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Kydr203cd-23 Fo Purifier Nanjing Luzhou Machine Co.,ltd
Kydr203cd-23 Fo Purifier Nanjing Luzhou Machine Co.,ltd
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- INSTRUCTION MANUAL
FOR OIL SEPARATORS
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KYDR203CD-23 I
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KYDR203CD-2360
KYDR303CD-2360
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•..•..•.....•....•...•..•..........• 4
3. Construction and Functions
4. Installation ························6
6. Application "13
8. Lubrication ·18
11. Maintenance
•.••..................•..••••.••................... 22
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This product IS to be accepted and tested as per the GB!T5745 Marine Disc
Separator.
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Working principle 2
The liquids and solids, which are interactive indissoluble and with different densities, will
be separated and sediment in the centrifuge and gravity force fields.
The separations that occur in the gravity field are called gravity separation and
sedimentation; in the centrifuge field called centrifugal separation and sedimentation.
Gravity separation
The indissoluble liquids and solids with different densities will be separated and sediment
slowly by the gravity in the gravitational fields. The solid particles freely settle down to the
bottom because of heavier gravity and the lighter liquid float up, so the separation and
sedimentation take place. This gravity separation and sedimentation need a very long time
and cover a large area.
Centrifuge separation
The indissoluble liquids and solids with different densities will be separated while they
are rotated at a high speed in the bowl, where the particles with heavier density move to the
inside wall of bowl body, the lighter liquid toward the center of the bowl . Because the
centrifugal force generated in the centrifuge fields in much larger than the gravity force, it
takes only very short time for the centrifuge separation to achieve the same separation
efficiency in the gravity fields. Especially the gravity separation can not be available, the
best method is centrifuge separation.
mixed liquid
Light liquid
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Separation space
,
There is a stack of discs installed in the bowl, which divide the bowl space into many ;
conical cavities. That can shorten the sedimentation distance and improve the separation
efficiency.
The moving trace ofthe limit particle "A" occurs between the discs(conical cavity).
Separation methods
As per the requirements of application and the bowl functions, there are 2 methods of
separation of both purification and clarification. •
1. Purification:
Purification method is to separate the mixture liquid into phase of Liquid-solid, the liquid
is the continuous phase. There is an inlet and two outlets on the separator machine.
2. Clarification:
Clarification method is to separate the mixture liquid into two phase of Liquid-liquid or
liquid-liquid-solid. The light phase liquid is the continuous phase. There is an inlet and two
outlets on separator machine.
Mixed llq~l i,
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The main structures of the drive system and bowl shall be described as follows:
1.Drive system
The electric motor drives the bowl by
means of the friction coupling and the
- Vertical shaft
gear drive.
The friction coupling can guarantee a
smooth acceleration and running, and
protect the electric motor and gear drive
• from overloading while starting the Worm gear'
•
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2.Bowl
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_"~-- - Distributor
Gravity ring -
Bowl cover
Top disc
Discs unit
Shaft sleeve
2.1 Structure
The bowl assembly is the key parts of the centrifuge. See the above figure. The large
lock ring locks the bowl hood. There are a distributor, a stack of discs and a top disc
installed in the bowl. There is a light phase chamber formed between the level ring and
the neck of the top disc, and also a heavy phase chamber formed between the small
lock ring and the top disc. There, one gravity ring is installed which can adjust the
interface of the light phase and heavy phase. The feeding raw oil and flushing water are •
all fed into disc stacks through the chamber under the dis~rlbutor.
2.2 Separation function
The lowing condition of liquid in the bowl: "
The raw oil to be treated in fed into the disc stack via feed pipe and distributor. The
solids, water and soap stock(heavy phase)move toward the wall of bowl body along the
under surface of discs, collected in the heavy pbase chamber and pumped out by the
heavy paring disc(heavy centripetal pump), The light phase moves tv wards the center
of the bowl along the outer cone surface of the discs, entering the collect and t)le sludge
gathering on the inner wall of the bowl. When purification, the light liquid is to be
discharged out by the gear pump from the center of the bowl. The sludge gathering on
the inner wall of the bowl will be manually discharged out when separators stops,
Sealing water:
In order to protect the light phase leakage from the heavy phase, the sealing water(hot
water)must be fed into the bowl through the sludge oil inlet pipe. The sludge oil can be
fed in only after water seal is completed,
Attention: The water sealing water is not allowed to feed into the bowl during
purification.
