Diesel Engine Power Plant - EN - tcm11-19484 PDF

Energy System Technology
High performance equipment for

diesel engine power plants
engineering for a better world
GEA Mechanical Equipment
Your Powerful Partner

The clever way to separate
Centrifugal separators have been an essential part

of the manufacturing program since the companys
foundation in 1893.
New applications have constantly been added to the
production schedule as a result of the continuous
program of research and development and the knowhow acquired over 110 years. Application-oriented,
innovative solutions in machine design and process
engineering are available for the mineral oil industry,
the dairy, beverage, food, chemical and pharmaceutical
industries and for biotechnology and pollution control.
Back in 1907 the centrifuge was first used for the
purification and dewatering of mineral oil. Since
then, thousands of centrifuges have been used in this
application for the reliable and economic treatment
of fuel and lube oils. Nine decades of experience in
this field form the basis for todays state-of-the-art
treatment plant concepts. The following development
trends show the continuous treatment of fuel oil, lube
oil, sludge and waste water.
Content
The clever way to separate
Waste water treatment
2 Your Powerful Partner
26 Protect the EnvironmentSelf-Cleaning

Centrifugal System
More quality in power stations
28 GEA Westfalia Separator minimaXx
4 Power Station System Solutions
Manual Cleaning Centrifugal System
Systems overview for diesel engine power plants
Fuel oil conditioning system
6 High Performance Equipment for Diesel Engine
30 VBU GEA Westfalia Separator
Power Plants
ViscoBoosterUnit:
Complete System Between
Centrifugal systems in power stations
Service Tank and Engine
8 Process Overview
Control units
Self-cleaning separators
32 Automatic Process
10 Double Centripetal Pump
Control More Safety, More Comfort
12 GEA Westfalia Separator unitrol
33 GEA Westfalia Separator minimaXx
SystemWMS/SMS in Single Stage
Process Control for Every Requirement
GEA Westfalia Separator minimaXx
Flexible systems
14 Manual Cleaning Separators
34 Energy Compact Units
15 Self-Cleaning Separators
Solutions for the Modern Power Plant

35 The Economical Solution
Diesel oil treatment

16 Manual Cleaning Solutions
Various additional systems and equipment
17 Self-Cleaning Solutions
36 Your Powerful Partner for Complete Systems

Process cooling systems
Crude oil treatment
38 PHE Plate Heat Exchanger
18 Plant Concepts with a System

19 Process Overview
Water desalination system

40 FWGFresh Water Generator
Heavy fuel oil treatment
41 Single Stage Evaporating System
20 Plant Concepts with a System

21 Process Overview
Service that counts

42 serv&care
Lube oil treatment
Proactive Service for Optimum Reliability
22 Plant Concepts for Efficient Operation
in Power Plants
23 Process Overview
Sludge treatment
24 System Concepts for the Future
25 Economical Advantages
Ecological Merits
Power Station System Solutions

More quality in power stations
The power station industry often uses diesel
Like clockwork
engines that burn heavy fuel oil, crude oil or diesel
Normally servicing is necessary only after 8000 to
oil. By supplying separ ation systems specifically
16,000 operating hours. Surveillance-free operation
designed for continuous operation under roughest
reduces personnel costs tremendously.
conditions, GEA Westfalia Separator Group provides

for optimum power output and a long service life for
The accumulated oil sludge can be processed directly
these engines while taking into consideration the high
in the power station, thereby reducing the disposal
environmental standards.
costs considerably. All separation systems are available

as modules. Other ready-to-connect systems are also
Self-cleaning separators with GEA Westfalia
available as compact units in combination with
Separator unitrol systems automatically monitor the
components such as GEA Westfalia Separator
water level in the oil and the separation of the solid
ViscoBoosterUnits (VBU) or Plate Heat Exchangers
material round the clock. As a result, optimum
(PHE).
separation efficiency for different fuel and lube oils

is ensured.
GEA Westfalia Separator minimaXx OTC 2
Energy Compact Unit for lube oil
Applications
Fuel oil separation
Lube oil separation
Separation of sludge
containing oil and water
Separation of waste water
System engineering
GEA Westfalia Separator eagleclass

