Installation Instructions PDF

Westfalia Separator
Mechanical Separation
Mineraloil Systems GmbH
Division
Installation Instructions
No.: 2058-9601-010
Edition: 0107
For: Separators
Westfalia Separator
2 Mineraloil Systems GmbH
Subject to modification!
GEA Westfalia Separator Mineraloil Systems GmbH reserves the right to modi-
fications without notice.
The authors will always be grateful for any comments on possible errors and
faults and for suggestions to improve this documentation. They can be sent to
GEA Westfalia Separator Mineraloil Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde
Copies of this documentation can be obtained from our local agencies.
© GEA Westfalia Separator
2058-9601-010 / 0107
Westfalia Separator
Mineraloil Systems GmbH 3
Preface
These installation guidelines
• are part of the overall documentation compiled for the separator.
• describe the procedures for constructing, manufacturing and design-
ing separators.
• contain fundamental instructions for installing separator installations.
• contain general guidelines for separator installations.
These guidelines specify the minimum specifications for designing and

constructing frames, tanks, piping and the electrical installation.
Putting together and installing the installation components must be car-

ried 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!
Attention must be paid to the operating, maintenance and mounting in-

struction manuals of all units and fittings.
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.
Note: • This symbol is not a safety precaution but rather a reference to infor-
mation which help to better understand the separator or plant com-
ponents and the processes.
• Use only genuine spare parts from Westfalia Separator.

The use of non-genuine parts leads to:
– safety risks,
– less durability and availability,
– increased service requirement.
If a safety risk occurs, this may have legal consequences for the re-
sponsible persons. In such cases, Westfalia Separator accepts no li-
ability or warranty claims.
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1 General 7
1.1 Safety precautions ...................................................................................8

1.2 Material ....................................................................................................8
1.3 Installation................................................................................................8
1.4 Storage ..................................................................................................10
1.4.1 Installation of controls ............................................................................10
1.5 Transport................................................................................................12
1.5.1 Transporting the separator ....................................................................14
1.6 Preservation measures on site ..............................................................19
2 Separator 21
2.1 Space requirement for separators .........................................................22

2.1.1 Separators with gear drive.....................................................................22
2.1.2 Separators with belt drive ......................................................................24
2.2 Bowl weights..........................................................................................25
2.3 Required hoist specifications for separators..........................................26
2.4 Ventilating the separator room ..............................................................26
2.5 Foundations ...........................................................................................28
2.6 Securing the separators......................................................................... 30
2.6.1 Separators OTB 3, OTB 9, OSC 5 ........................................................30
2.6.2 Separators OTB 18, OSC 15, OSC 30, OSC 50 ...................................32
2.6.3 Separators OTC 2, OTC 3, OSD 2 ........................................................34
2.6.4 Separators OSD 6, OSD 18, OSD 35, OSD 60.....................................35
2.6.5 Important mounting instructions ............................................................36
2.6.6 Dimensions of the studs ........................................................................37
2.7 Welding procedure for fastening the foundation frame ......................... 38
2.7.1 Installing the separator ..........................................................................39
2.8 Vibrations ...............................................................................................40
2.9 Pipelines on the separator .....................................................................41
2.9.1 Product line............................................................................................41
2.9.2 Operating, filling and displacement water lines .....................................41
3 Operating, filling and displacement water 43
3.1 Water quality..........................................................................................44

3.2 Supply pressure and temperature .........................................................44
3.3 Water connection for operating, filling and displacement water ............ 45
3.4 Dimensions and number of consumers .................................................45
3.5 Water quantity........................................................................................47
4 Compressed air 49
4.1 Compressed air quality ..........................................................................50

4.2 Supply pressure.....................................................................................50
4.3 Compressed air consumption of the separators OSC, OSD and OTB . 51
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5 Product lines 53
5.1 General ..................................................................................................54

5.2 Pipe cross-sections................................................................................54
5.3 Functional description............................................................................54
5.4 Information on pressure monitoring.......................................................54
5.5 Piping .....................................................................................................56
5.6 Maximum suction head..........................................................................57
5.6.1 Pressure line..........................................................................................57
5.6.2 Pre-filter .................................................................................................58
5.7 Feed pump.............................................................................................58
5.8 Oil pre-heater.........................................................................................58
5.9 Installation examples .............................................................................59
5.9.1 Steam-heated plate heat exchanger with PI controller.......................... 59
5.9.2 Steam-heated tubular heat exchanger with PI controller ...................... 60
5.9.3 Thermal oil-heated plate heat exchanger with PI controller .................. 61
5.9.4 Thermal-oil-heated tubular heat exchanger with PI controller............... 62
5.10 Securing plate heat exchangers ............................................................ 63
5.11 Safety valve ...........................................................................................64
6 Solids tank 65
6.1 Recommended criteria for solids tank ...................................................66

6.1.1 Tank vent ...............................................................................................67
6.1.2 Set-up of the solids tank venting ........................................................... 68
6.2 Solids discharge lines ............................................................................69
6.2.1 Solids discharge lines with shut-off flap.................................................70
6.2.2 Standard installation of shut-off flaps ....................................................70
6.2.3 Installation recommendation for shut-off flaps.......................................72
6.3 Operating and dirty water discharge lines .............................................73
6.3.1 Separators of the C-generation .............................................................73
6.3.2 Separators of the D-generation .............................................................74
7 Electrical installation 75
7.1 Control cabinet.......................................................................................76

7.1.1 Electrical connection.............................................................................. 77
7.1.2 External voltages ...................................................................................77
7.1.3 Shipboard operation ..............................................................................78
7.1.4 Onshore operation .................................................................................78
7.2 Electro-magnetically compatible installation..........................................79
7.3 Valves ....................................................................................................80
7.3.1 Solenoid valve block ..............................................................................80
7.3.2 Terminal box ..........................................................................................81
7.3.3 Separator with UNITROL monitoring function .......................................82
7.4 Temperature guard ................................................................................82
7.5 Dual-purpose thermometer....................................................................83
7.6 Electrical installation of transmitters and electric motors....................... 85
7.7 Electrical execution................................................................................ 85
7.7.1 Earthing the separator ...........................................................................86
7.7.2 Voltage equalisation of the separator ....................................................86
7.7.3 Voltage equalization of the electric heater............................................. 87
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7.7.4 Voltage equalization of the foundation frame ........................................87

7.7.5 Voltage equalisation of the control cabinet............................................88
7.8 Electric motors procured by the customer .............................................89
7.9 Installation and operation of control units .............................................. 90
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1 General
1.1 Safety precautions ...................................................................................8

1.2 Material ....................................................................................................8
1.3 Installation................................................................................................8
1.4 Storage ..................................................................................................10
1.4.1 Installation of controls ............................................................................10
1.5 Transport................................................................................................12
1.5.1 Transporting the separator ....................................................................14
1.6 Preservation measures on site ..............................................................19
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1.1 Safety precautions

• Pay special attention to the safety precautions contained in the
overall documentation compiled for the separator!
1.2 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.
1.3 Installation
Fig. 1 Installation example
1 Separator: 7 Solids tank venting

2 Separator foundation 8 Crane
3 Control unit 9 Cleaning table
4 Control cabinet 10 Aeration
5 Preheater 11 Venting
6 Solids tank
• The applicable regulations and standards of classification societies or other

authorised bodies 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
at a 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.
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• 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.
• These regulations and standards do 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, steam lines and thermal oil 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 (turned through 90°).
If this is not possible for space reasons, the dirt pan can be fitted vertically
with a throughflow from top to bottom. In this case, ensure that the strainer
can be dismantled.
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1.4 Storage
• 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).
IMPORTANT:
• Outdoor exposure is not admissible!
Pay attention to the following points on storage and transport packaging.
• Handle fragile goods with care!
• Protect the goods against moisture and humidity.
• Protect the goods against heat!
• Pay attention when erecting the goods.
1.4.1 Installation of controls
IMPORTANT:
• Select the installation site so that

