Westfalia Separator

Mineraloil Systems GmbH I

Installation Guidelines

No. 2020-9601-000

Edition 0905

Visco Booster Units

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II Mineraloil Systems GmbH

Subject to modification!

GEA Westfalia Separator Mineraloil Systems GmbH reserves the right to

make
modifications without prior notice.
The authors are always grateful for comments relating to
possible errors or omissions and suggestions for improving
this publication.
You can request copies of this publication from our local agencies.
Prepared by:GEA Westfalia Separator Mineraloil Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde

© 2005 – GEA Westfalia Separator

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Preface
These installation guidelines
• are part of the overall documentation compiled for the Visco
Booster Unit.
• describe the procedures for constructing, manufacturing and
designing Visco Booster Unit installations.
• contain fundamental instructions for installing Visco Booster Unit
installations.
• contain general guidelines for Visco Booster Unit installations.

These guidelines specify the minimum specifications for designing

and constructing frames, piping and the electrical installation.

Installation work on the installation must be carried 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 Visco Booster Unit!

For your safety

• Strictly adhere to instructions marked with this

symbol.
This avoids damage to the Visco Booster Unit 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.

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1 General 1

1.1 Safety precautions........................................................................................................................ 1

1.2 Material ........................................................................................................................................ 1
1.3 Installation.................................................................................................................................... 1
1.4 Storage.......................................................................................................................................... 2
1.5 Transport ...................................................................................................................................... 3
1.6 Preservation measures on site..................................................................................................... 5

2 Visco Booster Unit 6

2.1 Space requirement for Visco Booster Units................................................................................ 6

2.1.1 Standard Visco Booster Unit........................................................................................................ 6
2.1.2 Removing the heaters.................................................................................................................. 7
2.2 Foundations / Vibrations ............................................................................................................. 8
2.3 Securing the Visco Booster Unit.................................................................................................. 9

3 Supply pipes 11

3.1 Heating medium ........................................................................................................................ 11

3.2 Compressed air ........................................................................................................................... 11

4 Product lines 11

4.1 Maximum suction head ............................................................................................................. 13

4.1.1 Pressure line................................................................................................................................ 13

5 Electrical installation 14

5.1 Control cabinet........................................................................................................................... 14

5.2 Control panel of control cabinet .............................................................................................. 14
5.2.1 Electrical connection.................................................................................................................. 15
5.2.2 External voltages........................................................................................................................ 15
5.2.3 Shipboard operation.................................................................................................................. 16
5.2.4 Onshore operation..................................................................................................................... 16
5.3 Electromagetically compatible installation.............................................................................. 16
5.4 Electrical execution .................................................................................................................... 17
5.4.1 Voltage equalisation of the pumps .......................................................................................... 17
5.4.2 Voltage equalisation of the electric heater ............................................................................. 17
5.4.3 Voltage equalisation of the foundation frame ....................................................................... 18
5.5 Storing and handling the electrical equipment of VBU.......................................................... 19
5.6 Installation and operation of control units.............................................................................. 20

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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note

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1 General

1.1 Safety precautions • Pay special attention to the safety precautions contained
in the overall documentation compiled for the Visco
Booster Unit!

1.2 Material • The specified material must conform to the standards set out in
these installation guidelines as a minimum requirement.
• All materials used must be new and from the same series.

1.3 Installation

Fig. 1 - Installation example

• Special regulations issued by classification societies or other

authorised societies must be observed.
• Operating elements must not be mounted high than 2,300 mm
above the working platform.
• The installation must be arranged so that it does not cramp the
working area and so that it 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.
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 galvanised parts may be fitted in product-carrying lines (e.g.
heavy oil, diesel oil, thermal 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 (turned through
90°).
If this is not possible for space reasons, the dirt pan can be fitted
vertically with a through-flow from top to bottom. In this case,
ensure that the strainer can be dismantled.
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).
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.

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1.5 Transport

The adjacent
figure illustrates a
seaworthy
packaging from
Westfalia
Separator.

Fig. 2

• Transport the case with the aid

of a crane (see fig. 3 and 4).

Fig. 3

• 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.

Fig. 4

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Attention!
Prevent accidents by using suitably rated hoists for transport and installation.

• The rope must be properly

attached to the machine.

Fig. 5

Attention!
For safety reasons, the unpacked Visco Booster Unit may
only be lifted with the aid of a cross-beam.

The following example shows how the transport ropes must

be attached:

• When transporting the machine

using ropes, make sure that the
ropes do not damage the pipes,
control cabinet or heater, etc.
• The rope must be properly
attached to the cross-beam.
• Ensure that no pulling or
pushing forces act on machine
parts when using ropes.

Fig. 6

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• When transporting the

machine, make sure this is
done according to the
guidelines of Westfalia
Separator.

Fig. 7

1.6 Preservation After installation until commissioning

measures on site
• All parts such as tools and spare parts 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.