Smart. Strong. Reliable.
5
High Performance Equipment for

Diesel Engine Power Plants
Systems overview for diesel engine power plants
GEA Westfalia Separator Group offers leading
Product range overview
technologies and individual systems for power station

use. System engineering from one source, high
Fuel oil treatment
quality of workmanship or unrivalled worldwide
service GEA Westfalia Separator Group provides
Lube oil treatment
systems to rely on.
Sludge treatment
Central cooling system
Lube oil cooling system
10
14
6
2
11
12
1 Fuel oil service tank
9 Waste water tank
2 Fuel oil storage tank
10 Water desalination system
3 Fuel oil sludge tank
11 Auxiliaries
4 Lube oil sludge tank
12 Charge air cooler M.E.
5 Fuel oil conditioning system
13 Waste water treatment
6 Fuel oil treatment
14 HTcentral coolers
7 Sludge treatment
15 LTcentral coolers
8 Lube oil treatment
15
13
Process Overview
Centrifugal systems in power stations
The centrepiece of a fuel or lube oil treatment
Suitable types of centrifugal separators for
system is the centrifugal separator.
these duties:
Main duties of centrifugal separators:
Self-cleaning separators with disc bowl
Separation of solids
Manual cleaning separators with
Separation of water
solid-wall disc bowl
and automatic bowl ejection facility
Effective treatment ensures that only clean oil enters

the drive unit. The wear on the injection system and
on components such as cylinders, cylinder liners and
the crankshaft of the diesel engine is minimized.
Fuel oil
conditioning
system
Service tank
Fuel oil
treatment plant
with centrifugal
separator
Lube oil tank
Utilities
Utilities
Sludge
Sludge
Pump system
Lube oil
treatment plant
with centrifugal
separator
Pump system
Settling tank
Boiler plant
Pump system
Clean Oil
Storage tank
Water
Pump system
Sludge
treatment plant
with centrifugal
separator
Utilities
Concentrated
sludge
Disposal
e.g. incinerator
Waste watersystem
Waste oil tank
Separated oil
Treated water
Utilities
Waste water
treatment plant
with centrifugal
separator
Sludge
Pump system
Waste oil tank
Double Centripetal Pump

Self-cleaning separators with disc bowl and

automatic solids ejection are used where the
percentage of solids in the oil is too high for manual
cleaning. They are used mainly for the clarification and
purification of fuel oils such as gas oil, diesel oil, crude
oil, heavy fuel oil and lube oil. The separated solids
slide down the underside of the disc into the solids
holding space. Self-cleaning separators eject solid
matter automatically while the separator is running.
This avoids shutting down the separator frequently
for cleaning. The clean oil and the separated water
are conveyed to the discharge under pressure by a
centripetal twin pump.
Self-cleaning separators operate continuously. Solids
ejection occurs either by total or partial ejections or
in a combination of both. In case of total ejection and
combination of total and partial ejections, there is
additional self-cleaning of the disc stack.
Labour-intensive and costly measures to clean the
discs using CIP (cleaning in place with chemicals)
systems are not necessary. Optimum separation
efficiency over long operating times is ensured. Major
maintenance work is required only after 8000 to
16,000 operating hours.
Features
Automatic operation
Continuous operating mode
Self-cleaning effect of the bowl
without CIP system
Highly concentrated solids
High separation efficiency
Can be used as clarifier and purifier
Discharge of the light and heavy phase
under pressure by centripetal twin pump
Low noise level
Belt drive
10
Sealing and displacement water
Double centripetal pump
Untreated
oil feed
Separated
water discharge
Treated
oil discharge
Solids discharge
Bowl cross section of a self-cleaning

mineral oil separator with disc bowl
11
GEA Westfalia Separator unitrol System

WMS/SMS in Single Stage
Modern fuel oil and lube oil treatment plants
The oil is displaced prior to a bowl ejection. The
from GEA Westfalia Separator Group provide easy
precisely defined displacement volume minimizes
handling and optimum separating efficiency in
oil losses.
difficult situations.
A further innovative feature of these separators
The heart of these systems is a new gener ation
is the bowls new hydraulic system (GEA Westfalia
of self-cleaning mineral oil separators with
Separator hydrostop). Extremely short ejection times
unitrol system. These separators operate without
combined with maximized solid ejection ports pro-
regulating rings and can be applied for a wide range
vide highly concentrated solids. Further disposal
of heavy fuel oils with a specific density up to
measures are simplified, disposal costs reduced
1.01 g/I as well as for a wide range of lube oils.
and environmental considerations fully taken into

account.
The essential features of these separators are both,

the continuous monitoring of the oil for water and
During total ejections, preferred by GEA Westfalia
the continuous monitoring of the solids holding
Separator Group, the disc stack is also cleaned. Work
space for optimum solids filling, in one stage.
and cost intensive measures for cleaning the disc
Automatic monitoring means that regulating rings
stack by CIP systems are not necessary; this ensures
are unnecessary and operating errors caused through
optimum separating efficiency over a long period of
manual adjustment are eliminated.
operation. Maintenance work is required only after

