Westfalia OSD 6-91-067 User manual

Mechanical Separation
Division
Westfalia Separato
r
Mineraloil Systems GmbH
Instruction Manual and
Parts List
No.: 2058-9001-101
Edition: 0506
Designation: Mineral oil centrifuge with self-cleaning bowl
Model: OSD 6-91-067

Westfalia Separator
2Mineraloil Systems GmbH
2058-9001-101 / 0506
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
2058-9001-101 / 0506
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
2058-9001-101 / 0506
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
2058-9001-101 / 0506
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
1.9 The health hazards involved when handling heavy oils and lube oils...30
1.9.1 Code of practice and personal protective measures .............................30
2Machine description 31
2.1 Dimensioned drawing of the separator..................................................32
2.2 Section through separator .....................................................................34
2.3 General ..................................................................................................35
2.4 OSD ...-91-… .........................................................................................35
2.5 Main components of the separator ........................................................38
2.5.1 Bowl .......................................................................................................39
2.5.2 Bowl hydraulic system ...........................................................................40
2.5.3 Centripetal pump ...................................................................................43
2.5.4 Sensing liquid pump ..............................................................................44
2.5.5 Drive.......................................................................................................45
2.6 The regulating ring.................................................................................46
2.6.1 Determining the size of the regulating ring with the aid of the
diagram..................................................................................................46
2.6.2 Determining the regulating ring by experiment......................................48
2.7 Technical data .......................................................................................50
3Operation 53
3.1 Technical information.............................................................................54
3.1.1 Notes on separation...............................................................................54
3.1.2 General information on bowl ejection ....................................................54
3.2 Before start-up .......................................................................................56
3.2.1 Before the first start-up ..........................................................................56
3.2.2 Before every start-up .............................................................................56
3.3 Starting the separator ............................................................................57
3.4 Monitoring of operation..........................................................................57
3.5 Setting the separation time....................................................................58
3.5.1 Mathematical calculation .......................................................................58
3.6 Ejecting the bowl....................................................................................59
3.7 Shutting down the separator.................................................................. 60
3.8 Trouble shooting ....................................................................................62

Westfalia Separator
6Mineraloil Systems GmbH
2058-9001-101 / 0506
3.8.1 Trouble shooting ....................................................................................62
3.8.2 Bowl faults .............................................................................................64
4Installation - Maintenance - Repair 71
4.1 Installation of the separator...............................................................72
4.1.1 Transporting the separator ....................................................................74
4.1.2 Installing the separator ..........................................................................75
4.1.3 Motor......................................................................................................76
4.1.4 Direction of rotation of the bowl .............................................................77
4.1.5 Speed and starting time of the bowl ......................................................78
4.2 Maintenance and lubrication.................................................................. 80
4.2.1 Maintenance schedule...........................................................................80
4.2.2 Hoses and hose pipes ...........................................................................83
4.2.3 Lubrication .............................................................................................84
4.2.4 Lubrication Chart ...................................................................................86
4.2.5 Table of lubricating oils .......................................................................... 88
4.2.6 Comments on table of lubricating oils for separators from Westfalia
Separator ...............................................................................................89
4.3 Bowl .......................................................................................................90
4.3.1 Dismantling the bowl..............................................................................92
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).........................................121
4.3.9 Reworking the sliding piston ................................................................123
4.4 Closing the hood..................................................................................125
4.5 Motor and centrifugal clutch ................................................................127
4.6 Drive.....................................................................................................128
4.6.1 Important instructions ..........................................................................130
4.6.2 Removing the drive belt and spindle assembly ...................................132
4.6.3 Dismantling the spindle assembly .......................................................136
4.6.4 Removing the centrifugal clutch ..........................................................138
4.6.5 Fitting the spindle assembly ................................................................142
4.6.6 Fitting the centrifugal clutch.................................................................144
4.6.7 Fitting the motor...................................................................................149
4.7 Height adjustment................................................................................152
4.7.1 Bowl height ..........................................................................................152
4.7.2 Centripetal pump clearance.................................................................153
4.8 Final checks after assembling the separator .......................................155
4.9 Before a long-term shut-down of the separator...................................155
4.10 Before restarting ..................................................................................156
4.11 Standard tools......................................................................................158
5Accessories 161
5.1 Solenoid valve block ............................................................................162
5.2 Pressure switch ...................................................................................164

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Mineraloil Systems GmbH 7
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6Parts list 167
Guide to ordering spare parts......................................................................169
Set of plates......................................................................................................171
Frame, compl....................................................................................................173
Brake bolt, complete.........................................................................................174
Solenoid valve block, complete ........................................................................175
Solenoid valve block, compl. ............................................................................176
Drive, complete.................................................................................................179
Clutch shoes.....................................................................................................179
Set of drive parts – 50 Hz...............................................................................180
Set of drive parts – 60 Hz...............................................................................180
Spindle, complete - 50 Hz ..............................................................................183
Spindle, complete - 60 Hz ..............................................................................183
Centrifugal clutch, complete .............................................................................185
Bowl, complete .................................................................................................187
Disk stack, complete ........................................................................................188
Centripetal pump, compl. .................................................................................189
Hood, complete ................................................................................................191
Retaining bracket, compl..................................................................................192
Water feed line, compl......................................................................................193
Valve, complete ................................................................................................194
Corrugated hose, compl. ..................................................................................195
Set of tools and accessories ............................................................................197
Lubricants (hazardous materials!) ....................................................................197
Set of spare parts "bowl/hood“ (operation: 1 year or 8000 hours) ..................199
Set of spare parts "drive" – 50 Hz (operation: 1 year or 8000 hours) ............ 201
Set of spare parts "drive" – 60 Hz (operation: 1 year or 8000 hours) ............ 201
Set of spare parts "drive" – 50 Hz
(operation: 2 years or 16000 operating hours).................................................203
Set of spare parts "drive" – 60 Hz
(operation: 2 years or 16,000 operating hours)................................................203
11111111111111111111111111

Westfalia Separator
8Mineraloil Systems GmbH
2058-9001-101 / 0506

Westfalia Separator
Mineraloil Systems GmbH 9
2058-9001-101 / 0506
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 .............................................................................. 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
1.9 The health hazards involved when handling heavy oils and lube oils...30
1.9.1 Code of practice and personal protective measures ............................. 30

Westfalia Separator
10 Mineraloil Systems GmbH
2058-9001-101 / 0506
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.

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Mineraloil Systems GmbH 11
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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
2058-9001-101 / 0506
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
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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
2058-9001-101 / 0506
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.

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16 Mineraloil Systems GmbH
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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 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. 13
• Damaged parts must be replaced
immediately by new parts.

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Mineraloil Systems GmbH 17
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Fig. 14
•
A
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
f
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
r
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
2058-9001-101 / 0506
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
r
bowl top and on the lock ring must
be aligned.

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Mineraloil Systems GmbH 19
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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
correct 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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20 Mineraloil Systems GmbH
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Fig. 25
• Check that the product lines are set
to operation.
• Regularly check hoses for signs o
f
ageing.
• Check sight glasses for mechanical
damage.
• Replace damaged parts by recondi-
tioned or new parts.