GEA OSE 20-0136-067 User manual

GEA Mechanical Equipment / GEA Westfalia Separator Group
Instruction manual
Designation
Mineral oil centrifuge with self-cleaning bowl
Type
OSE 20-0136-067
No.
2064-9001-001
Edition
1010

2 2064-9001-001 / 1010
Westfalia Separator®
ORIGINAL INSTRUCTION MANUAL
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 (Germany)
Phone [phone], Fax [phone]
[email protected]om, www.westfalia-separator.com

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Westfalia Separator®
GEA Westfalia Separator Group GmbH
59302 Oelde, Germany
Type S/N:
Year of manufacture
Max. admissible rated bowl speed in min-1
Max. admissible density in kg/dm3of product
Heavy
liquid kg/dm
3
Solids kg/dm3
Min/max throughput m3/h
Min/max temp. of product in °C
Min/max housing pressure range in bar
This nameplate must be filled in by the operator.
Please transfer the data from the centrifuge nameplate.

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Westfalia Separator®
For your safety
•
Take special care when carrying out operations marked with this
symbol -
otherwise danger to life!
•Strictly adhere to instructions marked with this symbol.
This avoids damage to the separator and other equipment.
Note:
•This symbol is not a safety precaution but rather a reference to infor-
mation which help to better understand the separator or plant compo-
nents and the processes.
•Observe the accident prevention regulations!
The local safety and accident prevention regulations apply uncondi-
tionally to the operation of the separator. The plant operator must en-
sure compliance with these regulations.
•
When operating electrical apparatus, certain parts carry danger-
ous voltage.
Before working in electrical
components, take adequate preventive
measures according to the national provisions (in Germany in accor-
dance with the rules and regulations of the VDE (Verein Deutscher
Elektrotechnik / Association of German Electrical Engineering) or of
the local electric power company.
Non-
compliance with the protective measures can result in serious
damage to persons or property.
Any work on electrical components may only be carried out by an au-
thorized electrician.
•Only qualified or authorized specialized staff may operate, main-
tain and repair the separator.
Corresponding training courses take place in the manufacturer’s plant
or are held on site by the manufacturer.
•
Follow the instructions in the manual.
Follow only the instructions given in this manual.
Repair and maintenance work that goes beyond the scope described
in this manual may not be carried out.
•
Operate the separator only in accordance with agreed process
and operating parameters

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Westfalia Separator®
•Maintain the separator
as specified in this manual.
•Carry out safety checks on the separator,
as described in chapter "Safety precautions" in this manual
•Liability for the function of the machine passes to the owner.
Liability for the function of the machine passes unconditionally to the
owner or op
erator irrespective of existing warranty periods in so far as
the machine is improperly maintained or serviced by persons other
than GEA Westfalia Separator service personnel or if the machine is
not applied in accordance with the intended use.
GEA Westf
alia Separator shall not be liable for damage which occurs
as a result of non-observance of the above. Warranty and liability con-
ditions in the Conditions of Sale and Delivery of GEA Westfalia Sepa-
rator are not extended by the above.

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Westfalia Separator®
1Safety precautions 9
1.1 Correct usage ........................................................................................10
1.2 Non-compliance with the intended use..................................................11
1.3 Safety markings.....................................................................................12
1.3.1 Safety markings and their meaning.......................................................13
1.4 Basic operating principles......................................................................17
1.5 Operations on the separator..................................................................18
1.5.1 Demands on the operating and maintenance personnel.......................18
1.5.2 Spare part requirements........................................................................19
1.5.3 Assembly ...............................................................................................19
1.5.4 Electrical installation ..............................................................................22
1.5.5 Before start-up.......................................................................................23
1.5.6 Start-up..................................................................................................25
1.5.7 Shut-down and “Emergency-Off"...........................................................27
1.5.8 Voltage cutoff during operation..............................................................28
1.5.9 Maintenance and repair.........................................................................29
1.6 Corrosion ...............................................................................................33
1.7 Erosion...................................................................................................34
1.8 The health hazards involved when handling heavy oils and lube oils...36
1.8.1 Code of practice and personal protective measures.............................36
2Machine description 37
2.1 Standard dimensioned drawing of the separator...................................38
2.2 Section through separator .....................................................................40
2.3 General..................................................................................................41
2.4 OSE ...-0136-.........................................................................................41
2.4.1 Separator with water content and sludge space monitoring system
(WMS and SMS) for fuel oil treatment...................................................42
2.5 Main components of the separator........................................................43
2.5.1 Centripetal pump ...................................................................................45
2.5.2 Bowl .......................................................................................................46
2.5.3 Bowl hydraulics......................................................................................47
2.5.4 Drive.......................................................................................................50
2.5.5 Solenoid valve block..............................................................................51
2.6 Supervisory equipment..........................................................................55
2.6.1 Pressuretransmitter ...............................................................................55
2.6.2 Water detector .......................................................................................56
2.6.3 Solenoid valve .......................................................................................58
2.6.4 Vibration monitoring (Option).................................................................60
2.6.5 Speed monitoring...................................................................................61
2.7 Product feed line and product discharge line ........................................62
2.7.1 Throughput monitoring (product feed line A).........................................62
2.7.2 Throughput determination (product feed line A) -
only for control D10................................................................................63
2.7.3 Pressure monitoring (product discharge line B) ....................................64
2.8 Technical data .......................................................................................65
3Operation 67
3.1 Technical information.............................................................................68