– the control unit is not exposed to dust and aggressive atmosphere.
– the control unit is not installed in an excessively humid environment or
damp area.
– the sun cannot shine on the control panel or displays making operation and
observation more difficult.
– heating up of the control unit is avoided.
• Where appropriate, check screw-type and plug-type connectors for secure
contact.
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• Connect thermostatically controlled cabinet heating to external voltage and

switch it on.
• The control cabinet heating must switch on before the temperature drops be-
low the dew point.
• Bedewing can occur during the night which is not good for electronic appara-
tus.
• Check that the line voltage and frequency conform to the connection data of
the control unit (see nameplate).
• Pay attention to admissible installation and operating data:
Voltage fluctuations +/- 10 % of the line voltage

Frequency fluctuations +/- 2 % of the line voltage
Ambient temperatures + 5 to + 45 °C (41 to 113 °F)
Atmospheric humidity max. 50 % at 40 °C (104 °F)
max. 90 % at 20 °C (68 °F)
Installation height above sea level up to 1000 m
Transport temperatures – 25 to + 55 °C (–13 to 131 °F)
IMPORTANT:
Improper installation and operation discharges the supplier from the warranty
obligation.
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1.5 Transport
The adjacent packing illustrates a

seaworthy packaging from Westfalia
Separator.
Fig. 2
• After removing the side boards and

filling material, the bottom board can
be used as a special pallet for fork
lift trucks.
Fig. 3
• If no forklift trucks are available,

transport the case with the aid of a
crane (see diagram).
• Attach the ropes to the points on the
packing case as marked on the
packing case.
Fig. 4
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• Attach ropes round the case and

hang them into the load hook of the
crane.
• CAUTION!
Wind one piece of rope twice
round the hook to prevent the
ropes from slipping.
Fig. 5
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1.5.1 Transporting the separator
• IMPORTANT:
To avoid damage, the bowl must be
removed from the separator before
transport.
• The separator is normally delivered
without installed bowl.
Exception:
• The OTC 2, OTC 3 and OSD 2
separators are delivered and trans-
ported with installed bowl.
Fig. 6
CAUTION!
Prevent accidents by using suitably rated hoists for transport and installa-
tion.
• When transporting rope, make sure

that one piece of rope is wound
twice round the hook to prevent the
• The rope must be properly 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 (see Fig. 8).
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Separator with gear drive
• Hang the ropes into the eye bolts

and load hook of the hoist as illus-
trated.
Wind one piece of rope twice round
the hook to prevent the ropes from
slipping.
• Do not use the eye bolt of the mo-

tor to suspend the separator.
• Make sure the machine touches
down gently.
Fig. 8
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For OSD 6 or 18 – separator with belt drive
• Screw double nipple 1 into the hole

in the frame.
Fig. 9
• Attach the transport ropes

– to the machine as illustrated and
– hang them into the load hook of
the hoist as illustrated.
• Make sure that the ropes do not
damage any machine components.

down gently.
Fig. 10
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For OSD 35 – separator with belt drive
• Screw two eye bolts 1 into the upper

section of the frame.
• Screw double nipple 2 into the hole
in the frame.
Fig. 11

– around the double nipple.
– Thread through the eye bolts and

down gently.
Fig. 12
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For OSD 60 – separator with belt drive
• Check that
– two eye bolts 1 are screwed into
the upper section of the frame.
– Screw two eye bolts 2 with wash-
ers 3 into the intermediate flange /
frame holes.
Fig. 13

– Thread through the four eye bolts
and

down gently.
Fig. 14
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1.6 Preservation measures on site
After installation until commissioning

• 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 gear/drive chamber are lubricated at the factory which pro-
tects them for a period of 12 months.
• In the case of a storage and standstill period of longer than 12 months, the
time-dependent maintenance intervals specified in the instruction manual
must be adhered to before putting the machine back into operation.
• After this time (12 months) has expired, it must be checked at 12 monthly in-
tervals that all bearings and the spindle have sufficient lubrication.
• Oil to be used:
– Shell oil S.7294 (SAE 30/SAE 50) for bearings and spindle,
– roller bearing grease for the spindle cap.
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2 Separator
2.1 Space requirement for separators .........................................................22

2.1.1 Separators with gear drive.....................................................................22
2.1.2 Separators with belt drive ......................................................................24
2.2 Bowl weights..........................................................................................25
2.3 Required hoist specifications for separators..........................................26
2.4 Ventilating the separator room ..............................................................26
2.5 Foundations ...........................................................................................28
2.6 Securing the separators......................................................................... 30
2.6.1 Separators OTB 3, OTB 9, OSC 5 ........................................................30
2.6.2 Separators OTB 18, OSC 15, OSC 30, OSC 50 ...................................32
2.6.3 Separators OTC 2, OTC 3, OSD 2 ........................................................34
2.6.4 Separators OSD 6, OSD 18, OSD 35, OSD 60.....................................35
2.6.5 Important mounting instructions ............................................................36
2.6.6 Dimensions of the studs ........................................................................37
2.7 Welding procedure for fastening the foundation frame ......................... 38
2.7.1 Installing the separator ..........................................................................39
2.8 Vibrations ...............................................................................................40
2.9 Pipelines on the separator .....................................................................41
2.9.1 Product line............................................................................................41
2.9.2 Operating, filling and displacement water lines .....................................41
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2.1 Space requirement for separators

• No piping may be laid in the operating area apart from the feed and discharge
lines for the separator.
2.1.1 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
Fig. 15
Side view of separator
Fig. 16
Top view of separator
Fig. 17
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Table for determining the operating area for separators with gear drive
Separator Dimensions in mm
model A B D E F G X
OTB 3 1160 400 1220 500 1030 410 120
OTB 9 1150 360 1310 500 980 500 120
OSC 5 1150 360 1350 500 1090 550 120
OSC 30 1890 450 1450 700 1400 790 220
OSC 50 2120 390 1500 700 2030 920 250
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2.1.2 Separators with belt 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
Fig. 18
Side view of separator
Fig. 19
Top view of separator
Fig. 20
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Table for determining the operating area for separators with belt drive
model A B D E F G X Y
OTB 18 1400 600 1600 550 1600 540 180 200
OTC 2 800 300 800 120 - 280 100 150
OTC 3 800 300 800 120 - 280 100 150
OSC 15 1400 600 1600 550 1600 540 180 200
OSD 2 800 300 800 200 - 280 100 150
OSD 6 1400 600 1400 550 1450 540 180 150
OSD 18 1400 600 1400 550 1550 630 180 150
OSD 35 1800 700 1800 650 1950 850 230 200
OSD 60 2000 800 2000 700 2500 1000 300 200
2.2 Bowl weights
Fig. 21
Table with data for rating the lifting device

Bowl weight
Separator model b h
[kg]
OTB 3 210 190 16
OTB 9 258 243 50
OTB 18 350 300 75
OSC 5 275 256 48
OSC 15 300 320 72
OSC 30 425 420 190
OSC 50 536 530 360
OSD 6 255 270 42
OSD 18 300 320 72
OSD 35 425 420 190
OSD 60 536 530 360
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2.3 Required hoist specifications for separators
Gear separators
• The hoist must be travel-type or swivel-type.
• The hoist must be arranged so as to enable the following:
– Vertical fitting and removal of the bowl (see section 2.1.1, table - dimension
F).
– Horizontal removal and fitting of the drive motor (see section 2.1.1, table -
dimension X).
Flat belt separators

