MAB/MMB Separation System

System Description
&
Operating Instructions

Printed 3/29/2005
Document n° 53555432
Revision 0
File 53555432.doc
1 Scope
This description is valid for the following separator module system:

MAB 103 Module

MMB 304 Module

MMB 305 Module

MAB 206 Module

The MAB/MMB separation systems are designed for cleaning of turbine

lubricating oil in the power applications.

2 System Overview
In the separation process, heated lubricating oil is fed through the separator to
clean the oil by removing any solid particles and water.
A MAB/MMB system comprises:

• Separator.
• Ancillary equipment including a control panel.
• Oil feed pump.
• Oil heating system.

The MAB/MMB separator module operates normally as clarifier. The cleaned oil
is discharged continuously, while the solid particles are collected in the
separator and have to be removed manually.

(Note: The separator can be operated either as a clarifier or as a purifier.

When the oil contains only small amounts of water the separator is operated as
a clarifier, collecting the water together with the solid particles in the bowl.
When the oil contains high amounts of water it is operated as a purifier,
discharging the separated water from the bowl continuously).

Cleaned oil leaves the separator through the oil outlet while separated particles
and sludge accumulates at the periphery of the separator bowl and separated
water goes out from the outlet.
The control panel supervises the entire operation of the separation system and
performs control and alarm functions.
Water is used in the separation process and a specified amount of processing
water is added manually by the operator into the bowl to form a water seal.

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3 System Description and Layout
The drawing numbers of the modules are according to the below table:

Model Flow Chart n° System Layout n° Assembly Drawing n°

FC GSL AD
MAB 103 Module 1765733 1765793 53550520
MMB 304 Module 53550365 53550366 53550521
MMB 305 Module 53550365 53550366 53550521
MAB 206 Module 53550367 53550368 53550522

Refer to the appropriate flow chart diagram. Oil to be treated (201) flows to the
module, it is drawn by the built-on pump installed on the module and it is
heated up at the temperature suitable for its treatment. An electric heater
assures the heating function (for total power installed refers to the table below)
and a programmable electronic temperature controller regulates the correct
working oil temperature.

Model Heater Model Total heater power N° of coils

MAB 103 Module EHSI-14 14.4 kW 3

MMB 304 Module⊗ EHSI-44 44 kW 6
MMB 305 Module⊗ EHSI-44 44 kW 6
MAB 206 Module⊗ EHSI-88 88 kW 12

⊗ Note: A regenerative heater is also available as an option in the case of

higher heater power demand.

During start up, electric 3-way valve MV1 re-circulates oil, diverting flow back to
the tank whilst the heater raises the oil temperature to the set point value.
For proper and correct unit performance refer to temperature/oil capacity table
below.

Model Purification Capacity of Steam Turbine Oil

Oil Viscosity 32 46 [cSt/40OC]

Oil Working Temperature 60 70 [ OC]
MAB 103 Module 1100 1200 l/h
MMB 304 Module 2000 2200 l/h
MMB 305 Module 3750 3800 l/h
MAB 206 Module 5200 7800 l/h

Treated oil outlet (220) and the recirculation oil (209) must be connected
directly back to the oil tank. Pressure switch arrangement PS42 detect that no
water seal breakage happens. The regulating valve RV4 creates the suitable oil

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operating back pressure that must be adjusted about to 100-150 kPa. The free
separated water is discharged through the outlet (221).

4 Operations Before Start Up

Before start up the unit following checks are always to be applied:
• Read Separator Manual first, and follow the safety recommendations.
• Mount the bowl with the suitable gravity disc according to the Separator
Manual instruction.
• Separator gear housing must be filled with proper lube oil type.
• Oil in-out terminals of module must be connected (201) (220) (209).
• Drains must be connected (463) (221).
• Water for bowl seal must be connected (371H).
• Check if the voltage of the control cabinet matches the voltage of the line.
• Proper 3 phases supply voltage must be connected to the Control & Power
Cabinet.
• Make sure the separator’s brake has been released.

5 Start Up Operations
• Open all manual valves (oil in/out, press switch, drain etc.).
• Close oil drain valves V3 of electric heater and water seal V6.
• On Control panel the alarms, heater and 3-way valve switches must be in
“Off” position.
• Switch “On” the Main Power selector switch.
• All alarms lamps must be “On”.
• Turn the reset alarm selector switch, the alarm signals will disappear.
• Start separator by pushing the start button.
• Start feeding pump by start button. In this phase the oil is recirculating, out
(209) to the storage tank. (Not applicable on MAB103).
• IMPORTANT: Air must be completely removed from electric heater by
opening the safety valve SV1 or by proper vent ball valve on the top of
the heater.
• Check the absence of leakage on pipes and heater.
• Wait until the separator has reached the full speed.

WATER SEAL
• Open slowly the water seal valve V6 to torn the water seal in the bowl.
• When water visibly flows out the bowl from open funnel or sight glass, close
water seal valve V6.

HEATING
• Turn the heater section switch to “On” position.

