lynx 20-200 atex oim manual

Declaration of conformity Declaration according to directive 98/37/EC of the European Community Annex II, A

We: Alfa Laval Copenhagen A/S Maskinvej5 DK-2860 Soborg, Denmark

Herewith declare that: the machine consisting of : 1 Decanter; Manufacturer: Alfa Laval Type: Lynx2O-2O0 Serial no 5023273 with

1 Main Motor Manufacturer ABB; Type Type M3JP 200MLB 4 1 Back Drive Motor; Manufacturer ABB; Type M3JP 200MLB 2/4 1 Vibration Sensor; Manufacturer Robert Shaw; Type ATEX ExD 2 Limit switches; Manufacturer Honeywell Type EX-N15

1 Feed pump: Manufacturer Seepex ; Type BN 35-6L with 1 Gear Motor: Manufacturer SEW; Type RF77 VU41/HAA/EX/II3G DV132M4/1 1 Dry running protection TSE 230 with Pepperl+Fuchs Zenon barrier TypeZ757

1 Control Panel; Manufacturer CEAG; Type EXKO 733 200 L0002 No.

Project Name: Hesrom Lynx20-200 ATEX Project no. 32201.42040 ATEX Classification: II 3G MB c T3

has been designed in agreement with the special health and safety requirements of Annex 1 of the Machinery Directive 98/37/EC and the harmonised standard EN12547.

The non-electrical parts of the decanter & pump comply with ATEX Directive 94/9/EC ANNEX II The electrical equipment also comply with ATEX Directive 94/9/EC The following other EC directives have been applied for the machinery and its electrical systems and control systems:

> 73/23 EEC amended with 93/68 EEC (Low Voltage Directive). > 89/336 EEC amended with 92/31 and 93/68 EEC (EMC Directive).

The machine shall be installed, operated and maintained in accordance with the instructions provided.

Position; Project Manager; E&S Scborg Name: Rick Bennett Date: 31-01-2007

Declaration of conformity Declaration according to directive 98/37/EC of the European Community Annex II. A

Alfa Laval Copenhagen A/S Maskinvej5 DK-2860 Soborg, Denmark

Herewith declare that: the machine consisting of :

1 Decanter; Manufacturer: Alfa Laval Type: Lynx20-200 Serial no 5023274 with 1 Main Motor; Manufacturer ABB, Type Type M3JP 200MLB 4 1 Back Drive Motor; Manufacturer ABB; Type M3JP 200MLB 2/4 1 Vibration Sensor; Manufacturer Robert Shaw; Type ATEX ExD 2 Limit switches; Manufacturer Honeywell Type EX-N15

1 Feed pump: Manufacturer Seepex ; Type BN 35-6L with 1 Gear Motor: Manufacturer SEW; Type RF77 VU41/H/WEX/II3G DV132M4/1 1 Dry running protection TSE 230 with Pepperl+Fuchs Zenon barrier TypeZ757

1 Control Panel; Manufacturer CEAG; Type EXKO 733 200 L0002 No.

Project Name: Hesrom Lynx20-200 ATEX Project no. 32201.42040 ATEX Classification: Il 3G (IB c T3

has been designed in agreement with the special health and safety requirements of Annex 1 of the Machinery Directive 98/37/EC and the harmonised standard EN12547. The non-electrical parts of the decanter & pump comply with ATEX Directive 94/9/EC ANNEX II The electrical equipment also comply with ATEX Directive 94/9/EC

The following other EC directives have been applied for the machinery and its electrical systems and control systems:

> 73/23 EEC amended with 93/68 EEC (Low Voltage Directive). > 89/336 EEC amended with 92/31 and 93/68 EEC (EMC Directive).

The machine shall be installed, operated and maintained in accordance with the instructions provided.

Position: Project Manager; E&S Soborg Name: Rick Bennett Date: 31-01-2007

Installation, Commissioning, Operating & Maintenance Manual Engineering & Supply

Lynx 20-200 ATEX Atta Laval Copenhagen A/S Maskinvej 5 DK-2860 Soborg, Denmark

www.alialaval.com

Section 0 Index

CD-rom

Section 1 Declaration of Conformity

Section 2 Decanter Documentation

2.01 Installation Instructions Supplementary Documentation

2.02 Operation Instructions Supplementary Documentation

2.03 Spare Parts 2.04 Electrical Motor Data

Back Drive Main Drive

2.05 Instrument Data Vibration switch Micro switch

2.06 General Arrangement Drawing 2.07 Manufacturer's Declaration of Conformity

Client : Hesrom Project : Hesrom Description : Lynx 20-200 ATEX Alfa Laval Ref : 32201-42040


Alfa Laval Copenhagen A/S

Lynx 20-200 ATEX o S ' s o b o r g , Denmark

vAvw.alfalaval.com Section 3 Feed pump (Seepex) Documentation

Declaration of conformity ATEX95 (100a) Operating Insiruciions acc. To directive 94/9/EC General Safety Transport & intermediate storage Description of the Seepex pump & accessories Assembly & installation Commissioning / De-commissioning Pin joint assembly Holding band reassembly Breakdowns, reasons, remedies Auxiliary Seepex documentation Data sheet Characteristic curves Sectional drg. Parts list Shaft sealing Sectional drg. shaft sealing Burgmann mechanical seals Wearing parts & gaskets Dimensional drg. Tools Dry running protection device standard construction Sectional drg. TSK-pumpside parts Dry running device Ex-proof construction Declaration of conformity safety barrier ATEX Statement of conformity safety barrier ATEX Manufacturers documents from sub supplier: Geared motor RF77 VU41/H/WEX/II3G DVI3 Operating Instruction Gear units Seepex Subsidiaries

