPX Operating Instructions 2 Operating

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 time to next

I001071A
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

G001647A
values are always shown to the right):
1. the oil feed temperature. For the correct
separation temperature see the “Technical

I000741A
Data” in the “System Reference”
If the temperature sensor is not linked to
the control unit read the temperature

I001081A
indicator situated after the heater.

2. the oil feed temperature (if a second

I001421A
sensor for heater control is connected).
3. the accumulated operating time1 in hours.
I001431A

1% The values displayed in the pictures to

the right are examples and not
recommendations.

Continue pressing until the display returns to

I001071A

normal; i.e. the 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

1810029-02 15
2 Operating MMPX Operating Instructions

Check the back pressure:

read the pressure gauge situated by the low

pressure switch on the clean oil outlet line.

Plant set value: ........................... PS PI

P000093A
Check the intermediate tank level by looking
at the level indicator on the tank.
Empty, if necessary, by opening the left hand
valve on the air block. However, the control
unit normally empties the tank after each

P000911A
discharge.

If excessive vibration occurs press the

emergency stop button and evacuate the room.

DANGER

S005561A
Disintegration
hazard

Do not discharge a vibrating separa-

tor. Vibration can 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.

16 1810029-02
MMPX Operating Instructions 2 Operating

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.

1810029-02 17
2 Operating MMPX Operating Instructions

2.6 Check of Gravity Disc

Size During Operation
1. Carry out a discharge (for uninterrupted
time during check).
2. Close the isolating valves for both
pressure switches PS41 and PS42 (to
avoid pressure alarms during check).
3. Note the normal backpressure in the oil
outlet.
4. Close regulating valve RV4 completely.
5. Check that oil flows out through the
sludge outlet.
6. Re-open regulating valve RV4.
7. Check to see if oil is still flowing out
through the sludge outlet. Also observe
the backpressure.
• If oil is still flowing out, the gravity
disc is the correct size. The
backpressure is low. Go to item 8.
• If there is no oil flowing out, the gravity
disc is too small. The backpressure
remains normal.
Stop the separator and fit a larger
gravity disc. Restart and repeat the test.
8. Reset the system:
• Carry out a discharge.
• Reset normal backpressure in the oil
outlet using regulating valve RV4.
• Open both pressure switches PS41 and
PS42.

18 1810029-02
MMPX Operating Instructions 2 Operating

2.7 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.

G001647A
If the temperature sensor is not linked to
the control unit read the temperature
indicator situated after the heater.
4. Stop the oil feed pump at the pump starter.

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

6. Apply the brake after the EPC 41 display

shows OFF.
G024631A

7. Wait until the separator has come to a

complete stop (3-5 minutes; depends on
size).
8. Release the brake.
G024632A

1810029-02 19
2 Operating MMPX Operating Instructions

9. In order to empty the bowl, restart the

separator drive motor from the separator
starter and let it run for about 30 seconds.

P000022A

20 1810029-02
MMPX Operating Instructions 2 Operating

2.8 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.

2.9 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.

1810029-02 21
2 Operating MMPX 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.

22 1810029-02