Zhangjiagang PDSD14000 Disc Separator System Manual
Zhangjiagang PDSD14000 Disc Separator System Manual
Zhangjiagang PDSD14000 Disc Separator System Manual
System Manual
Operating Instruction of
Disk-Type Separator units
(Manual of Frequency-Conversion
Gravity Disk System)
This operating instruction or any part thereof shall not be reproduced or distributed by any
means or method without prior written permission of Zhangjiagang Peony Machinery Co., Ltd.
information only when the separator used as a part of the complete system provided by Zhangjiagang Peony
Contents
1. Safety......................................................................................................................................... 4
1.1 Safety instruction..................................................................................................................... 4
2. Overviews.................................................................................................................................. 4
2.1 Main Purpose........................................................................................................................... 4
2.2 Product Standard:..................................................................................................................... 4
3. System Components and Introduction.......................................................................................5
3.1 System Components................................................................................................................ 5
3.1.1 Common base....................................................................................................................... 5
3.1.2 Separator............................................................................................................................... 6
3.1.3 Electrical control box............................................................................................................ 6
3.1.4 Heating unit...........................................................................................................................6
3.1.5 Piping system........................................................................................................................ 6
3.1.5.1 Names and functions of the valves are as follows............................................................ 6
3.1.5.2 Oil transfer pump............................................................................................................... 8
3.1.5.3 Slag pump.......................................................................................................................... 8
3.1.5.4 Oil Filter............................................................................................................................. 8
3.1.5.5 Heating unit, see 3.4.......................................................................................................... 8
3.1.5.6 Instrument Elements.......................................................................................................... 8
Name.............................................................................................................................................. 8
Characteristics................................................................................................................................ 8
4. Installation and Adjustment....................................................................................................... 9
4.1 Requirements for Installation of Unit:..................................................................................... 9
4.2 Requirements for Installation of External System Piping of Unit.......................................... 9
5. Adjustment of Control Box Parameters before Operation........................................................ 9
5.1 Description............................................................................................................................... 9
5.2 Introduction of Control Box.................................................................................................. 10
6. Operation..................................................................................................................................18
6.1 Operating procedures............................................................................................................. 18
6.1.1 Starting................................................................................................................................ 18
6.1.2 Shutdown............................................................................................................................ 18
6.1.2.1 Automatic Cleaning......................................................................................................... 18
7. Maintenance and Repair.......................................................................................................... 19
Alarm: Oil transfer pump failure................................................................................................. 19
Alarm: Material temperature lower than set-point...................................................................... 19
Alarm: Low clean oil pressure alarm.......................................................................................... 20
Alarm: Material temperature higher than set-point (high temperature alarm)........................... 20
Alarm 11: High clean oil pressure alarm..................................................................................... 21
Alarm: No slag discharge alarm.................................................................................................. 21
Alarm: Abnormal speed alarm (optional).................................................................................... 21
Alarm: First class vibration alarm (optional).............................................................................. 21
Alarm: Vibration alarm (optional)............................................................................................... 22
1. Safety
1.1 Safety instruction
The separator is a high-speed rotating equipment and the drum will produce a
tremendous centrifugal force due to high-speed rotation during normal operation;
slightly improper operation or assembly may cause damage to the equipment while
severely improper may cause casualties and other serious accidents.
If the system is used for heavy fuel or lubricating oil, it must be heated to a
certain temperature to achieve the desired state of the material separation. The
temperature of heating medium and heated material is very high, so the operator
shall be careful to prevent accidental scalding when using it; please check the
assembly of the system before operation to prevent the liquid spilling or splashing
that may cause damage or injury.
In order to ensure the safety of the operating personnel and equipment, the
operator shall strictly comply with the safety rules (refer to the safety-related
sections of the operating manual for separator provided with the equipment).
2. Overviews
2.1 Main Purpose
The separator unit is an integrated module assembled with the separator,
electric equipment and related components and parts based on the systematic
diagram of the separator confirmed by both parties according to the requirement of
the owner, design institute and shipyard or user.
This unit is used to remove the water and mechanical impurities from the fuel
and diesel in the ship diesel engine, and for separation, purification and
regeneration of the lubricating oil from the lubricating system. It can also be used
for separation and purification of the fuel and oil in the diesel generator unit system
in the land-use power plant. The product can also extend its use for processing
different types of mineral oil products.
The operating system of the unit is an automatic control system.
* The automatic control refers to unmanned operation during normal
operation, but the product during normal operation can be unmanned operation,
and the separator must operate in attended status during start-up and shutdown
phases because the separator product has a certain risk in the phases of the
separator start-up and shutdown.