Client : Hesrom Project : Hesrom Description : Lynx 20-200 ATEX Alfa Laval Ref : 32201-42040


AHa Laval Copenhagen A/S

Lynx 20-200 ATEX Denmark

www.ajfalaval.com

Section 4 Electrical Documentation

4.01 Electrical Diagrams 4.02 Cable Block diagram 4.03 Control Panel Layout drawing, internal 4.04 Control Panel Layout drawing, external 4.05 Circuit wiring, diagrams 4.06 Cable List 4.07 Terminal connections 4.08 Control Panel Pans List 4.09 O&M Instructions 4.10 Functional description 4.11 Cause & Effect Diagram 4.12 Motoi Data & Settings 4.13 Control Panel Test Documentation 4.14 CE & ATEX Certificates 4.15 Photos

Client Project Description Alta Uval Ret :

H es rom H es rom Lynx 20-200 ATEX 32201-42040

Alfa Laval

Decanter Centrifuge

ID English EN

INSTALLATION DATA

Alfa Laval Rev. 2000-04 ID

INSTALLATION DATA

A B O U T T H I S M A N U A L

This Installation Guide (volume ID) forms part of a set of man-uals including Operators Manual (volume OM) and Spare Parts Catalogue (volume SP). The three volumes contain the necessary information for installing, running and servicing the Alfa Laval decanter centrifuges.

This manual contains information and sketches necessary for planning the installation of site and for the actual installation procedure.

W A R N I N G Never allow persons who have not read and understood the safety in-structions in this manual to operate or service the decanter.

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Alfa Laval Rev. 2000-04 ID Chapter Contents

1 S a f e ty I n s t r u c t i o n s

2 G e n e r a l I n f o r m a t i o n

3 S p a c e R e q u i r e m e n t s

4 F o u n d a t i o n

5 C o n n e c t i o n s a n d D u c t i n g for P r o c e s s M a t e r i a l

6 E l e c t r i c a l I n s t a l l a t i o n

7 S u p p l e m e n t a r y D o c u m e n t a t i o n The material inserted in section 'Supplementary Documenta-tion' consists mainly of technical documentation specific to the actual delivery of the decanter, i.e. installation dimensions, electrical wiring diagrams, extra control equipment, etc.

0.0-3


1 Safety Instructions

F A I L U R E T O F O L L O W T H E S E R U L E S M A Y R E S U L T I N S E V E R E P E R S O N A L I N J U R Y O R P R O P E R T Y D A M A G E .

T h e D e c a n t e r

1. The decanter delivered must not be used to separate flam-mable, toxic, corrosive, or radioactive process media without prior written approval from Alfa Laval.

2. Read this manual and the Operator's Manual before at-tempting to install or operate the decanter equipment, and follow all recommendations.

3. Do not operate the decanter with damaged or missing warning labels.

4. Do not operate the decanter if the vibration level exceeds 24 mm/sec (RMS) (US: 1 inch/sec).

5. Do not operate the decanter with feed temperatures ex-ceeding the limits stated on the DATA SHEET included in all three volumes of the Instruction Manual.

6. Never attempt to start the decanter wi th frozen water or frozen or hardened process material in the bowl.

7. Do not exceed the maximum bowl speed or solids density specified on the decanter name-plate and DATA SHEET.

8. Do not operate the decanter without belt guards and other guards provided.

9. Periodically check all the automatic shut-off devices and monitoring systems for correct operation.

amid...

i ' . . : . it 1.0-1

Alfa Laval Rev. 2005-05 ID 10. Do not attempt dismantling until the decanter has come

to a complete stop, the main power is shut off, and the dis-connected main switch is locked with a safety lock.

11. Do not operate the decanter if the bowl, motor, or sup-porting structure show cracks, pitting, holes, or grooves.

12. Do not use tools other than those recommended by Alfa Laval to dismantle and assemble the decanter.

13. Do not attempt to use the decanter for any application or process material other than that stated on the original pur-chase documentation without first consulting Alfa Laval.

14. Follow all lubricating procedures and schedules.

15. Check periodically - at least once a year - for loose bolts on foundation and supporting structures, covers, hatches and pipe connections of decanter and motor.

16. Do not get rags or loose clothing near rotating parts.

17. At all times follow the recommended sequence and proce-dures for dismantling, assembly, operation, and mainte-nance. Do not introduce new procedures without first consulting Alfa Laval.

18. Only allow trained personnel to operate, clean, dismantle or assemble the decanter.

19. Do not operate the decanter before the installation is com-plete.

20. Do not operate the decanter wi th any electrical motor run-ning in the opposite direction to that indicated by the ar-rows on the frame or otherwise specified.

contd...

