Westfalia Service Training

Mechanical Separation
Westfalia Separator Mineraloil Systems GmbH

Service Training by Ronald Eschmann, Service Center Hamburg
- model designation - installation - bowl parts - single mode - series mode - running mode -02- running mode -91- running mode -01- running mode -36- running mode -96- running mode -0196- Displacement - potable water - syphons - centripetal pump
- Foundation - clutch, clutch shoes - gear oil - wear to gear - bottom bearing - misc.: OSA7, OSA20, OSB35 - bowl unbalance - wear protection - refinery process / fuel problems - timing unit VESA, VESB, VESC - timing unit C7 - alarm list - trouble shooting list

model designation of separators
e.g. OSA7-02-066
26.04.2005
Ronald Eschmann, Service Dept., Hamburg

model designation of separators
OSA 7-02-066
application: Mineral Oil Separator with self-cleaning bowl A-series of WS-Separators size (efficiency) 7 bowl for clarification and separation with a disc stack separator with single centripetal pump and discharge by gravity of the heavy component (water) drive via centrifugal clutch, open frame, neck bearing standard or gas-tight; standard or EEx motor hinged hood, either cast design with cast-on feedand discharge line or welded design with welded-on or screwed-on feed and discharge connections flange-type motor (horizontal), type B5, with clutch
26.04.2005

Diagram of installation
Stuffing box oil Fuel
Settl. tank
Service tank
Sludge
Sludge tank
HFO - Sludge tank
LO - Sludge tank
Lube oil
26.04.2005 Ronald Eschmann, Service Dept., Hamburg
Bilge water
4

Diagram of installation: SINGLE MODE
instrument air solenoid f+d water
feed valve
pre-heater steam inlet motor starter
potable water clean oil discharge throttle valve pressure switch Separator solenoid operating water
control unit inspection cover pre-set valve water discharges feed pump pre-strainer dirty oil feed
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bowl: VARIZONE
dirty water discharges
clean oil discharge
dirty oil feed
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bowl: disk stack The disk stack consits a large number of conical disks situated on top of each other. Each disk is provided with spacers so that there are precisley defined narrow interspaces (very small radial sedimentation path). The solids will be collected on the upper wall of each inter-space. A smooth bottom disk surface is necessary to slide down the solids into bowl sludge holding space.
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bowl: disk stack
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Bowl: OSA7-02
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bowl: OSA20 UNITROL
CS
PSL
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10

bowl: OSB35-02
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11

Bowl: OSC4-02
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bowl: OSC4 UNITROL
CS
PSL
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13

bowl: OSC30-91
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14

bowl: OSD6-91
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diagram of installation: SINGLE MODE

conductivity sensor (WMS)
temperature switch high / low
pressure switch low (SMS)
6 3 7
1: displacement water 2: operating water 3: 3/2 way feed valve 4: circulation valve 5: water discharge valve 6: dirty oil feed 7: feed return line 8: clean oil discharge
pressure switch
ejection monitoring
motor protection
vibration monitor
flow switch
HFO: single / parallel mode: recommended with increased water content

26.04.2005 Ronald Eschmann, Service Dept., Hamburg 16

HFO
return line of feed valve led back to settling tank


LO
return line of feed valve led back to oil sump


diagram of installation: SERIES MODE
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HFO series mode: recommended with increased amount of solids in the feed

SERIES MODE of operation: HFO only
When running in series mode only the feed pump and pre-heater of the first stage (purifier) are in operation. An attached feed pump at the second stage (clarifier) must be disconnected from the horizontal shaft to avoid a run dry. If necessary the setpoint of TAL (temp. alarm low) needs to be lowered as well as the timer alarm bridging time needs to be increased at the timing unit of second stage in order to avoid PAL (discharge pressure low) alarms.

series mode of operation: process and installation diagram
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series mode with VESB-EC 1
holes open in separating disc
holes closed in separating disc
FIRST STAGE: PURIFIER Function keys to be pre-selected at timing unit type VESB-EC 1: F2, F3 and F13
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SECOND STAGE: CLARIFIER Function keys to be pre-selected at timing unit type VESB-EC 1: F2, F3, F4, F10 and F13
23

series mode with VESB-EC 1
VESB- Panel INPUTS - UNIT 2 OUTPUTS -UNIT 2 No. 2 I 111 I 112 I 113 I 114 O 1013 O 1014 O 1015 O 1016 X1-Terminals 23 24 26 25 27 28 30 29 59 60 61 62 63 64 65 66
24 VDC from unit 2
Series Mode FAIL
24 VDC from unit 1
Series Mode OFF
Feedback Signal
X1-Terminals 59 60 61 62 63 64 65 66 23 24 26 25 27 28 30 29 VESB- Panel O 1013 O 1014 O 1015 O 1016 I 111 I 112 I 113 I 114 No. 1 OUTPUTS - UNIT 1 INPUTS - UNIT 1
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Series Mode ON
Series Mode FAIL

24
Series Mode OFF
Feedback Signal
Series Mode ON

series mode with C7
FIRST STAGE: PURIFIER Function keys to be pre-selected at timing unit type C7: and
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SECOND STAGE: CLARIFIER Function keys to be pre-selected at timing unit type C7: and
25

series mode with C7

MPI-interface / MPI - code 3/4
on off
MPI-interface / MPI - code 1/2

on off
A
HFO 1 WMS-01-
HFO 2 SMS -36-
Terminal strip HFO 1

1 12 sc
Terminal strip HFO 2

1 12 sc
Cable type: UNITRONIC-BUS-FD P L2/F.I.P 1x2x0,25 mm2 + screen Attention: Not laying MPI-data cables parallelly to power cables

Separator type VARIZONE -02-
OSC4
VARIZONE -02-: no UNITROL valves on the hood but a regulating ring; suitable for products with max. density of 0,991 kg/dm @ 15C