• The hoist must be travel-type or swivel-type.
• The hoist must be arranged so as to enable the following:
– Vertical fitting and removal of the bowl (see section 2.1.2, table - dimension
F).
– Horizontal removal and fitting of the drive motor (see section 2.1.2, table -
dimension X).
2.4 Ventilating the separator room

• Pay attention to the correct arrangement of the air feed and discharge lines so
that
– the separator room is efficiently ventilated,
– the admissible room temperature – normally max. 45 °C (113 °F) – is not
exceeded.
The rating of the electrical apparatus is critical in this respect.
IMPORTANT:
If the admissible temperatures are exceeded, additional measures must be
taken. Maintenance intervals and maintenance measures may have to be ad-
justed accordingly.
Installation example of a ventilation

system
1 Aeration
2 Venting
Fig. 22
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Approximate values for air exchange
For small closed separator rooms 30 - 50 h-1

For large separator rooms 15 - 20 h-1
For niches in engine rooms 50 - 70 h-1
Table for air volumes
Separator Air volume

model [m³/h]
OTB 3 10
OTB 9 10
OTB 18 30
OTC 2 10
OTC 3 10
OSC 5 10
OSC 15 30
OSC 30 100
OSC 50 150
OSD 2 10
OSD 6 10
OSD 18 30
OSD 35 100
OSD 60 150
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2.5 Foundations
In order to avoid the influence of external vibrations,

• Foundations and foundation frames for Westfalia separators must not be rig-
idly connected to other foundations.
IMPORTANT:
• If the foundation does not have adequate rigidity and flexural strength, this
may result in loss of warranty.
Installation example for a founda-

tion frame
1 Foundation
Fig. 23
• The foundation frames must be de-

signed so that dimensions a and b
in the table below are adhered to.
• When using other sections, the sec-
tion modulus of the U-sections must
not be lower than the value speci-
fied in DIN 1026.
• The foundation must be rigid with a
maximum admissible deflection of
1:250.
• The separator feet must be fastened
on the neutral axis of the frame.
Fig. 24
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Table for dimensioning foundation frames
model a b
OTB 3 80 60
OTB 9 80 60
OTB 18 140 60
OTC 2 80 60
OTC 3 80 60
OSC 5 140 60
OSC 15 140 60
OSC 30 180 70
OSC 50 180 70
OSD 2 80 60
OSD 6 140 60
OSD 18 140 60
OSD 35 180 70
OSD 60 180 70
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2.6 Securing the separators

The following sections show how to secure the different separators:
2.6.1 Separators OTB 3, OTB 9, OSC 5
• Assembly of separators with the aid

of stud screws (see 2.6.6) on a steel
foundation frame.
1 Stud
2 Bottom disk
3 Rubber cushion
4 Top disk
5 Cup springs
6 Nut
7 Bush
Fig. 25
1 Steel foundation
Fig. 26
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• Mount the nuts as shown on page

36.
• IMPORTANT:
Pay attention to correct fitting of the
cup springs!
Fig. 27
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2.6.2 Separators OTB 18, OSC 15, OSC 30, OSC 50
Assembly of separators with the aid of

stud screws (see 2.6.6) on a steel
foundation frame.
1 Stud
2 Bottom disk
3 Rubber cushion
4 Top disk
5 Cup springs
6 Nut
Fig. 28
1 Steel foundation
Fig. 29
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• Mount the nuts as shown on page

36.
• IMPORTANT:
Pay attention to correct fitting of the
cup springs!
Fig. 30
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2.6.3 Separators OTC 2, OTC 3, OSD 2
Assembly of separators with the aid of

rubber-metal cushions on a steel
foundation frame.
Fig. 31
• Screw rubber-metal cushions 4 into

foundation 5.
• Screw studs 2 into rubber-metal
cushions 4.
• Place plate 3 over the studs.
• Place the separator on plate 3 and
• bolt tight with hexagon nuts 1.
Fig. 32
ATTENTION!
The tightening torque for the stud screw 2 (M10) must be 30 Nm.
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2.6.4 Separators OSD 6, OSD 18, OSD 35, OSD 60
• Align separator 1 with feet 2 and

plates 3 on foundation 4.
• Tack plates 3.
• Unscrew screws 5.
• Lift separator with feet (see section
1.5.1).
• Weld plates 3 to foundation 4.
• Place the separator on plates 3 and
• bolt tight with hexagon nuts 5.
• Screw tight hex head screws 6.
Fig. 33
ATTENTION!
The torques for the hex head screw 6 are specified in the table below.
Separator model Hex head screw Torque:
OSD 6
M 12 52 Nm
OSD 18
OSD 35
M 16 100 Nm
OSD 60
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2.6.5 Important mounting instructions
• Tighten the nut by hand.
Fig. 34
• Tighten the nut through a further

180°.
Fig. 35
• Tighten the second nut by hand.

• Lock the nuts.
Fig. 36
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2.6.6 Dimensions of the studs
Installation example on steel foun-

dation
• The dimensions for selecting the
studs are given in the table below:
Fig. 37
model L1 M
OTB 3 96 12
OTB 9 96 12
OTB 18 96 16
OSC 5 96 12
OSC 15 96 16
OSC 30 135 20
OSC 50 135 20
• When installing the separator, make sure the surface is absolutely even!
• Uneven surfaces can be levelled using shims which, however, must have a
close fit.
• The separators must not be warped

or twisted when installed on the
foundation.
Fig. 38
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2.7 Welding procedure for fastening the foundation frame

The following sections show the welding procedure for fastening the foundation
frame:
Mounting the separator installations

on board of a ship
• The foundation frame 2 can be di-
rectly welded onto the steel struc-
ture 2 from the shipyard.
Fig. 39
Example 1
• The length of the weld seams must
be 100 mm.
• The distance between the weld
seams must be approx. 350 mm.
This means that that there are 3 weld

seams with a length of 100 mm along
a length of one metre.
Example 2
• The foundation frame can likewise
Fig. 40 be welded all the way round.
Detail view
In this view you can see an example
for welding the foundation frame to the
steel structure.
The letter X indicates a fillet weld.
Fig. 41
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2.7.1 Installing the separator
Mounting the separator installations

on board of a ship
• The frames must be fitted beneath
the separator feet.
• The dimension a for the frame dis-
tance must be observed.
• The position of the separator feet is
given In sections 2.1.1 and 2.1.2.
Fig. 42
• The dimension a for the frame dis-

tance is given in the table below for
the respective separator model.
Fig. 43
Dimension “a”
Separator model
[mm]
OTB 3 320 mm
OTB 9 370 mm
OTB 18 640 mm
OTC 2 452 mm
OTC 3 452 mm
OSC 5 370 mm
OSC 15 640 mm
OSC 30 550 mm
OSC 50 600 mm
OSD 2 452 mm
OSD 6 350 mm
OSD 18 425 mm
OSD 35 555 mm
OSD 60 700 mm
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2.8 Vibrations
Fig. 44
Admissible vibra- Limit values for Vibro 1