1.0-2 INS'AIDA.IN I

Alfa Laval Rev. 2005-05 ID 21. If the decanter is fitted with a frequency inverter, make

sure that the maximum possible frequency wil l not cause overspeeding of the decanter. At least two separate pro-tections against overspeed must be provided. See section 6.9.

22. Do not turn on feed or water before the decanter has at-tained its full speed.

23. If the decanter is operated with hot, corrosive, or aggres-sive liquids, care should be taken that any incidental spill-age from the decanter cannot hit persons below the centre line of the decanter.

24. Never turn on feed or large amounts of hot, corrosive, or aggressive liquids when the decanter is at a standstill, as these liquids might hit persons below the centre line of the decanter.

25. Never start the feed pump or flush the decanter before opening the discharge valves or starting the discharge pumps, including any conveying means for the liquid and solids phases.

26. When personnel are working on a decanter with a hinged cover, care should be taken that the cover is not closed un-intentionally by other persons or by moving machinery, which might cause injury.

27. Do not touch the solids phase discharging from the de-canter as hard lumps being ejected with high speed might cause injury.

28. When using straps to lift the complete decanter or any of its parts such as the rotating assembly, make sure to pre-vent the part hanging by the straps from sliding.

29. When lifting the decanter, use the slings specified on the dimensioned drawing.

30. The lifting eyes in the bearing housings, if fitted, must not be used for lifting the bowl assembly.

cont4...

MMUMJNl 1.0-3

Alfa Laval Rev. 2005-05 ID E l e c t r i c a l I n s t a l l a t i o n

1. Install and earth all equipment in accordance with re-quirements of the Local Electricity Authority.

2. Use an "on-load" isolator or circuit breaker (a main switch for switching off during run-up) on the main power sup-ply.

3. Check that the voltage and the frequency are in agreement with labels on motors and other electrical equipment.

4. De-energize all equipment before connecting and discon-necting test equipment.

R e p a i r s

1. Major repairs to decanter must not be made without first consulting with Alfa Laval.

In no circumstances should weld repairs, heating with a naked flame, or other alterations be made to bowl shells, bowl hubs, gearbox adapter, shafts, or other rotating parts without prior written approval and instructions from Alfa Laval. Failure to obtain this approval may result in failure of parts involved with possible serious damage to equipment, property, or personnel.

2. Do not operate the decanter on completion of the repairs until the belt and/or other guards are re-fitted.

conld...

1.0-4

Alfa Laval Rev. 2005-05 ID 3. Do not exceed the maximum load carrying capacity of the

lifting tools. Only use the lifting tools for the intended purpose.

4. Replace worn or damaged parts with only original Alfa Laval parts.

Alfa Laval cannot beheld responsible for any damage to property or for injury to persons if genuine parts are not used.

5. Do not interchange bowl parts, since specific parts are bal-anced as a unit.

T h e Motor

1. Do not operate a decanter equipped with flame proof mo-tor(s) and control unit(s) until all enclosures have been as-sembled in accordance with the appropriate standards.

2. If a motor should become inoperative, immediately shut off the power.

3. Always follow motor manufacturer's specifications on bearing lubrication.

4. Do not attempt to operate a motor that is overheated due to frequent starts and stops. Allow motors to cool to am-bient temperature (as designated on the motor name-plate) before each restart.

Do not attempt to start motor unless the rotating elements turn freely.

conld...

W5TAU>A[NI 1.0-5

Alfa Laval Rev. 2005-05 ID C o r r o s i o n , E r o s i o n a n d P i t t i n g o f D e c a n t e r E q u i p m e n t It should be recognized that equipment sub-jected to severe erosive or corrosive environments may deteri-orate over a period of time, depending upon the severity of ex-posure and/or possible misuse. Users of high speed centrifu-gal equipment should be aware of this fact and also that ex-tremely high forces are brought into play when their equip-ment is in operation. Any weakening of highly stressed mem-bers by misuse, erosion, corrosion, chemical pitting, or stress cracking must be guarded against.

The following points should be noted and the recom-mended action taken:

1. Inspect the outside of the bowl for erosion and corrosion, at least every two months.

2. Do not operate equipment when:

2.1 Holes are worn through rotating parts. 2.2 Grooves greater than 2 mm (0.08 inch) deep are worn

in rotating parts. 2.3 Evidence of cracks is present in rotating parts. 2.4 Chemical pitting of 2 mm (0.08 inch) depth or greater

is present on rotating parts.

3. Chemical Pitting Observed:

All cases of chemical pitting, even under 2 mm depth, should be monitored carefully. This action is almost al-ways due to the breakdown of the passive fi lm on stain-less bowl shell walls, in the presence of chlorides. This of-ten occurs under deposits that have not been cleaned from the outside of the bowl wall. High temperature and high acidity accelerate the action.

4. Pay special attention to the bolts assembling the bowl sec-tions. If the process liquid or cleaning agents contain chlo-rides, check these bolls at least once a year and exchange them at least every three years. Contact Alfa Laval, if in doubt.

Contact Alfa Laval regarding the repair or replacement of pit-ted bowl shells or other parts.

