Gea Osd 35-0136-067 User manual

Mechanical Separation

Division

Westfalia Separato

Mineraloil Systems GmbH

Instruction Manual and

Parts List

No.: 2057-9001-020

Edition: 0905

Designation: Mineral oil centrifuge with self-cleaning bowl

Model: OSD 35-0136-067

OSD 35-0196-067

Westfalia Separator

2Mineraloil Systems GmbH

2057-9001-020 / 0905

Subject to modification!

The authors are always grateful for comments and suggestions for improving

the documentation. They can be sent to

GEA Westfalia Separator Mineraloil Systems GmbH

Werner-Habig-Str. 1

D-59302 Oelde

Westfalia Separator

Mineraloil Systems GmbH 3

2057-9001-020 / 0905

Westfalia Separator Mineraloil Systems GmbH

D-59302 Oelde (F. R. Germany)

Model S/N

Built in øin mm

Max. admissible rated bowl speed in min-1

Max. admissible density in kg/dm3of product

Heavy liquid

kg/dm3

Solids

kg/dm3

min/max throughput m3/h

min/max temp. of product in °C

min/max housing in bar

This nameplate must be filled in by the operator.

Please transfer the data from the centrifuge nameplate.

Westfalia Separator

4Mineraloil Systems GmbH

2057-9001-020 / 0905

For your safety

• Strictly adhere to instructions marked with this symbol.

This avoids damage to the separator and other equipment.

• Take special care when carrying out operations marked with this

symbol -

otherwise danger to life.

Note: • This symbol is not a safety precaution but rather a reference to infor-

mation which help to better understand the separator or plant 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.

• 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

• 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 operator irrespective of existing warranty periods in so far as

the machine is improperly maintained or serviced by persons othe

than Westfalia Separator service personnel or if the machine is not

applied in accordance with the intended use.

Westfalia Separator shall not be liable for damage which occurs as a

result of non-observance of the above. Warranty and liability condi-

tions in the Conditions of Sale and Delivery of Westfalia Separator are

not extended by the above.

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1Safety precautions 9

1.1 Correct usage ........................................................................................10

1.2 Safety markings .....................................................................................10

1.2.1 Safety markings and their meaning .......................................................11

1.3 Basic operating principles...................................................................... 14

1.4 Bowl speed and product ........................................................................14

1.5 Demands relating to service personnel and spare parts .......................15

1.6 Operations on the separator ..................................................................16

1.6.1 Assembly ...............................................................................................16

1.6.2 Electrical appliances .............................................................................. 18

1.6.3 Before start-up .......................................................................................18

1.6.4 Starting...................................................................................................21

1.6.5 Shut-down and »Emergency-Off« .........................................................23

1.6.6 Maintenance and repair.........................................................................24

1.7 Corrosion ...............................................................................................27

1.8 Erosion...................................................................................................28

2Machine description 31

2.1 Dimensioned drawing of the separator..................................................32

2.2 Section through separator .....................................................................34

2.3 General ..................................................................................................35

2.4 OSD ...-0136-... and OSD …-0196-… ...................................................35

2.4.1 Separator with water content monitoring system (WMS only!)

for fuel oil treatment (design -0136-) (for operation in series) ...............37

2.4.2 Separator with sludge space monitoring system (SMS only!)

for fuel oil treatment (design -0136-) (for operation in series) ...............38

2.4.3 Separator with sludge space monitoring system (SMS only!)

for lube oil treatment (design -96-) ........................................................39

2.4.4 Separator with WMS and SMS for lube oil treatment (design -0196-) .. 40

2.5 Main components of the separator ........................................................41

2.5.1 Bowl .......................................................................................................42

2.5.2 Bowl hydraulics...................................................................................... 43

2.5.3 Centripetal pump ...................................................................................46

2.5.4 Sensing liquid pump ..............................................................................47

2.5.5 Drive.......................................................................................................48

2.6 Technical data .......................................................................................49

3Operation 51

3.1 Technical information............................................................................. 52

3.1.1 Separation .............................................................................................52

3.1.2 Notes for separation with the UNITROL system....................................52

3.1.3 General information on bowl ejection ....................................................52

3.2 Before start-up .......................................................................................54

3.2.1 Before the first start-up ..........................................................................54

3.2.2 Before every start-up .............................................................................54

3.3 Starting the separator ............................................................................55

3.4 Monitoring of operation..........................................................................55

3.5 Setting the separation time....................................................................56

Westfalia Separator

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3.5.1 Mathematical calculation ....................................................................... 56