Tolerable vibration values at the
Separator tion value at the with installed vibration
separator installation surface c
model reference point d sensor e
max. [mm/s]
[mm/s] [mm/s]
OTB 3 1,8 2,8 2,8
OTB 9 1,8 2,8 2,8
OTB 18 2,8 4,5 4,5
OTC 2 1,8 2,8 2,8
OTC 3 1,8 2,8 2,8
OSC 5 1,8 2,8 2,8
OSC 15 2,8 4,5 4,5
OSC 30 2,8 4,5 4,5
OSC 50 2,8 4,5 4,5
OSD 2 1,8 2,8 2,8
OSD 6 2,8 4,5 4,5
OSD 18 2,8 4,5 4,5
OSD 35 2,8 4,5 4,5
OSD 60 2,8 4,5 4,5
c Measured at separator standstill and normal ship operating conditions
d Measured with separators in operation
e The Vibro sensor is attached in this range
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2.9 Pipelines on the separator

The following sections describe the general set-up of the piping system in the
separator installation:
2.9.1 Product line

• Product lines must be laid
– in accordance with the guidelines of Westfalia Separator or
– in accordance with the requirements of the classification societies.
• Use only genuine parts from Westfalia Separator!
• The lines must be flushed before commissioning to protect the valves and
units.
• The following lines must have no rigid connection with the separator in order
to prevent vibrations:
– Product feed and discharge
– Water connection
– Solids discharge
– Dirty water discharge
– Frame drain
• This can be realised by means of hoses or compensators, whereby there are

special requirements for shockproof separators.
• Hose pipes must be laid so that they cannot be twisted, kinked, clamped or
rubbed.
• Use only hoses from Westfalia Separator!
2.9.2 Operating, filling and displacement water lines

• Water lines must be laid so that they can be completely drained at the lowest
point with no dismantling.
• Y-strainers are fitted horizontally at the factory – with the strainer insert point-
ing downwards. See section 1.3 – Installation.
• The solenoid valves for operating, filling and displacement water to the sepa-
rator are fitted so that the hose between the separator and solenoid valves
cannot empty.
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3 Operating, filling and displacement water
3.1 Water quality..........................................................................................44

3.2 Supply pressure and temperature .........................................................44
3.3 Water connection for operating, filling and displacement water ............ 45
3.4 Dimensions and number of consumers .................................................45
3.5 Water quantity........................................................................................47
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Westfalia Separator
3.1 Water quality

• The water should be as pure as possible and meet the following standards:
Hardness:
– up to 55 °C (131 °F) separating temperature < 12° dH
– above 55 °C (131 °F) separating temperature < 6° dH
Note:
– When using demineralised water or condensate, corrosion must be
reckoned with.
– The use of boiler feed water is not permissible!
– Land water is not recommended because the degrees of hardness are
normally too high.
To convert the hardness values stated, use the following equation:
1° dH = 1,79° fH = 1,25° eH = 17,9 ppm CaCO3
pH 6,5 – 8,5
Chloride ions < 100 mg/l
Suspended matter max. 10 mg/l
Particle size max. 50 μm
3.2 Supply pressure and temperature
Fig. 45
Note:
The pressure after the water pressure reducer must not drop below 0.2 Mpa
with open operating water valve.
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Westfalia Separator
• The supply pressure and the temperature for the operating, filling and dis-
placement water must meet the following specifications:
Temperature min. 10 °C (50 °F)

max. 85 °C (185 °F)
Supply pressure 0.3 – 1.0 MPa
3.3 Water connection for operating, filling and displacement water

• Pay special attention to section 2.9.2!
3.4 Dimensions and number of consumers

• Collective lines must be dimensioned so that the separators are always sup-
plied with an adequate water volume to assure perfect functioning.
• Lines must be laid so that manual override of the valves and filter replace-
ment are possible.
• The maximum length between pressure reducer and solenoid valve must not
exceed 5 m.
• In the case of 1 consumer, the col-

lective line must have the same
nominal diameter as the feed lines
to the separator.
• The nominal diameter R is given in
the table below.
Fig. 46
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Westfalia Separator
Fig. 47
In the case of 2 consumers:

• the collective line must have a nominal diameter S (see table).
• the supply lines to the separator must have a nominal diameter R (see table).
Note:
When two separators request water at different times, the water supply can be
rated as for one separator.
In the case of 3 consumers:

• the collective line must have a nominal diameter of DN 32.
• the supply lines to the separator must have a nominal diameter R (see table).
Table for selecting the nominal diameters “S” and “R”.

Nominal diameter (DN)
Separator model Collective line Supply line
S R
OSC 5 25 20
OSC 15 25 20
OSC 30 32 20
OSC 50 32 20
OSD 2 25 20
OSD 6 25 20
OSD 18 25 20
OSD 35 32 20
OSD 60 32 20
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Westfalia Separator
3.5 Water quantity

For exact program control, with simultaneous actuation of the valves, the follow-
ing water quantities are required:
V2 V2 V3 Total con- Total con-

sumption sumption
Separator Displace- Operating per cycle per cycle
Filling water without fill-
model ment water water * ing water
l/s l/s l/s Approx. 1
OSC 5 0,1 0,1 0,5 3 2
OSC 15 0,1 0,1 0,8 5 3,5
OSC 30 0,1 0,1 0,8 10 6,5
OSC 50 0,1 0,1 0,8 23 13
OSD 2 0,25 0,25 0,25 2 1,5
OSD 6 0,1 0,1 0,5 3 2
OSD 18 0,1 0,1 0,8 5 3,5
OSD 35 0,1 0,1 0,8 10 6,5
OSD 60 0,1 0,1 0,8 23 13
* Ejection cycle = Σ (filling water + displacement water + operating water)
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4 Compressed air
4.1 Compressed air quality ..........................................................................50

4.2 Supply pressure.....................................................................................50
4.3 Compressed air consumption of the separators OSC, OSD and OTB . 51
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4.1 Compressed air quality
• The compressed air must be free from impurities and dry.
4.2 Supply pressure

Recommended set-up of compressed air line per treatment system.
Fig. 48 OSC / OTB separators
Fig. 49 OSD separators
• A supply pressure of 0.3 to max. 1.0 MPa is admissible.

• After the reducer station 0.3 MPa must still be available to the consumers.
• Note:
On OSD separators, a compressed air control unit is no longer included in the
standard scope of supply.
• If other pneumatic components are operated, the corresponding instructions
relating to air quality and air lubrication must be observed.
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Westfalia Separator
4.3 Compressed air consumption of the separators OSC, OSD and OTB
• The maximum compressed air consumption per separator is approx. 0.01
Nm3/h.
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2058-9601-010 / 0107
Westfalia Separator
5 Product lines
5.1 General ..................................................................................................54

5.2 Pipe cross-sections................................................................................54
5.3 Functional description............................................................................54
5.4 Information on pressure monitoring.......................................................54
5.5 Piping .....................................................................................................56
5.6 Maximum suction head..........................................................................57
5.6.1 Pressure line..........................................................................................57
5.6.2 Pre-filter .................................................................................................58
5.7 Feed pump.............................................................................................58
5.8 Oil pre-heater.........................................................................................58
5.9 Installation examples .............................................................................59
5.9.1 Steam-heated plate heat exchanger with PI controller.......................... 59
5.9.2 Steam-heated tubular heat exchanger with PI controller ...................... 60
5.9.3 Thermal oil-heated plate heat exchanger with PI controller .................. 61
5.9.4 Thermal-oil-heated tubular heat exchanger with PI controller............... 62
5.10 Securing plate heat exchangers ............................................................ 63
5.11 Safety valve ...........................................................................................64
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Westfalia Separator
5.1 General
• Pay special attention to section 1.3!
• The suction lines should be as short as possible to avoid pressure losses.
• The pipes must be installed with adequate clearance from the electronic
parts.
• Water pockets must be avoided! (water must be able to flow off freely).
• When different products are run through the same separator, it must be en-
sured that the corresponding product lines cannot be interchanged.
5.2 Pipe cross-sections