Separator type VARIZONE -02-, regulating ring
OSC15
OSA20
Regulating ring (ringdam)
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Separator type VARIZONE -02-, regulating ring To choose the correct size of regulating ring, the density of the oil as well as the separation temperature must be given. For example: density is given with 0,873 kg/dm @ 20C. Separation temp: 70C The density of oil decreases linear with increased temperature. Find the intersection of the density line with the line of 70C. Find the thick curves (here green). The number in the field between two curves shows the correct regulating ring: 70 mm.
OSC5-02-066
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Separator type VARIZONE -02-, regulating ring
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regulating ring hydrostatic balance
r2 r1
1 R r1 = 2 R r2
2 2 2
R = separation line (fixed diameter) r1 = oil weir (fixed diameter) r2 = inner diameter of regulating ring (variable) 1 = density of oil (changeable - HFO) 2 = density of water
OSB35 02
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regulating ring hydrostatic balance

2 2 Water rWater Oil rOil R= Water Oil
Separation line
2 2 ) = Water (R 2 rOil ) Oil (R 2 rOil
For example: OSC5-02 Diameter oil weir: Outer diameter of disk stack: Regulating ring in use: Density of water @ 98 C: Separation temperature: Density of oil @ 98 C: Calculated separtion line: 52 mm 124 mm 56,5 mm 0965 kg/dm 98 C 0,93 kg/dm 127 mm
Ringdam Oil weir
(+ 1 %) Density of oil @ 98 C: 0,9393 kg/dm Calculated separtion line: 145 mm ! -> next smaller regulating diameter to be selected (55 mm)

OSC30
-91-: same working principle as VARIZONE -02-. Dirty water is not drained by gravity into the hood but discharged under pressure by means of a second centripetal pump

1 Dirty oil feed 2 Clean oil discharge 3 Filling / Displacement water 4 Pressure switch (clean oil) 5 Regulating ring 6 Control unit 7 Centripetal pump (dirty water) 8 Centripetal pump (clean oil) 9 Separating disk 10 Sludge holding space 11 Dirty water discharge 12 Operating water discharge 13 Sludge discharge 14 Operating water feed 15 Solenoid valve block

clean oil discharge
dirty oil feed
dirty water discharge to frame drain
Two centripetal pumps


pressure switch in the dirty water discharge: PAH breakover water discharge
OSC30
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holes open !
All process parameters, timer adjustments, water flow rates, regulating ring diagrams etc. of separator type -91- are identically with -02- design. Please note, the screw pins needs to be removed from the lower centripetal pump chamber cover when running mode VARIZONE -91-.

regulating ring
Efficient dewatering of water-contained oils is only possible when the bowl is correctly adjusted to the difference in densities between oil and water. The inner diameter of the regulating ring can be determined from the diagram or by experiment. The general rule of thumb is: - narrow regulating ring for heavy oil - wide regulating ring for light oil

lower centripetal pump chamber cover
-UNITROLholes closed
-VARIZONEholes open
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OSC30
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Separator type UNITROL-WMS -01-
OSC50
UNITROL-WMS: no ringdam; with conductivity sensor, circulation- and water discharge valve, suitable for products with max. density of 1,01 kg/dm @ 15C
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Water Monitoring System:

PURIFIER - FIRST STAGE
42

Separator type UNITROL-WMS -011: dirty oil feed 2: clean oil discharge 3: displacement water feed 4: pressure indicator 5: conductivity sensor 6: pressure switch 7: circulation valve 8: water discharge valve 9: sensing liquid flow 10: sensing liquid pump 11: control unit 12: centripetal pump (clean oil) 13: separating disc 14: dirty water discharge 15: sludge holding space 16: sludge discharge
43
HFO
19 19: screw pins (holes open in separating disc !) p/n: 0019-9045-400

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17: operating water discharge 18: operating water feed


HFO 5 8
19
After the feed valve is open the WMS function is activated. The conductivity sensor (5) in the bypass line monitors the liquid concentration and leads off registered water by opening the water discharge valve (8). When running WMS 01- there is no need for filling water. To avoid emulsification, conductivity measurement is intermittent, i.e. the circulation valve (7) is closed via TIMER 15 for 60 seconds followed by opening of the circulation valve for 15 seconds via TIMER 16. Only during this time can the conductivity sensor register and discharge water until oil is detected again. Subsequently the measuring cycle is re-started.

PURIFICATION means the separation of liquid mixtures which consists of two liquids, with simultaneous removal of the solids contained in the liquids.CLARIFICATION is the removal of solids from a liquid.

CS
PSL
CS
PSL
Separation: Circulation valve open, CS not activated

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Water discharge: CS activated, water discharge valve open

46

WMS - measuring relais : type DNAR
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WMS - measuring relais : type DNAR
old version until 1996
turn clockwise to max. set to: 100 - 200
WS part number: 0005-3929-000 (220 VDC) 0005-3929-010 (110 VDC)


WMS - measuring relais : type RM-3 LA1
function: the time from that the conductivity sensor is detecting water until water is being discharged R-sector: the full scale adjustment: 50 k R-value : to be adjusted to approx. 20 means the actual setpoint has been adjusted to 20 k. When do the fine tuning at site (adding water manually) please check the switch back from water discharge to purification. The setpoint needs to be decreased in case the program does not switch back to purification Time value s: value of delay time: 1 sec
WS part number: 0005-3929-020 (since summer 1996)


WMS - measuring relais : type RM-3 LA1
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WMS - measuring relais : type RM-4 LA3 2MW
time delay adjustment: set to 1 sec sensitivity adjustment: set to 40 % of full scale, to be balanced at site. The setpoint is to be reduced in case the WMS does not switch back from water discharge to circulation.
empty / fill selection: set to empty sensivitiy range / delay function selection: set to 50 sensivity range: 0 - 50 k function: ON-delay (the time from detecting water to water discharge)
WS part number: 0005-3929-030; since summer 2003


replacement DNAR by RM3 / RM4
terminal
DNAR 11 12 14 O M A1 A2
RM3 / RM4 15 16 18 B2 B1 A1 A2
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WMS: conductivity sensor 0005-1347-000