* If the user modifies the system at his own discretion without prior consent
of the Technical Department of Zhangjiagang Peony Machinery Co., Ltd, the
customer shall be fully liable for all damages and losses arising therefrom.
The separator used in this unit is characterized by minimal vibration and
prolonged operation with high safety and reliability by checking of precisely
dynamical balancing.
3.1.2 Separator
The separator is the core component of the unit playing a role of completing
the material separation and purification (see the manual of separator).
The basic set point of the heater: the oil is set between 85-90 degrees, and the
120CST-380CST is set between 95-98 degrees. For specific instructions of the
heater see the manual of separator.
Cutoff valve (before Regulate the flow of material in the inlet pipe. Used for
pump inlet) cutting off the flow before pump to achieve flow control.
Cutoff valve (at outlet Regulate the outlet pressure of the clean oil pipe. The
of clean oil) maximum pressure shall not exceed 0.4Mpa, and the
minimum pressure shall not be less than 0.1Mpa.
Air reducing valve (for Filter the compressed air and keep the compressed air
air passage) pressure at 0.5 - 0.8MPa.
3/2 solenoid valve (for Control the three-way pneumatic valve in the oil pipe to
air passage) achieve automatic control of the oil pipe.
Three-way pneumatic Feeds material in the separator in normal operation of the
valve (installed after separator at proper temperature; and achieves oil return in
heating unit) start-up, shutdown, slag discharge and when the separator
operates improperly and different alarms sound.
Temperature control Only when the steam, hot oil or hot water is used to heat the
valve (installed at steam, oil, this temperature control valve can be used to
hot oil or hot water side) automatically adjust the temperature.
1. It uses electric self-operated structure. The temperature set
points are provided on the valve body where the basic set
point is: the oil set between 85-90 degrees and the fuel
120CST-380CST is set between 95-98 degrees. The valve
body determines the oil temperature with its own
temperature sensors, compares it with the temperature set
point, and then adjust the opening of the valve body with the
motor to control the temperature. If the heat source is
relatively stable, a relatively balanced value can be reached
in about 5 minutes. If the automatic adjustment is faulty, the
hand wheel on the valve body can be manually operated to
open or close in a short time. This time, the 220V cable from
this valve to the control box shall be removed to prevent
maloperation.
2. If the valve that performs temperature adjustment with
PLC is used, the program is set in PLC to adjust the opening
of the valve body.
High-temperature ball Only when using the steam, hot oil or hot water to heat the
valve (used in material, it is used for maintenance and emergency operation
conjunction with of the temperature control valve.
temperature control
valve)
Safety valve and The safety valve and temperature meter in the heating unit
temperature meter are used to ensure the safety of the heating equipment.
(used in steam, hot oil or
hot water heater)
Temperature sensor It transmits the temperature of material in real-time to the
(installed between heater electric control box for real-time display of the temperature,
and three-way valve) and compares it with the set-point.
Safety valve (in oil It prevents the pump valve overpressure.
passage)
By-pass valve (after It is used to split the flow after pump to achieve the purpose
pump outlet, at oil pipe of flow control.
inlet of oil transfer material because the oil pump is damaged or the coarse
pump) pre-filter is clogged that needs to be cleaned.
Pressure gauge (at It is used to indicate the pressure at the clean oil outlet.
clean oil outlet of
separator)
Pressure gauge (at There are two types of gauges: high pressure and low
clean oil outlet of pressure, and it can be configured according to the
separator) customer requirement that the alarm signal will be sent
when the pressure of clean oil at the separator outlet is
below 0.1Mpa. For the specific setting method, refer to
the description of pressure switch.
Vibration switch (on It is used to generate an alarm signal or shutdown in the
separator body) case of abnormal vibration.
(optional)
therefrom.
Some parameters in the program can be revised by the user, but the revision of
most of parameters is not allowed and the parameters are protected with password,
so the relevant revisions must be performed by professionals, if the customer
forces to decipher the code, our company shall not assume the liabilities for the
consequences caused therefrom.
