GEA OTC 3-02-137 User manual

Mechanical Separation
Division
Westfalia Separato
r
Mineraloil Systems GmbH
Instruction Manual and
Parts List
No.: 2051-9001-010
Edition: 1205
Designation: Centrifuge
Model: OTC 3-02-137
OTC 3-03-107

Westfalia Separator
2Mineraloil Systems GmbH
2051-9001-010 / 1205
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
© GEA Westfalia Separator

Westfalia Separator
Mineraloil Systems GmbH 3
2051-9001-010 / 1205
OTC 3-02-137
OTC 3-03-107
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
2051-9001-010 / 1205
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
r
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.

Westfalia Separator
Mineraloil Systems GmbH 5
2051-9001-010 / 1205
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 .............................................................................. 19
1.6.3 Before start-up .......................................................................................20
1.6.4 Starting...................................................................................................22
1.6.5 Shut-down and »Emergency-Off« .........................................................24
1.6.6 Maintenance and repair.........................................................................25
1.7 Corrosion ...............................................................................................28
1.8 Erosion...................................................................................................29
2Machine description 31
2.1 Dimensioned drawing of the separator OTC 3-02-137 .................32
2.2 Section through separator OTC 3-02-137....................................... 33
2.3 Dimensioned drawing of the separator OTC 3-03-107 .................34
2.4 Section through separator OTC 3-03-107....................................... 35
2.5 General ..................................................................................................36
2.6 OTC …-02-….........................................................................................36
2.7 OTC …-03-….........................................................................................37
2.8 Main components of the separator ........................................................39
2.8.1 Bowl .......................................................................................................40
2.8.2 Centripetal pump ...................................................................................42
2.8.3 Drive.......................................................................................................43
2.9 The regulating ring................................................................................. 44
2.10 Technical data .......................................................................................46
3Operation 49
3.1 Technical information............................................................................. 50
3.1.1 Separation .............................................................................................50
3.1.2 General information on cleaning the bowl .............................................50
3.1.3 Mathematical determination of the separating time...............................51
3.2 Before start-up .......................................................................................52
3.3 Starting the separator ............................................................................53
3.4 Monitoring of operation..........................................................................53
3.5 Shutting down the separator..................................................................54
3.6 Trouble shooting ....................................................................................55
3.6.1 Trouble shooting .................................................................................55
4Installation - Maintenance - Repair 57
4.1 Installation of the separator OTC 3-02-137 ...........................................58
4.2 Installation of the separator OTC 3-03-107 ...........................................59

Westfalia Separator
6Mineraloil Systems GmbH
2051-9001-010 / 1205
4.2.1 Transporting the separator ....................................................................60
4.2.2 Installing the separator .......................................................................... 64
4.2.3 Motor......................................................................................................65
4.2.4 Direction of rotation of the bowl and motor............................................66
4.2.5 Speed and starting time of the bowl ......................................................66
4.3 Maintenance and lubrication..................................................................67
4.3.1 Maintenance schedule .......................................................................67
4.3.2 Hoses and hose pipes ...........................................................................70
4.3.3 Lubrication .............................................................................................71
4.3.4 Lubrication Chart ...................................................................................73
4.3.5 Table of lubricating oils .......................................................................... 74
4.3.6 Comments on table of lubricating oils for separators from Westfalia
Separator ...............................................................................................75
4.4 Cleaning the solids holding space (bowl shell)...................................... 76
4.4.1 Cleaning the disk stack..........................................................................80
4.4.2 Cleaning the spindle inlet holes.............................................................80
4.4.3 Assembling the bowl after cleaning .......................................................82
4.5 Dismantling the separator...................................................................... 89
4.5.1 Cleaning the separator ........................................................................105
4.5.2 Cleaning the frame ..............................................................................106
4.5.3 Important instructions ..........................................................................107
4.5.4 Assembling the separator....................................................................109
4.6 Bowl shell insert...................................................................................130
4.6.1 Removing the insert.............................................................................130
4.6.2 Fitting the insert ...................................................................................132
4.7 Before a long-term shut-down of the separator...................................133
4.7.1 Before restarting ..................................................................................134
4.8 Standard tools......................................................................................135
5Accessories 137
5.1 Starter box ...........................................................................................138
5.1.1 Electrical connection............................................................................139
5.2 Evaluating unit .....................................................................................141
5.3 Flow detector .......................................................................................142
5.3.1 Float switch.......................................................................................... 142
5.4 Hood limit switch.................................................................................. 145
5.5 Flowmeter ............................................................................................146
6Parts list 147
Guide to ordering spare parts......................................................................149
Set of plates......................................................................................................151
Separator complete (OTC 3-02-137)................................................................153
Conversion parts for clarifier operation (OTC …-02-…)................................... 156
Separator complete (OTC 3-03-107)................................................................159
Set of drive parts – 50 Hz...............................................................................163
Set of drive parts – 60 Hz...............................................................................163
Corrugated hose, compl. ..................................................................................165
Set of tools and accessories.
(for maintenance and commissioning) – 50 Hz............................................. 167
Set of tools and accessories.
(for maintenance and commissioning) – 60 Hz..............................................169
Set of spare parts "bowl/hood" - 50 Hz (Operation: 1 year or 8,000 hours)...171