Gravity ring:
Due to the balance ofhydrodynamic pressure, the interface will be formed between the
light phase and heavy phase in the bowl while the bowl rotating, The gravity ring can"
adjust the inter face of light phase and heavy phase, As per the characteristic of the
feedstock and the processing requirements, select the proper gravity ring.
====="=======- -----=--==" •
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Installation 4
•
Attention: The centrifuge with the bowl can not be allowed to hauled and hoisted
during instaJlation, other wise the bearings and the spindle will be damaged!
Take into consideration the enough space available to maintenance and service the
centrifuge when installation. The foundation can be of steel structure or concrete, but
must be firm, plane and level, so that in can reduce the vibration.
All the outside pipes connection with the separator must be used with hose-pipe, so as to
isolate the outer vibration affecting the separator.
When install the separator on board, the horizontal shaft of the separator is
recommended to be kept paralleling to the longitudinal shaft of the ship thus it can reduce
influence when the ship swings.
The electric motor's connection shall meet the requirements as per the power supply of
Technical Specification and make sure that the rating direction is correct.
The overall dimensions shows in the following Figure .
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(1) water seal ing
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Means of the serial number (Pg.8)
(1) center of gravity
(2) vertical shaft center line
(3) pump of dirty oil outlet plan
(4) pump of cleaning oil and dirty oil inlet plan
(5) dirty water outlet center
(6) separator seat installation plan
(7) dirty water outlet plan
(8) vertical shaft center line
(9) installation hole diameter of separator seat
(10) center of gravity
(11) pump of cleaning oil inlet and outlet center
(12) motor-hand
(13) horizontal shaft center line
(14) pump of cleaning oil inlet and outlet center
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Adjustment 5
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Usage
6
1. Operation
Before start-up
Check the assembly of the centrifuge.
Make sure that the gravity ring is right.
Check the lubrication oil level in the gear housing.
Check whether the motor rotating direction is right.
Make sure that the brake is released.
Check whether the stop bar is turn out, and tighten the lock nut.
Check whether the recycle system of the wool fat is working properly.
Make sure that the valve before the wool fat delivery pump is opened.
Start up and running (separating:)
Switch on the power and start the centrifuge. If any abnormal vibration and noise
occur, switch off and stop immediately. And then check the centrifuge.
Check the rotating speed of speedometer is at full speed. The reading IS at 79~
83r1min for type KYDR203CD-23, at 95~ I02r/min for type KYDR203CD-2360
and KYDR303CD-2360.
stop
To close the heater and convert the valve, make the sludge go into the intermediate
tank from recycle system net.
To shut off the motor, apply the brake when the speed of the bowl slows down before
1000rlmin, or let it stop freely.
Attention:
1) The bowl must be cleaned when fmish the work every time.
2) Do not loosen any fixing fittings before the machine stops completely.
3) The oil seal on the machine is valid for 1 year. The oil seal should be done again when
over 1 year, or machine lays idle for long time.
-\3-
gravity and composition by selecting jhe ring with appropriate bore. In general, the
best separating effectiveness is obtained by the selection of the special gravity ring
with a larger bore, on condition that the water sealing in the separating drum. would
not be destroyed, and interface of oil and water should not be so near the wall of the
drum body that is would stay at the external circumference of the neck cover. If this
phenomenon takes place, oil will flow out of the circumference of the neck cover
along with water, and then water sealing is destroyed.
The selection of the special gravity ring for the oil separator can be made by reference
to fig.
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The appropriate bore of the special gravity ring can be readily obtained from the diagram,
when the temperature selected for separation ofthe oil.
