Instruction Manual: Mineral Oil Centrifuge With Self-Cleaning Bowl OSE 5-91-037
Instruction Manual: Mineral Oil Centrifuge With Self-Cleaning Bowl OSE 5-91-037
Instruction Manual: Mineral Oil Centrifuge With Self-Cleaning Bowl OSE 5-91-037
No. 2066-9001-200
Edition 0410
The authors are always grateful for comments and suggestions for improving
the documentation. They can be addressed to:
Type S/N:
Year of manufacture
Heavy
Solids kg/dm3
liquid kg/dm3
Note: This symbol is not a safety precaution but rather a reference to infor-
mation which help to better understand the separator or plant compo-
nents and the processes.
Carry out safety checks on the separator,
as described in chapter "Safety precautions" in this manual
Liability for the function of the machine passes to the owner.
Liability for the function of the machine passes unconditionally to the
owner or operator irrespective of existing warranty periods in so far as
the machine is improperly maintained or serviced by persons other than
GEA Westfalia Separator service personnel or if the machine is not
applied in accordance with the intended use.
GEA Westfalia Separator shall not be liable for damage which occurs
as a result of non-observance of the above. Warranty and liability con-
ditions in the Conditions of Sale and Delivery of GEA Westfalia Sepa-
rator are not extended by the above.
1 Safety precautions 9
1.1 Correct usage ........................................................................................ 10
1.2 Non-compliance with the intended use .................................................. 11
1.3 Safety markings ..................................................................................... 12
1.3.1 Safety markings and their meaning ....................................................... 13
1.4 Basic operating principles ...................................................................... 17
1.5 Operations on the separator .................................................................. 18
1.5.1 Demands on the operating and maintenance personnel ....................... 18
1.5.2 Spare part requirements ........................................................................ 19
1.5.3 Assembly ............................................................................................... 19
1.5.4 Electrical installation .............................................................................. 22
1.5.5 Before start-up ....................................................................................... 23
1.5.6 Start-up .................................................................................................. 25
1.5.7 Shut-down and “Emergency-Off" ........................................................... 27
1.5.8 Voltage cutoff during operation .............................................................. 28
1.5.9 Maintenance and repair ......................................................................... 29
1.6 Corrosion ............................................................................................... 33
1.7 Erosion ................................................................................................... 34
1.8 The health hazards involved when handling heavy oils and lube oils ... 36
1.8.1 Code of practice and personal protective measures ............................. 36
2 Machine description 37
2.1 Standard dimensioned drawing of the separator ................................... 38
2.2 Section through separator ..................................................................... 40
2.3 General .................................................................................................. 41
2.4 OSE ...-91-... .......................................................................................... 41
2.5 Main components of the separator ........................................................ 44
2.5.1 Centripetal pump ................................................................................... 45
2.5.2 Bowl ....................................................................................................... 46
2.5.3 Bowl hydraulics ...................................................................................... 47
2.5.4 Drive ....................................................................................................... 50
2.5.5 Solenoid valve block .............................................................................. 51
2.6 Regulating ring ....................................................................................... 55
2.6.1 Determination by table ........................................................................... 55
2.6.2 Determination by experiment ................................................................. 56
2.7 Supervisory equipment .......................................................................... 57
2.7.1 Pressure transmitter .............................................................................. 57
2.7.2 Vibration monitoring (Option) ................................................................. 59
2.7.3 Speed monitoring ................................................................................... 60
2.8 Product feed line and product discharge line ........................................ 61
2.8.1 Throughput monitoring (product feed line A) ......................................... 61
2.8.2 Determining the throughput rate (product feed line A) .......................... 62
2.8.3 Pressure monitoring (product discharge line B) .................................... 63
2.9 Technical data ....................................................................................... 64
3 Operation 67
3.1 Technical information ............................................................................. 68
3.1.1 Notes on separation ............................................................................... 68
3.1.2 General information on bowl ejection .................................................... 68
1 Safety precautions
Any operating mode deviating from this is not intended use and can result
in severe damage to property and persons!
Fig. 2
Fig. 5
Fig. 6
Note:
This adhesive plate is only used for
frequency converter operation.
Fig. 7
Note:
This adhesive plate is only used for hot
operation.
Fig. 8
Fig. 9
CAUTION:
The parts marked in this way can carry voltage even when the main
switch is off!
CAUTION:
The circuits marked in this way can
carry voltage even when the main
switch is off!
Fig. 10 Example 1
Fig. 11 Example 2
No te :
Orange coloured leads are fitted as standard at Westfalia Separator.
Different colour leads can be fitted if requested by the customer!
Fig. 12
Fig. 13
Under the influence of the centrifugal forces, separation of the liquid mixture
and/or ejection of the solids particles takes place most rapidly.
The specifically heavier components are displaced to the bowl periphery,
whereas the specifically lighter components are displaced towards the centre of
the bowl.
The high centrifugal force is produced by very high bowl speeds. On the one
hand, high bowl speeds signify high efficiency, while on the other hand, they
signify high material stressing of the separator.
Fig. 14
Assembly
Electrical installation
Before start-up
Start-up
Shut-down
Maintenance and repair
CAUTION!
Operating, maintenance or repair work by unqualified or unauthorized
personnel can lead to operating, assembly and handling errors and severe
damage to persons and property.
For operation, maintenance and repair work, personnel may only be deployed
who
have reached a minimum age of 18 years.
are demonstrably familiar with the state-of-the-art through briefings and train-
ing.
are adequately qualified for performing the work and checking it.
Electrical work may only be carried out by an authorized electrician!
1.5.3 Assembly
Fig. 16
Fig. 17
CAUTION:
Some bowl parts may be pre-
assembled and balanced only by
specialists from Westfalia Separa-
tor or in workshops authorized by
Westfalia Separator.