8000 to 16,000 operating hours.
The Water Monitoring System (WMS) ensures

reliable water separation. The water in the oil is
Just a few basic models are sufficient to cover all
separated out and discharged. The Sludge Space
capacity ranges with the benefit of very economical
Monitoring System (SMS) checks the solids space
spare parts storing and servicing.
for separated foreign matter.
Features
unitrol system in one stage WMS and SMS
Treatment of fuel oils up to 1.01 kg/I
Continuous processing
Regulating rings are not required
Self-cleaning effect of bowl
High separation efficiency even in
and disc stack by total ejection
critical situations
Versatility of application
Automatic adjustment as
Safe operation
clarifier or purifier
Belt drive
Automatic bowl ejection
Low noise level
12
Sealing and displacement water
GEA Westfalia Separator unitrol system
Untreated
oil feed
Separated
water discharge
Treated oil discharge
Solids discharge
13
Manual Cleaning Separators

Manual cleaning separators with solid-wall bowl and
Features
single centripetal pump are today mostly used for the

treatment of diesel oil and lube oil in smaller power
Suitable for both clarifying and purifying
stations.

Solid design
They are suitable for clarifying or purifying oils with
Versatility of application
a low solids content of up to 0.01% by vol.
Low noise level

Belt drive
The clean oil is discharged from the bowl under

press ure by means of a centripetal pump. The
separated solids slide down the underside of the disc
into the solids holding space which must be emptied
by hand periodically.
Sealing water
Untreated
oil feed
Treated
oil discharge
Separated
water discharge
Bowl cross section of a manual

cleaning mineral oil separator with
pressure discharge of the clean oil
by centripetal pump
14
Self-Cleaning Separators
Self-cleaning separators with disc bowl, single
Features
centripetal pump and automatic solids ejection are

used where the percentage of solids in the oil is too
Automatic operation
high for manual cleaning. These are used mainly for
Continuous operating mode
the clarification and purification of fuel oils such as
Self-cleaning effect of the bowl
gas oil, diesel oil and lube oil. Self-cleaning separators
without CIP system
discharge solid matter automatically while the separator
is running. This avoids shutting down the separator
High separation efficiency
frequently for cleaning.
Can be used as clarifier and purifier

Closed discharge of the light phase
under pressure by centripetal pump
Self-cleaning separators operate continuously. Solids

ejection occurs by total discharge with a self-cleaning
Low noise level
effect of the disc stack. Labour-intensive and costly
Belt drive
measures to clean the discs using CIP systems are not

necessary. Optimum separation efficiency over long
operating times is ensured.
The clean oil is conveyed to the discharge under
pressure by means of a centripetal pump. The separated
water flows under gravity via a regulating ring to the
discharge.
Sealing and
displacement water
Untreated
oil feed
Treated oil
discharge
Separated
water discharge
Solids discharge
Bowl cross section of a
self-cleaning mineral oil
separator with solid wall
disc bowl
Operating water discharge
15
Manual Cleaning Solutions

Diesel oil treatment
Its payback time
During the transportation from the refinery to the

power plant diesel oils are often contaminated with
sea water and other impurities. Centrifuges are essential
for the efficient control and removal of solids and
2
water from fuel oils in safety fuel oil treatment

1
systems; they will continue to be so in the future.

Efficient treatment protects the diesel engine from
wear of important components such as cylinder liners,

pistons, piston rings and the injection system. Big
cost savings because of less filter cleaning and less
3
replacements of filter inserts; no problems with bacteria

growth. The entire plant concept is completed with
the feeder unit.
4
1 Untreated oil feed
2 Strainer
3 Manual cleaning separator
4 Separated water discharge
Schematic illustration of a
diesel oil treatment system
with manual cleaning
separator without heater
5 Feed pump
6 Treated oil discharge
Compact unit CU D2 for diesel

oil treatment with self-cleaning
separator OSD 2 without heater.
16
Self-Cleaning Solutions
1 Feed pump
1

3 Untreated oil return
4 Strainer
5 Operating water
7 Operating water discharge

8 Solids discharge
9 Self-cleaning separator
10
Schematic illustration
for oil treatment system
with self-cleaning
separator without heater
17
Plant Concepts with a System

Crude oil treatment
Safety first
Centrifuges are essential for the efficient control and
Increasingly crude oil is used in diesel engine power
removal of solids and water from fuel oils in fuel oil
plants, especially for crude oil pipeline projects.
safety treatment systems; they will continue to be so
The crude oil is delivered to the power plant in a
in the future.
pre-cleaned and degassed condition. However, after

the pre-cleaning the fuel quality is still too poor to be
Crude oil fuels from different sources must be purified
burnt in a diesel engine.
efficiently. This treatment protects the diesel engine

from wear of important components such as cylinder
The viscosity ranges from diesel oil to heavy fuel oil.
liners, pistons, piston rings and the injection system.
As crude oil contains wax which is getting liquid only

