oa —— Westfalia Separator Mineraloil Systems GmbH Mechanical Separation Division Installation Guidelines No. 2058-9601-000 Edition 0202 Separators‘Subject to modification! ‘The authors are always grateful for comments and suggestions for improving the documentation. They can be sent to GEA Westfalia Separator Mineraloil Systems GmbH Werner-Habig-Str. 1 D-59302 Oelde © 2002 - GEA Westfalia SeparatorWestfalia Separator Mineraloil Systems GmbH ul > Preface These installation guidelines * are part of the overall documentation compiled for the separa- tor. * describe the procedures for constructing, manufacturing and designing separators. contain fundamental instructions for installing separator instal- lations. * contain general guidelines for separator installations. These guidelines specify the minimum specifications for designing and constructing frames, tanks, piping and the electrical installa- tion. Putting together and installing the installation components must be cattied out in accordance with the order-specific documents: + Installation diagram and equipment list * Dimensioned drawing (notes on required space for operating and servicing, minimum clearance from walls/pillars or other machines) We reserve the right to carry out technical modifications on the separator! For your safety * Strictly adhere to instructions marked with this symbol. This avoids damage to the separator and other equipment. * Take special care when carrying out operations marked with this symbol - otherwise danger to life. * Use only genuine parts from Westfalia Separator! Otherwise safety risks may arise. "2058 S60i-0OmI0R02Westfalia Separator Mineraloil Systems GmbH General 1 4.1 Safety precautions 2 12 Maternal 2 13. Installation 2 14 Storage 3 15 Transport 4 118.1. Transporting the separator 5 15.2 Transporting CIP installations T 116 Preservation measures on site... 8 Separator 9 2.4 Space requirement for separators 10 2.1.1 Separators with gear drive. 10 212. Separators with bet drive 12 22° Bowlweights 3 23 Required hoist specifications for separators. 13 24 Ventilating the separator room 14 25 Foundations 15 26 Securing the separators 16 26.1 Separators OTC 2, OTC 3. 16 26.2 Separators OSD 6, OSD 18, OSD 35, OSD 60, 7 263. Separators OTB 3, OTC 9, OSC 5 18 26.4 Separators OSC 15, OSC 30, OSC 50. 19 265 Important mounting instructions 20 26.6 Dimensions of the studs 21 27 Vibrations of the separator installation surface 22 2.8 Pipelines on the separator. 23 281 Product line 23 28.2 Operating, fling and displacement water lines 23 Operating, filling and displacement water 25 3.1 Water quality 26 32 Supply pressure and temperature 26 33 Water connection for operating, filling and displacement water. 27 3.4 Dimensions and number of consumers 27 35 Water quantity. 11 28 Compressed air 29 44 Pipes 30 42 Compressed air quality. 121-30 4.3 Supply pressure. 30 44 Compressed air consumption 30 Product lines 34 51 General 32 5.2 Pipe cross-sections 32 53 Piping. seseseee Oe "2058-9601-0000202Westfalia Separator Mineraloil Systems GmbH v 5.4 Centripetal pump discharge pressures. 35 5.5 Maximum suction head 36 5.5.1 Pressure line 36 5.5.2 Pre-fter 36 5.6 Feed pump, 38 5.7 Oil pre-heater 37 5.8 Installation examples 37 5.8.1 Tubular heat exchangers. 37 5.8.2 Steam-neated plate heat exchanger with P controller. 38 5.8.3. Steam-heated plate heat exchanger with PI controller 38 5.8.4 Steam-heated tubular heat exchanger with P controller 39 5.8.5 Steam-heated tubular heat exchanger with PI controller 39 5.86 Thermal-oil heated plate heat exchanger with P controller 40 5.8.7 Thermal oil-heated plate heat exchanger with PI controller. 40 5.8.8 Thermaloil heated tubular heat exchanger with P controller 41 5.89 Thermal-oll-heated tubular heat exchanger with PI controller. 4 5.8.10 Securing plate heat exchangers 42 6 _ Solids tank 43 6.1 Recommended criteria for solids tank 44 6.1.1 Tank venting 44 6.1.2 Setup of the solids tank venting .. 45 62 Solids discharge lines. 