Unqualified balancing can lead to
dangerous operating states (vi-
brations) and destruction of the
separator with danger to life.
Fig. 18
To avoid unbalance, when replacing
some bowl parts like
– Lock ring
– Bowl top
– Distributor
– Bowl bottom
– Water chamber bottom
Westfalia Separator must be con-
sulted.
These parts
– are marked with a footnote in the
separator manual (see section
“Bowl”).
Fig. 19
– are marked in the column “ETS” of
the parts list with a 3 or 4.
Fig. 21
Fig. 22
CAUTION:
A loose lock ring can endanger life!
Fig. 23
CAUTION:
A loose spindle screw can endanger
life!
Fig. 24
CAUTION:
A loose lock ring or cover can en-
danger life!
Fig. 25
Fig. 26
Fig. 27
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
1.5.6 Start-up
Fig. 35
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Fig. 40
Fig. 41
Fig. 42
Fig. 43
Fig. 44
Fig. 45
Maintenance and repair work may only be carried out to the extent described in
this instruction manual.
Maintenance and repair work not described in this manual may only be
carried out by the manufacturer or by "repair shops" authorized by the
manufacturer.
We, therefore, recommend in your own interest to have your separator inspect-
ed by our service engineers at regular intervals. These checks help to maintain
the operating safety and avoid unexpected downtime.
Fig. 47
Fig. 48
Fig. 49
Fig. 50
Fig. 51
All load suspension devices have to be checked for completeness and for
possible damage at least once a year.
In addition, when using load suspension devices and hoists, the applicable
legislation and safety rules have to be strictly observed.
Fig. 52
1.6 Corrosion
Corrosion can also affect bowl parts made of stainless steel. This corrosion can
be flat-spread or pit- or crack-shaped and merits special attention.
Corrosion on stainless steel bowl material should be examined thoroughly and
documented.
Flat-spread corrosion can usually be measured (reduction of wall thickness)
Pit- or crack-shaped corrosion cannot be measured without the risk of damage.
At the initial stage pit-shaped corrosion is generally caused by chlorine ions.
Depending on the stressing of the part, pit-shaped corrosion can result in crack-
shaped corrosion.
Fig. 53
Pittings
Pittings which are close together or
form a linear pattern can signify crack
formation beneath the surface.
Such pittings should be investigated by
a materials expert.
Fig. 54
1.7 Erosion
Erosion is caused by solid particles in the process liquid.
These solid particles grind marks into the surfaces with which they come into
contact.
The following factors favour the occurrence of erosion:
The first signs of erosion should be carefully observed and documented. Ero-sion
can deepen rapidly, thereby weakening the bowl material.
Fig. 55
1) the bottom of the distributor, the rising channels and the ribs,
2) the centripetal pump (cavitation),
3) all surfaces in the area of the solids discharge ports,
4) the nozzles.
Fig. 56
1.8 The health hazards involved when handling heavy oils and lube oils
As a result of the deterioration in quality of fuel oils, the danger has arisen that the heavy oils used on
board contain greater amounts of substances injurious to health. These include:
- polycyclic aromatic hydrocarbons,
- lead compounds,
- chemical residues.
An increased amount of polycyclic aromatic hydrocarbons is also present in used lube oils (waste
oils). The health hazards for the engine room staff depend to a large extent
on the concentrations of the dangerous substances,
the ambient air (inhalation of oil vapours/oil mist),
the intensity and duration of the contact with the skin or mucous membrane.
2 Machine description
Centre of gravity
Solids discharge
Product discharge
Product feed
Solids discharge
Water discharge / operating water
discharge
Centre of gravity
Product discharge
Product feed
Product discharge
Product feed
Solids discharge
Terminal box
Water discharge
Operating water discharge
The separator foundation must not have contact with the foundations of other units (e.g.
auxiliary diesel engines, pumps) to avoid damage to roller bearings.
Fig. 59
2.3 General
The machine described in this manual is a high-speed centrifugal separator with
self-cleaning bowl.
"Separation" means the separation of liquid mixtures which consist of two liq-
uids, with simultaneous removal of the solids contained in the liquids.
"Clarification" is the removal of solids from a liquid.
Prerequisite for treatment technology (separation) is that the components of the
product
– can be separated mechanically,
– have different densities and
– do not emulsify.
The bowl is automatically opened and closed for desludging at full bowl speed by
means of a remote controlled solenoid valve (17) in the operating water line. The
opening time of the solenoid valve is up to 3 seconds.
The control and monitoring unit (8) ensures unmanned operation.
Fig. 63
Fig. 64
2.5.2 Bowl
Fig. 65
4 Solids holding space collects the solids separated in the disk stack.
Fig. 66
Fig. 67
After starting the separator the solenoid valve for operating liquid is actuated
with the aid of the control unit, and the bowl is closed as follows:
Fig. 68
The solenoid valve for operating liquid is opened with the aid of the control unit,
and the ejection cycle is triggered as follows:
2.5.4 Drive
Fig. 69
Important!
– The driving effect of new clutch shoes will
improve after several starts.
– Smoking of the centrifugal clutch during the
first few starts is perfectly normal and will dis-
appear after a short time of operation.
– Wear to the clutch shoes depends on the
number of starts and the ejection frequency
(see section 4.3.1).
Fig. 70
Manual override A
1 closed
2 open
Fig. 71
SW = jaw span
Fig. 72
Technical data
ATTENTION:
Note the specifications on the nameplate of the solenoid valve block and
the installation guidelines.