at a temperature of min. 50C, the separating temperature
The whole plant concept for crude oil treatment is
is between 60C and 98C. Due to the low flash point,
rounded off with ViscoBoosterUnits.
the system must be equipped with explosion protection.
Crude oil treatment unit with control panel for hazardous area installation
18
Process Overview
Under normal circumstances, GEA Westfalia Separator Group recommends single-stage treatment for
crude oils.
The high efficiency of separation in a single stage
process ensures low wear of the engine. The high
reliability and long service intervals ensure low operating
costs and continuous, unattended automatic operation
for months. The stand-by centrifuge can be saved for
occasional use in abnormal conditionsduring
increased solids loading for example.
All equipment with electrical components are useable
for Ex zone 2 (Category 3) Explosion Group II A or B,
Temperature Class T3 in accordance to ATEX EG-RL94/9.
Purging/flushing for the separator is integrated.
10
2
3
7
16
11
8
12
14
15
13
6
5
1 Regulating valve
9 Strainer
2 Strainer
10 Operating water
3 Steam
4 Pre-heater
5 Condensate
6 Steam trap
14 Purging/flushing
15 Solids discharge
8 Feed pump

19
Single stage treatment

plant for fuel oil with
separator
Plant Concepts with a System

Heavy fuel oil treatment
Protect your engine
Centrifuges are essential for the efficient control and
Owing to its low price, residual oil is widely available
removal of solids and water from fuel oils in fuel oil
on the international market. During combustion
safety treatment systems; they will continue to be so
however, impurities cause corrosion and deposits.
in the future.
Depending on the application, treatment systems are

available both for high-grade and low-grade fuels.
Low-grade fuels from different refining processes such

as atmospheric or vacuum distillation as well as
When rating the throughput capacity of the plant,
from conversion plants such as catalytic cracker or
the following fuel oil data are of central importance:
visbreaker process must also be purified efficiently.
Viscosity (cSt)
This treatment protects the diesel engine from wear of
Density (kg/l)
important components such as cylinder liners, pistons,
Solids and liquid impurities (%)
piston rings and the injection system. The whole plant

concept for heavy fuel oil treatment is rounded off
The results of a research programme confirm optimum

treatment even of fuel oils with viscosities up to
1650 cSt/50C and densities up to 1.01 kg/l (15C).
Energy Compact Unit 2 with two

separators type OSD 35 for HFO treatment
20
with ViscoBoosterUnits.
Process Overview
Under normal circumstances, GEA Westfalia Separator

Group recommends single-stage treatment for heavy
fuel oils.
The high efficiency of separation in a single-stage
process ensures low wear of the engine. The high
reliability and long service intervals ensure low
operating costs and continuous, unattended automatic
operation for months. The stand-by centrifuge can be
saved for occasional use in abnormal conditionsduring
increased solids loading for example.
Single-stage treatment plant for

fuel oil with separator incl.
unitrol system
1
10
2
3
7
15
11
8
12
4
14
9
13
1 Regulating valve
6 Steam trap
2 Strainer
3 Steam
8 Feed pump
4 Pre-heater
9 Strainer
14 Solids discharge
5 Condensate
10 Operating water
21
Plant Concepts for Efficient Operation

Lube oil treatment
GEA Westfalia Separator lifecyclebenefit
Centrifugal separation is the most common method
During application lube oils are exposed to
of lube oil treatment. The separator is located in a
continuous contamination. Foreign matter such as
by-pass loop within the lube oil treatment system.
abrasives, dust, condensate and decomposition products

deposit in the lube oil sump. Furthermore, acids
contained in the oil and foreign matter from catalysts
can lead to premature aging.
In case of diesel engines, particularly trunk piston
engines, combustion residue and unused fuel find
their way into the crankcase compartment, especially
with partial load operation. Sulphurous residues
and cleavage products of the fuel condensate form
acid water with the water vapour produced during
combustion in the cylinder. All this culminates in
damage of bearings, pistons and cylinders.
Schematic illustration of a lube oil treatment

plant with manual cleaning separator
1
4
2
3
1 Feed pump
3 Strainer
4 Pre-heater

22
Process Overview
Self-cleaning mineral oil centrifuges are mainly used

for the purification and dewatering of lube oils,
especially if there is a requirement for 24-hour
unattended operation. Lube oil cleaning reduces
wear and prolongs the life of the lube oil.
The whole range of centrifuges is available for efficient
and reliable treatment of lube oil.
All fuel and lube oil treatment centrifuges from
GEA Westfalia Separator Group have identical design
features allowing the use of common components.
This simplifies store management and maintenance
immensely.
Schematic illustration
of a lube oil treatment
plant with self-cleaning
separator
7
2
3
8
4
9
10
1 Feed pump
11

3 Strainer
4 Pre-heater
5 Operating water
7 Regulating valve
8 Steam
12
9 Condensate
10 Steam trap
13
13 Solids discharge
23
System Concepts for the Future

