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

2064-9001-001 / 10103
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.

4 2064-9001-001 / 1010
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

2064-9001-001 / 10105
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.

6 2064-9001-001 / 1010
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

2064-9001-001 / 10107
Westfalia Separator®
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

8 2064-9001-001 / 1010
Westfalia Separator®
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

2064-9001-001 / 10109
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

10 2064-9001-001 / 1010
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!