Operating voltage: 24 V DC
Rating 8 W (per solenoid valve)
Coupler socket with built-in electronics,
24 V DC, LED and free-wheeling diode
with fitted cable (1.5 m long)
Pressure Medium 0 to 10 bar
Control range 1 to 6 bar
Pressure setpoint 2 bar
with open operating water solenoid
valve
Temperature: Medium -10 to +80 °C (14 – 176 °F)
The inner diameter of the regulating ring to be selected can be determined from
the table or empirically. The general rule of thumb is:
narrow regulating ring for heavy oil
wide regulating ring for light oil.
0,79 – 0,81 76
0,82 – 0,85 73
0,86 – 0,89 70
0,90 – 0,94 68
0,95 – 0,97 64
0,98 – 0,991 62
Important!
If light liquid discharges through the heavy liquid discharge, the next smaller
regulating ring must be fitted.
Effect:
– The discharging clean oil is free of
water.
– The discharging water is free of oil.
Fig. 74
Fig. 75
Effect:
– The discharging clean oil contains
water.
– The discharging water is free of oil.
Fig. 76
Note:
Refer to the circuit diagram in the control cabinet and the manual of the control
system.
Factory settings
(1) The product discharge pressure on the pressure gauge (separator) must be 0.5 to
1 bar above the switching point.
(2) The product discharge pressure on the pressure gauge (separator) must be 0.5 to
1 bar below the switching point.
IMPORTANT:
Pay special attention to order-specific settings (see operating data sheet in
the order documentation)!
Technical data
Voltage 24 V DC
Range 0 – 16 bar
Output signal 4 – 20 mA
Pressure connection G 1/4in outer (O-ring seal)
Tightening torque
Pressure connection max. 25 Nm
Connector plug M 12 x 1; 5-pole
Cable PUR-2 core, 1.5 m
Cable box M 12 x 1; 5-pole
Pin1-, white; Pin4+, black
Enclosure IP 67
Working temperature
-40 to +125 °C (-40 to +257 °F)
Medium temperature
ATTENTION!
Pay attention to the following instructions and plans:
instruction manual of the vibration monitoring system
instruction manual of the control unit
terminal allocation in the terminal diagram of the control cabinet
circuit diagram
Fig. 79
ATTENTION!
Pay attention to the terminal allocation in the terminal diagram of the
refer to the instruction manual of the control unit.
Fig. 80
Flowmeter – Scale: 0 – 10
Inner diameter of orifice
Throughput capacity plate
[l/h] [mm]
300 – 600 4
600 – 1 000 5
1 000 – 1 400 6
1 400 – 1 800 7
1 800 – 2 300 8
2 300 – 3 500 no orifice plate
Procedure:
Bowl
3
Solids holding space (total) 0.5 dm
–1
Speed 12 000 min
– for densities of the product up to
0.991 kg/dm3 (at 15 oC) and (see name-plate)
– for densities of the separated solids up to
1.4 kg/dm3
Speed for higher densities contact the factory
Centripetal pump
Output (depending on medium) 3 000 l/h
Pressure head 1 – 2 bar
Operating water
Qty. min. 1 800 l/h
Pressure (with open valve) 2–3 bar
DO 20 °C (68 °F)
LO 90 °C (194 °F)
LO HD 95 °C (203 °F)
Motor
Power rating 50 Hz 4 kW
60 Hz 4.6 kW
Speed 50 Hz 3 000 RPM
60 Hz 3 600 RPM
Design IM V1
Enclosure IP 55
Drive 50/60 Hz
Oil filling approx. 1 l
Oil quality, see section 4.3.3
Weights
Separator (with motor, without bowl) 110 kg
Bowl 30 kg
Motor 47 kg
Note
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Note
3 Operation
Procedure:
Select the desired operating mode on the control unit.
Set the separating time on the control unit.
Start the separator (see 3.2).
Displacement
When separating, the loss of feed liquid unavoidable during ejection can be
reduced to a minimum by displacing the feed liquid with water before sludge
ejection takes place (especially important when processing valuable feed liq-
uid).
The duration of displacement water supply is given in the timer overview (see
control unit manual).
If the displacement time is too long, water will discharge through the light liq-
uid outlet.
If the displacement time is too short, part of the product remains in the bowl
and is lost during desludging.
Flush ejection
If the solids cant be completely ejected,
– due to an excessively long dwell time in the bowl or
– are stuck too firmly on the wall of the solids holding space due to the solids
properties,
Program control
"Displacement", "ejection" and "flush ejections" at precisely defined intervals
are best carried out with the automatic control unit.
The clean oil discharge and water discharge can be monitored.
Faults can be signalled visually or audibly.
Note:
Safety precautions in chapter 1.
Instruction manual of the corresponding control unit.
Instructions “Settings and malfunctions”
Instruction manuals for other auxiliary equipment
Process-related deviations are possible
(refer to the order-specific operating data sheet!)
ATTENTION!
In order not to endanger the operating safety of the separator, keep
to the recommended maintenance intervals.
If the bowl has been out of operation for longer than 6 months (e.g. due
to a long standstill period or storage),
check all bowl parts as specified in the maintenance schedule (table
“Maintenance after 4000 operating hours or after 6 months at the latest”).
Replace if necessary.
If the separator has been out of operation for longer than 12 months (e.g.
due to a long standstill period or storage),
check all separator parts in accordance with the maintenance schedule
(table “Maintenance after 8000 operating hours or after 1 year at the lat-
est).
Replace if necessary.
Ensure that
the sight glass in the frame for observing the drive belt is clean.
the sight glass in the frame for observing the oil level is clean.
the drive chamber is filled with oil in accordance with section 4.3.3.
the bowl height is correct (see section 4.7.1).
the bowl can be rotated by hand.
the machine is correctly assembled.
– Tighten the bowl top securely (left-hand thread).