• All pipes, valves, fittings and instruments must be laid so that an insulation of
40 mm is possible.
• Dimensioning of the pipes is specified on the respective P&ID.
• The pipes can be selected with the aid of the following diagram. The specifi-
cations on the P&IDs have priority!
• Pipe resistances must be kept as low as possible.
• Taking into account the total pressure losses, the flow velocities must be
– between 0.5 m/s and < 1 m/s in suction lines,
– between 1 m/s and 3 m/s in pressure lines.
5.3 Functional description

The liquid is discharged from the separator by means of a pumping device, in
the following referred to as centripetal pump. At small capacities, the discharge
can be without pressure; in the case of larger capacities the centripetal pump
generates the required pressure to convey the liquid out of the separator
through the downstream lines by immersing more deeply into the liquid.
The pressure values can differ significantly. The following rule applies: The val-
ues are lower on small separators than on large separators.
Further influencing factors are capacity, system resistances (valve position, tank
position), product properties and process specifications.
5.4 Information on pressure monitoring

When the liquid is discharged from the separator under pressure, the operator
knows that the separator bowl is hydraulically closed.
A discharge pressure adjusts given a constant capacity or it is adjusted to the
desired value by throttling in the discharge.
In the standard application, the pressure sensor responds to falling discharge
pressure, an alarm is triggered via the control system. The control system can
also evaluate rising pressure and trigger an alarm.
Generally, the discharge pressure is set to 0.1 – 0.2 MPa. The pressure level
can deviate from this when separator size, capacity, product properties and
process specifications require. (for further information, see the order-specific
documentation)
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Westfalia Separator
A change in the discharge pressure may be caused by the following factors:

• Change in feed capacity
• Change in product data such as temperature, density, viscosity
• Change in discharge resistance
• Leakage at the separator bowl
This represents important information for the operator.
Selection diagram
Fig. 50
Q Flow
v Velocity in m/s
Example:
A flow rate of 5 m3/h produces a velocity of 1.2 m/s with a nominal diameter of
40.
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Westfalia Separator
5.5 Piping
Fig. 51 Lubrication oil schematic
1 LO tank
• When separating lube oil, the return line of the 3/2-way valve can be led into
the product discharge line of the separator.
Fig. 52 Diesel oil schematic
1 DO tank
2 Service tank
• When separating diesel oil, the return line of the 3/2-way valve must be led
into the DO tank 1.
WS does not permit leading the return line into the suction side of the
pump!
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Fig. 53 Heavy fuel oil schematic
1 Settling tank
2 Service tank
• When separating heavy oil, the return line of the 3/2-way valve must be led
into the settling tank 1.
5.6 Maximum suction head

• The suction head of the feed pump (gear pump) is max. 0.04 Mpa.
• The suction head of the feed pump (screw pump) is max. 0.05 MPa.
• The viscosity of the oil to be conveyed must be kept < 1 000 cSt, if necessary
by adequate pre-heating and trace heating.
• When dimensioning the suction line, it must be ensured that the total pressure
loss in the pipe does not exceed the maximum suction head of the pump.
• The maximum feed pressure in the suction line must not exceed 0.05 MPa.
5.6.1 Pressure line

• The pressure head of the feed pump is set to approx. 0.3 MPa.
• The pressure line from the feed pump via the pre-set valve, the pre-heater
and the 3/2-way valve to the separator must be kept as short as possible.
• When dimensioning the pressure line, it must be ensured that the total pres-
sure loss in the pipes does not exceed the maximum pressure head of the
pump.
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Westfalia Separator
5.6.2 Pre-filter
• The pre-filters are fitted in the suction line of the feed pump to protect it from
coarse impurities.
• During the installation, special attention must be paid to the operability.
• Use only strainers with a mesh

width of the strainer insert of 1 to
1.25 mm.
• Pay special attention to section 1.3!
Fig. 54
• Use only pre-strainers with a mesh

width of the strainer insert of 0.63
mm.
Fig. 55
5.7 Feed pump
To prevent the pre-heater from overheating,

• a pump post-running time must be programmed for pump units and product
pre-heating.
5.8 Oil pre-heater

• It must be installed so that there is no heat dissipation to the control cabinet.
To prevent a risk of accidents when venting due to discharging hot va-

pours and liquids,
• the discharge lines from vent valves must be laid at least to floor plate height.
• Discharge lines of safety valves must be laid so that there is no danger

of accident when the valve responds due to discharging liquid.
• The discharge line must be laid so that it can always be observed. It must not
be concealed by pipes, valves or other units!
2058-9601-010 / 0107
Westfalia Separator
• Steam traps
– must be fitted horizontally between two unions.
– should not be insulated to assure correct functioning.
– must be installed so that no condensate accumulation can occur on the pre-
heaters.
5.9 Installation examples

The following sections show installation examples for
– Tubular heat exchanger
– Steam-heated plate heat exchanger with PI controller
– Steam-heated tubular heat exchanger with PI controller
– Thermal oil-heated plate heat exchanger with PI controller
– Thermal-oil-heated tubular heat exchanger with PI controller
5.9.1 Steam-heated plate heat exchanger with PI controller
Fig. 56
A Oil inlet 0.1 Spring safety valve

B Oil outlet 1.0 Plate heat exchanger
C Steam inlet 1.1 Resistance thermometer (PT 100)
D Condensate outlet 2.1 Strainer
2.2 Motor control valve
2.3 Ball float condensate trap
2058-9601-010 / 0107
Westfalia Separator
5.9.2 Steam-heated tubular heat exchanger with PI controller
Fig. 57

B Oil outlet 1.0 Tubular heat exchanger
C Steam inlet 1.1 Resistance thermometer (PT 100)
D Condensate outlet 2.1 Strainer
2.2 Motor control valve
2.3 Ball float condensate trap
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Westfalia Separator
5.9.3 Thermal oil-heated plate heat exchanger with PI controller
Fig. 58

B Oil outlet 1.0 Plate heat exchanger
C Thermal oil inlet 1.1 Resistance thermometer (PT 100)
D Thermal oil outlet 2.1 Motor control valve
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Westfalia Separator
5.9.4 Thermal-oil-heated tubular heat exchanger with PI controller
Fig. 59

B Oil outlet 1.0 Tubular heat exchanger
C Thermal oil inlet 1.1 Resistance thermometer (PT 100)
D Thermal oil outlet 2.1 Motor control valve
2058-9601-010 / 0107
Westfalia Separator
5.10 Securing plate heat exchangers
Assembly instructions for soldered

plate heat exchanger
• Prepare an assembly plate support
and weld it to the foundation.
• Fasten assembly plate 50 with
screws 70 and nuts 80 to the as-
sembly plate support.
The assembly plate must be in-
stalled vertically relative to the pipe
axis.
IMPORTANT:
Welding the assembly plate to the
support is not permitted.
• Fasten heat exchanger with gaskets
40, 60, counterflanges 30, lock
washers 20 and screws 10 to the
assembly plate.
• Attach the pipes to the counter-
flanges by tack-welding.
• Dismantle the heat exchanger and
gaskets.
• Completely weld the pipes to the
counterflanges.
• Finally, re-assemble the parts as per
instruction.
Fig. 60
A The illustrated channel steel must be provided by the shipyard.