W5TAIBAIN1

Alfa Laval Rev. 2000-04 ID 2 - General Information

2.1 See the last pages "Supplementary Documentation" for precise data of the actual delivery of decanter.

2.2 Follow the recommendations below in order to facilitate daily operations and to create an effective and secure en-vironment for service and repair personnel.

2.3 The decanter and its electric equipment must be protect-ed against rain and snow, and temperatures below 0C (32aF). If it is not possible to avoid exposing the equip-ment to temperatures below 0C, make sure that the heat exchanger (if fitted) in the hydraulic back drive system is drained of water whenever not in use. Standard ABB motor complies with DIN/ISO IP 55 (ECB Brake IP 54). A l l other electrical equipment complies with an equal or higher protection class.

2.4 Place warning lamps and acoustic alarms in such a way that they can be seen or heard everywhere in the process area.

2.5 Place control panels and valves in a way that makes it easy for the operator to reach them.

2.6 Place control panels in a way that they are not damaged mechanically or sprayed by water or product during transportation, repair, maintenance, or operation.

MHMMIM 2.0-1

3 - Space Requirements 3.1 The passageways must be of adequate width to allow the

passage of necessary transport equipment (fork lifts etc.).

3.2 Lifting gear to remove the bowl from the frame must have adequate lifting height and capacity (see Dimen-sional Drawing).

3.3 Adequate space must be allowed to accommodate com-plete removal of the feed tube (see Dimensional Draw-ing)-

3.4 Allow adequate floor space around the decanter for work benches, tools, dismantled and new parts, and transport trolleys.

Alfa Laval Rev. 2000-04 ID 4 - Foundation

4.1 The decanter must be fastened securely to the floor or anv base frame or steel structure.

The maximum static and dynamic foundation loads from the dectinter are stated on the dimensioned draw-ing.

The maximum dynamic foundation loads are speci-fied due to the liquid-induced vibrations which may oc-cur at speeds, depending on decanter size, between 200 and 1300 rpm during run-down and start-up with a liq-uid-filled bowl.

All static and dynamic loads are distributed equally on each leg unless otherwise specified on the dimen-sioned drawing.

4.2 If the decanter is mounted on a steel frame it must be suf-ficiently stiff to be free from any resonance within the range from standstill to full speed of the decanter. The maximum permissible vertical and horizontal de-flection of the frame caused by a load in each direction of the same magnitude as the maximum static load is

0.5 mm for decanters with bowl size below 430 mm

1 mm for decanters with bowl size above 430 mm

4.3 Maximum permissible vertical misalignment of the vi-bration dampers:

2 mm for decanters with bowl diameter less than 430 mm.

4 mm for decanters with bowl diameter greater than 430 mm.

4.4 If a decanter and other machinery are placed in the same area, do not place the machinery in such a way that vi-brations or dynamic forces can be transmitted to the de-canter.

INlIAiO* 1*4 4.0-1

Alfa Laval Rev. 2000-04 ID 5 - Connections and Ducting for

Process Material 5.0 The feed pipe must always be pushed home in the de-

canter.

5.1 For plants comprising more than one decanter, each de-canter must have its own feed line with its own feed pump(s).

5.2 As the outlets for solids and liquid are placed under the decanter, enough space must be provided for collection of solids and liquid, and for transport equipment for their removal.

5.3 The installation must be made in such a way that the rev ta ting bowl or any scraping device cannot be reached from underneath the decanter.

could...

IMS (AIDA l US 5.0-1

Alfa Laval Rev. 2000-04 ID 5.4 The free flow from the liquid discharge must not be ob-

structed. For this reason: always dimension the liquid discharge duct accord-

ing to the flow rate. Do not make the inside diameter smaller than 200 mm.

avoid too sharp or too many bends.

always arrange for a slope in the liquid discharge duct.

never use a duct whose diameter is smaller than that of the decanter liquid discharge aperture.

t

FF '

t

1 S S

t

i 1

1 ' 5.

contd...

5.0-2 H T M O A M

Alfa Laval Rev. 2000-04 ID 5.5 Never reduce the dimensions of the solids discharge.

5.6 The liquid and solids discharge ducts or connections should be arranged in short easily assembled and disas-sembled sections to facilitate maintenance and replace-ments.

5.7 Material for connections and fittings should be chosen with respect to the process. Special attention must be paid to corrosion, temperature, and safety.

5.8 The connection between the external piping and the feed tube must be flexible. If the decanter blocks, the pressure in the system wil l increase to full pump pressure, there-fore high quality industrial hose compensator and fit-tings suited for the actual pressures must be used.

Take care not to bend or stress plastic connections.

5.9 All connections for feed tube, solids, and liquid discharg-es must be flexible. They must be able to compensate for vibration amplitudes of +/- 5 mm in any direction.

contd...