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3.1.1 Separating with the unitrolplus system..................................................68
3.1.2 General information on bowl ejection ....................................................68
3.2 Before start-up.......................................................................................70
3.2.1 Before the first start-up – after maintenance and repair........................70
3.2.2 Before every start-up.............................................................................72
3.3 Starting the separator ............................................................................73
3.4 Monitoring of operation..........................................................................74
3.5 Setting the separation time....................................................................76
3.5.1 Mathematical calculation .......................................................................76
3.6 Ejecting the bowl....................................................................................77
3.7 Shutting down the separator..................................................................78
3.7.1 Shut-down “Emergency-Off"..................................................................80
3.8 Trouble shooting....................................................................................82
3.8.1 Trouble shooting....................................................................................82
3.8.2 Bowl faults..............................................................................................84
4Installation - Maintenance - Repair 91
4.1 Installation of the separator ...................................................................92
4.1.1 Transporting the separator ....................................................................94
4.1.2 Installing the separator ..........................................................................96
4.1.3 Motor......................................................................................................97
4.1.4 Direction of rotation of the bowl...........................................................100
4.1.5 Speed and starting time of the bowl ....................................................101
4.2 Fitting orifice plates, flow indicator, pressure transmitter ....................103
4.2.1 Installing the orifice plates ...................................................................104
4.3 Maintenance and lubrication................................................................105
4.3.1 Maintenance schedule.........................................................................105
4.3.2 Hoses and hose pipes.........................................................................112
4.3.3 Lubrication ...........................................................................................113
4.3.4 Lubrication Chart .................................................................................116
4.3.5 Table of lubricating oils........................................................................118
4.3.6 Comments on table of lubricating oils for separators from
GEA Westfalia Separator.....................................................................119
4.4 Bowl .....................................................................................................120
4.4.1 Dismantling the bowl............................................................................122
4.4.2 Cleaning the bowl................................................................................138
4.4.3 Cleaning the frame ..............................................................................139
4.4.4 Cleaning the strainer and the operating water feeding system...........139
4.4.5 Cleaning the motor ..............................................................................140
4.4.6 Important instructions for assembling the bowl ...................................141
4.4.7 Assembling the bowl............................................................................143
4.4.8 Replacing the polyamide gasket (bowl top).........................................157
4.4.9 Replacing the polyamide gasket (bowl top).........................................159
4.4.10 Reworking the sliding piston................................................................166
4.5 Closing the hood..................................................................................167
4.6 Drive.....................................................................................................170
4.6.1 Important instructions for fitting and removing the drive......................172
4.6.2 Removing the drive belt and spindle assembly...................................174
4.6.3 Dismantling the spindle assembly.......................................................178
4.6.4 Dismantling the centrifugal clutch........................................................180
4.6.5 Fitting the spindle assembly ................................................................184
4.6.6 Fitting the centrifugal clutch.................................................................186
4.6.7 Fitting the motor...................................................................................192
4.7 Height adjustment................................................................................197
4.7.1 Bowl height ..........................................................................................197
4.7.2 Centripetal pump clearance.................................................................198
4.8 Final checks after assembling the separator.......................................200