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2 Visco Booster Unit

2.1 Space requirement for • No piping may be laid in the operating area apart from the
Visco Booster Units feed and discharge lines for the Visco Booster Unit.

2.1.1 Standard Visco • The hatched area represents the operating area.
Booster Unit • See the following table to determine the operating area.

Top view of Visco

Booster Unit

Fig. 8

Table for determining the operating area for Visco Booster Units:

Dimensions in mm
Visco Booster Unit A B C D
VBU 3.5 800 600 600 600
VBU 5.0 800 600 600 600
VBU 7.0 800 600 600 600
VBU 9.5 800 600 600 600
VBU 12.5 800 600 600 600
VBU 16.5 800 600 600 600
VBU 21.0 800 600 600 600
Fig. 9

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2.1.2 Removing the heaters

• Prior to installation of the Visco Booster Unit, special attention must be paid to the
height dimension (E + 200 mm) for removal of the heaters! The height dimension E
is specified in the order-specific installation diagrams!

Side view of Visco

Booster Unit

Fig. 10

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2.2 Foundations / Vibrations

1 Vibrations

Fig. 11

In the case of dynamic loads, the main distinction is between vibrations and shocks. In physical
terms, these two phenomena are similar. A distinction is nevertheless made between them,
because they have differing effects.

Vibrations recur periodically. Many of these phenomena are generally known, e.g. vibrations
caused by engines and the movements of ships in ocean swells, etc.

Shocks are limited to infrequently occurring events, such as those that can be observed in an
impact or when an object is dropped or falls over. The key concept is made clear in the terms
"nudging", "pushing off" and "shunting impact".

When installing the Visco Booster Unit, make sure that no vibrations or impacts are transmitted
into the Visco Booster Unit installation.

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2.3 Securing the Visco The following sections show how to secure the Visco Booster Unit
Booster Unit

Fitting the Visco Booster Unit

aboard a ship

• The foundation frame can

be welded directly to the
steel structure of the
shipyard if it can be
ensured that vibrations
will not affect the
installation.

Z= Foundation

Fig. 12

Fitting the Visco Booster Unit on land

• The foundation frame can be bolted directly to

the designated foundation.

Fig. 13

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Example 1

• The welds should be 100

mm long.
• The welds should be
spaced approx. 350 mm
apart.
• This means that three
welds with a length of
100 mm each are produced
per metre.

Example 2

• The foundation frame can

also be welded all round.

Fig. 14

Detail view X

• This view shows an example for

welding the foundation frame to
the steel structure.
Z= Filled weld

Fig. 15

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3 Supply pipes

3.1 Heating medium • In the case of operation with steam, provision must be made for
proper and correct discharge of the condensate.

3.2 Compressed air • The compressed air must be free from impurities.

Recommended set-up of compressed air line per treatment system:

• A supply pressure of 0.6 to max. 1.0 MPa is admissible.

• Compressed air must be available to components such as the
mixing tank, automatic filter and other valves.

4 Product lines

• 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.
• Dimensioning of the product pipes is specified in the order-specific documents.
• Pipe resistances must be kept as low as possible.
• Recommended feed velocities: 0.5 – 0.65 m/s
• Recommended discharge velocities: 1.5 – 1.8 m/s

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Selection diagram

Fig. 16

Q Flow
v Velocity in m/s

Example:
• A VBU 7.0 will serve as the basis in our example:

- with a feeder part flow rate of (40.83 l/min ) and a feed velocity
of 0.5 – 0.65 m/s the resulting diameter is
- with a booster part flow rate of (89.32 l/min) and a discharge
velocity of 1.5 – 1.8 m/s the resulting diameter is

• Feeder part: DN 40
• Booster part: DN 40

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4.1 Maximum suction • The suction head of the feed pump is 0.06 MPa (absolute). (The
head suction head is approx. 4 m water column for diesel oil.)
• 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.

4.1.1 Pressure line • The pressure head of the feed pump is set to approx. 0.4 MPa.
(refer to order-specific data sheet)
• When dimensioning the pressure line, it must be ensured that
the total pressure loss in the pipes from the VBU to the machine
does not exceed 0.05 MPa.

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5 Electrical installation

5.1 Control cabinet

Fig. 17

5.2 Control panel of control 1A1 Operator device

cabinet U10 Viscosity controller
P20 Consumption meter
H1 MDO mode
H2 HFO mode
1S1 Feed pump 1
Standby – 0 – Automatic
2S1 Booster pump 1
Standby – 0 – Automatic
3S1 Feed pump 2
Standby – 0 – Automatic
4S1 Booster pump 2
Standby – 0 – Automatic
13H1 Trace heating malfunction
13H2 Trace heating operation
1SH10 Feed pump 1
Manual 0 – 1
2SH10 Booster pump 1
Manual 0 – 1
3SH10 Feed pump 2
Manual 0 – 1
4SH10 Booster pump 2
Manual 0 – 1
13S1 Trace heating 0 - 1
1S01 Emergency Stop
Q1 Main switch, mains 1
Main switch, mains 2
Q2
Cabinet fan
M3

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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
mm
6 Wall

Fig. 18

• Select the installation site so that

– it must be possible to open the control cabinet door wide so that
the door latch can lock into place. (refer to section 2.1)
– 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.
• Although buttons and switches and the electronic control unit are
protected against moisture by protective foil and the door seal,
the cabinet nevertheless must 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 installation is at a standstill.

