Separator manual O-Sepa 750

O-SEPA 750 Separator

Installation, use and maintenance

CEMENGAL PLUG&GRIND XL

August 2016

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 Separator manual O-Sepa 750

Index

1. PREFACE ........................................................................................................................................................ 3

2. MAIN TECHNICAL DATA ................................................................................................................................. 3

3. GENERAL INSTRUCTIONS ............................................................................................................................... 4

4. SAFETY INSTRUCTIONS .................................................................................................................................. 6

5. SUMMARY OF ELEMENTS AND WORKING PRINCIPLE .................................................................................... 9

6. TRANSPORTATION AND STORAGE ................................................................................................................13

7. INSTALLATION REQUIREMENT ......................................................................................................................14

8. TEST AND TRIALS ..........................................................................................................................................21

9. OPERATION, MAINTENANCE AND SERVICE ...................................................................................................26

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 Separator manual O-Sepa 750

1. Preface

Dear users:

Thank you for placing your trust in the O-SEPA (type) high efficiency dynamic separator that our

company has developed. Please read this specification carefully before installing the separator.

As soon as you receive the product, please use the packing lists to review all the items that we have sent

you. In the same way, it is expected that the client will have prepared the equipment and machines that are

needed for the installation of the separator such as generic wiring, sensor systems and enough grease for the

manual pump system.

In the same way, we will be pleased to listen to your advice and your new propositions.

2. Main technical data

Main technical parameters of the separator are shown on next chart. Refer you to the main
drawing for further details.

Nominal Maximum
Motor
output feeding Rotor speed
Type power Lubrication
flow rate capacity (r/min)
(KW)
(t/h) (t/h)
O-Sepa 27 45 220-300 75 Grease

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3. General instructions

This instruction manual is delivered with the equipment and it shall be kept close to the
working area for practical use during the installation, operation or maintenance.

3.1 Product introduction summary

The O-SEPA separator, also called vortex separator, is widely used in the cement industry or
other sector where the separation of powder is necessary. The separation properties of the N
type, such as high efficiency, low power consumption, high power capability, easy maintenance,
the narrow distribution of particle size are all present in the O-SEPA model.

3.2 Environmental instructions

Environmental requirements for a proper opration:

Temperature (C) Humidity (%) Altitude (m)

-20C to 40C 50at 40C90at 20 1000m

3.3 Workspace requirements

The main motor must have a CE certification and its control system must be equipped with
overcurrent protections. In the same way, it must have specific starting and stopping
functionalities, as well as another functionality that avoids automatic start-up while the motor
is switched off. Finally, we would emphasize that motor earthing is mandatory.

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 Separator manual O-Sepa 750

In general terms, the separator must comply with IEC 60974-3: Electric arc welding equipment. (Part 3:

Arc striking and stabilizing devices) which details aspects such as:

1. Protection against electrical shocks

2. Thermal requirements and protection

3. Connection to the supply network and control circuits.

The following documents, in whole or in part, are normatively referenced in this document and

are indispensable for its application:

IEC 60974-1; 2012, Electric arc welding equipment. Part 1: Power sources for welding.

IEC 60974-7; Electric arc welding equipment. Part 7: Torches

IEC 61140; Protection against electric shock. Common aspects for installation and equipment.

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4. Safety instructions

4.1 Operating requirements

- In the control centre, operators must be equipped with anti-electrostatic clothing as well as

rubber-soled footwear.

- When working in the space in which the separator is located, should the noise level exceed 85

dB, operators must use protective earplugs or safety earmuffs.

- If the concentration of particles were to exceed 50 mg/m3, operators should use anti-dust

respirators.

4.2 Special danger

With regard to the drive system of the separator, this is shielded behind a safety grid. This

prevents any risk of entrapment.

In operating conditions, an increase in the temperature of the material passing through the

grinder may cause the surface temperature of the volute to exceed 55C; this entails a burn

hazard. When you complete the work needed to install the drive system, burn hazard symbols

must be placed at appropriate positions.

Do not open the inspection doors during the operation.

If necessary, ladders and scaffolding should be prepared in order to access the maintenance

points, always respecting EN ISO 14122. Such ladders and scaffolding should be manufactured

for this purpose from diamond plate sheet metal, which is typically used to prevent the risk of

slipping or falling.