3.6 Ejecting the bowl.................................................................................... 57

3.7 Shutting down the separator.................................................................. 58

3.8 Trouble shooting ....................................................................................60

3.8.1 Faults on the separator..........................................................................60

3.8.2 Bowl faults .............................................................................................62

4Installation - Maintenance - Repair 69

4.1 Installation of the separator...............................................................70

4.1.1 Transporting the separator ....................................................................72

4.1.2 Installing the separator .......................................................................... 73

4.1.3 Motor......................................................................................................74

4.1.4 Direction of rotation of the bowl .............................................................75

4.1.5 Speed and starting time of the bowl ......................................................76

4.2 Maintenance and lubrication.................................................................. 78

4.2.1 Maintenance schedule........................................................................... 78

4.2.2 Hoses and hose pipes ...........................................................................81

4.2.3 Lubrication .............................................................................................82

4.2.4 Lubrication Chart ...................................................................................84

4.3 Bowl .......................................................................................................86

4.3.1 Dismantling the bowl..............................................................................88

4.3.2 Cleaning the bowl ................................................................................102

4.3.3 Cleaning the frame ..............................................................................103

4.3.4 Cleaning the strainer and the operating water feeding system ...........103

4.3.5 Important instructions ..........................................................................104

4.3.6 Assembling the bowl............................................................................ 106

4.3.7 Replacing the polyamide gasket in the annular piston ........................ 119

4.3.8 Replacing the polyamide gasket (bowl top)......................................... 127

4.4 Closing the hood..................................................................................129

4.5 Motor and centrifugal clutch ................................................................131

4.6 Drive.....................................................................................................132

4.6.1 Important instructions ..........................................................................134

4.6.2 Removing the drive belt and spindle assembly ................................... 136

4.6.3 Dismantling the spindle assembly .......................................................141

4.6.4 Removing the centrifugal clutch .......................................................... 143

4.6.5 Fitting the spindle assembly ................................................................147

4.6.6 Fitting the centrifugal clutch................................................................. 150

4.6.7 Replacing the neck bearing springs (neck bearing bridge) .................156

4.6.8 Fitting the motor...................................................................................159

4.7 Height adjustment................................................................................162

4.7.1 Bowl height ..........................................................................................162

4.7.2 Centripetal pump clearance.................................................................164

4.8 Final checks after assembling the separator .......................................166

4.9 Before a long-term shut-down of the separator...................................166

4.10 Before restarting ..................................................................................167

4.11 Standard tools......................................................................................168

5Accessories 171

5.1 Solenoid valve block ............................................................................172

5.2 Solenoid valves....................................................................................174

5.3 Pressure switch ...................................................................................175

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6Parts list 179

Guide to ordering spare parts......................................................................181

Set of plates......................................................................................................183

Frame, compl.................................................................................................... 185

Brake bolt, compl..............................................................................................186

Solenoid valve block, complete ........................................................................187

Solenoid valve block, compl. ............................................................................188

Drive, complete – 50 Hz .................................................................................191

Drive, complete – 60 Hz .................................................................................191

Neck bearing bridge, compl.............................................................................. 192

Spindle assembly .............................................................................................195

Bearing bush, complete....................................................................................195

Centrifugal clutch, compl. – 50 Hz...................................................................197

Centrifugal clutch, compl. – 60 Hz...................................................................197

Bowl, complete .................................................................................................199

Accessories for the separating disk (for version -0136-)..................................200

Disk stack, compl..............................................................................................201

Hood, compl. ....................................................................................................205

Solenoid valve, compl. .....................................................................................206

Water feed line, compl......................................................................................207

Corrugated hose, compl. ..................................................................................208

Set of tools and accessories ............................................................................211

Lubricants (hazardous materials!) ....................................................................211

Spare parts "bowl/hood“ (operation: 1 year or 8,000 hours) ............................213

Set of spare parts "drive" – 50 Hz

(operation: 1 year or 8000 operating hours)..................................................... 215

Set of spare parts "drive" – 60 Hz

(operation: 1 year or 8,000 operating hours)....................................................215