Sludge treatment
Save natural resources
The concentrated sludge is discharged intermittently
The trend towards burning higher viscosity and
via the sludge transfer unit into a heated sedimentation
higher density fuel oils, together with an increasingly
tank where final concentration takes place. Excess
common usage of residuals, means that the amount
water and oil is allowed to overflow back to the
of sludge being created from both, fuel and lube oil
sludge tank. The concentrated sludge is pumped from
systems, is increasing.
the unit automatically by a solids discharge pump

controlled by a level switch.
The sludge is pumped from the sludge tank by an

eccentric screw pump and is fed via a heater to the
A microprocessor-based control cabinet supervises
centrifugal separator. The sludge components of
and controls the complete concentration process.
water, oil and solids are separated by centrifugal force.

The recovered oil and water is discharged under pressure
by centripetal pumps.
1
9
18
10
2
11
17
12
13
14
16
8
15
1 Regulating valve
7 Feed pump
13 Sludge concentration unit
2 Steam
8 Filter
14 Oily water
3 Pre-heater
9 Operating water
15 Concentrated sludge
4 Condensate
16 Sludge transfer unit
5 Steam trap
11 Vibration monitoring
17 Centrifugal separator
6 Feed of oil sludge mixture
24
Economical Advantages
Ecological Merits
Approximately 2.5% of a power plants fuel
consumption remains as an unwanted by-product in
the form of an oily water sludge mixture.
With increasing environmental awareness as well as
strict regulations and controls, most operators dispose
of this sludge by incineration or by shoreside
disposal using contract companies. In either case
sludge disposal is becoming an expensive problem for
the operators today.
The GEAWestfalia Separator Group sludge treatment
plant incorporating a specially designed centrifugal
separator is capable of reducing the volume of sludge
for disposal by up to 90%. In addition, fuel oil is
recovered for re-use and recovered lubricating oil can
be used as boiler fuel.
Benefits
Separation results sludge treatment

Portion
120
100
Oil
Water
80
Solids
Saves up to 90% disposal costs

Recovers valuable fuel oil
Unburdens the waste water
60
40
system from oil residues

Protects our sensitive power ecosystem
20
0
Feed
Oil outlet
Water outlet
Sample taken from
Sludge treatment system ESD 18 with

self-cleaning centrifugal separator to
reduce the disposal costs
25
Protect the Environment

Self-Cleaning Centrifugal System
Water is the source of life
in many conventional plants under practical opera-
The treatment of waste water is strictly controlled by
tion conditions anyway. The further we can reduce
national and international laws.
this value, the greater the benefit for our environment. Waste water is a mixture of the following
Waste water may only be discharged after prior
constituents:
de-oiling with specially approved treatment systems.

The maximum oil content must not exceed 15 ppm. The
Cooling water leakages
limit has even been reduced to 10 ppm in some areas.
Fuel and lube oil leaks

Drainages from settling and sludge tanks
Effluent from various cleaning processes
Our water must stay clean

Water is the source of all life on earth. The environment
The product (i.e. oily water without excessive emul-
is the habitat of all life and therefore needs our special
sion) is sucked up from the oily water tank and fed by
protection. Indeed we have a responsibility to future
the feed pump through the filter and pre-heater via
generations who have the same right on a rich nature
the feed valve to the separator. During the start-up or
as we do.
ejection program it is led back into the oily water tank.
15 ppm is too much
The product flows from above into the centre of the
Oily water may only be discharged if the oil content
separator bowl. The heavy water phase is separated
in the effluent is below 15ppm. 15 parts of oil to one
from the finest oil particles and then conveyed under
million parts of water seems small but GEA Westfalia
pressure by a centripetal pump to the discharge.
Separator Group believes this is still too high. Moreover, practice has shown that this value is not attained

system WSD 18
26
The separated impurities accumulated in the sludge

space are discharged into the sludge tank periodically.
The treated water discharge is monitored by an oil
content meter and discharged into the environment.
If the oil content exceeds 15 or 10ppm the water is
recirculated into the oily water tank. If an oil content
of 10 ppm is required, our treatment systems are
generally fitted with an absorption filter that can be
connected to ensure that the required result is
achieved.
6
3
11
9
1
14
15
13
16
2
7
12
8
1 Steam
2 Condensate
9 Emulsion breaker
3 Automatic filter
10 Solids discharge
4 Heater
11 Recovered waste oil
5 Untreated waste
water return
6 Pre-de-oiled waste
water feed
14 Treated waste water return
7 Operating water
16 Oil monitor
10
Centrifugal waste water treatment
with self-cleaning separator in
combination with absorption filter
and emulsion breaker
13 Absorption filter
15 Treated water discharge
27