5.2 Introduction of Control Box
When starting the control box for the first time or restarting it after a power
failure, a welcome page will be displayed on the screen system as shown below:
按下进入系统键,可直接 系统当前的时间及日期,此
进入主系统操作届面 时间由 PLC 给定,用户无法
Press the ENTER key to 修改
enter the main system The current system time and
operating interface date, the time is given by PLC
directly that can't be revised by the
user
停机按钮
Shutdown button
密封测试选择按钮
Seal test selector
button
程序停止按钮
Program stop button
程序启动按钮
Program start button
届面切换按钮
Interface switching button
报警状态显示栏
Alarm status display box
独立密封测试按钮
Individual seal test button
运行时间记录
Running time record
运行状态显示栏
Running status display box
可返回系统主届面
Return to main interface
Click the "Process Monitoring" to enter this interface, which is the status
display interface, when "Waiting" is displayed, click "Program start" to enter
separate cycle phase, if the program is required to stop at any time, single click the
"Program Stop", and the "Shutdown" is to enter the slag discharge phase after the
implementation of the current separation cycle, and then the separator, the pump
loses power to stop operating, and the temperature control valve is automatically
closed; when the "Seal Test" is "Yes", i.e. the separator drum shall be detected for
sealing before each separation cycle, if it is "NO", the detection phase shall be
skipped.
And the "Individual Seal Test Button" can independently implement the
program to determine whether the drum is sealed as the separator start is completed;
when the program running is completed, the processing is in continuous waiting
phase, and manual operation of program implementation is required to carry out
material separation. This program is conducive to determine whether the separator
is sealed to avoid loss of material. In this process, the program will calculate
automatically the operation time of the water sealing water, and can introduce
the calculated running time of the water sealing water into the water seal
parameters in the current pressure condition, that is more favorable to the
normal operation of the separator, therefore it is recommended to implement
this program after each start of the separator.
The interface button describes the operation method and precautions of the
interface:
可返回主届面
This button can be used to return back to the main interface from any interface,
and can also use the interface switching button to switch over among a variety of
interfaces.
This program contains five sub-interfaces, namely: process monitoring
interface, real-time data interface, manual operation interface, parameter setting
interface and alarm inquery interface.
The five sub-interfaces can be switched over at any time by pressing the
interface switching button.
运行状态显示栏
This display bar shows the operating state of the separator, they are: Waiting,
Preparation for running, Separating, Slag Discharging, and Stopping
Waiting: refers to that when the separator is started, the pump is started, and
the temperature is in the preset range, this Waiting status appears. The display of
this status also represents that the separator is ripe currently for pressing the
program button to start.
Preparation for Running: the separator operates for sealing, water sealing
water entering, slag-discharging, as well as a series of preparations performed
before feeding material.
Stopping: Stops the separation process, and cuts off the power to separator
and pump.
实时数据届面
Press Real-Time Data under the screen, the following contents can be seen,
and display in real time the current operating status of separator and system.
In this interface, the running state of all valves and controllers are visible, and
the light on indicates in running status.
At the same time, it also displays the separator speed, vibration amplitude,
heavy phase pressure, separator current, oil temperature, outlet pressure, separation
cycle and other parameters. All the contents above are displayed only when the
corresponding sensing devices are installed, otherwise the display will be null; the
installation of the sensors shall be recognized as in delivery condition in the
technology status confirmation, and the adding sensors to the installation in the late
period may be necessary to change the pipes or involve a larger cost.
手动操作届面
There are manual operation buttons of all control valves that can be used to
carry out manual fault diagnosis, artificially manual operation in normal separation
cycle is not recommended, so as to avoid the occurrence of unpredictable
accidents.
There is also a control button of residual slag pump in this interface to carry
out artificially independent operation in the existence of slag pump, so that the slag
pump can run in cycling operation. Or independently starts operating.
参数设定届面
All parameters are well adjusted in the factory, so further adjustment is not
required, and when the on-site debugging is completed, it is recommended that all
operators record all the setting data, in order to avoid loss of data in the late period.
The high-pressure water of the operating water is stabilized between 2.5-3.0 bars
and the low-pressure water is maintained in the range of 0.5-1.0 bars; for the
material separation temperature, the heavy fuel is 95-98oC, lubricant is 85-95oC
and the diesel separation is at room temperature.
Explanation of different parameters:
Water seal: the time to carry out drum water sealing or oil transfer operation,
the time will be fuzzily calculated automatically according to the site water
pressure or real time water pressure, and will assign the calculated value to the
water seal time while modifying the original parameters. If no "Sealing Test" is
conducted, the program will run as by manual input parameters. When performing
sealing test for the first time, more tests are required by modifying the value in
"Sealing Test 1" to the low value, and the program will automatically be corrected
in order to achieve the calculated value of optimum site conditions.
Sealing: used for running time of the operating water for drum water sealing.
Opening: used for running time of the operating water for opening drum or
producing slag discharge action.
Waiting: used for waiting time for speed self-repair of drum or other internal
running processes.
Starting Time: the time control of the separator from start to full speed state.