– Tighten the centripetal pump lock ring securely (left-hand thread).
the hood is correctly mounted (see 4.5).
the handle connection piece is tightly bolted to the centripetal pump (see 4.5).
the hoses and hose pipes are undamaged and connected (see section 4.3.2).
the feed and discharge lines are connected (see 4.5).
the supervisory equipment is complete, mechanically and electrically func-
tional.
Important!
Check the remaining plant components such as hose pipes, sight glasses for
signs of aging and mechanical damage.
Damaged plant components must be replaced immediately by new parts.
Ensure that
the sight glass in the frame for observing the drive belt is clean.
the sight glass in the frame for observing the oil level is clean.
the drive chamber is filled with oil in accordance with section 4.3.3.
the machine is correctly assembled.
– Tighten the bowl top securely (left-hand thread).
– Tighten the centripetal pump lock ring securely (left-hand thread).
the hood is correctly mounted (see 4.5).
the handle connection piece is tightly bolted to the centripetal pump (see 4.5).
the hoses and hose pipes are undamaged and connected (see section 4.3.2).
the feed and discharge lines are connected (see 4.5).
the supervisory equipment is complete, mechanically and electrically func-
tional.
the product and supply lines are ready-for-operation.
– Pay attention to the air and water pressures (see order-specific operating
data sheet).
the product heating devices are ready for operation (option).
– Pay attention to the volumes, pressure and temperature (see order-specific
operating data sheet).
the plant components such as valves, water pressure reducer, compressed
air control unit etc. are operational.
the motor is correctly mounted.
Important!
Check the remaining plant components such as hose pipes, sight glasses for
signs of aging and mechanical damage.
Damaged plant components must be replaced immediately by new parts.
ATTENTION! Before the first start-up – after maintenance and repair work
on the separator -
Check the direction of rotation of the bowl.
The bowl must rotate in clockwise direction when looked at from above.
Fig. 82
ATTENTION! Before the first start-up – after maintenance and repair work
on the product feed pump -
Check the direction of rotation of the product feed pump.
The direction of rotation of the product feed pump is correct when the fan
wheel of the pump motor rotates clockwise.
Put the preheater in operation (option).
P re -c o n d itio n s :
– Steam or thermal oil feed and discharge valves are open!
– Electric preheater is switched on!
Open the product discharge valve in the product discharge line (option).
1 Shut-off flap
2 Solids tank
3 Solids discharge
Fig. 83
ATTENTION!
Check the discharges for solids and dirty water; there must be no oil flow
during the separating process!
Inspection
We, therefore, recommend in your own interest to have your separator in-
spected by our service engineers once a year. These checks help to
– maintain the operating safety of the machine and
– avoid unscheduled downtime.
Im p o rta n t!
Regularly check plant components such as hose pipes, sight glasses for
signs of aging and mechanical damage.
Damaged plant components must be replaced immediately by new parts.
V’ 0.375
t= ——— • 60 • 100 = —————— • 6 000 = 45 min = 0.75 h
V • p 1 000 • 0.05
(1)
Solids content and throughput capacity must be determined on site or taken from
the order specification.
Automatic operation
Automatic operation
ATTENTION!
If the control unit or the control voltage 24 VDC fails, the automatic post-run
phase of the product feed pump is disabled.
The product feed pump may never be switched off to the steam shut-off valve
without a delay time. The pre-heater could get damaged!
All heaters (e.g. steam-fired, thermal oil, electric heaters) must be manually
shut down.
Manual shut-down of the product feed pump must be carried out delayed.
Close the product feed valve in the suction side of the product feed pump (op-
tion).
Switch the separator motor off.
Close the discharges.
Close the supply lines such as heating steam, water, compressed air lines
with hand valves.
Fig. 84
ATTENTION!
Only after standstill of the bowl,
Close the shut-off flap in the solids
discharge (option).
1 Shut-off flap
2 Solids tank
3 Solids discharge
Fig. 85
Fig. 86
Fig. 87 Example 1
“Emergency-Off”-switch (yellow-
red) and main switch (grey-black)
Actuate the “Emergency-Off switch.
– The complete drives of the control
unit are de-energised.
– The separator is shut down in a
controlled manner with two total
ejections.
Note
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Note
The O marks of
the bowl bottom
and the bowl top
must be aligned.
Bowl hydraulics
Bowl hydraulic system is soiled. Remove hood and
or dismantle and clean the bowl (see
section 4.4.1 and 4.4.2).
Thoroughly clean all bores.
Gaskets and piston guide ring are Replace all sealing elements.
damaged or Use set of spare parts "bowl/hood“
(see list of spare parts).
Important: Time-consuming instal-
lation!
Change polyamide gasket 3 only
when it is damaged (see section
4.4.9).
Sealing rim of sliding piston 19 is Lightly remachine the sealing sur-
damaged. face of the sliding piston – max. 1
mm! – see section 4.4.10) or
send in the sliding piston for repair.
Bowl hydraulics
Bowl hydraulic system is soiled. Remove hood and
or dismantle and clean the bowl (see
section 4.4.1 and 4.4.2).
Thoroughly clean all bores.
– Thoroughly check outlet bore 17
and clean if necessary.
Gaskets and piston guide ring are Replace all sealing elements.
damaged. Use set of spare parts "bowl/hood“
(see list of spare parts).
Important: Time-consuming instal-
lation!
Change polyamide gasket 3 only
when it is damaged (see section
4.4.9).
Thoroughly check polyamide gasket
3 for proper location in its groove.
Note
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Note
Centre of gravity
Solids discharge
Product discharge
Product feed
Solids discharge
Water discharge / operating water
discharge
Centre of gravity
Product discharge
Product feed
Product discharge
Product feed
Solids discharge
Terminal box
Water discharge
Operating water discharge
The separator foundation must not have contact with the foundations of other units (e.g.
auxiliary diesel engines, pumps) to avoid damage to roller bearings.