Manual Cleaning Centrifugal System
Protect the environment

The waste water treatment system will be supplied as
a Compact Unit (CU). The CU consists of four main
components:
minimaXx separator
Pump/Prefilter
Absorption filter
Control unit
All the components are small and lightweight to make
them easy for transporting and fitting into the engine
room. The components are installed on a common base
frame. The modular concept can be incorporated into
an existing system.
28
The clever solution

The waste water treatment system with the
minimaXx separator type WTC was specially
designed for small capacities.
The product (i.e. oily water without excessive emulsion)
is fed by the feed pump into the centre of the separator
bowl. Within the rotating bowl, the product is
separated into heavy and light phase.
The heavy water phase is separated from the finest
oil droplets and dirt particles and then conveyed

under pressure by the centripetal pump to the
discharge. If the oil concentration on the clean
water outlet of the centrifuge exceeds 15 ppm the
water is led through an absorption filter. The lighter
oil phase flows to the centre of the bowl and is
discharged by gravity.
5
8
The separated sludge is collected in the solids holding

space and must be removed by hand.
An intelligent control and monitoring system assures
problem-free, round-the-clock unmanned operation.
It also ensures that only water with an oil content

lower than 15ppm is released into the environment.
A pre-heater is recommended if the waste water contains oils of a higher viscosity.
1 Pre-de-oiled waste water feed
2 Pre-filter
3 Waste oil collection tank
4 Treated waste water return

5 Feed pump
7 Treated water discharge
8 Oil monitor
9 Absorption filter
29
VBUGEA Westfalia Separator

ViscoBoosterUnit: Complete System Between
Service Tank and Engine
Safety first
To be able to ensure a high plant availability and
With the ViscoBoosterUnits, GEA Westfalia
to achieve the high plant capacities, several diesel
Separator Group offers a complete, compatible system
generators are frequently installed in power stations.
for a safe and economic fuel oil treatment from the

service tank to the engine.
We recommend splitting the classical Energy Unit

into a Feeder Unit and, depending on the number
ViscoBoosterUnits are supplied as package systems.
of engines, into several Booster Units.
They are designed for 24-hour unattended operation.

GEA Westfalia Separator Group has developed the right
Efficient operation of power station diesel engines
systems for this task.
requires optimum fuel supply. This key condition is

accomplished by the ViscoBoosterUnits developed by
GEA Westfalia Separator Group for fuel conditioning.
This unit consists of a treatment system that meets the
Benefits
fuel requirements between the clean oil tank and injection

system for the diesel engine in terms of the required
injection viscosity and temperature. Supply and booster
Easy adjustment to the engines in

operation
Higher availability of the complete
pumps are provided for a stable system pressure.
installation
The modules are designed for the different engines as
Simple switch-over to
well as to the required injection viscosity (approx.
HFO/MDO for each engine
1024cSt) and corresponding temperature (approx.
Easy adjustment if the system is

upgraded later
135150C).
30
Features
Compact, robust design
Good operability
Automatic viscosity control
Automated control system via control
cabinet with redundant power supply
Automatic, compressed-air controlled
filter system for particle separation
Low weight
VBU (divided module)
Easy installation
Low maintenance costs
12
15
13
7
3
17
21
4
22
10
18
14
19
5
2
11
20
16
1 HFO
8 Fuel from engine
15 Regulating valve
2 MDO
9 Automatic backflushing filter
16 Steam trap
3 Feeder pump
10 Flow-meter
17 Steam or thermal oil
4 Strainer
11 Mixing/Degassing tank
18 Pre-heater
5 Stand-by
12 Degassing valve
19 Stand-by
6 Pressure control valve
13 Booster pump
20 Condensate or thermal oil
7 Fuel to day tank
14 Stand-by
21 Viscosity sensor
22 Fuel to engine
31
VBU for power plant

application
Automatic Process Control

More Safety, More Comfort
Control units
The E40 control unit is specifically designed for

the eagleclass. Even the most complex separator and
system applications are controlled with precision.
Touch display with

backlighting and
4 lines
Easy handling by
Micro Memory Card
which stores setting
and history data for
D10 and E40.
Keys F1 F4
Soft keypad, screen
dependent
Status LEDs
Keys 1 0
Function keypad with
fixed allocation
D10 with
text display
The E40 control unit performs process and control
port. Sm@rt Client allows remote servicing to be
functions over and above those of the D10. To
effected quickly and simply. The machine can be
facilitate understanding, operating states, current
operated and observed from any workstation within
process values, faults and changes in system status
the customers network.
are shown by a change in color in the color display.

