Safety Precautions and User Instructions

for
Machine and Plant Components

No. 2058-9601-100

Edition 1110

GEA Mechanical Equipment / GEA Westfalia Separator Group

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ORIGINAL INSTRUCTIONS
Subject to modification!

The authors are always grateful for comments and suggestions for improving
the documentation. They can be addressed to:

GEA Mechanical Equipment

GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde
Tel. +49 2522 77-0, Fax +49 2522 77-2488
ws.info@geagroup.com, www.westfalia-separator.com

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1 About this document 5

1.1 Scope of application ................................................................................ 6

1.2 Qualification of the personnel .................................................................. 6
1.2.1 Operating personnel ................................................................................ 6
1.2.2 Service and repair personnel ................................................................... 6
1.3 Structure of the documentation................................................................ 7
1.4 Symbols used .......................................................................................... 7
1.5 Warnings .................................................................................................. 8

2 Safety precautions 9

2.1 Intended use .......................................................................................... 10

2.2 Non-compliance with the intended use .................................................. 10
2.3 Residual risk .......................................................................................... 10
2.4 Safety markings ..................................................................................... 11
2.5 Safety instructions for the personnel ..................................................... 12
2.6 Adjustments / commissioning ................................................................ 12
2.7 Maintenance and servicing .................................................................... 12
2.8 Special types of hazard ......................................................................... 12
2.8.1 Electricity................................................................................................ 12
2.9 Oils, greases and other chemical substances ....................................... 13

3 Product overview 15

3.1 Description and operating principles ..................................................... 16

3.2 Operating conditions .............................................................................. 16
3.3 Transport................................................................................................ 16
3.4 Storage .................................................................................................. 16

4 Installation 17

4.1 Measures to be taken prior to installation .............................................. 18

4.2 Mounting ................................................................................................ 18
4.2.1 Fitting with threaded connection ............................................................ 18
4.2.2 Fitting with flange connection ................................................................ 18
4.3 Electrical connection .............................................................................. 19
4.4 Pneumatic connection ........................................................................... 19
4.5 Explosion-hazarded zone ...................................................................... 19

5 Maintenance and servicing 21

5.1 Cleaning and care .................................................................................. 22

5.2 Maintenance .......................................................................................... 22
5.3 Repair .................................................................................................... 22

6 Disposal 23

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7 Spare parts 23

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1 About this document

1.1 Scope of application ................................................................................ 6

1.2 Qualification of the personnel .................................................................. 6
1.2.1 Operating personnel ................................................................................ 6
1.2.2 Service and repair personnel ................................................................... 6
1.3 Structure of the documentation................................................................ 7
1.4 Symbols used .......................................................................................... 7
1.5 Warnings .................................................................................................. 8

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1.1 Scope of application

These Safety Precautions and User Instructions provide important support for
– avoiding risks,
– reducing repair cost and down times, and
– extending the life cycle of components
The term “component” will be used in singular although this document is appli-
cable to all components incorporated in the separators/plants.
To ensure perfect operating safety of the component, these safety precautions
and user instructions have to be thoroughly read and understood prior to:
– installation
– transport, storage
– maintenance work (cleaning and care, maintenance, servicing, repair) and
– disposal
For questions that cannot be solved with the aid of this documentation, please
check back with GEA Westfalia Separator Group.

1.2 Qualification of the personnel

Using these safety and user instructions and direct handling of the component
require specialist qualification of the staff. For identifying the qualification level
GEA Westfalia Separator Group uses the following standard terms:

1.2.1 Operating personnel

• Qualified staff have the necessary technical know-how and extensive ex-
perience enabling them to avoid the risks that can arise when handling elec-
trical or mechanical components. English language skills are prerequisite.
• Trained staff are instructed or supervised by qualified staff to enable them to
avoid the risks that can arise when handling electrical or mechanical compo-
nents.
When installing, operating and testing the equipment, the staff has to adhere to
the safety rules applicable in the respective industry.

1.2.2 Service and repair personnel

Service and repair work require specialist knowledge and skills. Such work may
be carried out only by competent persons in terms of specialist knowledge and
skills. Documents in English are provided for this circle of persons. It is essential
that this circle of persons has an adequate command of English.

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1.3 Structure of the documentation

Danger through non-observance of the documentation

• Refer to all the documents listed!
– Instruction manuals for separators and/or start-up and shut-down instruc-
WARNING! tions for plants
– Safety and user instructions on machine and plant documentation
– Component manual
• All safety precautions and warning instructions given in the documents have
to be adhered to!
• Access to the documentation on site must be ensured at all times.