48 6.2.1 Solids discharge lines with shut-off flap. a7 63 Operating and dirty water discharge lines 49 7 Electrical installation 51 7.4 Control cabinet. 52 7.4.1 Electrical connection 53 7.1.2 External voltages 53 7.1.3 Shipboard operation 54 7.1.4 Onshore operation ninemsn 54 72 Electromagnetically compatible installation 55 73 Valves 56 7.3.1 Solenoid vaive block 56 7.3.2 Terminal box. 57 7.3.3. Separator with UNITROL monitoring function 57 7.4 Temperature guard eae 58 75 Duak-purpose thermometer. 58 75.1 Electrical connection 59 7.6 Electrical installation of transmitters and electric motors. 60 7.7 Pressure switch 61 78 Electrical execution 62 7.8.1 Earthing the separator: 62 7.8.2 Voltage equalisation of the separator 62 7.8.3 Voltage equalization of the electric heater. 63 7.8.4 Voltage equalization of the foundation frame 63 7.85 Voltage equalisation of the control cabinet 64 7.9 Electric motors procured by the customer: 65 7.10 Storing and handling the electrical equipment 66 7.11 Installation and operation of control units. 67 "2058 S60i-0OmI0R02vl Westfalia Separator Mineraloil Systems GmbH '2058-8601-00010202Westfalia Separator Mineraloil Systems GmbH General Safety precautions Material Installation Storage Transport Transporting the separator BaaaRoRS Preservation measures on site Transporting CIP installations... "2056-9601-00010202Westfalia Separator Mineraloil Systems GmbH 2 1.1 Safety precautions —_« Pay special attention to the safety precautions contained in the overall documentation compiled for the separator! 4.2. Material ‘* The specified material must conform to the standards set out in these installa- tion guidelines as a minimum requirement. ‘= All materials used must be new and from the same series, 4.3 Installation Fig.t 1 Separator 7 Solids tank venting 2 Separator foundation 8 Crane 3 Control unit 9 Sink 4 Control cabinet 10. Ventilation 5 Preheater 44. Venting 6 Solids tank ‘+ Special regulations issued by classification societies or other authorised so- Gieties must be observed. ‘All lubricating points and the gear / drive housing of the separator must be easily accessible without having to remove pipes or gratings, + All operating elements must be within comfortable reach of the operator and ata suitable height ‘* Operating elements must not be mounted higher than 1800 mm above the working platform. ‘+ All units must be arranged so that they do not cramp the working area and so that they can be safely serviced and operated, 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH 3 1.4 Storage All fixed piping and fittings must be safely supported to reduce vibrations and movement to a minimum, Contact points or supports must be fitted so that the pipes are able to move with changing temperatures without creating tension in the pipes. Pipes and pipe connections must be accessible for maintenance. Pipes must not be used for supporting distributors or appliances. This does not apply to small purpose-built parts whose durability, accessibility and operation are not influenced. They must be fitted in accordance with the manufacturer's recommendations. No galvanized parts may be fitted in product-carrying lines (e.g. heavy oil, diesel oil and steam lines). This does not apply if type-tested pipe joints are fitted in pipe trace heating systems. Y-strainers should preferably be fitted horizontally with the strainer insert pointing downwards or to the side (tured through 90°). If this is not possible for space reasons, the strainer can be fitted vertically with a throughflow from top to bottom. In this case, ensure that the strainer can be dismantled. Parts may be stored only in original Westfalia Separator transport packaging, A storage time of more than 12 months is only possible after consulting the manufacturer. ‘The storage site should be a closed, dry room. The storage temperature must not be below 5°C (41 F) and must not exceed 50°C (122 °F. A Pay attention tothe fllowing points on storage and transport packaging U ‘+ Handle fragile goods with care! ‘= Protect the goods against moisture and humidity. xy Ke '* Protect the goods against heat. Se "2056-9601-000102024.5 Transport Fig. 2 Fig. 3 Fig. 5 Westfalia Separator Mineraloil Systems GmbH The adjacent packing illustrates a seaworthy packaging from Westfalia Separator. After removing the side boards and filling material, the bottom board can be used as a special pallet for fork lft trucks, If no fork lft trucks are available, « transport the case with the aid of a crane (see diagram below). * Attach ropes round the case and hang them into the load hook of the crane. * Attention! Wind one piece of rope twice round the hook to prevent the ropes from slipping, 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH 1.5.1 Transporting the sepa-| rator A 78 # To avoid damage, the bow! must be removed from the separator before transport. # The separator is normally delivered without installed bow! © The OTC 2 and OTC 3 separators are delivered and transported with installed bowl Fig. 6 Cautiont Prevent accidents by using suitably rated hoists for transport and installation, ‘+ When transporting rope, make sure that one piece of rope is wound twice round the hook to prevent the ropes from slipping + The rope must be property attached to the separator. * Ensure that no pulling or pushing forces act on machine parts when using ropes. Fig. 7 The following examples show how the transport ropes must be attached on the different frame designs. "2056-9601-00010202Fig. 9 Westfalia Separator Mineraloil Systems GmbH Separator with gear drive © Hang the ropes into the eye bolts and load hook of the hoist as illus- trated + Do not use the eye bolt of the motor to suspend the separator. Make sure the machine touches down gently Separator with belt drive Attach the ropes around the ma- chine and hang them into the load hook of the hoist. * Do not use the eye bolt of the motor to suspend the separator. Make sure the machine touches down gently 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH 7 1.5.2 Transporting CIP in- stallations Fig. 10 1 Case cover 3° Fork lift tuck 2. Side board 4 Bottom board ‘After removing the side boards and filling material, the bottom board of the original Westfalia Separator case can be used as a special pallet for fork lift trucks, "2056-9601-00010202Westfalia Separator 8 Mineraloil Systems GmbH 1.6 Preservation measures after installation until commissioning onsite ‘All parts such as tools, spare parts and bowl must be stored in the original packaging in a suitable place until commissioning ‘+ The parts must be stored at 5 to 50°C (41-122°F) in dry, weatherproof rooms to prevent the packaging from getting damaged ‘+ The spindle and gearidrive chamber are lubricated at the factory which pro- tects them for a period of 12 months. ‘= After this time (12 months) has expired, it must be checked at 12 monthly intervals that all bearings and the spindle have sufficient lubrication. Oilto be used: = Shell oil S.7294 (SAE 30/SAE 50) for bearings and spindle, roller bearing grease for the spindle cap. 72058-9601-00010202Westfalia Separator Mineraioil Systems GmbH 9 Separator 24 ‘Space requirement for separators 10, 2.11 Separators with gear drive. 10 2.12. Separators with bet drive 12 22 Bow! weights. 13, 23 Required hoist specications for separators re 2.4 Ventilating the separator room 14 25 Foundations ae 15, 26 — Securing the separators. 16 26.1 Separators OTC 2, OTC 3 16 262 Separators OSD 6, OSD 18, OSD 35, OSD 60. 17 2.6.3 Separators OTB 3, OTC 9, OSC 5 18 264 Separators OSC 15, OSC 30, OSC 60. 19 26.5 Important mounting instructions 20 2.66 Dimensions of the studs 21 27 Vibrations of the separator installation surface 22 28 Pipelines on the separator. 23 2.8.1 Product line. boossnseneensne sve 23 28.2 Operating, filing and dspiacement water lines 23 "2056-9601-00010202Westfalia Separator 10 Mineraloil Systems GmbH 2.4 Space requirement for + No piping may be laid in the operating area apart from the feed and discharge separators lines for the separator. 