Note: This separator has not been prepared for use in a place where there is a risk of explosion. If

such a risk were to exist, workers must obey special safety standards.

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4.3 Environmental protection requirements

When carrying out a complete overhaul of the separator, waste such as old ball bearings,
cracked gaskets, nuts, bolts or worn out anti-wear parts should be processed in accordance
with your countrys national legislation.

4.4 Hoisting instructions

Hoisting equipment must not be overloaded.

Before hoisting, all conveyor devices and guide wires must be checked in order to ensure

that they are strong enough to withstand the loads, thereby providing a guarantee of

safety.

Before proceeding with the hoisting process, check that all parts are correctly positioned

and oriented. This avoids having to repeat movements due to planning errors.

Hoisting points are marked on all machines and should be used to carry out the hoisting

process correctly. If there is no obvious or visible point, you must find the centre of gravity

of the element in order to decide which are the correct hoisting points.

In order to avoid damage to the surfaces or even possibly slicing the cable, the hoisting

cable must not touch machined surfaces or the corners of the equipment.

4.5 Welding instructions (exclusively for this equipment)

Once all the parts have been installed, and once all the technical requirements have been met,

please follow these instructions:

Tighten the bolts of the vertical flange of the volute and completely weld the two parts of the

volute together. Then polish that area and put the aluminium cladding plates into place.

Use spot welding for the main bracket and the beams.

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4.6 Marked symbols on equipment

All areas where there is a slight danger, whether of burns, entrapment or any other danger

deriving from the operation of the separator, must carry small informative signs that alert

the worker. The clearest example is found on the outer surface of the volute, which can

reach high temperatures.

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5. Summary of elements and working principle

5.1 Summary of the elements of the separator

The main elements of the separator are: volute, rotor, main shaft, drive system, lubrication system

and grit funnel.

Figure 1 Separator general arrangement

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The separators volute comprises a housing in the form of a spiral with an entrance and an exit that

connects to a large-diameter pipeline that permits evacuation through the top of the thin material.

Install the blades that route the material, the plates that serve to anchor these blades and the sealing

gaskets together with this volute. The cylindrical wall of the volute comes equipped with two inspection

doors (located on opposite sides), and the inner surface has been carefully designed to be coated with

alumina parts laid out in a mosaic in areas where there is risk of abrasion. The outlet pipeline and the

lower part of the rotor shaft are coated in the same way, the part that is in contact with the material.

Deflection plates (guide vanes) have been installed on the outlet cone to force the material to slide

over itself and thus prevent abrasion.

The top cover of the volute is responsible for taking the weight of the entire rotor assembly. This

assembly comprises the rotor housing, which is joined to the main shaft by connecting elements such as

a shaft keyway with its corresponding gaskets. The main shaft is operated by a system of pulleys and a

belt.

Bearings are mounted on the main shaft and are separated by a certain height. They are lubricated

with grease and sealed by a rubber gasket.

The drive system consists of a motor positioned in a vertical position (with its corresponding

bracket structure), connected by means of a system of pulleys and belts to the rotor shaft.

The lubrication system is composed of an electrical pump with two outlets, one facing each of the

separators bearings (the upper and the lower one) by means of rubber hoses.

Images of all these separator elements can be seen in the following paragraphs, which explain the

installation processes for each one of them.

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5.2 Working principle

The material from the grinder falls by force of gravity and the centrifugal effect of the rotation is

directed toward the outer plates that make up the rotor. The particles are then subjected to centrifugal

and drag forces caused by the air flow. These forces begin to even out (drag and centrifuge with gravity)

and that is when the efficient separation of those elements begins; particles of a larger diameter fall due

to gravity and slide through the bottom of the separator (through a duct in the shape of a funnel), while

particles that are thin enough are swept up by the draft of air from the fan and continue their course in

the system until they reach the process filter. These particles are now considered as final product.

Figures 2 and 3 indicate the material and airflow, respectively, in the separator.