B Westfalia Separator recommendation as example channel steel according
to DIN1026-1-50.
IMPORTANT:
Distortion or warping or other stress of the soldered connection points must be
avoided!
Pipelines must be correspondingly arrested.
10 20 30 40 50 60 70 80
Pos./
type Allen screw Lock Groove- Gasket Plate Gasket Hex head Hexagon
washer faced screw nut
flange
ISO 4762 - DIN127 - 1 in - 32.92 x 3.53 313 x 125 x 59 x 70 x 1.5 ISO 4017 - ISO 3032 -
M10 x 45 B10 SAE3000P (4 x) 12 (4 x) M12 x 40 M12
B 10 (16 x) (16 x) SI (1 x) (2 x) (2 x)
(4 x)
ISO 4762 - DIN127 - 2 in - 56.74 x 3.53 427 x 264 x 97 x 102 x ISO 4017 - ISO 3032 -
M12 x 55 B12 SAE3000P (4 x) 12 1.5 M12 x 40 M12
B 35 (16 x) (16 x) SI (1 x) (4 x) (2 x) (2 x)
(4 x)
ISO 4762 - DIN127 - 2 in - 56.74 x 3.53 559 x 264 x 97 x 102 x ISO 4017 - ISO 3032 -
M12 x 55 B12 SAE3000P (4 x) 12 1.5 M12 x 40 M12
B 45 (16 x) (16 x) SI (1 x) (4 x) (2 x) (2 x)
(4 x)
2058-9601-010 / 0107
Westfalia Separator
5.11 Safety valve
Safety valve in vertical fitting posi-

tion
Fig. 61
• The safety valve outlet should be

led via a funnel (pos. “1”).
A discharge line is welded to the
funnel via which the medium can be
discharged.
IMPORTANT:
• Do not use galvanized compo-
nents and hoses.
Fig. 62
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Westfalia Separator
6 Solids tank
6.1 Recommended criteria for solids tank ...................................................66

6.1.1 Tank vent ...............................................................................................67
6.1.2 Set-up of the solids tank venting ........................................................... 68
6.2 Solids discharge lines ............................................................................69
6.2.1 Solids discharge lines with shut-off flap.................................................70
6.2.2 Standard installation of shut-off flaps ....................................................70
6.2.3 Installation recommendation for shut-off flaps.......................................72
6.3 Operating and dirty water discharge lines .............................................73
6.3.1 Separators of the C-generation .............................................................73
6.3.2 Separators of the D-generation .............................................................74
2058-9601-010 / 0107
Westfalia Separator
6.1 Recommended criteria for solids tank
Note:
This information does not apply to sludge transfer units on compact units.
• There should always be separate solids tanks for the lube oil and fuel sys-
tems.
• Tank heating should be installed in dependence of the viscosity or ambient
temperature.
• The general designs and constructions are subject to the valid regulations.
1 Monitoring
2 Venting
3 Tank heating
4 Utilizable volume
Fig. 63
Minimum solids tank volume

Volume Maximum utilizable volume
Separator model
[l] [%]
OSC 5 200 60
OSC 15 200 60
OSC 30 300 60
OSC 50 300 60
OSD 2 80 60
OSD 6 200 60
OSD 18 200 60
OSD 35 300 60
OSD 60 300 60
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Westfalia Separator
6.1.1 Tank vent

• In the case of one or more separators which are connected to a solids tank,
the nominal widths DN to be used are given in the table below:
Note:
Connect the tank vent to the on-board venting system.
Tank vent
Separators DN in mm
per solids tank
OSC 5 OSC 15 OSC 30 OSC 50
1 100 100 125 125
2 100 125 150 150
≥3 2x125 2x150 2x150 2x150
OSD 2 OSD 6 OSD 18 OSD 35 OSD 60

1 50 80 80 125 125
2 50 100 100 150 150
≥3 80 125 125 150 150
• In the case of a combination of separator models on one solids tank

– the total number of all separators must be taken as a basis
– and the nominal width of the largest model used.
The following criteria must be taken into consideration when venting the tank:
• Installation in accordance with the guidelines of the classification societies
• Controlled discharge of oil vapours
• An uncontrolled discharge of the sludge must be avoided.
• The vent lines must be laid so that a chimney effect develops.
• All possible loops in the vent lines must be stepwise.
2058-9601-010 / 0107
Westfalia Separator
6.1.2 Set-up of the solids tank venting
Solids tank with one separator

• The nominal width DN is given in
the table above (section 6.1.1).
Fig. 64
Solids tank with several separators

• The nominal width DN is given in
the table above (section 6.1.1).
Fig. 65
Solids tank with wash plates

A solids tank with wash plates is re-
quired when movements of the ship
cause faulty functioning of the level
monitoring.
• When using wash plates, each sec-
tion must be vented.
• The vent lines must be brought to-
gether.
Fig. 66
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Westfalia Separator
6.2 Solids discharge lines
• The solids discharge lines should

always be vertical if possible.
• The solids discharge must always
end 50 – 100 mm below the tank
top.
• The maximum level in the solids
tank must be monitored by means of
a float switch.
• The piping for the solids discharge
should be without reduction and with
vibration compensators.
• The length of 2 m may not be ex-
ceeded without trace heating.
Fig. 67
• If there is a deviation from the verti-

cal, an angle of 45° must not be ex-
ceeded.
Fig. 68
IMPORTANT:
• This piping arrangement is not ad-
missible!
Fig. 69
2058-9601-010 / 0107
Westfalia Separator
6.2.1 Solids discharge lines with shut-off flap

• A shut-off flap in the solids discharge line prevents the penetration of vapours
into a stationary separator during the desludging of another separator.
• If more than one separator is used for a sludge tank, a shut-off flap must be
installed in the sludge discharge at the shipyard.
• Shut-off flaps are not included in the standard scope of supply of Westfalia
Separator but can be ordered from Westfalia Separator.
• CIP units or modules supplied by Westfalia Separator and equipped with
more than one separator are always delivered with shut-off flaps.
6.2.2 Standard installation of shut-off flaps
Separators of the C-generation
Fig. 70
I Solids discharge IV Tank vent

II Hood outlet V Shut-off flap
III Frame drain
• Discharges I, II and III must be configured as illustrated in Fig. 74).
• See section 6.1.1, table IV for tank vent connection.
2058-9601-010 / 0107
Westfalia Separator
Separators of the D-generation
Fig. 71
I Solids discharge III Tank vent

II Hood and frame drain IV Shut-off flap
• Discharges I, and III must be configured as illustrated in Fig. 76).

• See section 6.1.1, table.
ATTENTION!
It must be ensured that the shut-off flaps are open during separator operation.
2058-9601-010 / 0107
Westfalia Separator
6.2.3 Installation recommendation for shut-off flaps
• The solids discharge must always

end below the tank top.
• For dimension X, see section 6.2,
Fig. 67.
I Shut-off flap
II Flange
III Pipe
IV Hose (supplied with separator)
V Solids tank cover
Fig. 72
Fig. 73
2058-9601-010 / 0107
Westfalia Separator
6.3 Operating and dirty water discharge lines

• The discharges for operating and dirty water can be conveyed into a separate
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
limit.
IMPORTANT:
Operating and dirty water discharges may not be discharged into public
canals, draining ditches and waters!
6.3.1 Separators of the C-generation
• The water discharges must be sub-

merged under all conditions
(roll/pitch).
• Dimension h is:
– min. 50 mm for shipboard opera-
tion,
– min. 20 mm for stationary plants.
I Solids discharge
II Hood outlet
III Frame drain
IV Tank vent
Fig. 74
• 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.
I Solids discharge
II Hood outlet
III Frame drain
IV Tank vent
V Siphon for frame drain
VI Siphon for hood outlet
Fig. 75
Table for defining siphon length, dimension ”h1” and “h2”:
Siphon length [mm]