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4.9 Before a long-term shut-down of the separator...................................200
4.9.1 Preserving the separator .....................................................................200
4.9.2 Preserving the motor ...........................................................................201
4.10Storage ................................................................................................202
4.10.1 After delivery........................................................................................202
4.10.2 Separator.............................................................................................202
4.10.3 Control system.....................................................................................202
4.11 Before restarting ..................................................................................203
4.12 Disposal...............................................................................................204
4.12.1 Gear and lubricating oils......................................................................204
4.12.2 Cleaning liquids ...................................................................................205
4.12.3 Separator.............................................................................................205
4.13 Standard tools......................................................................................206
4.14 Special tools ........................................................................................208
5Spare parts 211
5.1 Spare part requirements......................................................................212
5.2 Guide to ordering spare parts..............................................................212

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Westfalia Separator®
1 Safety precautions
1.1 Correct usage ........................................................................................10
1.2 Non-compliance with the intended use..................................................11
1.3 Safety markings.....................................................................................12
1.3.1 Safety markings and their meaning.......................................................13
1.4 Basic operating principles......................................................................17
1.5 Operations on the separator..................................................................18
1.5.1 Demands on the operating and maintenance personnel.......................18
1.5.2 Spare part requirements........................................................................19
1.5.3 Assembly ...............................................................................................19
1.5.4 Electrical installation ..............................................................................22
1.5.5 Before start-up.......................................................................................23
1.5.6 Start-up..................................................................................................25
1.5.7 Shut-down and “Emergency-Off"...........................................................27
1.5.8 Voltage cutoff during operation..............................................................28
1.5.9 Maintenance and repair.........................................................................29
1.6 Corrosion ...............................................................................................33
1.7 Erosion...................................................................................................34
1.8 The health hazards involved when handling heavy oils and lube oils...36
1.8.1 Code of practice and personal protective measures.............................36

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Westfalia Separator®
1.1 Correct usage
Centrifugal separators – called separators in short – are used
•for the separation of liquid mixtures which consist of two liquids, with simulta-
neous removal of the solids contained in the liquids.
•for removing (clarifying) solids from a liquid.
The separator is designed
•for a very high bowl speed.
The admissible bowl speed depends on the chemical and physical properties
of the product:
– Temperature
– Density of the fluid and solid components.
•for products which contain no corrosive and erosive components.
The aggressiveness of the product influences the careful selection of the bowl
material.
Only products conforming to the specifications on the nameplate may be
processed.
•in accordance with the method of application of the separator agreed with
GEA Westfalia Separator. Refer to the data sheet and contractually agree-
ments.
•in accordance with the admissible utilities (cleaning agents, lubricants, operat-
ing liquids etc.) specified in the documentation or on the data sheet.
Intended use involves
•paying attention to the safety precautions, the instruction manual of the sepa-
rator and the safety markings on the separator.
•adhering to the data on the nameplate, e.g. maximum admissible bowl speed.
Further information on the intended use of the separator such as
– agreed areas,
– density of the product
– throughput capacities
– temperatures
– pressures etc.
is given in the documentation or the data sheet furnished with the documenta-
tion.
The contractually agreed conditions agreed with GEA Westfalia Separator on
the intended use of the separator must be passed on to the operating personnel
by the plant operator.
Any operating mode deviating from this is not intended use and can result
in severe damage to property and persons!

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Westfalia Separator®
1.2 Non-compliance with the intended use
Any use that deviates from the intended use is considered to be non-
compliant.
The separator may not be operated by:
•Persons who have not read and understood these basic safety precautions.
•Persons who have not read and understood the instruction manual of the
separator.
•Persons who have not been briefed on proper and correct operation.
•Persons who have not been adequately trained.
•Persons who have not reached the minimum age of 18 years.
The separator may not be operated
•when the product fed does not conform to the specifications on the name-
plate.
– Product with excessively high density
– Solids with excessively high density
– Product with excessively high temperature
•when the max. admissible bowl speed has been exceeded through electrical
or electronic manipulation of the drive.
•in an incomplete state of assembly, e.g.
– required supervisory equipment is not activated or has been switched off.
– the required safety and/or protective covers have not been installed.
•by persons who are not adequately trained.
•when the separator is operated with spare parts which do not come from GEA
Westfalia Separator.
Non-compliance with intended use can result in severe damage to prop-
erty and persons!