Figure 2 Material flow

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Figure 3 Air flow schema

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6. Transportation and storage

- Handle the separator with extreme caution when loading and unloading. You should avoid

collisions as well as exposure to rain or other harmful agents. Other requirements during

transportation should follow regulations.

- To ensure proper storage, this machine has the following environmental requirements:

Temperature: -25C/+55C

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7. Installation requirement

Before installation, the main parts of the equipment must be inspected, verifying that there has been

no distortion during transportation. Check the main dimensions and plan the hoisting procedure while

everything is stored temporarily in a suitable place.

7.1 Housing installation

Join the two parts of the volute together using bolts and ensure proper integration of the flat

surfaces by welding the slots together and then polishing the area. The last step of this stage will be to

attach the ceramic coating.

Hoist the volute in line with the four hoisting points as shown in figure 4 and place it on the stand.

At the same time, you must check that the air inlet flanges maintain their dimensions after both parts

have been assembled. Fix the volute to the bracket base by tightening the bolts in a moderate way, by

way of a temporary mounting. Adjust the gaskets on the bracket base, ensure that the deviation of the

beam with respect to the bracket is around 1 mm, and then the fixing bolts should be tightened with

an appropriate torque.

Figure 4 Hoisting points

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7.2 Installing outlet elbow

Attach a sealing gasket to the flange of the volute. Then hoist the outlet duct, position it above the

gasket and tighten the main connecting bolts.

7.3 Structures installations

Place the anchor structure on the bracket in such a way that the holes that are designed to join the

two surfaces coincide, and install temporary fixing bolts. Using gauges of various thicknesses, ensure

that the deviation does not exceed 0.5 mm/m. Then tighten all the bolts definitively.

The upper structure is then put in place, together with the ROSTA motorbase mount, on which the

motor will be placed. This base allows the motor to be moved, thereby making it possible to then fully

align the entire drive system unit, including the pulleys and the belts. This will be explained in detail

later on.

7.4 Main shaft installation

Following the specifications set out on the diagram, use the hoist rings on the casing of the main

shaft to fit it onto the flange of the volute bracket, adjusting its position so that the space intended for

the lubrication duct and the temperature sensor are visible. Then, gently drop the shaft until the

threaded portion penetrates the lower part. The last task is to adjust the general tolerances using

gaskets on the bottom bracket, ensuring that the shaft is perpendicular.

Note: The surfaces of the shaft and the axle housing must be properly cleaned prior to installation.

We also recommend you use oil (with a spray gun) to assist in the assembly of the two metal surfaces.

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 Separator manual O-Sepa 750

7.5 Rotor assembly and top sealing

Assemble the rotor and the shaft using keys, and fix them with nuts. Introduce the rotor through

the bottom of the volute (an open space until the outlet cone is sealed down - the last step of the

process).

Adjust the play between the sealing gasket mounted on the rotor assembly and the slot on the top

seal that you will find welded to the volute.

If the axial play does not meet the requirements that are shown in the chart below, loosen the bolts

of the bracket structure and, using a traction cable, add or remove gaskets between the bracket and the

housing to adjust the available play. Meanwhile, as far as the radial play is concerned, you can adjust this

by moving the bracket arm horizontally, taking into account that a small play of 1.5 mm can be

adjusted using traction cables.

Separator model O-SEPA 750

Axial clearance (mm) 82

Figure 5 - Detail of the clearance between the sealing gasket (1) and the slot (2)

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Make sure that the rotating part of the separator (which includes the whole rotor assembly and

the main shaft) rotates smoothly and stably, and if so, tighten all the bolts.

Note: When you install this part, please take care not to hurt other people.

7.6 Drive installation

Once the rotor has been properly positioned on the main shaft, attach the pulley to the head of the

electric motor, as per figure 6. Then align the motor shaft with the axis of the main shaft using a bubble

level and allowing for a maximum difference of 0.5.

The alignment of the pulleys should be checked before and after you install the tapered bushings.

Then ensure that the concentricity between the motor shaft and the rotor shaft is less than 0.1 mm, and

if that is the case, tighten all the bolts.

Figure 6 Drive assembly

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7.7 Grit funnel installation

Before attaching the volute to the upper structure of the separator, we recommend that you

inspect the inside of the grit funnel as well as the tertiary air valves. Once you have made sure that that

there are no imperfections, install a sealing gasket and connect both sides as shown in figure 7.