Separator model
h2 h1
OSC 5 / OSC 15 250 500
OSC 30 / OSC 50 300 800
2058-9601-010 / 0107
Westfalia Separator
6.3.2 Separators of the D-generation
• The water discharges must be sub-

merged under all conditions
(roll/pitch).
• Dimension h is:
– min. 50 mm for shipboard opera-
tion,
– min. 20 mm for stationary plants.
I Hood and frame drain

II Solids discharge
III Tank vent
Fig. 76
• When a siphon is installed, the

frame drain need not be submerged
below the minimum level because a
liquid seal is assured.
• Dimension h1 is given in the table
below.
I Solids discharge
II Hood and frame drain
III Tank vent
IV Siphon for hood and
frame drain
Fig. 77
Table for defining siphon length, dimension “h1”
Siphon length [mm]

Separator model
h1
OSD 6 / OSD 18 500
OSD 35 / OSD 60 800
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Westfalia Separator
7 Electrical installation
7.1 Control cabinet.......................................................................................76

7.1.2 External voltages ...................................................................................77
7.1.3 Shipboard operation ..............................................................................78
7.1.4 Onshore operation .................................................................................78
7.2 Electro-magnetically compatible installation..........................................79
7.3 Valves ....................................................................................................80
7.3.1 Solenoid valve block ..............................................................................80
7.3.2 Terminal box ..........................................................................................81
7.3.3 Separator with UNITROL monitoring function .......................................82
7.4 Temperature guard ................................................................................82
7.5 Dual-purpose thermometer....................................................................83
7.6 Electrical installation of transmitters and electric motors....................... 85
7.7 Electrical execution................................................................................ 85
7.7.1 Earthing the separator ...........................................................................86
7.7.2 Voltage equalisation of the separator ....................................................86
7.7.3 Voltage equalization of the electric heater............................................. 87
7.7.4 Voltage equalization of the foundation frame ........................................87
7.7.5 Voltage equalisation of the control cabinet............................................88
7.8 Electric motors procured by the customer .............................................89
7.9 Installation and operation of control units .............................................. 90
2058-9601-010 / 0107
Westfalia Separator
7.1 Control cabinet
Control cabinet configuration
1A1 Control unit

S1 Main switch
Fig. 78 Front view
SC Screening
PE Earthed conductor
1U1 Power supply unit

1F1 Safety cut-out
1U3 Measuring transducer
1K11 Interface relay
1X... Strip terminals
Fig. 79 Interior view
Mounting example
1 Gasket 10,5x23x5
2 Threaded bolt M 8 (embedded
in the wall)
3 Washer
4 Rear panel of control cabinet
5 Washer
6 Wall
mm
Fig. 80
• The control cabinet

– 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.
2058-9601-010 / 0107
Westfalia Separator

– it can be easily operated and observed.
– an ambient temperature of 50 °C (122 °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-
still.
7.1.1 Electrical connection

• 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 rated connection voltage is
115 VAC or 230 VAC which must be protected by a 6 A slow-blow fuse.
7.1.2 External voltages

• 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 mm2 Cu is adequate for all control and interlocking
lines.
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Westfalia Separator
7.1.3 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 lines can be laid jointly without clearance.
• 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
Female ∅ Cable outer Earthing device +

Cable gland
thread [mm] Inner parts design
M 20 x 1.5 7,0 – 8,5 M 24 x 1.5 for data cable without screen

M 20 x 1.5 8,5 – 10,5 M 24 x 1.5 A4 + Z10
M 20 x 1.5 10,5 – 12,5 M 24 x 1.5 A6 + Z12
M 20 x 1.5 12,5 – 14,5 M 24 x 1.5 A6 + Z14
M 25 x 1.5 14,5 – 16,5 M 24 x 1.5 A7 + Z16
M 25 x 1.5 16,5 – 17,5 M 24 x 1.5 A8 + Z17
M 25 x 1.5 17,5 – 18,5 M 30 x 2 A9 + Z18
M 32 x 1.5 18,5 – 20,5 M 30 x 2 A10 + Z20
M 32 x 1.5 20,5 – 22,5 M 36 x 2 A 11 + Z22
M 40 x 1.5 22,5 – 24,5 M 36 x 2 A12 + Z24
M 40 x 1.5 24,5 – 26,5 M 36 x 2 A13 + Z26
M 40 x 1.5 27 – 28,5 M 45 x 2 A14 + Z28
M 40 x 1.5 30,5 – 32,5 M 45 x 2 A15 + Z32
M 50 x 1.5 39,0 – 41,5 M 56 x 2 A17 + Z41
7.1.4 Onshore operation

• The local rules and regulations of the operator must be observed!
• for onshore operation
– Normally, armoured "ölflex" cables are used and "NSSHÖU" for outside in-
stallation.
– 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.
2058-9601-010 / 0107
Westfalia Separator
7.2 Electro-magnetically compatible installation

• The control cabinet is designed to be electro-magnetically compatible.
• The following must be taken into account with electro-magnetically compatible
installations:
– Earthing straps
– Voltage equalization
– Screening lines
– Separate line routing
– Use of erase elements in case of inductance.
In the case of HFO series operation, proceed in accordance with the following
wiring diagram:
Fig. 81
A Switch ON D Connecting terminals

B Control cabinet HFO No. 1 F Cable type
C Control cabinet HFO No. 2 E Customer shipboard installation
IMPORTANT:
• Use only data cable UNITRONIC-BUS-FD P L2/F.I.P (1 x 2 x 0.25 mm² +
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
• Faulty or broken cable connections are displayed with error code no. 551.
• Check all connections.
2058-9601-010 / 0107
Westfalia Separator
7.3 Valves
Only original valves from Westfalia Separator with integrated suppressor diode
and reverse battery protection in the connection head may be used in filling,
displacement and operating water lines.
7.3.1 Solenoid valve block
This diagram shows an original valve

block from Westfalia Separator which
is used in filling, displacement and op-
erating water lines.
Fig. 82
Connections
A Connecting terminal + 24 V DC
B Connecting terminal + 0 V DC
C Earth
D Status LED
Fig. 83
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Westfalia Separator
7.3.2 Terminal box
All valves and monitoring instruments

are installed ready-to-connect on a lo-
cal terminal box at the separator.
• The connection to the control cabi-
net must be carried out by means of
a joint cable in accordance with the
adjacent connection diagram.
A Control cabinet
B Product discharge pressure
C “Self-Think” system
D Water sensor
E Circuit valve
F Water discharge valve
G Filling, displacement water valve
H Operating water valve
Fig. 84
2058-9601-010 / 0107
Westfalia Separator
7.3.3 Separator with UNITROL monitoring function
Fig. 85
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.
7.4 Temperature guard

The temperature guard (min./max.) serves to monitor the temperature of the
dirty oil 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. 86
• The temperature guard must be fitted

– before the 3-way piston control valve.
– in such a way that the immersion sleeve is always flushed with oil.
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Westfalia Separator
7.5 Dual-purpose thermometer

• The dual-purpose thermometer is used
– to monitor the temperature of the dirty oil after the pre-heater and
– for local temperature indication.
ATTENTION!
• The dual-purpose thermometer is used only in conjunction with a C7 control
system.
Fig. 87 Fitting proposals
• The dual-purpose thermometer must always be fitted before the 3-way piston
control valve.
• All sensors must be installed so that they are continuously flushed with oil.
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Westfalia Separator
7.5.1 Electrical connection
Fig. 88
A C7-control unit
B Analogue input A1-3 for product temperature monitoring
C Screened line
D Potentiometer for max. temperature adjustment
E Measuring transducer PT-00 / 4 – 20 mA
F Feelers
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 VDC!)
2058-9601-010 / 0107
Westfalia Separator
7.6 Electrical installation of transmitters and electric motors