Fig. 94
Fig. 95
Fig. 97
Screw in the screw plug 1.
Fig. 98
Fig. 99
4.1.3 Motor
at
50 Hz 60 Hz De- Enclo- 50 Hz 60 Hz
sign sure *
rpm min s kW rpm rpm
IP 55
* WS standard
The separator is driven by a three-phase AC motor via a centrifugal clutch and
the drive belt.
The specified motor ratings are minimum values which are based on the in-
creased starting current. Since the current consumption of the motor drops after
start-up, overloading of the motor during operation is not possible.
The starting time depends on the
– flywheel effect of the bowl,
– number of clutch shoes used,
– condition of the clutch shoes.
The starting current can peak at about 1.8 - 2 times the rated current (see start-
up diagram). This is to be considered when selecting switches, lead-in wires and
fuses.
The motor
– can be started direct online (WS standard) or via a motor control for star-
delta switching (Ex-zone).
Note:
The temperature feelers must be connected to a commercial tripping device.
External voltage higher than 2.5 volts must not be applied to the connection
terminals of the temperature feelers.
When testing for continuity, use an ohmmeter and not a test lamp.
Electrical connection
The terminal board in the terminal box can be connected in star or delta.
Check correct switching of the motor (star or
delta). Refer to the motor instruction manual.
Fig. 102
Fig. 103
IMPORTANT:
In the case of additional electrical components, PTC thermistors or space
heaters, refer to the motor manual.
Shipboard operation
When operating the machine on board of ship, pay attention to the installation
guidelines issued by the respective classification societies.
When using ship wiring cables, cable entry must be by means of marine-type
glands.
provided that:
– The drive chamber is filled with oil
roughly up to the lower edge of the
charge hole.
Switch on motor.
Fig. 104
The bowl must rotate in clockwise direction when looked at from above.
Fig. 105
CAUTION!
Operate the separator with fre-
quency converter, speed monitor-
ing device and hardware-
controlled speed shut-off device.
Do not under any circumstances
manipulate the frequency con-
verter to exceed the permissible
bowl speed (see nameplate)!
Check from time to time that
– the bowl speed (see nameplate)
and
Fig. 107 – motor frequency (see nameplate
and frequency converter display!)
coincide with the separator speed.
Fig. 108
Flowmeter 3
Remove the plug from the corresponding hole of 3/2-way valve 4.
Secure the thread of flowmeter 3 with Loctite 245.
Install flowmeter 3 into 3/2-way valve 4.
Fig. 109
Fig. 110
Note
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Note
ATTENTION!
The following maintenance intervals are recommendations which apply only for normal operating
conditions.
Negative operating conditions (e.g. low-grade fuel, excessively high temperature, strong vibrations,
frequent starting and stopping of the separator etc.) can necessitate shorter maintenance intervals.
Fig. 111 Set of spare parts „bowl/hood“ (operation: 1 year or 8,000 hours)
Date of commissioning:
(to be filled in by user)
Fig. 112 Set of spare parts „bowl/hood“ (operation: 1 year or 8,000 hours)
Fig. 113 Set of spare parts „bowl/hood“ (operation: 1 year or 8,000 hours)
Maintenance work
– After 48,000 operating hours – after 6 years at the latest
Protective hose 1
Fig. 114
4.3.3 Lubrication
The spindle bearings are splash-lubricated from a central oil bath.
MOTOR BEARINGS
For re-greasing the motor bearings, refer to the instructions of the motor manu-
facturer.
The viscosity class SAE 30 covers a larger viscosity range than specified here.
However, only oils with the viscosity range specified here may be used.
OIL QUANTITY
Filling in oil
Fill the drive with oil before commis-
sioning the separator.
Unscrew the screw plug and
fill in oil through the charge hole.
Filling quantity: approx. 1 litres
Fig. 115
Oil level
OIL CHECK
OIL CHANGE
Note
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Note
CLP
100
Manufac-
Viscosity
Designation at 40 °C (104 °F)
Lubricating oil table turer mm2/s (cSt)
for separators in onshore and shipboard opera- BLASIA 100
tion RADULA 100 100
DIESEL GAMMA 30
Separator Lube oil
m
-
D
N
S
b
o
y
g
n
a
o
n
a
n
g
5
1
5
0
2
s
c
c
(
)
l
I
i
ATLANTA MARINE 30
Viscosity 105
lling
Oilfi
DISOLA M 3015
MONTANOL HK 100 100
Kinematic
Type viscosity ENERGOL GR-XP 100 100
at 40 °C ENERGOL DL-MP 30 114
(104 °F)
4.3.6 Comments on table of lubricating oils for separators from Westfalia Separator
Faultless functioning of separators very much depends on the proper type of lubricating oil used, since a
high grade oil, selected to meet all service requirements, will minimize the wear, thus extending the ser-
vice life and increasing the operating safety.
For the lubrication of our separators we recommend to use the oils specified by us since continuous qual-
ity checks are performed by Westfalia Separator. Oils proposed from some firms are not subjected to these
tests.
Therefore, Westfalia Separator cannot give a performance guarantee for those oils.
Be sure to select only high grade solvent refined products.
The specified oil types meet the requirements according to DIN. Under unfavourable operating condi-tions,
e.g. high temperatures, the quality of the oils may be insufficient so that more efficient oils, e.g. synthetic
oils, must be used. If necessary, consult Westfalia Separator.
For the different separator types and oil types the viscosity ranges are specified in the table of lubricating
oils.
The operating temperature of the separator exceeds normally 80 oC (176 oF). At those temperatures some
oils age quickly, so that they have to be changed prematurely.