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Mineraloil Systems GmbH 7
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Set of spare parts "bowl/hood" - 60 Hz (Operation: 1 year or 8,000 hours)...171
Set of spare parts "drive" (operation: 2 years or 16,000 hours)....................... 173
Starter box (motor) 220/230 V, 4 – 6 A, IP 55..................................................174
Starter box (motor) 380/400 V, 2,5 – 4 A, IP 55...............................................174
Starter box (motor) 440 V, 2,5 – 4 A, IP 55...................................................... 174
Starter box (motor) 660/690 V, IP 55 ...............................................................174
Float switch.......................................................................................................175
Evaluating unit (220/230 V – 50/60 Hz) ...........................................................176
Evaluating unit (110/115 V – 50/60 Hz) ...........................................................176
Conversion kit „OTC …-02-… in OTC …-03-…“ (bowl parts)..........................178
Conversion kit „OTC …-03-… to OTC …-02-...“ (bowl parts) .........................179

Westfalia Separator
8Mineraloil Systems GmbH
2051-9001-010 / 1205

Westfalia Separator
Mineraloil Systems GmbH 9
2051-9001-010 / 1205
1 Safety precautions
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 .............................................................................. 19
1.6.3 Before start-up .......................................................................................20
1.6.4 Starting...................................................................................................22
1.6.5 Shut-down and »Emergency-Off« .........................................................24
1.6.6 Maintenance and repair.........................................................................25
1.7 Corrosion ...............................................................................................28
1.8 Erosion...................................................................................................29

Westfalia Separator
10 Mineraloil Systems GmbH
2051-9001-010 / 1205
1.1 Correct usage
The separator is designed
• in accordance with the chemical and physical properties of the product speci-
fied by the customer and
• in accordance with the method of application of the separator agreed with
Westfalia Separator.
In particular, products not conforming to the specifications on the nameplate
may not be used.
Any mode of operation deviating herefrom is not proper and correct.
Prior to any intended deviation from the agreed operating mode, it is therefore
imperative to obtain the consent of Westfalia Separator.
1.2 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 Safety sticker
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.

Westfalia Separator
Mineraloil Systems GmbH 11
2051-9001-010 / 1205
1.2.1 Safety markings and their meaning
The following safety markings must be attached to the separator as adhesive
labels.
Fig. 2
Fig. 3
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 com-
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!

Westfalia Separator
12 Mineraloil Systems GmbH
2051-9001-010 / 1205
Fig. 4
Before carrying out work, dis-
connect power to the 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. 5
Danger o life and limb through
rotating machine parts!
• Do not loosen any part and do not
carry out maintenance or repai
r
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. 6
Warning of unusual noises o
r
vibrations!
When unusual noises or vibrations oc-
cur 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.

Westfalia Separator
Mineraloil Systems GmbH 13
2051-9001-010 / 1205
Fig. 7
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 fo
r
frequency converter operation.
Fig. 8
Warning of extreme surface
temperatures!
The surfaces of the separator and
plant components can be hot!
Note:
This adhesive plate is only used fo
r
hot operation.