1 2 3 4 5 6 7 8 9 10 11 12 housing isolating piece cover hex head screw sensor threaded piece gasket (2 pcs) gasket (2 pcs) cable head cable plug plug 0005-1347-010 0005-1347-020 0005-1347-030 0019-6842-400 0005-1347-100 0019-0576-600 0007-2507-750 0007-1866-830 0005-0637-000 0005-0400-008 0019-0644-600 0019-1492-000
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Separator type UNITROL -SMS -36-
OSC50
UNITROL-SMS -36-: no ringdam; pressure switch and circulation valve in use, running in second stage when running in series mode only, HFO clarifier
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Sludge Monitoring System:

CLARIFIER - SECOND STAGE
56

Separator type UNITROL -SMS -361: dirty oil feed 2: clean oil discharge 3: displacement water feed 4: pressure indicator 5: conductivity sensor 6: pressure switch 7: circulation valve 8: water discharge valve 9: sensing liquid flow 10: sensing liquid pump 11: control unit 12: centripetal pump (clean oil) 13: separating disc 14: dirty water discharge 15: sludge holding space 16: sludge discharge
57
HFO
19 19: screw pins (holes closed in separating disc !) p/n: 0019-9045-400

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17: operating water discharge 18: operating water feed


HFO 6
19
A small amount of sensing liquid is diverted via the separating disc (13). It is conveyed by the sensing liquid pump (10), the circulation valve (7) to the pressure switch (6) and recycled back into the feed. If the sensing liquid intake becomes blocked due to water or solid accumulation in the sludge holding space (15) the pressure switch sends a pulse to the control unit. The automatic solids ejection program for both first stages is triggered (so called self thinker). The pressure switch is working as PSL. The circulation valve is open over the whole period of time of separation.

A clarifier is not able to discharge water continiously just by de-sludgings only. The system of WMS -01- and SMS -36- are identically. To rebuild the separator from WMS into SMS just close the holes in the separating disc by means of two screw pins and re-adjust the timing unit.

CS PSL
CS
PSL
CS PSL
Separation: circulation valve open, sensing liquid pressure above the setpoint of pressure switch
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Separation: circulation valve open, sludge holding space filled up with solids, sensing liquid pressure dropped below setpoint
Ejection: on both stages triggered by the self thinker, feed valve closed .
60

OSC50
UNITROL-SMS-96-: no ringdam; pressure switch and circulation valve in use, designed for LO only; same working principles as SMS-36-, holes open in sep. disc.
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Sludge Monitoring System for Lube oil

61

CS PSL
CS PSL
CS PSL
Filling: no pressure at the PSL, CS not in use, holes in separating disc open, bowl partially pre-filled
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Separation: sensing liquid pressure above the setpoint
Separation: sludge holding space filled up with water and solids, sensing liquid pressure dropped below setpoint, ejection triggered
62

Separator type UNITROL -SMS -961: dirty oil feed 2: clean oil discharge 3: displacement water feed 4: pressure indicator 5: conductivity sensor 6: pressure switch 7: circulation valve 8: water discharge valve 9: sensing liquid flow 10: sensing liquid pump 11: control unit 12: centripetal pump (clean oil)
LO
19 19: screw pins (holes open in separating disc !) p/n: 0019-9045-400 17: operating water discharge 18: operating water feed
13: separating disc 14: dirty water discharge 15: sludge holding space 16: sludge discharge
63
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LO 6
19
A small amount of sensing liquid is diverted via the holes in the separating disc (13). It is conveyed by the sensing liquid pump (10), the circulation valve (7) to the pressure switch (6) and recycled back into the feed. If the sensing liquid intake becomes blocked due to water or solid accumulation in the sludge holding space (15) the pressure switch sends a pulse to the control unit. The automatic solids ejection program is triggered (so called self thinker). The pressure switch is working as PSL. Before feed valve is open the bowl is partially filled with water. This is not to create a water seal but will improve the clarification (discharge of solids from the oil).

When running with UNITROL SMS -96- the flowrate of filling- and displacement water must not exceed 0,1 l/s. To achieve this reduced flowrate a orifice plate of bore 3,0 mm needs to be installed in the filling- and displacement water assy.

LO: Separator type UNITROL-WMS+SMS -0196-
UNITROL-WMS+SMS: no ringdam; conductivity sensor, circulation- and water discharge valve as well as pressure switch in use. For LO only.
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Water Monitoring System + Sludge Monitoring System

66

Separator type UNITROL WMS+SMS -0196-
CS
PS
CS
PS
After the ejection the bowl is empty. Sliding piston as well as annular piston are in sealing position.
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FILLING: the bowl will be filled with water timer controlled. The signal of the pressure switch will override the timer.
67

CS
PS
CS
PS
SEPARATION: the upper centripetal pump is acting as a gravity disk. Dirty water will be discharged continiously.
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HIGH WATER: Alarm will be given once that a certain amount of water is being discharged (Timer controlled)
68

CS
PS
CS
PS
SMS mode: after the WMS mode is over by timer the SMS mode is activated. Water will be added timer controlled.
26.04.2005
SMS mode: Both valves are closed. No signal of the pressure switch means: sludge holding space is filled up.
69

CS
PS
CS
PS
SMS mode: Ejections will be triggered timer controlled. The signal of the pressure switch will override the timer (T20)
26.04.2005
BREAKOVER: Alarm will be given when the water seal has been lost however: Signal from the PSL but no signal from the CS.
70

non-self-cleaning type: solid wall bowl
Type OTA
Type OTB
Type OTC
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Separator type UNITROL -DISPLACEMENT-
CS
PSL
CS PSL
CS PSL
Separation: sludge holding space filled up with solids, sensing liquid pressure dropped below setpoint
Displacement: Filling + Displacement and circulation valve open, clean oil displaced to the clean oil discharge
Ejection: on both stages triggered by the self thinker, oil losses minimized
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Potable water
condensate as well as desillate is not permissible


Potable water
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Potable water
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Potable water
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water discharges: syphons
If no syphon is installed, the frame drain as well as the dirty water discharge must always be submerged below the minimum tank level so as to produce a liquid seal.

water discharges: syphons
If a syphon is installed, submerging of the water discharges is not required because a liquid seal is already present. The dimension h min for defining the syphon lenght is specified in the table.

centripetal pump
upper centripetal pump

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lower centripetal pump

79

centripetal pump
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OSA, OSB, OSC: Foundation
Vibrations from the vessel / ship structure into the separator skid must be reduced as good as possible (rubber cushion, cap springs, flexible hoses, stiff foundation etc.)