Figure 7 Grit funnel

7.8 Air valves assembly

We must distinguish the primary fresh air valve (rectangular in cross-section and located on the

volute) from the secondary and tertiary fresh air valves (circular in cross-section and located on the

separators outlet cone). Make sure that the connections are tight and that the sealing gaskets have

been properly installed.

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7.9 Lubrication system installation

A number of hoses run from the lubrication pump to the upper (axial and radial) bearings and the

lower (radial) one. The distance between the grease pump and the separator should be no greater than

10 m, and the hoses should be able to withstand 3 times the nominal pressure of the circuit (total 0.5

Mpa). For specific information on this equipment, please refer to the suppliers manual.

Figure 8 Lubrication system

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 Separator manual O-Sepa 750

7.10 Precautions before start-up

Once they have made all the appropriate connections, installers should follow the instructions

marked on the drawings as well as the most important technical requirements.

Make sure that all the temporary transport brackets have been removed, that all of the tools used

during the installation have been gathered up and that any waste has been cleaned and removed.

After installation, the following parts should be inspected:

1. All contact surfaces and also check that all gaskets have been properly put in place and sealed.

2. You must be able to move the rotor of the separator with your hand; check that it that rotates easily

and without friction.

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8. Test and trials

Only when the inspection of the installation has been successfully completed, you can proceed with

the first operational tests.

Preventive maintenance prior to the first test:

1. The rotor rotates smoothly and there is no friction phenomenon to prevent it from doing so.
2. The electric motor rotates in the correct direction.
3. Check that all the bolts are tightened in accordance with their torque.

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 Separator manual O-Sepa 750

8.1 Requierements for oprating continously at high rotational speeds

Continuous operation during 2-4 hours at high speed must meet the following requirements:

- The unit works without any problems and with vibration values that do not exceed the limit.

- The noise level of the pulleys and belt drive system does not exceed 85 dB.

- The temperature of the bearings must not exceed 85 C. At this point, the warning alarm will go off

and should the temperature reach 90 C it will force the machine to shut down.

- There should be no sign of any leakage of grease throughout the entire lubrication circuit.

- The monitoring by the sensors, the indicators and generally speaking, the entire control system must

be sensitive to changes and must deliver accurate magnitudes.

- Observe and record any power fluctuations.

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8.2 Load test trial

Only when the operational vacuum test of the separator has been performed can we move on to the load

test.

8.2.1 The order in which the units of the system should be started up:

8.2.1.1 Start up the process filter and the ventilator (Note: Regulate the outlet of the fan to

make sure that the airflow increases gradually).

8.2.1.2 Start up the separator.

8.2.1.3 Start up the auger of the grinder outlet.

8.2.1.4 Start up the grinder.

8.2.1.5 Start up the conveyor belt that feeds the grinder.

8.2.2 During the load test of the separator, in addition to fulfilling the major requirements, the

instructions set out in table 1 must also be followed.

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Table 1

Item Inspection points

- The temperature of the upper bearing should not be more

than 40 C higher than room temperature. If this value is

Separator exceeded, you must stop the machine and inspect it carefully.

- Unusual noise or vibration.

- Loose bolts or nuts.

- The motors electric current.

- The drive system protection (pulleys and belt): Check the

mounting and clean said protection to prevent a lack of

ventilation.

Drive system - The belt: Check the voltage of the entire system before

start-up.

- The pulley: Align the pulleys using a laser system.

- General tolerances in the entire drive system.

- Make sure that all connections have been made properly to

Lubrication system
avoid any grease leakage.

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 Separator manual O-Sepa 750

8.2.3 The shutdown order

Shutdown must follow the start-up order described in the previous paragraph, but in the

opposite direction.

8.2.4 For periodic post-operational inspections, refer to table 2.

Table 2

Item Inspection points

- Loose bolts or nuts.

- Check that the mosaic of the alumina anti-wear plates remains

properly adhered in its position.

Separator
- The sealing gasket and the slot that the outlet cone rests on

- The material dispersion plates

- The damping plate

- The belt: Check that there has been no unusual wear and tear and that

no cracks are visible. Also, be sure to check that the voltage is correct.