For example: knowing that the special gravity ring of oil to be separated at 60'C is 0.888,
and the separation temperature is 70'C ,find the bore of the ring.
First draw a vertical line upward from 60'C on the left part of Fig. Intersecting with the'
horizontal special gravity line at 0.888, and then at the intersecting point draw a line
parallel to the inclined lines until it intersects with the transition line; and then from the
-14-
intersecting point draw a curve parallel to the curves in the right part until it intersects with
the verticalline3 denoting the separation temperature of 70 e and the reading on the right
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vertical axis is between 75 and 78 of the bore of the required ring, approximately cP78rnm,
so it is suitable for the bore of the gravity ring at cP78rnm.
If the gravity of the oil cannot be determined, you will get the best ring after more and
more tests.
In order to keep the separator running normally, the checks should be often carried out
during the course of operation. The check items are as follows:
U±10% lh .
I Voltage V
U±10% lh
2 Current A
KYDR203CD-23
79~83
Speed of 8h KYDR203CD-2360
3 r/min 95~102
speedometer KYDR303CD-2360
95~I02
Lih lh
4 Capacity ~1500
Light phase liquid MPa ~O.2 lh
5 outlet pressure
Dirty oil suction MPa ~O. 04 Ih
6 intensity
The set
Separating ·C temperature lh
7 temperature e±2
Oil temperature in "C ~85 8h
8 gear box
mrn/s ~7. 1 Ih
9 Vibration speed
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10 leakage
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Trouble Shooting 7
Mechanical Troubles Trouble Shooting (mechanical functions)
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Start
Speed Start Start Brake Water
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I Abnormal time Speed
smell noise too power power time too in gear Probable Causes Method
,' vibration too too high
low to low too high long box
long
Unbalance ()f the bowl. Cause: not Stop the machine at right; check out the
discharging in time; incorrect assembly; cause and remedy incorrect assembly of
some bowl parts interchanged with other large lock ring will cause fatal danger;
centrifuge; buffer dampers damaged; the replace the buffer dampers and axial buffer
axial buffer springs damaged springs every two years,
Normal for the friction lining while start NOll
1- Bearing overheating Replace them
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No enough oil ill the gear box Check the quality or lubrication oil in gear
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The water sealing in the bowl is broken Slop feeding the oil, and refill the sealin:
though. water.
Poor sealing between bowl and hood. Re-assembly and check the seal ring.
.. I•
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Lubrication 8
Lubrication ensures that the centrifuge can run reliably and normally. Improper brand,
poor quality of lubricant oil and much more or less quantity can result in bad lubrication or
serious trouble, so that the user should pay attention to lubrication carefully.
Check the oil level of the gear housing regularly to ensure the lubrication is in good
condition.
The bearings in the Drive System (horizontal shaft and vertical shaft) are splash
lubricated by the worm wheel.
The recommended lubricant oils are HH-20 air aviation lubrication oil, or SAE40,
SAE50 lubrication oils. The lubricant oil must be replaced at the first time after)50 hours'
running. The afterward replacement of lubricant oil shall be periodic and dependent on the
quality of the oil.
Clean the gear housing carefully at every replacement.
The following positions must be lubricated and coated by lubricant or grease while
reassembling the complete bowl:
(1) The screw threads of the large lock ring and the bowl body shall be coated with
MoS];
(2) The screw threads of the small lock ring and the bowl hood shall be coated with
MoS];
(3) The fit surfaces between the large lock ring and the bowl hood shall be coated
with MoS];
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SpecialTools 9
21410027
etracting threaded rod
11032063
main lock ring spanner
11033083
(
lifting tool for bowl
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----------------------------_._---- ----------------------
-20-
Disassembly and Assembly 12
Attention: Never dismount any part of the centrifuge before th~ bowl
is completely stationary!
1. Disassembly
1) Bowl:
The bowl, in which the sludge oil separating process is performed, is the key
component of the centrifuge. It consists of bowl body, bowl cover, disc stack and
main lock ring, etc.