Westfalia Separator
14 Mineraloil Systems GmbH
2051-9001-010 / 1205
1.3 Basic operating principles
Separators are used for the separation of liquid mixtures or for the separation of
solids out of liquids or liquid mixtures.
Fig. 9
High centrifugal forces are produced in
the rotating bowl.
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,
whereas 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.
1.4 Bowl speed and product
The max. permissible bowl speed is an important parameter when rating the
separator. It depends on the chemical and physical properties of the product
such as
• temperature, if higher than 100 °C (212 °F) or lower than 0 °C (32 °F),
• density of the fluid and solid components,
• aggressiveness of the product as regards corrosion and erosion (has influ-
ence on the selection of the bowl material).
The bowl speed is determined on the basis of these parameters allowing for an
adequate safety margin.
Before using a product with properties different from those stated when placing
the order, it is imperative to obtain the manufacturer's approval.

Westfalia Separator
Mineraloil Systems GmbH 15
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1.5 Demands relating to service personnel and spare parts
Fig. 10
• Use only genuine spare parts from Westfalia
Separator.
The use of non-genuine parts leads to:
– Safety risks
– Lower durability and availability
– Increased maintenance requirement
If a safety risk arises, this may have legal con-
sequences for the responsible persons. In this
case, Westfalia Separator shall assume no li-
ability or warranty.
• Deploy only well trained personnel for maintenance work, e.g. service per-
sonnel from Westfalia Separator or personnel trained by Westfalia Separator.
An incorrectly maintained/assembled machine poses a safety risk for the op-
erators.

Westfalia Separator
16 Mineraloil Systems GmbH
2051-9001-010 / 1205
1.6 Operations on the separator
Fig. 11
The separator works reliably, provided
that it is operated and maintained in
accordance with our operating instruc-
tions.
Special attention must be given to:
• assembly
• starting
• shutting-down
• maintenance and servicing
1.6.1 Assembly
Fig. 12
• If the plant has several separators,
be sure not to interchange parts o
f
the different separators.
Some parts are marked with the se-
rial-number of the machine or with
the last three digits of the serial-
number.
Fig. 13
• Damaged parts must be replaced
immediately by new or recondi-
tioned parts.

Westfalia Separator
Mineraloil Systems GmbH 17
2051-9001-010 / 1205
Fig. 14
•
A
fter installing certain critical spare
bowl parts, the bowl must be re-
balanced.
Fig. 15
• Some bowl parts have to be ar-
ranged in fixed positions relative to
one another.
• Locking devices and alignment
marks must be in perfect condition.
The separator must not be operated
if these locking devices and align-
ment marks are not in perfect condi-
tion.
Fig. 16
• When transporting and assembling
machine parts, avoid crushing and
shear strain.
Fig. 17
• When assembling the bowl, be sure
to strictly adhere to the instructions
given in chapter "bowl", in order to
avoid undue imbalance.
• Before starting the bowl, be sure to
fit all parts.
• Tighten the bowl lock ring securel
y
(left-hand thread).

Westfalia Separator
18 Mineraloil Systems GmbH
2051-9001-010 / 1205
CAUTION:
A loose lock ring can endanger life!
Fig. 18
• Securely tighten all other lock rings
(left-hand thread).
Fig. 19
• Pay attention to the position of the
marks!
• The "O" marks must be aligned.
Fig. 20
• Carefully fasten hood 1, feed and
discharge housing 2 and centripetal
pump 3.

Westfalia Separator
Mineraloil Systems GmbH 19
2051-9001-010 / 1205
Fig. 21
• Check if the machine is completely
assembled and properly installed.
1.6.2 Electrical appliances
Fig. 22
• The local regulations apply for the
electrical appliances and installa-
tions.
• Especially the installation guidelines
of Westfalia Separator have to be
adhered to.
• 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,
– Guidelines issued by the classification authorities.

Westfalia Separator
20 Mineraloil Systems GmbH
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1.6.3 Before start-up
• Check that the machine is correctly assembled.
Fig. 23
• The motor must run clockwise (pay
attention to direction of rotation ar-
row!).
• See section 4.2.4.
Fig. 24
• The separator may only be operated
with protection devices conforming
to EN 294.
• Equip solid and liquid discharges
accordingly.
Fig. 25
• Check that the lubrication and cool-
ing systems are serviceable.