Be sure not to use lubricating oils with viscosities lower than those specified in the table. Due to the pos-
sibility of the oil film breaking down, oil of too low a viscosity will give insufficient lubrication, resulting in
increased wear. However, oils with a slightly higher viscosity than specified may be used.
Bear in mind that the viscosity groups SAE 30, 40 and 50 (SAE = Society of Automotive Engineers) cov-
er larger viscosity ranges and be sure to select lubricating oils with viscosities not lower than the mini-mum
values of the viscosity ranges restricted for the different separator types.
4.4 Bowl
(1)
470 Bowl bottom
480 Gasket
490 Washer
500 Hex head screw M 8 x 12
510 Gasket
520 Gasket
530 Annular piston
540 Gasket
550 Closing chamber bottom
560 Piston guide ring
570 Gasket
580 Gasket
590 Gasket
600 Sliding piston
610 Gasket
620 Distributor base
630 Gasket
640 Gasket
650 Gasket
(1)
660 Bowl top
670 Disk stack
680 Blind disk
690 Threaded pin ISO 4026 - M 10 x 10 -1.4571
700 Gasket
710 Threaded ring
720 Gasket
730 Gasket
740 Gasket
750 Lock ring
760 Centripetal pump chamber
cover
770 Regulating ring
780 Gasket
790 Centripetal pump chamber
cover
801 Centripetal pump
802 Sensing liquid pump
830 Gasket
840 Gasket
Fig. 119
CAUTION:
Certain bowl parts (see sect. 4.4)
may be pre-assembled and bal-
anced only by specialists from
Westfalia Separator or in work-
shops authorized by Westfalia
Separator.
Unqualified balancing can lead to
dangerous operating states (vi-
brations) and destruction of the
separator with danger to life.
Fig. 120
Fig. 121
Fig. 122
Fig. 123
If necessary:
Disconnect product feed line 1 and
product discharge line 2:
– Unscrew coupling nuts 3.
Note:
The connectors 4 must be glued in
with Loctite 275.
Fig. 124
Fig. 125
Fig. 127
Fig. 128
Fig. 129
Fig. 131
Fig. 132
Required special
tool – ring spanner 1
Fig. 133
Important:
The O-marks of the bowl top and of
the bowl bottom must be visible.
– Do NOT hide them under ring
spanner 1!
The arrow and the "open" mark must
show upwards.
Bolt ring spanner 1 to the bowl top.
Screw in two hex head screws 2 of
the ring spanner and tighten firmly.
Fig. 134
Fig. 136
Fig. 137
Fig. 138
Fig. 139
Fig. 141
Fig. 142
Fig. 144
Fig. 145
Fig. 146
Fig. 147
Fig. 148
Fig. 149
Fig. 150
Fig. 151
Fig. 153
Fig. 154
If necessary:
Separate annular piston 1 from clos-
ing chamber bottom 2 by tapping with
a mallet – as illustrated.
Take the gaskets out of the annular
piston and closing chamber bottom.
Fig. 155
If necessary:
Remove gaskets 1, 2, 4 and piston
guide ring 3.
Fig. 156
If necessary:
Turn bow bottom through 180o (up-
side down).
Unscrew four hex head screws 1.
Force off disk 2 with the screwdriver
and remove it.
Take out gasket 3.
Fig. 157
Fig. 158
Clean the small holes for the feed and discharge of the operating liquid with
particular care to ensure trouble-free bowl ejections.
Apply a thin coat of grease to the guide surfaces and threads of the bowl
parts after drying (see 4.3.4 Lubrication schedule).
ATTENTION!
Do not use acid or chloric cleaning agents.
Chlorine attacks stainless steel parts.
Dissolve dried scale with citric acid.
Clean the inside of the upper section of the frame from time to
time: To do this:
– Refer to the maintenance schedule (section 4.3.1),
– dismantle the bowl (section 4.4.1).
Fig. 159
4.4.4 Cleaning the strainer and the operating water feeding system
The strainer and the operating water feeding system must be cleaned de-
pending on the quality of the operating water and overall load. See section 4.3.1
Maintenance schedule
Use citric acid in case of furring.
Thoroughly clean the parts with water.
Fig. 160
ATTENTION!
Before assembling the bowl, check to be sure that the guide and contact sur-
faces of the bowl are clean.
Grease the guide surfaces as specified in the lubrication schedule (see 4.3.4).
Some bowl parts are arranged in
fixed positions relative to one anoth-
er.
Locking devices and alignment
marks must be in perfect condition.
IMP ORTANT:
The bowl must otherwise not be op-
erated.
Fig. 161
Fig. 162
Fig. 163
Fig. 164
If necessary:
Turn bow bottom through 180o (up-
side down).
Insert gasket 3 in the bowl bottom.
Screw in the four hex head screws 1
connecting disk 2 with the bowl bot-
tom tight.
Torque: 25 Nm
Turn the bowl bottom through 180o
(fitting position).
Fig. 165
Fit gaskets 1, 2, 4 and piston guide
ring 3 in the grooves of the bowl bot-
tom.
Grease guide surfaces as specified
in the lubrication schedule (see
4.3.4).
Fig. 166
Fig. 167
Fig. 168
Fig. 169
Fig. 170
Fig. 171
Fig. 172
Fig. 173
Fig. 174
Fig. 175
Fig. 176
Fig. 177
Fig. 178
Fig. 179
Fig. 180
Fig. 181
Important:
If threaded pins are screwed into the
bowl top, undo them with a screw-
driver.
The O mark of the bowl top must be
visible.
– Do NOT hide them under ring
Fig. 182
spanner 1!
The arrow and the "open" mark must
show upwards.
Bolt ring spanner 1 to the bowl top.