OSA, OSB, OSC: Foundation
wrong !
wrong !
Tighten the lower nut lightly by hand. Use an open-end wrench to tighten the nut by a further turn. Then check the tightened nut with the upper nut by counterholding.
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Foundation
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foundation / max. vibration limit
max. vibration limit at installation surface with stopped separator


OSD: Foundation
0021-3308-750 0021-3309-750
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OSD: Foundation
OSD 6 / OSD 18 pos. 340: pos. 350:

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OSD 35 / OSD 60 pos. 390: pos. 400: 2057-1467-000 0021-3309-750

86
2058-1467-000 0021-3308-750

clutch, clutch shoes
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fitting of clutch shoes
for OSC15 (belt drive only)


clutch driver, clutch shoes OSA, OSB, OSC
For all gear driven separators
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OSD: clutch, cluch shoes
One friction pad for all OSD type of separators
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clutch drive: permissable wear holding slit
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gear oil - oil level in gear box
OTC2 OTC3
Check oil level daily. Check whether the oil bath contains water (milky colouring) or product (HFO - dark colouring). If so change immediatly.

gear oil CLP100
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gear oil CLP220
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gear oil ISO-VG 220
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gear oil ISO-VG 68
For belt driven separators only.


synthetic gear oil, running in procedure
list of approved oils:

MOBIL SHC 630 SHELL Delima HT 220 CASTROL Alphasyn T 220 CASTROL Alphasyn HG 220 BP Enersyn HTX 220 ESSO Teresso SHP 220 ELF (Lub Marine) EPONA SA 220 FINA Gearan 220
The gear must be run in with mineral lube oil for approx. 1500 - 1750 running hours. The running-in marks must be clearly visible on each tooth of worm wheel. b = min. 1,5 - 2,5 mm for OSC4, OSC5, ESC4, OTA7, OTB9, OTA14 etc. b = min. 2,0 - 3,0 mm for OSA20, OSB/C30, OSA/B35, OTA18/30, OSC50 etc. All approved oils are in accordance with ISO-VG 220 and on poly-alpha-olefin basis (WS p/n: 0015-0018-200). In case of very high ambient temperature gear oil of ISO-VG 320 is recommended for OSA20, OSB/C30, OSA/B35, OTA18/30 and OSC50. The remaining viscosity @ 100 C is approx. 30 cSt [mm/s]. For OSC15 (flat belt drive !) synthetic gear oil of ISO-VG 68 is recommended.

synthetic gear oil, running in procedure
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wear to gear
The gear parts (both worm wheel as well as vertical spindle needs to be replaced incase the tip of tooth worn out to 1/2 to dimension h.
The gear parts (both worm wheel as well as vertical spindle needs to be replaced incase the base of the tooth shows sign of wear.
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bottom bearing
OSC50
- both bearings may only be replaced together (same maker) ! - the bottom bearings may only be loaded axially in one direction ! - fit both bearings so that the outside narrow rim faces upwards to the bowl ! - incorrect fitting will decrease service life dramatically (crash) ! - heat bearings and protection ring to approx. 80 C before fitting

bottom bearing : sherical plain bearing
This joint is not a crack but necessary to fit the inner ring in the factory. There is no special instruction how to install the bearing.

OSB35 - modified hydraulic system
new
previous
2 x 0007-1674-750 393,1/407,1x7
1 x 0007-1892-750 385/405x10
102

OSB 35: hard metal ring of sliding piston
The sealing surface of the sliding piston can be remachined several times when worn (up to 1,5 mm in total) before replacement of sliding piston becomes nescessary. When re-machining, make sure that the shoulder on diameter X is at least 1.0 mm. When in doubt check dimension Y of which must be at least 21.0 mm Remachine the sealing surface as soon as possible as there are sligh-test traces of erosion (of 0.2 - 0.3 mm depth). After the re-machining the polaymid gasket in the bowl top needs to be replaced. Rebalancing of bowl is not necessary.
103
OSB35
Guide values for re-machining: Tool: carbide-tipped tool of M30 or K20 Speed: 10 - 12 rpm Depth of cut: max. 0.15 mm Rate of feed: max. 0.1 mm/rev
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OSB 35: correction of bowl height
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104

OSA20 - modified hydraulic system
new
2040-9958-000
previous
2178-9959-000
2 x 0007-1851-750 304,2/318,2x7
1 x 0007-1851-750 304,2/318,2x7
105

OSA20 - threaded ring 2178-6627-010
In some cases the threaded ring pos. 308 cannot be loosened. To take off the ring by means of a lathe please use carbide-tipped tool and about 40 to 70 m/min. Control the thread of the bowl bottom and the leading surface regarding marks. Smooth the surface. CAUTION: the threaded ring can be loosen during cut off.

OSA 20 - hard metal ring of sliding piston
Guide values for re-machining: Tool: carbide-tipped tool of M30 or K20 Speed: 10 - 12 rpm Depth of cut: max. 0.15 mm Rate of feed: max. 0.1 mm/rev
OSA20
The sealing surface of the sliding piston can be re-machined several times when worn (up to 1,0 mm in total) before replacement of sliding piston becomes nescessary. When remachining, make sure that the shoulder on diameter X is at least 1.5 mm. Remachine the sealing surface as soon as possible as there are slightest traces of erosion (of 0.2 - 0.3 mm depth). After the remachining the polaymid gasket in the bowl top needs to be replaced. Rebalancing of bowl is not necessary.