2.1.4 Separators with gear drive ‘The hatched area represents the operating area. ‘+ See the following table to determine the operating area. Before installing the separator, pay special attention to the removal dimension X for the electric motors! Front view of separator Side view of separator Fig. 2 Top view of separator 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH "1 Table for determining the operating area for separators with gear drive: Separator Dimensions in mm model A B D E E S x OTB 3 1160 | 400 | 1220 | 500 | 1030 [ 410 | 120 OTB9 1150 | 360 | 1310 | 500 | 980 | 500 | 120 Osc 1150 | 360 | 1350 | 500 | 1090 [ 550 | 120 OSC 30 4890 | 450 | 1450 | 700 | 1400 [ 790 | 220 OSC 50, 2120 [ 390 | 1500 | 700 [ 2030 | 920 | 250 "2056-9601-00010202Westfalia Separator 12 Mineraloil Systems GmbH 2.1.2 Separators with belt drive + The hatched area represents the operating area ep {\] « Discharges |, Il and Ill must be de- 2.8|| "signed in accordance withthe order specific documentation * See section 6.1.1, table for tank vent connection IV. Fig. 66 1 Solids discharge Option: " Hood outlet 1. Manual operation lL Frame drain 2° Automatic operation IV Tank vent Alternative installation * Discharges |, II, Ill, V and VI must be designed in accordance with the ‘order-specific documentation * See section 6.1.1, table for tank vent connection IV. Fig. 67 | Solids discharge Il Hood outlet II Frame drain IV. Tank vent V__ Siphon for frame drain VI. Siphon for hood outiet "2056-9601-00010202Westfalia Separator Mineraloil Systems GmbH 48 Separators of the Standard installation D-generation + Discharges 1 and ll must be de- Fig. 68 1 Solids discharge " Hood and frame drain lil Tank vent signed in accordance with the order- ‘specific documentation * See section 6.1.1, table for tank vent connection IIL Option: 1 Manual operation 2 Automatic operation 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH 49 6.3 Operating and dirty The discharges for operating and dirty water can be conveyed into a separate water discharge lines tank for oily water. ‘* The piping for the operating and dirty water discharge should be vertical, without reduction and with vibration compensators. There is no upper length lit Separators of the * The water discharges must be sub- C-generation merged under all conditions il (eollptcn), t * Dimension h is: =min. 50 mm for shipboard opera- tion, iL ~ min. 20 mm for stationary plants. Fig. 69 ‘When a siphon is installed, the frame drain need not be submerged below the minimum level because a liquid seal is assured ‘© Dimensions h1 and h2 are given in the table below. | Solids discharge Il Hood outlet IIL Frame drain IV Tank vent V__ Siphon for frame drain Fig. 70 VI_ Siphon for hood outlet Table for defining siphon length, dimension h1 and h2. Separator Siphon length [mm] model ht h2 Osc 5 250 500 OSC 15 250) 500) ‘OSC 30 300) 800) ‘OSC 50 300) 800) "2056-9601-00010202Westfalia Separator 50 Mineraloil Systems GmbH © The water discharges must be sub- merged under all conditions (rollipitch), ‘= Dimension h is: =min. 50 mm for shipboard opera tion, = min. 20 mm for stationary plants. Separators of the D-generation @| Fig. 71 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH 51 7 Electrical installation 7.1 Control cabinet. 52 7.4.4 Electrical connection 53 7.1.2 External voltages 53 7.1.3. Shipboard operation 54 7.1.4 Onshore operation 54 7.2 Electromagnetically compatible instalation 55 73 Valves . son 58 7.3.4. Solenoid valve block. 56 7.32 Terminal box. 57 7.3.3. Separator with UNITROL monitoring function 57 7.4 Temperature guard 58 7.5 Dual-purpose thermometer. 58 7.5.1. Electrical connection 59 7.6 Electrical installation of transmitters and electric motors 60 77 Pressure switch 61 78 Electrical execution 62 7.8.1. Earthing the separator ..cnnnennnne 62 7.8.2 Voltage equalisation of the separator. 62 7.8.3 Voltage equalization of the electric heater. 