Set of spare parts "drive" – 50 Hz

(operation: 2 years or 16,000 operating hours)................................................ 217

Set of spare parts "drive" – 60 Hz

(operation: 2 years or 16,000 operating hours)................................................ 217

7Appendix 219

7.1 Table of lubricating oils ........................................................................ 220

7.1.1 Comments on table of lubricating oils for separators from

Westfalia Separator .............................................................................221

7.2 The health hazards involved when handling heavy oils and

lube oils................................................................................................222

7.2.1 Code of practice and personal protective measures ...........................222

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Mineraloil Systems GmbH 17

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Fig. 14

•

fter installing certain critical spare

bowl parts, the bowl must be re-

balanced.

Fig. 15

• The bowl parts are arranged in fixed

positions relative to one another.

• Locking devices and alignment

marks must be in perfect condition.

The bowl must not be operated i

these locking devices and alignment

marks are not in perfect condition.

Fig. 16

• When assembling the bowl, be sure

to strictly adhere to the instructions

given in chapter "bowl", in order to

avoid undue unbalance.

• Before starting the bowl, be sure to

fit all parts.

• Tighten the bowl lock ring securely:

the "O" marks on the bowl bottom o

bowl top and on the lock ring must

be in line with each other.

Fig. 17

• Check if the machine is completely

assembled and properly installed.

Westfalia Separator

18 Mineraloil Systems GmbH

2057-9001-020 / 0905

Fig. 18

• Carefully fasten hood 1, feed and

discharge housing 2 and centripetal

pump 3.

1.6.2 Electrical appliances

Fig. 19

• The governing accident prevention

regulations apply for the electrical

appliances and installations.

• The frequency and voltage of the

power supply must correspond to

the machine specifications.

• Carry out voltage equalization.

• Observe legal regulations; e.g. in

the EU:

– Low-voltage guideline 73/23/EWG

– Electro-magnetic compatibility

89/336/EWG.

1.6.3 Before start-up

Fig. 20

• Check that the bowl lock ring has

been firmly tightened.

• The "O" marks on bowl bottom o

bowl top and on the lock ring must

be aligned.

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Fig. 21

• The bowl must rotate in clockwise

direction (see arrow on frame or sol-

ids collector).

Fig. 22

• The separator may only be operated

with protection devices conforming

to EN 294.

Equip solid and liquid discharges

accordingly.

Fig. 23

• Check that the lubrication and cool-

ing systems are serviceable.

Fig. 24

• Check whether the supervisory

equipment is operational and the co-

rrect limit values are adjusted.

• When hoods, concentrate collectors

and vessels are pressurized, e.g. by

– inert gas,

– cooling,

– steam sterilization etc.

the pressures stated on the name-

plate must not be exceeded.

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Fig. 25

• Check that the product lines are set

to operation.

• Regularly check hoses for signs o

ageing.

• Check sight glasses for mechanical

damage.

• Replace damaged parts by recondi-

tioned or new parts.

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Fig. 202

• Insert the pressure piece.

Fig. 203

• Position plate 2 and assembling de-

vice 1.

• Insert assembling device in the bowl

bottom.

Fig. 204

• Screw the assembling device onto

closing chamber bottom as illus-

trated:

– with four washers 1 (8.4x24x2)

and

– with four hex head screws 2 (M

8x55).

Fig. 205

• Lower the closing chamber bottom

by turning the spindle counter-

clockwise.

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Fig. 206

• Remove the pressure piece.

Fig. 207

• Remove the mounting ring.

Fig. 208

• Remove the annular piston.

Fig. 209

If the dimension of the pressed-in gas-

ket is more than 0.5 mm,

• the polyamide gasket must be fur-

ther pressed in the vice.

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Fig. 210

• By carrying out several measure-

ments around the entire circumfer-

ence of the annular piston, check

that the polyamide gasket is seated

parallel in the groove.

Fig. 211

FITTING – VARIANT II

• Thoroughly clean and dry the groo-

ve.

• Heat the gasket in approx. 80

(176 °F) water for 5 minutes.

• Gasket:

– clean and wipe dry

– lightly press into the groove.

Fig. 212

• Pull the polyamide gasket into the

groove applying a vice at four dia-

metrically opposite points.

Then

• pull the gasket bit by bit into the

groove with the vice.

Use smooth copper jaws.

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6 Parts list