OSA 20 - frame venting
In order to improve the frame venting a pipe should be installed in the frame drain as shown above.

hard metal ring of sliding piston OSA7
OSA7
Guide values for re-machining: Tool: carbide-tipped tool of M30 or K20 Speed: 10 - 12 rpm Depth of cut: max. 0.15 mm Rate of feed: max. 0.1 mm/rev The sealing surface of sliding piston can be re-machined several times when worn (up to 1,0 mm in total) before replacement of sliding piston becomes nescessary. When re-machining, make sure that the shoulder on diameter X is at least 1.5 mm. Re-machine the sealing surface as soon as possible as there are sligh-test traces of erosion (of 0.2 - 0.3 mm depth). After the re-machining the polaymid gasket in the bowl top needs to be replaced. Re-balancing of bowl is not necessary
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bowl: Table of bowl heights

60 Hz [rpm] 10030 10030 8510 7500 7500 6540 6500 6500
type OSC4 OSC5 OSA7 OSC15 OSA20 OSC30 OSB35 OSC50 -oldOSC50 -new-
X [mm] Y [mm] 50 Hz [rpm] 54-56 54-56 80-82 37-39 120-122 16-18 38-40 43-45 34-36 * * 1,50 * 2,00 2,00 2,00 2,00 2,00 9980 9980 8520 7500 7500 6440 6500 6500
9960 / 10240 11490 / 11470
*: height not adjustable
adjustment of bowl height: - unscrew bottom bearing cap (3) - remove gasket (1) - Adjust the bowl height by turning bottom bearing threaded piece (2). A full turn will raise or lower the bowl by the dimension Y. bowl is too high: turn anti-clockwise bowl is too low: turn clockwise
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separator bowl - unbalance
when having trouble with unbalance of bowl please check if:

- all 0 marks are in-line and all locking devices are in perfect condition - the disc stack pressure has been lost (blind disk or disk to be added) - any damages / erosion / corrosion / cavitation are to be noticed - the bowl has been re-assembled completely (missing parts ?) - all bowl parts are arranged in fixed positions to one onother - bowl parts from different bowl has been mixed
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separator bowl - unbalance
The bowl needs to be exchanged when the bowl top or bowl bottom has been damaged. These bowl parts cannot be replaced without re-balancing of complete bowl because of the positions of balancing area.

bowl: taper seat of bowl bottom / spindle
The conical seat of bowl bottom and worm spindle must be absolutely dry when assembling the bowl.

separator bowl: chrome layer peeling
The sliding surfaces of bowl are protected with a crome layer to prevent bowl parts from seizing during the run-ning-in phase. This crome layer is necessary during the first few hundret running hours only and may peel off. The scope and location of this peeling can differ from bowl to bowl. The product, the operating mode and the number of ejections etc. can influence the overall picture. There is no effect on the separation efficiency, maintenance schedule and service life of bowl.

separator bowl OSA, OSB - wear protection
Bowls type OSA and OSB are equipped with wear protection against erosion when running with HFO: wear liner, wear inserts and hard metal ring. Please never run bowl without wear protection with HFO or any other abrasive product (sludge, palmoil etc.)

Refinery process
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cat fines
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Residual Marine fuel standards
ISO, BSI, CIMAC


Incompatibility of Fuels
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Sludge of an asphalt nature may be produced if fuels from different refineries are mixed and this sludge may cause serious trouble. If this happens the fuels are said to be incompatibile. Such disruptions first become evident in the centrifuge in the form of excessive amounts of sludge separating out. Asphalt sludge may also clog the pipes, pre-heater and filter and collect in the tanks. Changing the temperature of the oil has virtually no effect on the formation of sediment. The reason is that the more intensive refining process and particularly the use of the visbreaker, produces a higher content of aspahltenes. Many of these large molecules are at the limit of their solubility in the parent oil (are in a labile state). It is ensured that the above disorders do not occur in refineries by appropriate management of the process and by admixing selected components (e.g. cracked gas oil to act as a low-viscosity component). If however a heavy oil of this kind is mixed with a fuel with a lower capacity for dissolved asphaltenes, then the asphaltenes precipitate. Instability of this nature exists even when for example admixed component is a paraffin-base destillate.

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Stability of Fuels
Occationally layers of low and high-viscosity oil occure which have nothing to do with stability but are due to inadequate blending of the components. This may cause an oil overflow to the dirty water discharge. The chemical stability of a residual oil decreases the more deficient the carbon molecules is in the hydrogen atoms which would be needed to occupy all its free valences. Therefore it is easy for external influences to bring about a change in the chemical make-up of the molecules. This danger is thus accentuated with the fairly hydrogen-deficinet residues from cracking plants (catalytic crackers and visbreakers). The residues in question oxidise by absorbing oxygen from the atmosphere and as a result of polymerisation (linking) of molecules they form fairly large structures which precipitate as sludge. The tendency to oxidise increases with the content of unsaturated hydrocarbons, of which there is a particularly high concentration in residues from cracking. The tendency also increases sharply as temperature rises. For this reason feed tanks should not be heated very much above the pump temperature.

Precipitation of Paraffin (wax) / Spot test
It must be remembered that fuel oils may contain components of a paraffine nature. Paraffins in the narrower sense are usually understood to be those members of a homologues series of saturated straight-chain hydrocarbons which exits as a solid phase at room temperature. So long as the fuel oil is kept at an appropriate temperature, the paraffines remain in solution but as their solubility decreases as temperature drops, paraffin components may separate out in solid form if the fuel oil cools down. The temperature at which the precipitation of the paraffin begins depends on the mean molecular weight of the fuel oil and also on the amount of paraffins present and their melting points. As the majority of fractions of this kind are cracked off in cracking plants, the precipitation of paraffins is more frequently encountered with residues from pure destillation. A small amount of the phase flowing out on the water side is heated to approximately 100 C and a spot placed on a filter paper. If a nucleus collects, then what is involved is the precipitation of asphaltenes or the separating out of products of oxidation and if not then it is the precipitation of paraffins.

fuel problem: contamination with chemicals
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124

fuel problem: contamination with chemicals
pittings / cavitations at the sensing liquid pump (HFO)


electrical equipment -general layout plan
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126

Diagram of installation: SINGLE MODE

feed valve pre-heater
solenoid filling/ displacement water
Motor starter
control unit pressure switch
Separator
solenoid operating water
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127

Timing unit type VESA
Voll Elektronische Steuerung A- Typ

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timing unit type VESA installed 1980 - 1990

Ronald Eschmann, Service Dept., Hamburg 128

Voll Elektronische Steuerung A- Typ

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timing unit type VESA installed 1980 - 1990