MM1HUNS 5.0-3

Decanter Centrifuge Data Sheet Decanter Specification, Type LYNX 20 - 200

Machine No.: 5023273

Specification: 882018431-1

Process liquid: Min. 0C (32F) - max. 100C (212F)

Max. density of compact wet cake at max. bowl speed: 1.2 kg/dm 3

Date of issue: 2006-04-28

Bowl Maximum main speed: Bowl length: Bowl diameter: Beach angle: Solids discharge type: Solids discharge radius: Solids transportation aids, cylindrical section: Solids transportation aids, taper section: Material - hubs: Material - bowl shell: Material - bolts: Material - seals: Liquid outlet, type: Liquid outlet, radius:

4000 rpm 1460 mm 353 mm 6s with integral double cone 360 s - type with 8 wear liners - tungsten carbide scrapers 110 mm Ribs Ribs AL 111 2349 (AISI 316) AL 111 2349 (AISI 316) A4-80 (AISI 316)

4 Plate dams 112 mm (fitted from factory: 115 mm )

Conveyor Material - flights: Material - hub:

AL 111 2349 (AISI 316) AL 111 2349 (AISI 316)

Wear Protection Bowl solids discharge:

Bowl feed zone liner Conveyor flights:

Conveyor feed zone: Frame / casing:

Wear liner in tungsten carbide. 8 pieces Part No. 61237284-01 None Tungsten Carbide Tiles / TM42 (flame sprayed tungsten carbide) Tungsten Carbide wear liners Wear liner in upper casing

Frame and Casing Material - casing / cover: Inside surface of casing: Gaskets / seals - casing:

Stainless steel (AISI 316) Stainless steel (AISI 316) Nitrile

Alfa Laval Rev. 2000-04 ID 5.10 The Dimensional Drawing (see supplementary section of

this book) gives the dimensions for pipe and flange con-nections. The flexible connections should preferably be fitted directly to the flanges shown in the dimensional drawing.

For the solids and liquid outlets under the decanter the maximum permissible distance from the flange to the flexible connection is 600 mm and the maximum permis-sible weight of any adaptor is 30 kg.

The weight of any connection fitted between the end of the feed tube and the flexible connection must not ex-ceed 5 kg, and the maximum permissible distance be-tween the feed tube connection and the flexible connec-tion is 200 mm.

MAX. 200 tin

5.11 A l l collecting containers must be well ventilated.

5.12 Ensure that large amounts of water vapour from tanks positioned below the decanter w i l l not pass through the liquid and solids discharge lines during long periods of standstill as the bearings might be damaged.

5.13 For Decanters with Paring Disc A blockage of the liquid discharge opening may result in a very high pressure.

For that reason, the downstream pipings and valves on the centrate side should always be open for flow. If it seems probable that this is not the case (logical, electrical or operator's fault) a safety valve which must be set at max 5 bar should be connected to the liquid discharge opening.

5.0-4 NSfAlDAINS

Alfa Laval Rev. 2000-04 ID 6 - Electrical Installation

6.1 Alfa Laval cannot be held responsible for any damage or injury caused by faults in installation, design or manu-facturing of electrical equipment not supplied by Alfa Laval.

6.2 The electrical connections and the cable size must be in conformity with Local Electricity Authority regulations.

6.3 For decanters supplied with an electrical panel from Alfa Laval the diagram is shipped within the panel.

Always study the diagram carefully before starting installation work. Ask your Alfa Laval representative if in doubt.

6.4 The cables on the decanter are normally wired to a junc-tion box. A drawing of the connections to this box is en-closed in the rear of this manual.

6.5 The safety functions must be checked before the first start.

6.6 Contactors and Cables for Star-Delta Connected Motors: When a star-delta starter is used to start the decanter, contactors and cables must be dimensioned to withstand the load during the starting period.

ATTENTION The starting time in star connection is 2.5 to 4 minutes de-pending upon motor size and the decanter speed. Dur-ing this period of time the amperage is approx. 2.3 times the full load amperage of the motor.

Example: The full load amperage of a 3 X 380V, 37 kW motor is 75. During start-up the amperage increases to 170. Consequently contactors and cables must be dimensioned to carry 170 Amp.

amid...

INSIAIOAtSfl 6.0-1

Alfa Laval Rev. 2000-04 ID 6.7 Contactors and Cables for Motors with Hydrau-

lic or Frictlonal Start Coupling: When a start coupling is used to start the decanter, con-tactors and cables must be dimensioned to withstand the load during the starting period.

ATTENTION In most installations the motor is accelerated in the star mode for maximum 5 seconds to attain its ful l speed.

|\ During this period the maximum amperage will be 2.3 times full load amperage.

The delta mode is used to accelerate the decanter to its full speed. The starting time in delta connection is 1 to 1.5 minutes depending on motor size and full speed. During this period the maximum amperage will be 3 times the full load amperage.

6.8 Cables and electrical wires must not be attached to tine decanter by means of stiff connections. Arrange for the cabling and wiring to absorb decanter vibration ampli-tudes of +/-5 mm in any direction.

contd...

6.0-2 INS'AIDA f MA

Alfa Laval Rev. 2000-04 ID 6.9 Control panels must not be placed in rooms where the at-

mosphere is corrosive as this might cause serious dam-age to the built-in electronic equipment, such as back-drive controllers, frequency converters, PLCs, amplifi-ers, etc.

This applies especially to control equipment with built-in ventilation. In such cases external supply of clean cool-ing air must be provided. As an alternative the control equipment could be installed in a separate room.