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• Wait until the oil temperature reaches the set point (approx. 60 °C). Thermo-
regulation function is performed automatically. It is possible to change the oil
temperature set point by pushing the buttons “Up” and “Down” on
temperature controller.

START SEPARATION (when oil has reached set point temperature)

• Turn 3-way valve selector switch to “On” position, with this step the oil flow is
diverted to the separator.
• Adjust the back pressure on the oil outlet side by the regulating valve RV4 to
reach the pressure of 100-150 kPa on pressure switch gauge.
• From now on the unit can be run without operator supervision.

⊗ Note (only for MAB 103 Module): Valve V7 must always be left opened in
order to feed “full pump flow” to separator. Closing valve V7 the oil is diverted
back to feed pump by opening the relief valve.

6 Stopping Operation
• Turn 3-way valve selector switch to “Off” position. The oil flow then
recirculates.
• Turn heater section switch to “Off” position.
• Push feed pump stop button.
• Push separator stop button.
• Wait for separator to completely stop (use the brake in order to reduce the
stopping time).
• Close oil valves.
• Turn Main power selector switch to “Off”.

7 General Remarks
7.1 Heater

IMPORTANT

Check regularly that the coil holder flanges are tightened.

After a long storage of the heater, the seal on the coupling could be worn. It is
advisable to renew the packing.

Long storage can decrease the electric insulation value of the coils.
Generally, the continuous working brings up again the insulation to normal
values.

If the value is lower than 1 MΩ, energize the coils in open air for 3 - 4 hours
with half rated voltage or leave them in an oven for 1 hour at a temperature of
max. 80 °C (completely el. disconnected in this case).
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Coil Cleaning

• for non water soluble deposits, circulate a cleaning solution inside the
section;
• for other kind of deposits, apply a specific cleaning product as recommended
by the maker.

Always ascertain that the products used are compatible with the material
circulating inside the heat exchanger.
In some special cases, also using brushes can assist cleaning.
In this case, utmost care must be taken to prevent deterioration of the external
surface of the heating element.
Frequent cleaning makes the de-scaling process easier.
During disassembly, special care should be taken not to damage the coils and
the gasket seats.

7.2 Separator Maintenance

Periodical cleaning operations have to be performed on the bowl for removing

the sludge.
For cleaning operation and gearbox oil changing refer to the Separator Manual.

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 MAB/MMB Separation System

Alarms and Fault Finding

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Low Oil Pressure (PS 42)

Causes Corrective actions

Broken water seal: Check water pressure 200-600 kPa

Water pressure too low and correct amount also check oil
temperature correct
Too low oil feed Check the oil feed pump
Strainer before the oil feed pump is Clean the strainer
clogged
Oil feed pump has stopped Check the feed pump
Change over valve (MV1) is in Check MV1 and operation
recirculation position

Too low back pressure Increase the back pressure with the
regulating valve RV4 to correct back
pressure (about 100-150 kPa)

Automatic actions at alarm Automatic actions after alarm reset*

Alarm lamp on Alarm lamp off
Oil feed (MV1) off MV1 valve on

* In order to reset this alarm the operator should switch off the three-way valve in “0” position.

Emergency Stop (XS2)

Causes Corrective actions

Emergency stop button has been 1. Remedy the cause for the
pushed emergency stop.
2. Reset the alarm by switching the
power off and on.
3. Restart the separator.
4. Restart the process.

Automatic actions at alarm Automatic actions after alarm reset

All alarms lamp on Alarm lamps off
The separator is stopped and the
heater turned off
Feed pump stopped (only MAB 103)
Oil feed (MV1) off

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Low Flow (FS)

Causes Corrective actions

Too low oil feed Check the oil feed pump

(Max suction 40 kPa available)
Check if oil valves are open
Clogged heater Clean heater
Air in the heater Drain out air from heater
Strainer before the oil feed pump is Clean the strainer
clogged
Oil feed pump has stopped Check the oil feed pump

Automatic actions at alarm Automatic actions after alarm reset

Alarm FS lamp on Alarm lamp off
Heater cut off Heater on

High temperature (TS)

Causes Corrective actions

Temperature switch on heater tripped 1. Flush until temperature became

normal.
2. Investigate the temperature switch
setting.
3. If step 2 is OK, check that heater is
clean.

Temperature set point higher than Reduce temperature set point

temperature switch
Oil flow stopped Check pumps, valves and piping

Automatic actions at alarm Automatic actions after alarm reset

Alarm TS lamp on Alarm lamp off
Heater cut off Heater on

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Motor Overload

Causes Corrective actions

Separator and feed pump electric 1. Check if the thermal switch is set to
motors overload the correct amperage according
with the maximum electric motor
consumption.
2. Check electric motors and
mechanical motion parts.
3. Check if the voltage supplied is in
accordance with the control panel
label.

Automatic actions at alarm Automatic actions after alarm reset*

Alarm lamp on Alarm lamp off
Electric motor overloaded is cut out Motor ready to start

* In order to reset this alarm the operator should reset the circuit breaker by opening the door of
the control panel and pushing the reset button inside.

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