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d1: Waiting d2: Displacement d3: Ejection d4: Speed recovery time d5: Filling d6: Bridging time after ejection d7: Alarm delay time d8: Ejection monitoring time digital adjuster at the rear side of VESA

Timing unit type VESB
Voll Elektronische Steuerung B- Typ
timing unit type VESB installed 1990 - 1999





PLC100/1WS-part number : 0005-4050-260 PLC100/2WS-part number : 0005-4050-270 PLC100/3WS-part number : 0005-4050-280 PLC100/4WS-part number : 0005-4050-290

137

Timing unit type VESB: PLC100
1: control unit PLC 100 2: LED off / input status 3: LED on / output status 4: Cursor up 5: Cursor down 6: Output range 7: Input range 8: Counter range 9: Timer range 10: Copy program 11: Status text 12: display 13: Operation LED (control unit READY) 14: numeric keys 15: Enter key 16: Specific call-up in preselected mode 17: Function keys: F0 - TEST

Timing unit type VESB: PLC100, function keys
F0 F1 F2 F3 F4 F5 F6 F10 F11 F12 F13 F14 F15 F16 SHIFT

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program STOP with ejection program START with ejection displacement flushing clarifier operation: step FILLING suppressed diagnostics: help function alarm acknowledgement self-thinker control ON free free (displacement with product) series operation ON free diesel oil operation: alarm TAL suppressed free gives access to key F10 to F16

Timing unit type VESB: PLC100
PLC100 without EPROM
PLC100: 16 inputs, 8 + 8 outputs, maker: SCHLEICHER


Timing unit type VESB: replacing PLC100
1. Please make a note of the original settings of all timer and counter 2. Please switch off the main switch and plug off all plug connectors as well as the EPROM (please never plug off EPROM while contol cabinet is energized) 3. Replace the PLC100 and plug in the connectors and (new) EPROM (check both fuses and the output of the 24 V power supply: must be 24 VDC steady otherwise the power supply is damaged) 4. Switch on the main switch and press following keys: STATUS then # then TEST 5. Enter the password: 02522 and finally press the ENTER-key 6. Press the COPY-key, then ENTER and STATUS again. 7. Now you can change the present timer and counter setting`s to the original ones. To do this please press the "TIMER" key. By means of the cursor keys you can scroll trough the timer list and change the settings . To call up the timer please press the "ENTER" key. PLC100/1 can be replaced by PLC100/1 or PLC100/3. PLC100/2 can be replaced by PLC100/2 or PLC100/4.

Timing unit type VESB: Password PLC100
To download the soft-ware from the EPROM into the CPU by means of the COPY function as well as to change the timer settings in the timer list, the password protection needs to be lifted. Please follow the procedure.
Please note: the EPROM must not returned to WS in case the PLC 100 is gone.

VESB function keys - HFO series mode -01-36-
First stage: WMS -01-: VESB-EC-1, with DISPLACEMENT and FLUSHING. Please pre-select function key F2 for DISPLACEMENT, F3 for FLUSHING and F13 to activate the series mode. Second stage: SMS -36-: VESB-EC-1, with DISPLACEMENT and FLUSHING. Please pre-select function key F2 for DISPLACEMENT, F3 for FLUSHING, F4 for CLARIFIER OPERATION, F10 to activate the SMS and F13 to activate the series mode.

Timing unit type VESC
Voll Elektronische Steuerung C- Typ

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timing unit type VESC installed 1995 - 1999



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Timing unit type VESC, check of PSU card


Timing unit type VESC , check of PSU card
R13
four pin socket
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148

R13 burned
rear side of PSU card


R13 new
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150

power supply unit, part number: 0005-4097-100 VESC-1-W (8155-0202-050) to be installed on the wall VESC-1-S (8155-0202-060) to be installed inside control cabinet.


EPROM; software: 0005-2045-100

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EPROM; software: 0005-2045-100
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153

Timing unit type C7
0005-4050-300 0005-4050-310 0005-4050-320 0005-4050-340 0005-4050-350 0005-4050-360
C7-623 (A) C7-626 (A) C7-626 (A) DP C7-623 (P) C7-626 (P) C7-626 (P) DP
UD700: 0005-4040-190 (software update)
C7-623
C7-626
timing unit type SIEMENS C7 installed from 2000


Timing Unit type C7-626
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155

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158

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Display
Softkeys
Status /fault indicator
Function key
Softkeys
System keys
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Timing Unit type C7- softkeys
ALARMS: Picture-dependent function key as per display. On the PROCESS page you can use this key to call up and view alarm message buffer. OPERATION: Pressing this key takes you from any display page to the main menue (PROCESS page - this is the graphic process picture) UP and DOWN: Keys are normally used in the display to access the next / previous level. Other functions are picture-dependent and are shown in the display.
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SEPARATOR PROGRAM OFF This key stops the separating program, closes the feed valve in separation mode and empties the bowl. On the OSC separators two total ejections are triggered automatically.
SEPARATOR PROGRAM ON This key starts the separating program. When the ejection program has run the feed valve is openend. The ejection monitoring system is suppressed after pressing this key because there is no de-sludging when the bowl is empty (on C-type of separators only)
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162

WMS 01: WATER MONITORING SYSTEM UNITROLHFO: single or parallel mode of operation, first stage in series mode SMS 36: SLUDGE MONITORING SYSTEM UNITROLHFO: second stage in series mode
SMS 96: SLUDGE MONITORING SYSTEM UNITROL-LO
SERIES MODE for UNITROL-HFO only.
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Timing Unit type C7- function keys
The LED in the keys shows the actual status: permanent lighting: OPERATION slow flashing: FAULT from motor protection rapid flashing: winding up time or delay to stop time No other function.
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Timing Unit type C7- function keys
PARTIAL EJECTION: OSC type of separators allow partial ejections. To do this, pre-select the number of partial ejections on Counter C01 to be triggered before the total ejection and the press the key PARTIAL.
HEATER RELAESE: Press this key only if an EXTERNAL FEEDPUMP is fitted. An optional heating system will be relaesed which is then process-dependently controlled.
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165