Screw the stopping bar in the grooves on outside surface of the bowl body to
keep it stationary.
Loosen the lock ring (left hand thread) by the wrench.
Attention: If only to change the gravity ring, first screw out the gravity lock with
the gravity lock wrench, then lift off the bowl hood, frame and separating cover unit.
Loosen the large lock ring (left hand thread) by the wrench.
Using special tool (spade, etc.) to remove off the dirt.
Unscrew out the nut on the vertical shaft, loose the stopping bar and release the
brake, then lift up the bowl body off the vertical shaft.
The bowl components please see the decompose drawing attached.
2) Vertical shaft system
The vertical shaft system is the main component of power transmission of the
centrifuge, it consists of vertical shaft, worm, buffer device, bearing, etc.
Drain out the lubricant oil from the drainage outlet of gear housing ..
Dismount the tachometer.
Dismount the mechanical seal and loosen the nuts left hand thread.
Dismount the buffer casing on the frame, lift up the spindle by the lift eye.
Remove the round nut and lock washer, dismount the bearing and worm with the
copper bar knock at slightly.
Attention: Dismounting of the vertical shaft must be carried out after
dismounting of horizontal shaft.
Please see the decompose drawing attached.
3) Horizontal shaft system
The horizontal shaft system is the main component of power transmission of the
centrifuge, it consists of horizontal shaft (spindle) worm wheel, friction couple,
bearing, etc.
-24-
Dissemble the pump components on the right side.
Dissemble the transmission gear, door cover on the body and the tachometer
unit.
Dissemble electrical motor, friction block, friction drum and the oil sealing base.
Dissemble the bolt of the bearing cover and the driving pin on the coupling of
the horizontal shaft and take out the horizontal shaft together with the bearing,
cover and fiction drum from motor side. And then take out the worm wheel from
gear chamber.
4) Oil pump
Oil pump is the component of power transmission of the centrifuge. It is of
single gear type, and consists of driving gear, driven gear, pump seat, pump cover
pump. I
maintenance.
Note: The common components for type KYDR203CD-23, KYDR203CD-2360
and KYDR303CD-2360 are not listed in the component list. The component
different with each type will be remarked.
For e.g. the vertical shaft with item No.1 ,220000 13 on page 34 is used for the
three types. Worm gear with item No. is used for KYDR203CD-23, item No.
25620002 is used for both KYDR203CD-2360 and type KYDR303CD-2360.
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44 GB806-88 MIO Nut 1
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51 21020039 Washer 1
52 21320046 i\ut 1
53 21520015 Clean oil pIpe 1
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7 21310005 Nut
8 20320006 Bearing seat
9 27520009 Plate spring
10 21310006 Vertical shaft nut 1
11 21010014 Washer
12 GB67-85 M6X10 Screw 3
13 20330003 Shield cover 1
14 21010009 Seal ring 1
15 20730003 Press cover
17 GB93-87 10 Washer 6
18 20750005 Press cover
19 21050047 .Washer
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NO. Code Description Qnty Remark
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1 GB6170-86 MI0 Nut 1
2 GB848-85 10 Washer 1
3 29130001 Pump cover 2
4 21030015 Washer 4
5 21510003 Sleeve 6
17 GB6170-86 M8 Nut 1
18 20130015 Flange 2
19 3/16" L=185 Packing 1
20 21320048 Cover type nut 2
21 21020044 Washer 4
22 21320049 Nut 2
23 20320008 Spring seat 2
24 21810021 Spring 2
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~;) 22820001 Safety valve 2
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Annex
Supplying description
In this instruction manual:
• Type KYDR203CD-23 separator IS designed specially to fit to the frequency 50HZ of
electricity source.
• Type KYDR203CD-2360 separator is designed specially to fit to the frequency 60HZ of
electricity source.
• Type KYDR303CD-2360 separator is designed specially to fit to the frequency 60HZ of
electricity source as well as to process the oil with corrosive properties.
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