– Screw in two hex head screws 2 of the ring spanner and tighten firmly.
CAUTION:
A loose bowl top can endanger life!
Fig. 183
Fig. 184
Fig. 185
Fig. 186
Fig. 188
Fig. 189
Fig. 190
Fig. 191
Fig. 192
Fig. 194
CAUTION:
A loose bowl top can endanger life!
Strike the bowl top with a hammer
until the "O" mark is reached (left-
hand thread).
Fig. 195
Screw in two threaded pins using a
screwdriver.
Fig. 196
Fig. 197
Fig. 198
Fig. 199
Fig. 200
Fig. 201
Fig. 202
Fig. 203
Fig. 204
Fig. 205
REMOVAL
ATTENTION: Sensitive bowl part!
– Do NOT damage the bowl top groove
when drilling!
Fig. 207
Fig. 208
Note:
If the polyamide gasket cannot be removed, repeat this procedure.
FITTING
Thoroughly clean and dry the groove.
Heat the gasket in approx. 80 oC (176 °F) water for 5 minutes.
Wipe dry the gasket.
Fit the gasket into the groove of the
bowl top (with the narrow side facing
the bowl top).
Place on a smooth wooden block.
hammer the gasket evenly into the
groove.
Fig. 209
Fig. 210
REMOVAL
Fig. 211
Fig. 212
Note:
If the polyamide gasket can’t be removed, repeat this procedure.
FITTING
Fig. 214
Fig. 215
Fig. 216
Fig. 217
Fig. 218
Fig. 219
Fig. 220
After facing
fit a new polymide gasket B into the
bowl top (see section 4.4.8)!
Fig. 221
Fig. 222
Fig. 223
Fig. 224
Fig. 225
Fig. 227
Fig. 228
Note:
The connectors 4 must be glued in
with Loctite 275.
Fig. 229
4.6 Drive
1 Retaining ring 95 x 3
2 Retaining ring 60 x 2
3 Clutch pulley
4 Grooved ball bearing
5 Spacer bush
6 Grooved ball bearing
7 Retaining ring 95 x 3
8 Clutch driver
9 Clutch shoe
10 Washer 11 x 27 x 4
11 Retaining ring 60 x 2
12 Washer
13 Hex head screw M 10 x 65
14 Drive belt
15 Spindle
16 Hex head screw M 10 x 20
17 Bearing cover
18 Bearing cover
19 Grooved ball bearing
20 Retaining ring 35 x 1,5
21 Ball bearing protection ring
22 Angular contact ball bearing
23 Bearing sleeve
24 Gasket
25 Rubber-metal cushion
26 Pivoting bearing
27 Retaining ring 90 x 3
28 Gasket
29 Bearing cover
30 Hex head screw M 10 x 20
31 Hex head screw M 6 x 16
(This hex head screw is glued in with Loctite
275.)
32 Hex head screw M 12 x 18
(This hex head screw is glued in with Loc-
tite 275.)
33 Washer
34 Cup spring
Fig. 231
Fig. 232
Fig. 233
Fig. 234
ATTENTION!
Pull the drive belt off the clutch pul-
ley (centrifugal clutch) downwards.
Fig. 235
Lift the motor with centrifugal clutch
out of the lower section of frame.
Fig. 236
Fig. 237
Remove spindle cap 1 with fitted
gasket.
Fig. 238
Fig. 239
Fig. 240
Fig. 241
Note:
If the vibration absorber is also pulled out
of the lower section of the frame:
Loosen it from the spindle assembly by
striking the spindle on a wooden base.
Fig. 242
Fig. 243
If necessary:
Undo three hex head screws 1.
remove bearing cover 2 with sealed
hex head screws, disk and cup
springs 3 from the lower part of the
frame.
Fig. 244
If necessary:
Take out gasket 1.
Fig. 245
Spindle assembly
Required tools:
– Pulling device
– Open ended wrench
– Pliers with outer snap jaws
Fig. 246
Fig. 247
Fig. 248
Fig. 249
Fig. 250
Fig. 251
Fig. 252
ATTENTION!
Pull the drive belt off the
clutch pul-ley (centrifugal clutch)
downwards.
Fig. 253
Fig. 254
Fig. 255
Undo retaining ring 1.
Take off disk 2.
Fig. 256
Fig. 257
Fig. 258
Fig. 259
Fig. 261
Fig. 263
Fig. 264
Required tools
– Disk (Ø 86 – 94 mm)
– Wooden block
– Hammer
Fig. 265
If necessary:
Insert gasket 1 in the groove in the
lower section of frame.
Fig. 266
If necessary:
Fig. 267
Fig. 268
Fig. 273
Required tools:
– Disk 2 (Ø 86 – 94 mm)
– Wooden block –
Hammer
Fig. 274
Fig. 275
Fig. 276
Fig. 277
Required tool:
– Disk 1 (Ø 61 – 69 mm)
Fig. 278
Fig. 279
Required tools:
– Wooden block
– Rubber hammer
Fig. 280
Fig. 281
Fig. 282
Required tools:
– ring spanner 2
– Hex head screw 3 (M 10 x 200)
– Hexagon nut 4 (M 10)
Fig. 283
Fig. 284
Fig. 285
Fig. 286
Fig. 287
Insert disk 2.
Fit the retaining ring 1 in the groove
of the clutch driver.
Fig. 288
Fig. 289
ATTENTION:
Remove the grease from the belt
contact surfaces of the spindle and
clutch drum.
Fit the drive belt:
– through upper section of frame
opening 1 and
– through brake housing opening 2
(centrifugal clutch).
Pay attention to correct seating of the
drive belt on clutch pulley and spindle
pulley.