C7 display: contrast, background illumination
626
623
The contrast at C7 623 is adjusted by pressing the SHIFT and +/- key.
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166

Timing Unit type C7- system keyboard
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167

C7 control cabinet, inside view
Use only approved shielded cables for wiring the analog in - and outputs as well as the IM, V.24 and MPI interfaces

C7 control cabinet, inside view
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C7: view from rear, interfaces
1: IM port 2: Analog inputs 3: Analog outputs 4: AUX digital inputs 5: Serial interface V.24 6: Digital inputs (top) 7: Digital outputs (bottom) 8: DI/DO 24 VDC power supply
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C7 series mode: first and second stage
MPI-plug: 0005-1408-000
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171

C7 series mode: first, second, third stage
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D10 Display - starting

Firmw.: V1.01 Bootl.: V1.01 Startup < V 1.01 < <
1 0
Mainswitch
C7-613
> $ 008 > >
12 9 6 3
CPU is in Stop !
$ 002
transfer
> Downloading User < > Data < Westfalia Separator Mineraloil Systems Plaese press >> ENTER << Customer I Adjustment I I Service I I I D10 F1 F2 F3 F4
ENTER
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D10 Display Customer Program, Timer

Customer I Adjustment I I Service I I I D10 F1 F2 F3 F4
Home
F4
F1
Program I Timer I I Settings I I I Info F1 Sequence: Operation Step: CIRCULATION Product-Temp.: 98 C Separat. Time: 7200 sec Sep. Typ: OSD60 Motor current: 25.0 A Starttime: 0 sec Mode: single Status - Feed pump: ON Status sludge pump: ON
F2
F3
F4
Operator Timer T20: Separation P: 7200 sec A: 1234 sec T01: Displacement T02: Filling T10: Separator-Start T11: Alarm bridging

D10 Display Customer Settings

Program I Timer I I Settings I I I Info F1 F2 F3 F4
F3
ANALOG IN I ANALOG OUT I I COUNTER I I I PID-Co F1 AI 0 Motor current 1U3 7/9 25.0 A Ejection monitoring Offset: 30.0 A AI 1 bowl - speed 1U2 12+/13 6600 rpm Max: 7000 rp (Option) AI 2 AI 3 Pt100 Temp. Product - Temp PID Controller Product Temp recording F2 F3 F4 PID MODE - AUTO ModeValve>regulate< F2 Valve close F3 Valve open Setpoint Actual value Kp (P-Part) Tn (I-Part) 98 C 97 C .08 100 sec
AO 0.1 Motor- current 25.0 A (option) AO 0.2 Temperature 98 C (option)
Z 1: Flushing Counter P: 5 A: 0 Z 2: Part. Ejection only OSC / OSD Type P: 5 A: 0 Z 3: SMS Filling P: 5 A: 0
AI 3: PID Controler 1X2 76/77 95 C Final value: 120 C
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D10 Display Customer - Info

Program I Timer I I Settings I I I Info F1 F2 F3 F4
F4
ALARM_C I SERVICE I INFO I I F1 Sep. operation datas OP-hours: 12345 h Ejections: 999 Starts: 123 WMS / per.: WMS / tot.: SMS / per.: SMS / tot.: PTC-Alarm: PAL-Alarm: PAH-Alarm: FSH-Alarm:
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F2
F3
F4
Serial-number Separ. -> 9017-898 <Start-up date -> 26.11.2003 <Prog: 8105-0D10-703 Version: 10/02 MPI-2 control system Part.No: 0005-4050-380 DATE: 31-01-2004 TIME: 22h 50m 28s Sep. opert. hrs: 12345
0 123 0 88 0 0 0 0
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D10 levels Adjustment Separator, Timer

Home
F4
F2
SEP. I TIMER 1 I I TIMER 2 I I I F1 PSL - Monitoring Button - F1 > OFF < PID Controller Button F2 > ON < Sep. OFF by idle time Button F1 > OFF < Separator cooling Button F2 > ON < WMS 01: ButtonF1> ON SMS 36: ButtonF2>OFF SMS 96: ButtonF3>OFF SERIE: ButtonF4>OFF
F2
F3
F4
T00 Part-Ejection T24 Sludge p/p - delay
T25 Vibro 1 T 41 CU-Sludgep/pBreak

D10 levels Service - Inputs, Outputs

Home
F4
F3
INPUT I OUTPUT I I MAINTEN I I I F1 DI 0.0: >1< DI 0.1: >0< Separator-ON 1X2 01/02 Separtor-fail 1X2 03/04 DO 0.0 >1< DO 0.1 >0< DO 1.6 >1< DO 1.7 >0< F2 F3 F4
Productvalve 1X2 41/42 Watervalve 1X2 43/44 PID - open (option) 1K18 PID - close (option) 1K19
Maintenance-Intervall Adjust operating hrs Set: 4000 h Actual: 1234 h
DI 2.6: free >0< 1X2 73/74 DI 2.7: E-Stop Feed p/p >0< 3K1
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D10 Display D10

Home
F4
F4
Date/Time I ALARMS I I LANGUAGE I I I CONTR F1 DATE/TIME 31.01.2004 change 22:51:19 F2 F3 F4 Display contrast: contrast: 4
<alm.mes.> 0 001/256 #016 LSHH-TANK At 11.11.03 11:11:11 <alm.mes.> 0 002/256 #005 VIBRO 2 At 10.10.03 12:12:12 <alm.mes.> 0 003/256 #010 PAL-Cleanoil At 09.09.03 13:13:13
Select langauge: Current: ENG new: ENG Select langauge: Current: ENG new: GER Select langauge: Current: ENG new: FRA
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179

D10 password protection
Westfalia Separator AG
Customer Password login: Level I Adjustment : 4 0 Password I I : .1 Service .9 . .0 .. . 0 1. 7 I I I D10