63 7.8.4 Voltage equalization of the foundation frame. 63 7.85 Voltage equalisation of the control cabinet, 64 7.9 Electric motors procured by the customer. 65 7.10 Storing and handling the electrical equipment 66 7.11 Installation and operation of control units. 87 "2056-9601-0001020252 7A Control cabinet Fig. 74 ‘© The contro! cabinet Westfalia Separator Mineraloil Systems GmbH Control cabinet configuration 41 Control cabinet $1 Main switch SC Screening PE Earthed conductor 11 Power supply unit 1F1 Safety cutout 1U3_ Measuring transducer 41K11 Interface relay 1X... Strip terminals Mounting example 4 Gasket 10,5x23x5 2 Threaded bolt M 8 (embedded in the wall) Washer Rear panel of control cabinet Washer Wall must be allocated to the corresponding separator by means of its designa- tion, must be mounted on a frame or wall in the vicinity of the separator. conforms to enclosure IP 54. ‘= It must be possible to open the control cabinet door wide so that the door latch can lock into place. 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH A A 7.1.4 Electrical connec tion 7.1.2 External voltages 53 Select the installation site so that it can be easily operated and observed. an ambient temperature of 45°C (113 °F) is not exceeded. If necessary, make sure there is an adequate supply of fresh air. If the control cabinet is mounted on a wall, a wall clearance of 20 m must be ‘observed to achieve a vibration-free fastening arrangement. Although buttons and switches and the electronic control unit are protected against moisture by protective foil and door seal, the cabinet must neverthe- less not be installed in an excessively humid environment or damp area. To keep the temperature inside the unit constant after commissioning, the main switch should be kept turned on even when the separator is at a stand- stil The control unit is designed for a connected voltage as indicated on the nameplate inside the control cabinet. In the case of a version without motor starter, the connection voltage is 115 VAC or 230 VAC which must be protected by a 6 A slow-biow fuse. ‘The voltage-free contacts of the output modules carry external voltage (even when the main switch is off!) —can be identified by the orange coloured wiring ~can be used in external control systems up to 250 VAC. A cross-section of 1.5 mm? Cu is adequate for all control and interlocking lines. "2056-9601-000102027.4.3 Shipboard operation + For shipboard operation only armoured lines type "MGCH" according to DIN 89 158 may be used. ~ brass unions according to DIN 89 280 must be used. — load and control ines can be laid jointly without clearance, Westfalia Separator Mineraloil Systems GmbH ‘* In the case of HFO separators in series operation, the signal exchange be- tween the control cabinets as per the terminal diagram for the connecting ca- ble must be taken into account (see section 7.2). Cable glands for shipboard installation © Cable outer Earthing device + Fomale thread | C&P Suter | cable gland | inner parte ye of design M20xi8 [70-85 124 x 7,5 | for data cable without soon M20x15 [8510.5 M24 x15 [Ad + 210 M20x15 [105-125 [M24x15 [Ab +Z12 M20x18 [125-145 [M24x1,5 [Ab +214 M25x15 [145-165 |M24x15_ [AT+Z16 M25x15 (165-175 [M24x1,5 _[AB+Z17 M25x18 [175-185 [M30x2___|A9+Z18 M278 [185-205 |M30x2 | A10+Z20, M32x15 [205-225 |M36x2___|A 11+ 222 M40x45 [225-245 |M36x2 [A124 724 M40x15 [245-265 |M36x2_ |A13 +226 M40x15 [27-285 M45 x2 [Ata + 228 M40x45 [305-325 _|M45x2___|At5 +232, M50x1.5 [390-415 |MSax2__| AIT +241 7.4.4 Onshore oper + For onshore operation =Normally, armoured “8ilex'cables are used and "NSSHOU! for outside in- stallation. ion —_» The local rules and regulations of the operator must be observed! — Commercially available cable glands can be used ~ Separate cable routing must be used for the load and control lines. ‘* Cable entries with plastic or metal glands are admissible. 