Drives system
- The pulley: Check for wear and tear using precision gauges. Also, check

that there have been no misalignments. To do so, we recommend that

you use a laser system.
- Grease deterioration
Lubrication
system - Accumulation of particles in the filter.

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 Separator manual O-Sepa 750

9. Operation, maintenance and service

9.1 Air flow control

The primary fresh air valve (located on the volute) is normally closed to begin with, but once
production stabilises and more air is required, it is normally set at 20% open to permit a fixed
production of airflow. On the other hand, the fresh air valves of the outlet cone are opened up to 40%,
which helps the air to travel faster and to prevent cement dust from a building up in the volute.

Note: These values are indicative. The actual percentage of air opening will depend on the

operating conditions and on the location of the plant.

9.2 Speed control

The rotation speed can be regulated within the range indicated in the table of manual features that
you will find at the start of this manual. The objective of this regulation is to obtain different cement
fineness in the final. A higher rotor speed allows you to obtain finer particles (Blaine value).

Important: Regulating the airflow to obtain a finer final product is not an approved practice. A
volume that is greater or less than the specified volume may affect efficiency when classifying and
distributing particles.

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 Separator manual O-Sepa 750

9.3 Maintenance
Pay attention at all times to the operation of the rotor. If there is any variation in the level of
vibration or noise, stop the unit immediately and check it. An extraordinary vibration can be due to
various reasons: the rotor may be unbalanced, the particle size of the material may be highly
dispersed or the bearings may be suffering from inadequate lubrication.

The temperature of the lower bearing should not exceed 85 C.

Check that the lubrication flow is performed at appropriate intervals. Also, if you do discover
any failure or malfunction in the bearings, remedy it in good time.

Check that all the gaskets on the parts that connect the shaft and the bearings are not showing
any signs of abrasion. If they are, they must be replaced.

All the air ducts should be cleaned periodically in order to prevent dust from building up.
Eliminate any trace of humidity that may be caused by condensation or perhaps rain.

See table 3 for a basic description of the lubrication of the separator.

Table 3

Lubricant
Lubrication points Interval
Description Lubricant

Upper bearing Daily Multi-purpose grease NGLI 2

Lower bearing Daily Multi-purpose grease NGLI 2

Special grease for electric

Motor Every 14,000 h NGLI 3
motor bearings

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 Separator manual O-Sepa 750

9.4 Revision

The separator must only be serviced once the machine has stopped. The main inspection door
should not be opened until all the dust in the inside has completely sedimented. An informative notice
should be attached to the units control panel while such work is being carried out, to prevent anyone
from unwittingly turning the machine on.

Note: The separators power supply must be shut down and blocked while it is being serviced or

maintenance work is being carried out. This is in order to avoid any form of electrical accident.

To reinstall the parts in the correct order and position, it is advisable to make small marks on the
connections between them.

The order in which the separator should be dismantled

1. Switch off the electricity.

2. Dismantle all the metal elements that connect with the separator.
3. Dismantle the drive system (pulleys and belt), and then remove the engine from its brackets.
4. Remove the nuts and bolts and the sealing gaskets from the outlet duct.
5. Dismantle the outlet cone.
6. Remove the rotor shaft by means of its cotter pins.
7. Remove the rotor at the bottom.
8. Withdraw the main shaft.
9. Dismantle the axle and the engine support structure.

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Principle maintenance programmes

1. Check whether the bearings have suffered any abrasion and clean them if the lubricant is
seen to contain any impurities. If these impurities have caused excessive wear and tear, you
will need to replace them.
2. Thorough review of bolts and nuts to verify that they remain tight. Check that none of them
has been damaged.
3. Clean the cement dust from the separators ductwork.
4. All measuring devices must be sensitive to such changes as may arise.
5. If there is any abrasion of or damage to the alumina plates in the interior surfaces of the
volute, the outlet duct or in the outer part of the rotor shaft, they must be repaired. The
same thing applies to the anti-wear material of the volute blades, which will need to be
replaced if they show visible signs of wear or peeling.

6. Maintenance of the grease pump: refer to the manual of the unit you are using.

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