The standard documentation for components comprises:

1. Instruction manuals for separators and/or start-up and shut-down instruc-

tions for plants
2. Safety and user instructions on machine and plant documentation (this
document).
3. Reference to component manual and / or technical datasheet of the com-
ponent.

1.4 Symbols used

This symbol gives information for better understanding the compo-

nent and its functions.

• A bullet point used when describing work and/or operation steps.

Be sure to proceed in correct order: from top to bottom.

– The dash (horizontal bar) is used for listing.

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1.5 Warnings
Hazards are marked as warnings with a signal word reflecting the gravity and
probability and allocated safety colours according to ANSI Z535;

Warning Meaning

Stands for an impending threat of a hazard which will result in

severe physical injury or even death.

ALARM

Stands for a potentially hazardous situation which could result

in severe physical injury or death.

WARNING!

Stands for a potentially hazardous situation which could result

in minor physical injury. This signal word can also be used for
warnings against damage to assets.
CAUTION!

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2 Safety precautions

2.1 Intended use .......................................................................................... 10

2.2 Non-compliance with the intended use .................................................. 10
2.3 Residual risk .......................................................................................... 10
2.4 Safety markings ..................................................................................... 11
2.5 Safety instructions for the personnel ..................................................... 12
2.6 Adjustments / commissioning ................................................................ 12
2.7 Maintenance and servicing .................................................................... 12
2.8 Special types of hazard ......................................................................... 12
2.8.1 Electricity................................................................................................ 12
2.9 Oils, greases and other chemical substances ....................................... 13

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The machine or plant component is built according to state-of-the-art and to

prevailing safety rules and regulations. However, when using the component,
risks may arise for the user or third party or the component or other assets
might get damaged if it is
– operated by untrained or uninstructed staff,
– incorrectly used,
– inadequately maintained or serviced.

2.1 Intended use

The component is incorporated in machines and plants.
Precise details on the function of the component are found in the component
manufacturer’s manual.
The characteristics of the medium specified in the data sheet and the pressure
and temperature limit values for the medium mentioned in the specification must
be adhered to at all times.
The specific values stated in the documents furnished with the component have
to be observed and adhered to.
Any use in an explosion-hazarded area is not allowed. The only exception: this
is confirmed in the order or is mentioned in the Instruction Manual or in the
manufacturer’s data sheet.

2.2 Non-compliance with the intended use

Any use that deviates from or exceeds the intended use is considered to be
non-compliant. Solely the user of the machine/plant will be responsible for dam-
age resulting from incorrect usage. This also applies to modifications performed
on one’s own.
Non-intended use is the use of
– materials with excessively high temperature
– materials under excessively high pressure
– material containing smouldering, burning, or sticking particles
– highly explosive and pasty materials
– materials chemically reacting with the material of the component
The user is solely responsible for the operation and/or rating of the component.

Incorrect usage of components

Death or severe bodily injury to persons or damage to assets through disre-
garding mechanical, chemical and electrical risks.
WARNING!
• The specific values stated in the documents furnished with the component
have to be observed and adhered to.

2.3 Residual risk

An element of risk will remain when using the components, even when strictly
adhering to all safety rules and regulations.
Any person working with the component has to be aware of these remaining
risks and must follow all the instructions avoiding accidents or damage.

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Hazardous voltage - danger to life

Risk of death or serious injury through electric shock!
DANGER • Work on electric apparatus and/or on live component equipment must be
performed by qualified staff only.
• Disconnect the power supply to electric equipment if required.
• Secure against unexpected restarting.
• Apply a warning sign prohibiting switching back on.

Danger when not using personal protective equipment

Risk of lethal injury when not using personal protective equipment (PPE)!
• Operating/maintenance staff must be obliged to wear PPE.
DANGER
• Wear safety boots, safety goggles, ear protection, etc., depending on tasks
and conditions.
• When surface temperatures of > 50 °C or < 0 °C (> 122 °F or < 32 °F) pre-
vail, wear temperature-resistant protective gloves when working on compo-
nents.

Danger through lack of attention when working in the area of the compo-
nent
Crushing, cutting and abrasion injuries.
WARNING! • Be sure to work and move carefully in the area around the component.

Risk of eye and/or skin injuries when medium discharges under high
pressure
Abrasive or corrosive substances destroy the component!
WARNING!
• Wear protective goggles or face-mask with eye protection against spouting
medium.

2.4 Safety markings

The following markings (adhesive and metal plates) are fastened to the compo-
nent or its accessories:

Warning of dangerous voltage!

The sign is fastened on the electric terminal box.