(The time shall be increased by at least 60 seconds on the basis of actual starting
time, otherwise it may cause actual operation fault)
For the frequency-conversion starting separator, the starting time must be set
to be greater than the time of the frequency converter from 0Hz to actual common
frequency that is usually 10 minutes, but 11 minutes is recommended.
Water draining: used for the time for draining water in the initial phase of the
material separation of the separator.
Pre-sealing: used for the time to conduct drum evacuation and sewage
discharge operation after the separator starting is completed.
Separation cycle: the running time of the separator from material separation to
slag discharge operation.
Water Sealing Test 1: the time for adding water sealing water for the first time
when conducting "sealing test", the time shall be counted initially according to the
following method, and when the separator starting is completed, manually add
water sealing water, manually force to open the drain valve while starting timing
until the water is drained out from the drain valve outlet, the time minus 5 seconds
can be regarded as the setting value of the water sealing test 1.
Water Sealing Test 2: the time for accurately adding water when conducting
"Sealing Test", the time is usually set to 1S.
Water Sealing Stop: means the interval time between two "Sealing Test 2"
when conducting "Sealing Test".
Minimum Outlet Pressure: used for determining the pressure value of
unsealed drum, this value is generally set at 0.5-1bar.
Heavy Phase Pressure Comparison: used for determining the value of water
sealing water content of material components in the drum, this value is generally
set at 0.5-1.5bar.
Separation Current Comparison: used for determining the normal slag
discharge when the drum is operating for slag discharge.
Slag Pump Start: used for the running time of the slag pump when the pump is
running.
Vibration alarm: used for separator vibration unfavorable to separator running
tendency and generates an alarm when it is equipped with vibration alarm device.
Vibration Shutdown: used for separator vibration unfavorable to separator
action and generates an alarm to perform separator shutdown operation.
Times for water sealing: Maximum times allowed to add "Water Sealing
Water 2", if exceeded, the drum is regarded as not sealed.
Minimum Temperature: minimum temperature for material separation
Maximum Temperature: maximum temperature for material separation
The following is a record table of real operating parameters, they are recorded
according to actual condition:
Name Time (s) Name Time (s)
Water seal Water sealing test 1
Sealing Water sealing test 2
Opening Water sealing stop
Waiting Minimum outlet
pressure
Starting time Heavy phase pressure
comparison
Water draining Separation current
comparison
Pre-sealing Slag pump start
Separation cycle Vibration alarm
Vibration Shutdown
Times of water sealing
Minimum temperature
Maximum temperature
报警查询届面
Alarm Inquiry Interface
This interface retains the last 20 alarm records including the alarm time, and
the causes and status of the alarms, and can perform timely adjustment and
judgment operations.
6. Operation
6.1 Operating procedures
6.1.1 Starting
Note: The following procedure is implemented without setting the system
parameters, if necessary, set the system parameters in reference to the
(descriptions for parameters setting).
1. Check before starting (refer to the "Check before Starting" in the Manual of
Separator)
The check contents include brakes, oil level, motor direction and valve switch
and others.
2. Open the master control valve in the control waterway; it is appropriate to
control the pressure in waterway between 0.3-0.5Mpa.
3. Open the master compressed air control valve: Set the compressed air pressure
to 0.5-0.8MPa.
5. Open the flow control valve in clean oil pipe.
6. Open the master control valve in heating pipe.
7. Turn on the mains switch of the electrical control box.
8. The screen can be used to start operating after about a minute.
9. Press the "Oil Transfer Pump Start" button on the control box to start the oil
transfer pump, now the system is in Backflow status displayed in the temperature
control valve instrument.
10. When the temperature parameters are displayed, press the "Separator Start"
button on the control box to start the separator.
Please Note: when the frequency-conversion starting separator is started, unless
special requirements are necessary, it is generally converted automatically into
common frequency and the frequency converter is disengaged.
11. When the separator is started, and the material temperature is at separation
temperature, the waiting status display will appear.
12. A sealing test is recommended, if no any problem, when returning to Waiting
status, press the Program Start Button.
13. Adjust the flow adjusting valve in the inlet pipe, and adjust the clean oil outlet
pressure to between 1.5-2.0bar.
6.1.2 Shutdown
Press the Shutdown button, then the separator will automatically cut off the
material and conduct drum cleaning
6.1.2.1 Automatic Cleaning
1. Turn off the Mains switch on the control box.
2. Close the flow control valve in oil outlet pipe.
3. Close the flow control valve in oil inlet pipe.
4. Close the master control valve in heating pipe.
5. Close the master control valve in compressed air pipe.
6. Close the master control valve in control waterway.
Common alarms