A control panel must fulfi l the following minimum safe-ty requirements:

Obligatory Alarms:

The following alarms are obligatory:

disengaged cover switch

conveyor load high (see also 'Other Control Panel Requirements' below)

tripped thermal protection for main motor

Extra Alarms:

l he most common extra alarms are: speed too high (main drive controlled by frequency

converter) vibration level high

high oil temperature in the hydraulic system

low oil level

low / high brake speed

high bearing temperature

contd...

MHMMJW 6.0-3

Alfa Laval Rev. 2000-04 ID Functions which must be switched off by an activated alarm, emergency stop, or main switch:

Each of the mentioned alarms, the activation of the emer-gency stop, or stop by means of the main switch must en-gage the following actions (if decanter is equipped with the appropriate items):

stop main motor

stop feed pump (incl CIP liquid, water, polymer, etc.)

stop sun wheel motor or electric motor for hydraulic back drive (timer)

stop solids scraper

stop vibrator for solids

stop solids conveyor

Restarting: On a tripped alarm, an activated emergency stop, or a broken mains supply circuit automatic restarting of the decanter must not be possible before having eliminated the conditions which caused the alarm to trip and reset the tripped alarm and the emergency stop, and after this remedy a signal has been given to start the decanter again.

Other Control Panel Requirements:

It must not be possible to start the feed pump before the decanter has attained its full speed. This can be achieved by using a timer relay or an interlocking to the main mo-tor star-delta starter.

For decanters fitted with an automatic back drive, two alarm levels are defined: one which should only stop the feed pump, and one which stops all as above.

Driving a decanter by means of a frequency converter in-volves the immediate risk of overspeeding the decanter. Consequently, electric control panels for decanters must contain at least two mutually independent circuits for the shut down of the decanter in case of overspeeding. These circuits can be:

frequency converter frequency

speed signal from main speed sensor.

6.0-4 IN!1AU>A(N4


7 - Supplementary Documentation

SIAID* IN? 7.0-0


7- Supplementary Documentation

7.0-0

Ilesrom Lynx20-ATEX Machine nos. 5023273 & 5023274

Important Notice:

These machines are supplied with dual power motors suitable for operation with cither:

3 x 400 V / 50 Hz or 3 x 460 V / 60 Hz

Before the Power cable supply is connected the supply voltage shall be confirmed and the correct supply voltage shall be selected at the control panel & the selection switch locked. Refer to Control Panel documentation.

It is understood that these machines are intended to be run only on 50Hz supply & therefore only pulleys & belts for this mode have been supplied.

Lynx 20 - ATEX - Hesrom Proj 32201-42040 Machine nos. 5023273 & 5023274

Power Mam rrolor N O T BOW. Motor pul oy Motor pulley V- bell V-belt supply speed (rpm) speed from) dia mm Comp. No. L mm Comp. No. (Hz)

50 1500 3250 315 6120.7335-31 2240 61240141-22 5C 1500 26C0 250 6120.7335-25 2120 61240141-21 50 1500 1557 150 6120.7335-16 ?:oo 61240141-20

I

Baroid Lynx20-ATEX Installation & Maintenance Guidelines

Introduction This Document is Supplementary Documentation lo the standard Installation Data (ID). Installation guidelines.

Data Organisation and References Electrical Panel Drawing, EX - Decanter Control Panel: CEAG dig EXK0733200LOOOO Installation Data Manual ID with supplement for ATEX installation. Functional Description FD whh Cause and Effect Chart. For further information about the function of this panel, see the function description and the electrical drawings for this panel

General Rules and regulations as laid down in IEC 600079 Part 17, Inspection and Maintenance of electrical installation in hazardous areas shall be adhered to. The user shall establish procedures for verifying the integrity of the installation on a periodic basis.

Environmental Conditions: Electrical apparatus in a hazardous area can be adversely affected by the environmental conditions in which h is used. Some of the key elements to consider are corrosion, ambient temperature, ultraviolet radiation, ingress of water, accumulation of dust or dirt, mechanical effects and chemical attack.

AH parts of the installation shall be kept clean and free from accumulations of dust and deleterious substances of such nature as could cause excessive rise in temperature.

The apparatus is subject to vibrations, special care shall be taken to ensure bolts and cable entries remain tight.

Isolation of apparatus: Electrical apparatus cor.taining live parts shall not be opened without isolating all incoming connections. The enclosure shall noi be opened until sufficient time has allowed to permit any surface temperature or stored electrical energy to decay.

Earthing and equipotential bonding: Care shall be taken to ensure thai the earthing and potential equalization are maintained in good condition.