Machine or system-specific display screens with
Program control
assigned touch keys reduce the possibility of
The control unit controls the program automatically
operating faults even further. MMC cards function as
as well as monitoring the separator completely. In
program memory; the lifetime data of the systems
addition to all the electrical components on the sepa-
can be read out by technical staff for interval or
rator itself, it is also possible to incorporate in the
preventive maintenance purposes.
control and monitoring system the peripherals

required for a customers specific application.
As an option, the control unit can be patched into the

worldwide web using the Sm@rt Client server
function of the panel and the integrated Ethernet
32

Process Control for Every Requirement
1 Motorstarter box
Motorstarter separator
Motorstarter feed pump
2 OMB 220

Overflow monitoring box
Water seal broken alarm

3 Control unit MC-1
Flow monitoring FAH
4 Control unit CC-1

Flow monitoring FAH
Temperature monitoring TAL / TAH
Preheater interlocking
5 Control unit CD-1
Control and monitoring system for

self-cleaning minimaXx separator.
Flow monitoring FAH
Flow monitoring FAL
Clean oil outlet
Temperature monitoring TAL/TAH
Preheater interlocking
Sludge pump control
D10
33
Energy Compact UnitsSolutions for

the Modern Power Plant
Flexible systems
GEA Westfalia Separator Groups design engineers

have integrated flexibility into all their products.
Single-, Double- and Triple-Energy Compact Units
(ECU) with optimum layout to meet power plant
requirements are available as standard modules.
ECU 2
ECU 1
ECU 3
34
The Economical
Solution
Customer benefits
All systems:
Require small installation costs
Are installed, piped and electrically wired,
Are of very compact design, small volume and
ready for operation on rigid,

stable foundation frames
Are completely checked and tested
weight (less transportation costs)

Can be started up immediately
Are very easy to operate
35
Your Powerful Partner for Complete Systems

Various additional systems and equipment
GEA Westfalia Separator Group prov ides various

systems tailor-made to customers needs.
Modern module design ready for installation.
System intergration into the power plant concept.
Engineering and total system design. All available
from GEA Westfalia Separator Group.
Module supply
Heat recovery module
Fuel oil unloading module

Fuel oil transfer module
Heat recovery module
Desalting module for fuel oil
Additive dosing module
Water booster module
Air compressor module
Container enclosure for complete modules
Desalting module for fuel oil washing
Fuel oil unloading module
Container enclosure for complete modules

36
Water booster module
Additive dosing module
Air compressor module
Fuel oil transfer module

37
PHEPlate Heat Exchanger

Process cooling systems
PHEs are used for cooling purposes, e.g. mainly for
Features
central, lube oil, jacket water circuits, as well as for

High heat transmission coefficient
auxiliaries, charge air, etc.
Optimised heat transfer surfaces

A wide range of flexible plate configurations are
Compact design
offered to cover all heat exchange applications. Suitable
Low life cycle costs
materials like titanium, different grades of stainless
Simple inspection and maintenance
steel, etc. are available.
Low liquid content

Glued and glueless gaskets
38
14
13
2
3
7
12
9
11
10
1 From main engine
5 To main engine
9 Lube oil cooler
13 HTcentral cooler
2 To main engine
6 Circulation pump
10 Cooling water pump
14 Cooling water
3 Circulation pump
7 Auxiliaries
11 Cooling water
4 From main engine
8 Charge air cooler
12 LTcentral cooler
39
FWG Fresh Water Generator

Independent generation of fresh water by single

stage evaporation technology.
Sea water
Jacket water
Fresh water
generator
Sea water is fed through the condenser, where it
Fresh water
absorbs the latent heat of the condensing vapour.

Some sea water is used as feed water for the evaporator
whilst the remaining brine and non-condensible
Fresh water
Process overview
gases are discharged using a combined ejector. In

the evaporator the sea water is heated up to the
saturation temperature corresponding to the
vacuum maintained by the ejector, and part of it
is evaporated.
it is either led to the distillate tank or, if the maximum
The evaporator generally utilizes the waste heat from
allowable residual salt content is exceeded, back to
the main diesel engine jacket water, however, other
the evaporator.
heating media may also be used (e.g. steam, thermal oil).

All parts in contact with sea water are made of
The vapour produced passes through the demister
corrosion-resistant materials (CuNi, stainless steel).
located in the upper casing to remove trapped droplets
The plates are made of titanium.
of water and is led to the condenser. The distillate

is drawn from the condenser by the distillate pump
On request GEA Westfalia Separator Group can also
and discharged through the salinity measuring unit.
supply Multi Flash Water Generators in a range from
Depending on the residual salt content of the distillate,
100 3000 t/d.
40
Single Stage Evaporating System
Benefits
Compact
Low maintenance costs
Easy operating, fully automatically controlled
Integrated anti-scaling system
Reliable
Corrosion resistant materials
Low weight
High performance
Thermal oil/hot water heated
11
8
12
9
2
13
10
3
16
15
7
14
1 Heat exchanger
7 Condensate
13 Feed water
2 Jacket water
8 Sea water
14 Brine
3 Circulation pump
9 Distillate
15 Brine
4 Steam heated
10 Heating water
16 Demister
5 Steam
11 Jacket water heated
6 Steam jet liquid pump
12 Circulation pump
41
serv&care Proactive Service for Optimum