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1.3 Safety markings
The safety markings (adhesive and metal plates) are attached to all separators
on the hood and frame of the respective separator in such a way that they are
clearly visible.
All safety markings on the separator, control system and plant components must
always be in perfect condition.
•Clean dirty safety markings.
•Replace damaged safety markings.
Fig. 1 Example of markings on a separator
1
Pictograms (safety stickers)
2
Oil quality
3
Plates
4
Nameplate
5
Maker's nameplate
The texts and part numbers of the safety markings change depending on the
languages required by the customer.

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1.3.1 Safety markings and their meaning
The following safety markings must be attached to the separator as adhesive
labels.
Fig. 2
Refer to the machine documen-
tation!
•
Every person who is assigned the
task of installing, operating, main-
taining and repairing the machine
must have read and understood the
documentation.
•The documentation must be co
m-
plete kept near to the machine and
be readily accessible to the opera-
tors. It must be available to the op-
erators at all times!
Fig. 3

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Westfalia Separator®
Before carrying out work, dis-
connect power to all compo-
nents of the monitoring system!
Risk of injury due to electrical voltage
and unintended start-up of the separa-
tor!
Before carrying out
work on the
separator and electrical plant com-
ponents:
•
Make sure the separator is at a
standstill.
•
Switch off all electrical appliances
via the main switch,
•
Lock the installation to prevent it
from being accidentally switched on.
Fig. 4
Danger to life and limb through
rotating machine parts!
•
Do not loosen any part and do not
carry out maintenance or repair
work on the separator before the
separator is at a standstill.
Methods of how to check standstill
are described in the machine docu-
mentation.
Fig. 5
Warning of unusual noises or
vibrations!
When unusual noises or vibrations
occur on the separator:
•Immediately shut down the separa-
tor with filled bowl via “emergency-
off”.
•Never trigger a bowl ejection!
•Evacuate the room.
•Do not re-enter the
room until the
centrifuge has come to a standstill.
Fig. 6

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Westfalia Separator®
Frequency converter operation!
•When setting the frequency con-
verter, do not exceed the admissible
bowl speed (see nameplate)
Note:
This adhesive plate is only used for
frequency converter operation.
Fig. 7
Warning of extreme surface
temperatures!
The surfaces of the separator and
plant components can be hot!
Note:
This adhesive plate is only used for hot
operation.
Fig. 8
Danger due to electrical voltage!
Non-
compliance with the protective
measures can result in serious dam-
age to persons or property.
Before working on electrical separa-
tor/plant components:
•
Switch off all electrical appliances
via the main switch.
Fig. 9
CAUTION:
The parts marked in this way can carry voltage even when the main
switch is off!
•Lock the separator/plant to prevent it from being accidentally switched on.
•Take adequate preventive measures according to the national provisions (in
Germany in accordance with the rules and regulations of the VDE (Verein
Deutscher Elektriker / Association of German Electrical Engineers) or of the
local electric power company.
•The work may only be carried out by competent persons (qualified technical
specialists).

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Pictograms with warning text
Pictograms can be meaningfully supplemented as illustrated in the two following
examples:
– With warning text (Voltage is also present . .),
– with signal word (ATTENTION!) and warning text.
Bei ausgeschaltetem
Hauptschalter
unter Spannung!
Voltage also present
when main
switch is turned off!
Sous tension même
en position d’arrêt de
l’interrupteur principal !
Con el interruptor
principal desconectado se
encuentra bajo tensión!
Danger through external voltage!
Voltage also present when main switch
is turned off!
CAUTION:
The circuits marked in this way can
carry voltage even when the main
switch is off!
Fig. 10 Example 1
ACHTUNG!
Auch bei ausgeschaltetem
Hauptschalter können
orangefarbige Leitungen
unter Spannung stehen.
ATTENTION!
Also in case of switched off
main isolator orange coloured cores
can be under voltage.
ATTENTION!
Lorsque le commutateur principal
est éteint les files orange
peuvent être sous tension.
Danger through external voltage!
ATTENTION!
Also in case of switched off main isola-
tor orange coloured cores can be un-
der voltage.
CAUTION:
The circuits marked in this way can
carry voltage even when the main
switch is off!
Fig. 11 Example 2
Note:
Orange coloured leads are fitted as standard at GEA Westfalia Separator.
Different colour leads can be fitted if requested by the customer!