Drives Power supply: Gearbox, lype: Gearbox, max. torque: Gearbox, ratio: Back drive:

Back drive parts: Operating main speed: Max. diff. speed and torque (at operating speed): G-force at operating speed: Main motor

Main motor, protection:

3x400 V / 5 0 H z Planetary - 2-stage DD DD 3.5 kNm 1:52 2 Speed Drive 22kW, EEx d lie T4, ATEX zone II (460V, 60Hz) - diff. speed 67 rpm at 3.2 kNm or 34 rpm at 3.2 kNm (Back drive motor, 460VD, 1800rpm. 60Hz, part no. 61195506-53) (710 61240912-80)

3250 rpm 67 rpm / 3.2 kNm

2084 G 35kW ABB 460VO Y/D (200ML) EEx d ItC T4. ATEX zone II, B5-Flange - part No. 61195507-03

Documents & Drawings Manuals, language: Dimension drawing: Diagram, decanter junction box:

Manuals in English 61240273 61211229

Spare Parts Important: When ordering spare parts, always state:

Machine number and type indicated above Part number and designation Quantity

Baioid Lynx20-ATEX Inslallation & Maintenance Guidelines

Movable apparatus and its connection: Precautions shall be taken to ensure that movable electrical apparatus is used only is areas and for uses appropriate to its type of protection. For each location controlled procedures shall assess the suitability of the apparatus to the specific environment and use. For each new installation the apparatus shall the installation be verified and be re-commissioned

Cable entry devices: The tightening check on cable entry devices at a close inspection can be carried out by hand without removing shrouds.

Fault loop impedance or earthing resistance: The integrity of the earthing shall be checked at the initial and subsequent inspection by measurement of resistance. The measurement may be made using intrinsically safe resistance measuring equipment (within the procedures specified by the manufacturer),

Non-intrinsically safe equipment may only be used if the location where potentially incentive sparking could occur can be guaranteed, by those responsible for the area, to be free from explosive gas atmosphere.

Insulation resistance: The insulation resistance for apparatus and associated cabling up to 500 V (excluding SELV) shall be measured at 500 V d.c. The insulation resistance shall be at least 0,5V ohm.

Overloads: Check that the protective device is set to the rated current In (or less)

EEX (d), Flame proof protection, joints When reassembling flame proof enclosures, all joints shall be thoroughly cleaned and lightly smeared with a suitable grease to prevent corrosion and assist weather-proofing. See manufactures instructions for each type of enclosure usee on the installation.

Labeling: Labels shall be inspected to ensure that they are legible.

Unauthorized modifications: Unauthorized modifications are not permitted.


Cables: Cables shall be inspected to ensure that cables comply wilb the documentation and are not damaged.

Separation between intrinsically safe and non-intrinsically safe circuits. The Feed pump Dry running protection is intrinsically safe. Cabling shall be routed separate from non-intrinsically safe cabling.


Installation & Maintenance Check I ic: Inspection Schedule i New Periodic

! Installation - interval 1 Apparatus: ---.'! i . l Apparatus is appropriate lo area classification \ 1.1 There are no unauthorized modifications X 12 Bolts, cable entry devices and blanking elements are

of correct tvpe and tight. X X

1.3 Flange faces arc clean and undamaged and gaskets, if any, are satisfactory.

X X

1.4 [lecirical connections arc n'qhl X X 2 Installation: t ^ ' - -2.1 Tvpe of cable Is appropriate

X H 2.2 There is no obvious damage lo cables X X 2.3 Earthing connections, including any supplementary

earthing bonding connections are satisfactory (for example connections are tight and conductors are of sufficient cross section).

X X

2.4 Fault loop impedance (TN systems) is satisfactory X X 2.5 Automatic electrical protective devices operate within

permitted limits. Functional checking according to cause & effect chart i

X X

2.6 Automatic electrical protective devices are set correctly

X X

2.7 Special conditions of use arc applied to (manufactures instructions)

X

2.8 Variable voltage/frequency installations in accordance with documental ion

X

3 Environment. 3.1 Apparatus is adequately protected against corrosion,

weather, vibrations and other adverse factors. X X

3.2 No undue accumulation of dust and dirt X X 3.5 Electrical installation is clean and dry X X

-

Note Account shall be taken of the possibility of an explosive atmosphere in the vicinity of the apparatus when using electrical test equipment.

Safety instructions for Decanters in potentially explosive or flammable atmospheres

These safety instructions apply for decanters used in potentially explosive and flammable atmospheres. The instructions are for decanters, which comply with the ATEX Directive 94/9EC. Decanters complying with the ATF.X directive wil l be marked as shown in the table below.

Category 2 Gas Category 3 Gas Category 3 Dust

Marking 112C IIBcT3 Il 3G IIIK-T3 II 3D c T=200"C

Allowed in Zone 1 and 2 - Gas Zone 2 - Gas Zone 22 - Dust

A l l the electrical equipment and all controls for the decanter must be designed and certified in accordance with the requirements of the ATEX directive 94/9EC for the relevant EX-zone.

The decanter must never be modified in any way from the original specification without written permission from the Decanter Development department of Alfa Laval. Only the correct original spare parts must be used. All ATEX classified decanters are equipped with certified antistatic drive belts, and it must be ensured that they are always replaced with the correct antistatic drive belts according to the spare parts manual for the decanter. Decanters for use in zone 1 wil l be equipped with temperature sensors on both main bearings. In zone 2, the temperature sensors are optional. The control system for the decanter must monitor the bearing temperatures continuously and immediately stop the feed and bring the decanter to a safe stop in case of too high bearing temperature. The alarm level shall be set to 110 deg. C. Decanters for use in zone 1 wil l always be equipped with a vibration switch. In zone 2, the vibration switch is optional. The control system must immediately stop the feed and bring the decanter to a safe stop in case of a vibration alarm. A l l wires for electrical grounding between individual parts of the decanter must be connected before the decanter is started. The user of the decanter must have a formal routine for regular cleaning and visual inspection of the condition of the decanter for faults, leakages. Any build-up of solids in the decanter casing shall be removed. The decanter must be completely inspected after 8000 hours or one year of operation. The decanter main bearings must be replaced after 16000 hours or two years of operation.