The terminal box may only be opened by a qualified electrician.

Nameplate The nameplate contains specific component data.

All safety markings must always be in perfect condition.

• Clean dirty safety markings.
• Replace damaged safety markings.

• Note the safety marking.

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2.5 Safety instructions for the personnel

The component must be operated only in perfect condition, for the intended use,
taking into account security rules and being aware of risks, duly adhering to the
documentation.
Any fault – especially those potentially impairing safety - must be remedied im-
mediately!
Clearly define and adhere to responsibilities for operation and maintenance.
This is the only way to avoid errors – especially in dangerous situations.
Do not use the component until all protection and safety devices are installed
and serviceable! Do NOT remove them during operation.
In case of malfunction or safety-relevant change in operational behaviour, shut
down and secure the separator or the plant. Have faults remedied by qualified
staff immediately.
Leaking dangerous material must be discharged so as to avoid danger to the
operator and to the environment.
Do NOT touch damaged, cracked and, especially, live components.

2.6 Adjustments / commissioning

The medium throughput might change or be interrupted while the component is
being commissioned. Prior to commissioning, make sure that there will be no
risk for people or the environment while performing adjustments.
Each adjustment must be followed by a functional check.
Take appropriate measures to prevent crushing injuries by moving adjustment
devices.

2.7 Maintenance and servicing

When carrying out maintenance work, strictly adhere to all rules and regulations
applicable for handling the component or the medium (e.g. protective clothing,
no smoking).
Adhere to the check-up or inspection intervals specified in applicable laws
and/or in the documentation.
Check wires and hoses for damage and replace if necessary, especially on
moving components.

2.8 Special types of hazard

2.8.1 Electricity
Never carry out work on live parts!
Do not change safety-related design parameters! Especially, do NOT restrict
leakage paths, air gaps, and clearances with insulating coatings.
Check wires for damage at regular intervals and replace if necessary.

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2.9 Oils, greases and other chemical substances

When handling oils, greases, and chemicals, adhere to the applicable rules and
regulations and manufacturers’ data sheets for these materials concerning stor-
age, handling, usage, and disposal!
After eye or skin contact, rinse the affected area immediately with water.

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Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note

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3 Product overview

3.1 Description and operating principles ..................................................... 16

3.2 Operating conditions .............................................................................. 16
3.3 Transport................................................................................................ 16
3.4 Storage .................................................................................................. 16

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3.1 Description and operating principles

The detailed description and functional principle of the respective component
are given in the corresponding component manual.

3.2 Operating conditions

Housing and gasket materials are selected in accordance with operating condi-
tions. Operating conditions essentially determine the service live of the compo-
nent.
• Technical characteristics and the essential permissible limit values, especially
for pressure and temperature of the medium, are given in the manufacturer’s
manual.
• Care must be taken that the component is only used where the rating criteria
comply with the values stated on the nameplate. Correct transport and appro-
priate storage are prerequisite.
• Faults arising from moving elements must be prevented by taking appropriate
measures.

3.3 Transport
Be sure to comply with the following:

Danger through contact with substances hazardous to health

During operation the component might have come into contact with substances
that are hazardous to health.
WARNING!
• De-contaminate the component prior to packing and/or transport.

• Use lifting devices to transport heavy components that cannot be moved by

hand.
• Screw eye bolts or lugs into the component and suspend them properly to the
lifting device, and then transport.
• When using lifting straps, place them around the component, provide sharp-
edge protection if required, and watch for proper weight distribution.
• During transport, protect the component against external force (impacts, vi-
bration, etc.).
• Protect the sealing surfaces of connections against damage.
• Do not damage the corrosion-preventive coating.

3.4 Storage
• Protect the component against external impacts and contamination.
– Keep the storage room as dry and dust-free as possible.
– Avoid water condensation.
– Protect open connection ports from dirt.

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4 Installation

4.1 Measures to be taken prior to installation .............................................. 18

4.2 Mounting ................................................................................................ 18
4.2.1 Fitting with threaded connection ............................................................ 18
4.2.2 Fitting with flange connection ................................................................ 18
4.3 Electrical connection .............................................................................. 19
4.4 Pneumatic connection ........................................................................... 19
4.5 Explosion-hazarded zone ...................................................................... 19

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• Refer to the component manual for specific information on the component.

• Before installation, read and follow the instructions in the chapter “Safety pre-
cautions”.
• Observe the accident prevention regulations!

4.1 Measures to be taken prior to installation

Packaging damaged during transport and/or storage

Component might not comply with safety rules.
• Check for possible damage prior to installation.
CAUTION!
• Do not install any defective component.