Reliability on Board
The proactive, risk-free services of serv&care optimize operating
reliability and permanent availability of the drive systems.
Safety first: this is precisely what the service concept
Training provided on site or in the modern training
serv&care stands for.
centre of GEA Westfalia Separator Group ensures that

the plant operators employees receive training in the
Shipowners not only benefit from traditional
proper handling of the high-tech installations. This
services such as inspection, maintenance, original
provides additional safety.
spare parts and repair work provided by the original

manufacturer; they also benefit from proactive
Authorized workshops worldwide
solutions which avoid risk, e.g. online and offline
And if problems occasionally occur or if a spare part
monitoring with GEA Westfalia Separator wewatch.
is required at short notice, the specialists are able
These preventive services are the best pre-condition
to attend to the ships quickly. This is ensured by a
for a smooth operation.
global network with more than 50 sales and service

companies. Authorized workshops are able to service
Enhanced process efficiency also follows from

maximum operating reliability and machine
availability. Accompanying modernization or
upgrading to state-of-the-art technology also offer
the option of boosting performance as required.
42
every location in the world at short notice.
serv care
serv&care accordingly makes for maximum operating
In addition to traditional services

such as maintenance or repair,
serv&care also provides solutions
which avoid risk and with which
the installation availability can be
proactively assured.
reliability, machine availability, process efficiency

and budget security. And these benefits are
provided throughout the entire life cycle of the
entire installation.
Service from the original manufacturer:
Service engineers quickly on site
Extensive service network
Risk avoidance through service provided
by the original manufacturer
Proactive solutions
Upgrading to boost performance
Crew training
43
Excellence Passion Integrity Responsibility GEA-versity
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX Europe 600 Index.
GEA Mechanical Equipment
GEA Westfalia Separator Group GmbH
Werner-Habig-Strae 1, 59302 Oelde, Germany

Phone: +49 2522 77-0, Fax: +49 2522 77-1778
www.gea.com
The information contained in this brochure merely serves as a non-binding description of our products and is without guarantee. Binding information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete
inquiries. Printed on chlorine-free bleached paper Printed in Germany Subject to modification Westfalia, Westfalia Separator, lifecyclebenefit, minimaXx and wewatch are registered trademarks of GEA Mechanical Equipment GmbH.
B_EN-12-10-0002 EN
We live our values.

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Energy System Technology

High performance equipment for

engineering for a better world

GEA Mechanical Equipment

Your Powerful Partner

Centrifugal separators have been an essential part

Waste water treatment

2 Your Powerful Partner

26 Protect the EnvironmentSelf-Cleaning

More quality in power stations

28 GEA Westfalia Separator minimaXx

4 Power Station System Solutions

Manual Cleaning Centrifugal System

Systems overview for diesel engine power plants

Fuel oil conditioning system

6 High Performance Equipment for Diesel Engine

30 VBU GEA Westfalia Separator

Centrifugal systems in power stations

Service Tank and Engine

10 Double Centripetal Pump

Control More Safety, More Comfort

12 GEA Westfalia Separator unitrol

33 GEA Westfalia Separator minimaXx

SystemWMS/SMS in Single Stage

Process Control for Every Requirement

GEA Westfalia Separator minimaXx

14 Manual Cleaning Separators

34 Energy Compact Units

Solutions for the Modern Power Plant

Diesel oil treatment

Various additional systems and equipment

36 Your Powerful Partner for Complete Systems

Crude oil treatment

38 PHE Plate Heat Exchanger

18 Plant Concepts with a System

Water desalination system

Heavy fuel oil treatment

41 Single Stage Evaporating System

20 Plant Concepts with a System

Service that counts

Lube oil treatment

Proactive Service for Optimum Reliability

22 Plant Concepts for Efficient Operation

Power Station System Solutions

The power station industry often uses diesel

engines that burn heavy fuel oil, crude oil or diesel

Normally servicing is necessary only after 8000 to

oil. By supplying separ ation systems specifically

16,000 operating hours. Surveillance-free operation

designed for continuous operation under roughest

reduces personnel costs tremendously.

conditions, GEA Westfalia Separator Group provides

The accumulated oil sludge can be processed directly

these engines while taking into consideration the high

in the power station, thereby reducing the disposal

costs considerably. All separation systems are available

Self-cleaning separators with GEA Westfalia

available as compact units in combination with

Separator unitrol systems automatically monitor the

components such as GEA Westfalia Separator

water level in the oil and the separation of the solid

ViscoBoosterUnits (VBU) or Plate Heat Exchangers

material round the clock. As a result, optimum