Maintenance work on the decanter in any zone must under no circumstances be carried out before it is ensured that an explosive atmosphere does not exist at the work place. This must be ensured by a "permission to work" system. Steel tools generating single sparks are permitted in zone 1 and 2. Grinders, saws and similar equipment are permitted when it is ensured thai there is no risk of an explosive atmosphere during the work.

In zone 22- dust - normal steel tools can be used. Grinders and saws must only be used when the workplace is shielded from other areas, dust deposits are removed and the workplace is kept wet. For decanters processing flammable feed it is not allowed to dismantle or remove any of the decanter covers or other parts of the decanter before it is ensured that an explosive atmosphere does not exist inside or in the vicinity of the decanter. The feed should not contain large hard particles or stones. Decanters used in dust areas must be regularly cleaned for dust to prevent accumulations of dust and excessive dust layers. Particular attention shall be given to locations inside the gearbox covers and belt drive covers.

Decanters operated with potentially explosive or flammable feed.

Continuous operation with an explosive or flammable atmosphere inside the decanter casing and the decanter outlet channels is not permitted.

If the decanter is operated with a feed, which is potentially explosive or flammable in the presence of oxygen, the decanter must always be operated in a closed system, and it must be ensured by purging with an inert gas that the oxygen level is below the critical level for ignition.

It is the responsibility of the end user to carry out a review of the complete installation with all outlet lines and collecting tanks and to take precautions ensuring that the oxygen level inside the decanter is below the critical level.

Only gaslight decanters with gas-purged seals can be used for operation with potentially flammable or explosive feed. The instructions for operation of the seals in section 3.10 of the operator's manual must always be followed. The low oxygen level inside the casing during operation can be maintained by having a slight overpressure inside the casing and a continuous supply of inert gas through a venting flange on the casing.

General safety rules for decanters operated with inert gas systems

1. The inert gas system must operate correctly and be well maintained.

2. The decanter must never rotate when the mechanical seals are not pressurized. Ref. section 3.10 of the operator's manual. This can damage the seals.

3. The installation must have an interlock preventing the decanter from being started before it has been flushed with inert gas to a safe oxygen level. Flushing with at least 5 times the casing volume is required.

4. The pressure inside the decanter casing must be below the pressure for the inert gas supply for the circumferential seals in order to prevent contamination of the seals.

5. If the process line or decanter casing has been opened for ingress of oxygen, the flushing procedure shall be repeated.

6. During operation, the flow rate of inert gas must be sufficient to keep a safe oxygen level inside the decanter. There must be an alarm, which stops the process feed and the decanter, if the inert gas supply is disrupted.

7. The ventilation outlet from the installation should be piped to safe area.

8. The decanter must be thoroughly flushed with inert gas before it is opened for cleaning or servicing.

9. If the installation or the decanter contains explosive gases, these gases must be evacuated before any work is carried out on the decanter.

Alfa Laval DATASHEET Machine No.: Decanter Type:

Noise Declaration Noise emission data for the decanter declared in accordance with the re-quirements in EN ISO 4871 and EN12547:

Operating Speed

Irpml

Sound Power Level J-wAd

IB(A) re 1 pWJ

Sound Pressure Level L pAd

IdB(A) re 20 uPa]

4000 9.9 82

3580 9.8 81

3250 9.7 80

2900 9.6 79

2700 9.4 77

L w A d : Declared A-weighted sound power level from the decanter

LpAd : Declared A-weighted emission sound pressure level in a free field over a re-flecting plane at 1 m distance from the decanter

Uncertainty on declared values : Lw,\d : K w A = 2 d B

LpAd : K p A = 4 d B

The noise does not contain significant impulsive or tonal components and the peak C-weighted instantaneous sound pressure level L p C p e a k is below 130 dB(C) at all operat-ing speeds.

The emission sound power level is measured according to ISO 9614-2 while operating the decanter wi th water as process medium. The sound pressure level is determined from the measured sound power level according to EN ISO 11203.

The sound pressure level can vary - l d B to 2 dB at different positions around the decanter.

For decanters with hydraulic back drive some operating modes w i l l give up to 2dB in-crease in sound pressure at the back drive end of the decanter.

The declared values are based on measurements conducted on typical new decanters.

Note that the sound pressure levels arc based on free-field conditions and not guaran-teed values. In a normal indoor installation the sound pressure level w i l l be significant-ly higher than the declared free-field sound pressure level due to the reflection of sound from walls and surroundings.

In order to minimise the sound pressure level at the decanter it is recommended to i n -stall the decanter in a room with low reflection of sound from the walls and always keep the decanter in a properly maintained condition.

lynx 20-200 atex oim manual

Documents

atex directive

decanter manufacturer

manufacturer seepex

alfa laval type

atex project

ec annex

machinery directive

eec emc directive