Fig. 290
Fig. 291
Fig. 293
Fig. 294
Note:
Due to the design concept used, the spindle is at an inclined angle relative to
the opposite side of the motor when the drive belt has not been fitted or ten-
sioned (see Fig. 295, pos. 2).
The spindle is pulled into the centric axis when the belt is tensioned (see Fig.
295, pos 1)!
Check
– that the spindle 1 can be turned
easily.
– whether the spindle 3 has been
pulled into the centric axis by
tensioning the drive belt 3 (see
Fig. 198.
Fig. 296
Fig. 298
Fig. 299
Fig. 301
Screw in oil drain screw 1 with fitted
gasket.
Screw in the sight glass 2.
Fill in oil as described in section
4.3.3 and
Screw in plug 3 with gasket.
Fig. 302
CAUTION:
A loose bowl top can endanger life!
Tighten the bowl top firmly.
– The O marks of the bowl bottom
and the bowl top must be aligned.
Fig. 303
Fig. 304
If it does prove necessary to readjust the bowl height, consult the factory.
Fig. 306
Fig. 307
Fig. 308
Checks Section
1. Bowl height 4.7.1
2. Oil level in drive chamber 4.3.3
3. Direction of rotation of the bowl 4.1.4
4. Bowl speed 4.1.5
5. Starting time of bowl / current consumption 4.1.5
6. Running characteristics of the separator 3.8.1
7. Suction line of the product pump (if installed) for leakage
Checks Section
1. Temperature of product
2. Observe discharges for water, solids and oil to see if the 3.3
bowl is operating correctly.
CAUTION!
Risk of injury through rotating separator parts.
Keep a safe distance away from the rotating spindle.
After switching off the separator, wait until the spindle has stopped rotating.
Take off the drive belt.
4.10 Storage
ATTENTION!
Improper and incorrect storage of the separator and control unit can dam-
age or destroy their components.
Note:
Gaskets, hoses and hosepipes, for example, change their physical properties in
unfavourable storage conditions. This can result in a shorter service life. They can
be rendered useless due to excessive hardening, softening, permanent de-
formation, flaking, cracks or other surface damage.
IMPORTANT:
Outdoor exposure is not admissible!
IMPORTANT:
A storage time of more than 12 months of the separator and control unit is only
possible after consulting the manufacturer.
4.10.2 Separator
The following procedure applies
– for storing the separator before commissioning and
– for storing the separator before a prolonged standstill period.
IMPORTANT:
Store the separator with dismantled bowl!
Store the clean, greased bowl in a dry place.
Store the gaskets in a cool, dry, frost-free, dust-free dark room to prevent
them from becoming brittle.
Recommended storage temperature: + 5 to +50 °C (41 - 122 °F)
The separator with dismantled bowl must be stored dry and free from vibra-
tions.
(Vibrations during standstill can cause bearing damage!).
Protect the drive spindle and motor from dust.
Store all other separator parts dry and frost-free.
Note:
If the bowl has been out of operation for longer than 6 months (e.g. due to a
long standstill period or storage),
check all bowl parts as specified in the maintenance schedule (table “Mainte-
nance after 4000 operating hours or after 6 months at the latest”).
Replace if necessary.
If the separator has been out of operation for longer than 12 months (e.g. due
to a long standstill period or storage),
check all separator parts in accordance with the maintenance schedule (table
“Maintenance after 8000 operating hours or after 1 year at the latest).
Replace if necessary.
Procedure:
Drain the slushing oil.
Observe the local regulations on disposal of the slushing oil.
Remove the grease from all unpainted machine parts.
Check gaskets.
Replace damaged, very swollen, hardened or brittle gaskets immediately.
Assemble the bowl (see section 4.4.7).
Check the ball bearings of the spindle and centrifugal clutch (if
applicable). When damaged, replace the ball bearings immediately !
Fit drive belt (see section 4.6.5 or 4.6.7).
When damaged, replace the drive belt immediately !
Assemble the separator correctly.
Fill the drive chamber with the specified lube oil as specified in section 4.3.3.
4.12 Disposal
When the equipment is no more useful or the separator has reached the end of
its service life, the operator is responsible for appropriate, environmentally
friendly disposal of its components and materials such as
– metal,
– caoutchouc and rubber
– plastics,
– glass,
– gear and lube oils on a mineral-oil basis,
– synthetic gear and lube oils,
– cleaning liquids,
– electric and electronic apparatus.
ENVIRONMENTAL PROTECTION!
Be sure to adhere to applicable environment-protection legislation!
More information on disposal matters can be obtained from local authorities.
Note:
Pay particular attention to the directive issued by the operator on handling the
cleaning agents used and the local disposal regulations.
4.12.3 Separator
Before disposing of the separator
Drain the gear oil and dispose of it properly in accordance with section 4.12.1.
Dismantle the separator, remove any lubricant sticking to separator parts and
dispose of them separately or recycle them where appropriate.
Fig. 310
Pos. Designation
1 Screwdriver
2 Torque wrench (0 - 100 Nm)
with inserts and extension
3 Caliper gauge
4 Electric oil heater for ball bearings
5 Ratchet
6 Standard hammer and mallet
7 Inner snap pliers with offset
jaws (Ø 40 mm)
8 Outer snap pliers (Ø 35 mm)
9 Hand tachometer
10 Wrench, adjustable
11 Brushes
12 Puller (200 x 200 mm (H x W))
13 Open-ended wrench (jaw widths: 17, 19, 32, 55 mm)
14 Wooden blocks
15 Drill
16 Drill bit (Ø 2 mm)
17 Wooden screws (max. Ø 4 mm x 50 mm length)
Fig. 311
Pos. Designation
Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note
5 Spare parts
Only required when ordering spare parts for pump and pump connection parts:
Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note
Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note