• The connection of motors and transmitters by means of cable loop enables
easy replacement and function testing of the components.
Example 1
Fig. 89
Example 2
Fig. 90
7.7 Electrical execution

The electrical execution must be in accordance with the following standards and
recommendations in so far as specifications and standards issued by the classi-
fication societies do not have to be met.
The applicable standards at Westfalia Separator are

– the European standard EN 60 204 – Part 1 or
– VDE 0113 – Part 1
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Westfalia Separator
7.7.1 Earthing the separator
• The separator must always be

earthed.
The earthing connection A is always

located on the motor side beneath the
motor flange.
Fig. 91
7.7.2 Voltage equalisation of the separator
Including the insulated installed sepa-

rator in the voltage equalisation of the
installation is done via the voltage
equalisation connection on the motor
side. This applies always.
If there is no protective conductor in

multi-core cables and leads (e.g. in the
armoured marine cable), the drive mo-
tor must likewise be included in the
voltage equalisation.
The same applies for pump motors
and electric pre-heaters.
Fig. 92
The cross-section of the voltage

equalisation conductor, normally insu-
lated green-yellow, is dimensioned to
the largest external conductor on the
respective consumer.
In practice, table 1 in EN 60204-1 is

used for this.
Westfalia Separator selects:

10 mm2 < S < 25 mm2 Cu
Fig. 93
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Westfalia Separator
7.7.3 Voltage equalization of the electric heater
Fig. 94
7.7.4 Voltage equalization of the foundation frame
• The foundation frame must be fitted

with a marked connecting bolt for
voltage equalisation by the cus-
tomer.
Fig. 95
Fig. 96
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Westfalia Separator
7.7.5 Voltage equalisation of the control cabinet

• The connection is via the PE-bar or terminal inside the cabinet to the frame
connection.
PE connection
Fig. 97
PE connection
Fig. 98
PE connection
Fig. 99
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Westfalia Separator
7.8 Electric motors procured by the customer

• When the motors are procured by the customer, they must have the following
specifications and comply with the following standards:
Design IM B5* according to IEC 34 – Part 7
Rating Classification according to IEC 72 – Part 2
Enclosure IM B5 according to IEC 34 – Part 5

Quality stage N * / S *according to IEC 34 – Part
Vibration severity 14,
Full key balanced * / Half key balanced *
50 Hz 60 Hz
Synchronous speed
3000 * / 1500 * 3600 * / 1800 *
Type of cooling 1C411 according to IEC 34 – Part 6
Flange dimensions according to IEC 72
Shaft dimensions according to IEC 72
Direction of rotation according to IEC 34 – Part 8
Insulation material class F according to IEC 34 – Part 1
PTC thermistors as full motor protection

• The PTC resistors mist be fitted in the end
Motor protection windings – one per strand.
• PTC resistors – temperature feelers which are
mounted on the winding package from the
outside are not acceptable!
Operating mode SI according to IEC 34 – Part 1
* dependent on separator model
ATTENTION!
Consequential damage on the separator caused by motors procured by
the customer cannot be accepted as a warranty claim by Westfalia Sepa-
rator.
2058-9601-010 / 0107
Westfalia Separator
7.9 Installation and operation of control units
IMPORTANT:

– the control unit is not exposed to dust and aggressive atmosphere.
– the control unit is not installed in an excessively humid environment or
damp area.
– the sun cannot shine on the control panel or displays making operation and
observation more difficult.
– heating up of the control unit is avoided.
• Where appropriate, check screw-type and plug-type connectors for secure

contact.
• Connect thermostatically controlled cabinet heating to external voltage and
switch it on.
• The control cabinet heating must switch on before the temperature drops be-
low the dew point.
• Bedewing can occur during the night which is not good for electronic appara-
tus.
• Check that the line voltage and frequency conform to the connection data of
the control unit (see nameplate).
• Pay attention to admissible installation and operating data:
Voltage fluctuations +/- 10 % of the line voltage

Frequency fluctuations +/- 2 % of the line voltage
Ambient temperatures + 5 to + 45 °C (41 to 113 °F)
Atmospheric humidity max. 50 % at 40 °C (104 °F)
max. 90 % at 20 °C (68 °F)
Installation height above sea level up to 1000 m
Transport temperatures – 25 to + 55 °C (–13 to 131 °F)
ATTENTION!
Improper installation and operation discharges the supplier from the war-
ranty obligation.
2058-9601-010 / 0107
Westfalia Separator
2058-9601-010 / 0107
Westfalia Separator
Mineraloil Systems GmbH
Take the Best – Separate the Rest
A company of GEA Group
Westfalia Separator Mineraloil Systems GmbH ● Werner-Habig-Straße 1 ● D-59302 Oelde (F.R. Germany)
Tel.: +49 (0) 25 22/77-0 ● Fax: +49 (0) 25 22/77-23 94 ●
http://www.westfalia-separator.com/ ● mailto:info@gea-westfalia.de

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Westfalia Separator

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© GEA Westfalia Separator

These guidelines specify the minimum specifications for designing and

Putting together and installing the installation components must be car-

We reserve the right to carry out technical modifications on the

Attention must be paid to the operating, maintenance and mounting in-

For your safety

• Use only genuine spare parts from Westfalia Separator.

1.1 Safety precautions ...................................................................................8

2.1 Space requirement for separators .........................................................22

3 Operating, filling and displacement water 43

3.1 Water quality..........................................................................................44

4.1 Compressed air quality ..........................................................................50

5.1 General ..................................................................................................54

6.1 Recommended criteria for solids tank ...................................................66

7.1 Control cabinet.......................................................................................76

7.7.4 Voltage equalization of the foundation frame ........................................87

1.1 Safety precautions ...................................................................................8

1.1 Safety precautions

Fig. 1 Installation example

1 Separator: 7 Solids tank venting

• The applicable regulations and standards of classification societies or other

Pay attention to the following points on storage and transport packaging.

• Handle fragile goods with care!

• Protect the goods against moisture and humidity.

• Protect the goods against heat!

• Pay attention when erecting the goods.

1.4.1 Installation of controls

• Select the installation site so that

• Connect thermostatically controlled cabinet heating to external voltage and

Voltage fluctuations +/- 10 % of the line voltage

The adjacent packing illustrates a

• After removing the side boards and

• If no forklift trucks are available,

• Attach ropes round the case and

1.5.1 Transporting the separator

• When transporting rope, make sure

Separator with gear drive

• Hang the ropes into the eye bolts

• Do not use the eye bolt of the mo-

For OSD 6 or 18 – separator with belt drive

• Screw double nipple 1 into the hole

• Attach the transport ropes

• Do not use the eye bolt of the mo-

For OSD 35 – separator with belt drive

• Screw two eye bolts 1 into the upper

• Attach the transport ropes

• Do not use the eye bolt of the mo-

For OSD 60 – separator with belt drive

• Attach the transport ropes

• Do not use the eye bolt of the mo-

1.6 Preservation measures on site

After installation until commissioning

2.1 Space requirement for separators .........................................................22

2.1 Space requirement for separators

2.1.1 Separators with gear drive

• The hatched area represents the operating area.

Front view of separator

Side view of separator

Top view of separator

2.1.2 Separators with belt drive

• The hatched area represents the operating area.