5.2.1 Electrical • The control unit is designed for a connected voltage as indicated
connection on the nameplate inside the control cabinet.

5.2.2 External voltages • The floating contacts of the output modules

– carry external voltage (even when the main switch is off!)
– can be identified by the orange coloured internal 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
2

interlocking lines.

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5.2.3 Shipboard • For shipboard operation

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.
Cable glands for shipboard installation

Cable outer
Female Screw Earthing device + type of
∅
thread coupling inner parts
[mm]
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 A11 + 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

5.2.4 Onshore operation • The local rules and regulations of the operator must be
observed!
• for onshore operation
– Normally, unarmoured "ölflex" cables are used and "NSSHÖU" for
outside installation.
– 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.

5.3 Electromagetically • The control cabinet is designed to be electromagnetically

compatible compatible.
installation
• The following must be taken into account for electromagnetically
compatible installations:
– Earthing straps
– Voltage equalisation
– Screening lines
– Separate line routing
– Use of suppressers in case of inductance.

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5.4 Electrical executionThe electrical execution must be in accordance with the following
standards and recommendations in so far as specifications and
standards issued by the classification societies do not have to be met.
The applicable standards at Westfalia Separator are
– the European standard EN 60204 – Part 1 or
– VDE 0113 – Part 1

5.4.1 Voltage Inclusion of the installed pumps

equalisation of the in the voltage equalisation of the
pumps installation is done via the
voltage equalisation connection
on the motor side. This always
applies.
If there is no protective
conductor in multicore cables
and leads (e.g. in the armoured
marine cable), the drive motor
must likewise be included in the
Fig. 19 voltage equalisation.

The cross-section of the voltage

equalisation conductor, normally
insulated green-yellow, is
dimensioned according to the
largest external conductor on the
respective consumer.
In practice, table 1 in EN 60204-1
is used for this.
Westfalia Separator selects:
2 2
10 mm < S < 25 mm Cu

Fig. 20

5.4.2 Voltage
equalisation of the
electric heater

Fig. 21

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5.4.3 Voltage • The foundation frame is fitted

equalisation of the with a marked connecting bolt
foundation frame for voltage equalisation by the
customer.

Fig. 22

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5.5 Storing and

• If the installation site is not yet completed or the masonry work is
handling the
not finished, do not remove the original packing or the protective
electrical
foil.
equipment of VBU
• It must be ensured that during storage the electrical equipment is
not exposed to temperatures above + 55 °C (131 °F) or below
+ 2 °C (35.6 °F) or to an aggressive atmosphere and that neither
soiling nor dew formation occurs.
• Windows and displays on control cabinets must be covered to
protect them during assembly and up to commissioning.
• Monitors as desktop models which are not suitable for operating
and observing in the immediate vicinity of the machine may only
be installed in dry rooms, air conditioned where appropriate, e.g.
control rooms. This also applies to controls and control stations in
enclosure IP 54.
• Dust and aggressive atmospheres are not admissible.
• Cabinet heating – if available – has to be connected to the
external voltage and switched on in time, i.e. before the
installation is put into operation.
• Bottom plates for cable entry in standing cabinets and desks must
not be removed.
• If dust has penetrated, the control cabinet must be blown out with
dry air before it is taken into operation.
• The bags with drying agent may only be removed after switching
on the control cabinet. The drying agent is active for about one
year.
• The ambient temperature must not exceed + 45 °C (113 °F) and the
relative atmospheric humidity must be < 70 %.

IMPORTANT:
Improper storage and handling discharges the supplier from
the warranty obligation.

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5.6 Installation and • Outdoor exposure is not admissible!

operation of
• Select the installation site so that
control units
– 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.
• 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 mains voltage
Frequency fluctuations +/- 2 % of the mains frequency
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 altitude above sea level up to 1,000 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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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note

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Note
Notes
Notizen
Anotaciones
Notizen
Notes
Note

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Mineraloil Systems GmbH
Mechanical Separation
Division

A company of the GEA Group

Westfalia Separator Mineraloil Systems GmbH • Werner-Habig-Straße 1 • D-59302 Oelde •

Tel. +49 (0) 25 22 / 77-0 • Fax +49 (0) 25 22 / 77-2394 •

http://www.westfalia-separator.com / mailto: info@gea-westfalia.de