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH 55 7.2. Electromagnetically compatible installation | ‘= The control cabinet is designed to be electromagnetically compatible, The following must be taken into account with electromagnetically compatible installations: ~Earthing straps Voltage equalization —Screening lines ~Separate line routing — Use of suppressor elements in case of inductance. In the case of HFO series operation, proceed in accordance with the following wiring diagram: Fig. 75 A. Switch ON D Connecting terminals B Control cabinet HFO No. 1 F Cable type © Control cabinet HFO No. 2 E Customer shipboard installation Attention! ‘* Use only data cable UNITRONIC-BUS-FD P L2/F.LP (1 x 2 x 0.25 mm? + Screen). Do not lay data cables directly next to load cables as this can cause prob- lems with electromagnetic compatibility ‘* Pay attention to the different software status on the C7 units: = 1. unit has the MPI addresses 1/2 ~2. unit has the MPI addresses 3 / 4 ~3. unit has the MPI addresses 5/6 ‘* Faulty or broken cable connections are displayed with error code no. 551. ‘© Check all connections. "2056-9601-00010202Westfalia Separator 56 Mineraloil Systems GmbH 7.3. Valves ‘+ Only original valves from Westfalia Separator with integrated free-wheel di- ‘odes and reverse battery protection in the connection head may be used in filing, displacement and operating water lines. This diagram shows an original valve block from Westfalia Separator, which is used in filing, displacement and ‘operating water lines. 7.3.4 Solenoid valve block Connections Connecting terminal + 24 V DC Connecting terminal + 0 V DC Earth Status LED ooo> Fig. 77 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH 57 7.3.2 Terminal box 12 aaa a a Fig. 78 7.3.3 Separator with UNITROL monitoring function All valves and monitoring instruments are installed ready-to-connect on a local terminal box. * The connection to the control cabi- net must be carried out by means of a joint cable in accordance with the adjacent connection diagram. AControl cabinet B Product discharge pressure C Solf-thinker system D Water sensor E Circuit valve F Water discharge valve G Filling, displacement water valve H Operating water valve When using separators with UNITROL system for fuel oil treatment (WMS/SMS ‘monitoring functions), the components on the hood are wired to the distribution box. "2056-9601-00010202Westfalia Separator 58 Mineraloil Systems GmbH 7.4 Temperature guard The temperature guard (min.max.) serves to monitor the temperature of the dirty oll after the pre-heater. Fitting proposal 1 Dirty oil to 3-way Piston control valve 2 Dirty oil to pre-heater 3. Temperature guard Fig. 60 ‘* The temperature guard must be fitted ~before the 3-way piston control vaive. in such a way that the immersion sleeve is always flushed with ol 7.5 Dual-purpose ther- The dual-purpose thermometer mometer serves to moritor the temperature of the dirty ol after the pre-heater and —for local temperature indication, © The dual-purpose thermometer must always be fitted before the 3- way piston control vaive. * All sensors must be installed so that they are continuously flushed with oil Fig. 81 —Fiting proposals 72058-9601-00010202Westfalia Separator Mineraloil Systems GmbH 59 7.5.4 Electrical connection 5, vva.scl 61a + : Fig. 62 A. C7-control unit B_ Analogue input A1-3 for product temperature monitoring © Screened line D Potentiometer for max. temperature adjustment E Measuring transducer PT 100 / 4 ~ 20 mA. F Feolers G Internal connection H_ Potentiometer for max. temperature adjustment K Bridge L_ Important! Pay attention to polarity! ‘* Use only screened cable and pay attention to correct connection of the measuring transducer in accordance with the connection diagram, ‘* Follow the wiring instructions in the circuit diagrams and connection diagram on the terminal box of the thermometer. + When replacing the thermometer, be sure to turn off the main switch on the unit. Otherwise the analogue inputs will be destroyed by bonding with the connect- ing lines (wiring 24 VOC!) "2056-9601-00010202