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Westfalia Separator®
Potential equalisation (protec-
tive-earth terminal)
The grounding protection is a
measure
which, in the case of a malfunction,
leads off the touch voltage into the
earth.
Fig. 12
1.4 Basic operating principles
Separators are used for the separation of liquid mixtures or for the separation of
solids out of liquids or liquid mixtures.
High centrifugal forces are produced in
the rotating bowl.
Fig. 13
Under the influence of the centrifugal forces, separation of the liquid mixture
and/or ejection of the solids particles takes place most rapidly.
The specifically heavier components are displaced to the bowl periphery, whe-
reas the specifically lighter components are displaced towards the centre of the
bowl.
The high centrifugal force is produced by very high bowl speeds. On the one
hand, high bowl speeds signify high efficiency, while on the other hand, they
signify high material stressing of the separator.

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Westfalia Separator®
1.5 Operations on the separator
The separator works reliably, provided
that it is operated and maintained in
accordance with our operating instruc-
tions.
Fig. 14
Special attention must be given to:
•Assembly
•Electrical installation
•Before start-up
•Start-up
•Shut-down
•Maintenance and repair
1.5.1 Demands on the operating and maintenance personnel
Operating, maintaining or repairing the separator or the separator plant requires
specialized knowledge.
CAUTION!
Operating, maintenance or repair work by unqualified or unauthorized
personnel can lead to operating, assembly and handling errors and severe
damage to persons and property.
GEA Westfalia Separator accepts no liability for damage caused by un-
qualified or unauthorized personnel!
For operation, maintenance and repair work, personnel may only be deployed
who
•have reached a minimum age of 18 years.
•are demonstrably familiar with the state-of-the-art through briefings and train-
ing.
•are adequately qualified for performing the work and checking it.
Electrical work may only be carried out by an authorized electrician!
The operator of the separator or separator plant
•is responsible for the necessary skills and knowledge of the personnel.
•is responsible for briefing and training the personnel.
•must be sure that the personnel have read and understood the manuals nec-
essary to carry out their work.

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Westfalia Separator®
GEA Westfalia Separator offers an extensive range of training and advanced
training courses. You can obtain further information from GEA Westfalia Sepa-
rator or from one of the authorized representatives.
1.5.2 Spare part requirements
•Use only genuine spare parts from GEA
Westfalia Separator. The original spare parts
are listed in the spare parts catalog.
The use of non-genuine parts leads to:
– safety risks,
– reduced durability of these parts,
– reduced availability of the separator and
– increased service requirement.
If a safety risk occurs when using non-
original
spare
parts, this may have legal consequences
for the responsible persons. In such cases,
GEA
Westfalia Separator accepts no liability or war-
ranty claims.
Fig. 15
1.5.3 Assembly
•
If the plant has several centrifuges,
be careful not to interchange parts of
different bowls since each bowl has
been balanced individually.
The bowl parts are marked with the
serial-
number of the machine or with
the last three digits of the serial-
number.
Fig. 16
•
Damaged parts must be replaced
immediately by new or
reconditioned
parts.
Fig. 17

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CAUTION:
•Some bowl parts may be pre-
assembled and balanced only by
specialists from GEA
Westfalia
Separator or in workshops au-
thorized by Westfalia Separator.
Unqualified balancing can lead to
dangerous operating states (vi-
brations) and destruction of the
separator with danger to life.
Fig. 18
•
To avoid unbalance, when replacing
some bowl parts like
– Lock ring
– Bowl top
– Distributor
– Bowl bottom
– Water chamber bottom
GEA
Westfalia Separator must be
consulted.
These parts
–
are marked with a footnote in the
separator manual (see section
“Bowl”).
–
are marked in the column “ETS” of
the parts list with a 3 or 4.
Fig. 19
•
Some bowl parts are arranged in
fixed positions relative to one an-
other.
•Locking
devices and alignment
marks must be in perfect condition.
The bowl must otherwise not be op-
erated.
Fig. 20
•
When transporting and assembling
machine parts, avoid crushing and
shear strain.
Fig. 21