F1 F2 F3 F4
F1
F2
F3
F4
1
SF DC5V FRCE RUN STOP
2
Progr. Start
3
Lamp Test
4
Series. mode Help
5 ESC 0
Home
Progr. Stop
6
Centri -fuge
7
Feedpump
8
Sludge Pump PID
EDIT
ENTER
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180

alarm list
no. 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017
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description motor protection separator-motor clean oil discharge pressure low clean oil discharge pressure high breakover water discharge temperatur low temperatur high ejection monitoring system sludgetank level high high free motor protection feed pump motor protection sludge pump vibro stage 1 vibro stage 2 series mode failure minimum sep. time not o.k. free WMS alarm- high water content
PTC PAL PAH FSH TSL TSH ISL LSHH PTC PTC NAH NAHH
181

C7: error messages
alarm 001: MOTOR-PROTECTION

Temp. > max. C Motor shut off Help informations: Please check: > fuses in starter > Thermistor relais > clutch > correct numbers of clutch shoes > brake > motor current

C7: error messages
alarm 002: PAL-CLEANOIL-OUTLET

pressure < setpoint Separation stop Help informations: Please check: > adjusting of back pressure > flow-rate feedpump > hydraulic function > leaking of hydraulic liquid > clutch of feedpump > condition of pre-strainers

C7: error messages
alarm 003: PAH-CLEANOIL-OUTLET

pressure > 3,0 bar Separation stop Help informations: Please check: > valve / position in cleanoil outlet pipes > adjusting of back pressure > flow rate > oil temperature-setting > setpoint of frequency converter
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184

C7: error messages
alarm 004: FAH-WATER-OUTLET

Flow too high Separation stop Help informations: Please check: > adjustment of back pressure > flow rate feedpump > adjusting of setpoint > leaking of hydraulic liquid
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185

C7: error messages
alarm 005: TAL-PRODUCT-FEED

Temp. min: < Setpoint Separation stop Help informations: Please check: > Temp. setting of Analog / Input > Temp. indicator in feedline > function of heating system
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186

C7: error messages
alarm 006: TAH-PRODUCT-FEED

Temp. max: > Setpoint Separation stop Help informations: Please check: > Temp. setting of Analog / Input > Temp. indicator in feedline > function of heating system
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187

C7: error messages
alarm 007: EJECTION MONITOR

current < Setpoint Separation stop Help informations: Please check: > Ejection current > Setpoint of ejection monitor > Amount of operating water > clutch shoes > function of bowl
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188

C7: error messages
alarm 008: LSHH- SLUDGETANK

level-high Separation stop Help informations: Please check: > Function of sludge pump > Function of level switch / wiring > Handvalve position > clutch shoes > system / leakages
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189

C7: error messages
alarm 010: FEED-PUMP

Motor-protection pump out of order Help informations: Please check: > Fuses / breaker in motorstarter > Function of pump > Function of motor > Motor temperature > Nominal current
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190

C7: error messages
alarm 011: SLUDGE-PUMP

Motor-protection pump out of order Help informations: Please check: > Fuses / breaker in motorstarter > Function of pump > Function of motor > Motor temperature > Nominal current
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191

C7: error messages
alarm 012: VIBRATION STAGE 1

Vibration > 4,5 mm/s start ejection program Help informations: Please check: > operation water system > bowl hydraulic > sludge outlet > vibration monitor > correct bowl assembly > setpoint stage 1

C7: error messages
alarm 013: VIBRATION STAGE 2

Vibration > 7,0 mm/s Motor switch off Help informations: Please check: > operation water system > bowl hydraulic > sludge outlet > vibration monitor > correct bowl assembly > setpoint stage 2

C7: error messages
alarm 014: SERIES MODE FAILURE

connection / pre-set failure
Help informations: Please check: > key SERIES 1<=>2 on both timing units > MPI-cables / plugs on both timing units > Both separators in Ready for operation
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194

C7: error messages
alarm 015: MIN. SEPARATION TIME < 10 min

high water content
Help informations: Please check: > water content in dirty oil feed > Leakage of water valve > control holes in separation disk HFO / LO
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195

C7: error messages
alarm 017: WMS - alarm high water content

WMS-SYSTEM NOT OK high water during Timer 22 Help informations: Please check: > WMS-signal > settings of measuring relais > function of WMS > function of water discharge valve
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196

C7: error messages
alarm 018: Water seal broken during Timer 35

SMS- FUNCTION NOT OK
Help informations: Please check: > function of SMS pressure switch > amount of filling water > product feed
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197

C7: error messages
alarm 019: PSL pressure switch monitoring

Clean oil outlet pressure
Help informations: Please check: > adjusting of back pressure > flowrate feedpump > bowl closing > hydraulic function > leaking of hydraulic liquid > clutch of feed pump

C7: error messages
alarm 020: Bowl monitoring

Closing water impulse T06
Help informations: Please check: > adjustment of closing water impulse > operating water pressure > clutch shoes > function of bowl
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199

C7: error messages
alarm 021: Separator off

Separator off function active T39 (no ACK after alarm raised) Help informations: Please check: > Separator off function active > Separator shut down after T39 elapsed
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200

Service Training
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26.04.2005
201

Westfalia Service Training

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Mechanical Separation

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

model designation of separators

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

model designation of separators

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

Stuffing box oil Fuel

HFO - Sludge tank

Westfalia Separator Mineraloil Systems GmbH

Diagram of installation: SINGLE MODE

instrument air solenoid f+d water

pre-heater steam inlet motor starter

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

dirty water discharges

clean oil discharge

dirty oil feed

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

bowl: disk stack

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

bowl: OSA20 UNITROL

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

bowl: OSC4 UNITROL

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

diagram of installation: SINGLE MODE

temperature switch high / low

pressure switch low (SMS)

HFO: single / parallel mode: recommended with increased water content

Westfalia Separator Mineraloil Systems GmbH

diagram of installation: SINGLE MODE

return line of feed valve led back to settling tank

Westfalia Separator Mineraloil Systems GmbH

diagram of installation: SINGLE MODE

return line of feed valve led back to oil sump

Westfalia Separator Mineraloil Systems GmbH

diagram of installation: SERIES MODE

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator Mineraloil Systems GmbH

diagram of installation: SERIES MODE

Westfalia Separator Mineraloil Systems GmbH

SERIES MODE of operation: HFO only

Westfalia Separator Mineraloil Systems GmbH

diagram of installation: SERIES MODE

series mode of operation: process and installation diagram