Ta ke th e fo llo win g m e a s u re s p rio r to in s ta lla tio n :

• Check that the line system and the component are perfectly clean.
• Remove protection caps from the connectors directly before installation only.
• Do NOT damage sealing surfaces and threads respectively.

4.2 Mounting
• Remove all packaging material immediately before installation only.
• No dirt particles must seep into the component!
• Bear in mind the flow direction indicated on the component if required.

Afte r in s ta lla tio n

• Check for possible leakage and for proper function.
• Create the specified operating status.

4.2.1 Fitting with threaded connection

• Use appropriate sealing aid.
• Arrange the piping layout so that flux across the component will be avoided.

4.2.2 Fitting with flange connection

• Use the specified screws. Use all the flange bores provided.
• Insert appropriate seals and center them properly between the flanges.
• Tighten the screws evenly and crosswise to prevent warping. Under no cir-
cumstances should the pipeline be pulled against the component.
• Watch for proper location of seals.
• Tighten screws to the specified torques.

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4.3 Electrical connection

For a component with electric equipment:

Hazardous voltage - danger to life

Risk of death or serious injury through electric shock!
DANGER
• Work on electric apparatus and/or on live component equipment must be
performed by qualified staff only.
• Disconnect the power supply to electric equipment.
• Prevent unexpected restarting.
• Apply a warning sign prohibiting switching back on.
• Earth the component according to local rules.
• Take adequate preventive measures according to the provisions of the local
electric power company.

4.4 Pneumatic connection

Actuate only with treated compressed air. If necessary, install a compressed air
control unit upstream-

4.5 Explosion-hazarded zone

Any use in an explosion-hazarded area is not allowed. The only exception: this
is confirmed in the order or is mentioned in the Manual or in the manufacturer’s
data sheet.

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Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note

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5 Maintenance and servicing

5.1 Cleaning and care .................................................................................. 22

5.2 Maintenance .......................................................................................... 22
5.3 Repair .................................................................................................... 22

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This chapter comprises: cleaning and servicing, maintenance and repair.

• Before carrying out maintenance and repair, read and follow the instructions
in the chapter “Safety precautions”.

5.1 Cleaning and care

Damage to the component, caused by a layer of dirt

Clogging of functional openings. Impairment of heat dissipation!
• Arrange for efficient covering of the component when carrying out dirty work
CAUTION!
near the separator or the plant (e.g. laying concrete, brickwork, painting, sand-
blasting).
• Clean the component regularly.

Malfunction due to damage to the component

Risk of material damage through inappropriate cleaning!
• When cleaning with aqueous detergents, note the type of protection of electric
CAUTION! components. Do not apply them when in doubt!
• Do not use aggressive cleaning agents. Otherwise metal or plastic surfaces as
well as hose connections might be attacked.
• Never clean sensitive components with hard brushes applying excessive force.
• Use lint-free cleaning rags only.

5.2 Maintenance
• The maintenance intervals have to be re-determined (shortened) by the op-
erator according to prevailing operating conditions.
• Check or maintain the component for safety reasons. When doing so, observe
the following minimum requirements:
– Check visible condition of the component and its accessories at regular in-
tervals.
– Actuate the component parts on a regular basis to ensure that proper func-
tioning of all moving parts will not be impaired by long-term standstill.

5.3 Repair

Material damage due to mechanical overload on component parts

Impacts by kicks, mechanical stress originating from connected pipelines, ex-
cessive ambient temperatures will destroy the component!
WARNING!
• Install parts without force. Avoid tension and strain.
• Avoid excessive load, e.g. impacts by kicks (wrongfully climbing on the com-
ponent).
• Avoid welding and thermal treatment.
• Avoid working on the components with tools (e.g. drilling).

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6 Disposal

• Comply with the prevailing statutory regulations to ensure proper, environ-

mentally sound disposal.

Danger through contact with substances hazardous to health

During operation the component might have come into contact with substances
that are hazardous to health.
WARNING!
• Decontaminate prior to disposal.

7 Spare parts

Spare, wear parts and operating materials can cause damage

to persons and assets if they do not meet the requirements.
Genuine spare parts and operating materials from GEA West-
falia Separator Group satisfy all requirements for the operating
safety of the machine or installation.
• Use only genuine spare parts.
• Use only original operating materials.
• Use the spare parts catalogue supplied.

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Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note

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®
Westfalia Separator
GEA Mechanical Equipment
GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde (Germany)
Phone +49 2522 77-0, Fax +49 2522 77-2488
ws.info@geagroup.com, www.westfalia-separator.com