Diesel%20engine%20power%20plant en tcm11 19484

engineering for a better world GEA Mechanical Equipment

Energy System Technology

High performance equipment for diesel engine power plants

The clever way to separate

Centrifugal separators have been an essential part

of the manufacturing program since the company‘s

foundation in 1893.

New applications have constantly been added to the

production schedule as a result of the continuous

program of research and development and the know-

how acquired over 110 years. Application-oriented,

innovative solu tions in machine design and process

engineering are available for the mineral oil industry,

the dairy, beverage, food, chemical and pharmaceutical

industries and for biotechnology and pollution control.

Back in 1907 the centrifuge was first used for the

purification and dewatering of mineral oil. Since

then, thousands of centrifuges have been used in this

application for the reliable and economic treatment

of fuel and lube oils. Nine decades of experience in

this field form the basis for today‘s state-of-the-art

treatment plant concepts. The following development

trends show the continuous treatment of fuel oil, lube

oil, sludge and waste water.

Your Powerful Partner

2

The clever way to separate

2 Your Powerful Partner

More quality in power stations

4 Power Station System Solutions

Systems overview for diesel engine power plants

6 High Performance Equipment for Diesel Engine

Power Plants

Centrifugal systems in power stations

8 Process Overview

Self-cleaning separators

10 Double Centripetal Pump

12 GEA Westfalia Separator unitrol

System – WMS / SMS in Single Stage

GEA Westfalia Separator minimaXx®

14 Manual Cleaning Separators

15 Self-Cleaning Separators

Diesel oil treatment

16 Manual Cleaning Solutions

17 Self-Cleaning Solutions

Crude oil treatment

18 Plant Concepts with a System

19 Process Overview

Heavy fuel oil treatment

20 Plant Concepts with a System

21 Process Overview

Lube oil treatment

22 Plant Concepts for Efficient Operation

23 Process Overview

Sludge treatment

24 System Concepts for the Future

25 Economical Advantages –

Ecological Merits

Content

Waste water treatment

26 Protect the Environment – Self-Cleaning

Centrifugal System

28 GEA Westfalia Separator minimaXx® –

Manual Cleaning Centrifugal System

Fuel oil conditioning system

30 VBU – GEA Westfalia Separator

ViscoBoosterUnit:

Complete System Between

Service Tank and Engine

Control units

32 Automatic Process

Control – More Safety, More Comfort

33 GEA Westfalia Separator minimaXx® –

Process Control for Every Requirement

Flexible systems

34 Energy Compact Units –

Solutions for the Modern Power Plant

35 The Economical Solution

Various additional systems and equipment

36 Your Powerful Partner for Complete Systems

Process cooling systems

38 PHE – Plate Heat Exchanger

Water desalination system

40 FWG – Fresh Water Generator

41 Single Stage Evaporating System

Service that counts

42 serv&care –

Proactive Service for Optimum Reliability

in Power Plants

3

The power station industry often uses diesel

engines that burn heavy fuel oil, crude oil or diesel

oil. By supplying sepa ration systems specifically

designed for continuous operation under roughest

conditions, GEA Westfalia Separator Group provides

for optimum power output and a long service life for

these engines while taking into consideration the high

environmental standards.

Self-cleaning separators with GEA Westfalia

Separator unitrol systems automatically monitor the

water level in the oil and the separation of the solid

material “round the clock”. As a result, optimum

separation efficiency for different fuel and lube oils

is ensured.

Like clockwork

Normally servicing is necessary only after 8000 to

16,000 operating hours. Surveillance-free operation

reduces personnel costs tremendously.

The accumulated oil sludge can be processed directly

in the power station, thereby reduc ing the disposal

costs considerably. All separation systems are available

as modules. Other ready-to-connect systems are also

avail able as compact units in combination with

components such as GEA Westfalia Separator

ViscoBoosterUnits (VBU) or Plate Heat Exchangers

(PHE).

More quality in power stations

Power Station System Solutions

GEA Westfalia Separator minimaXx® OTC 2 Energy Compact Unit for lube oil

4

GEA Westfalia Separator eagleclass

Smart. Strong. Reliable.

Applications

• Fuel oil separation

• Lube oil separation

• Separation of sludge

containing oil and water

• Separation of waste water

• System engineering

5

High Performance Equipment for Diesel Engine Power PlantsSystems overview for diesel engine power plants

GEA Westfalia Separator Group offers leading

technologies and individual systems for power station

use. System engineering from one source, high

quality of workmanship or unrivalled worldwide

service – GEA Westfalia Separator Group provides

systems to rely on.

Product range overview

• Fuel oil treatment

• Fuel oil conditioning system

• Lube oil treatment

• Sludge treatment

• Waste water treatment

• Central cooling system

• Lube oil cooling system

• Water desalination system

6

1 Fuel oil service tank

2 Fuel oil storage tank

3 Fuel oil sludge tank

4 Lube oil sludge tank

5 Fuel oil conditioning system

6 Fuel oil treatment

7 Sludge treatment

8 Lube oil treatment

9 Waste water tank

10 Water desalination system

11 Auxiliaries

12 Charge air cooler M.E.

13 Waste water treatment

14 HT – central coolers

15 LT – central coolers

1

2

3 7 9 13

151112

14

10

4

5

6

8

7

The centrepiece of a fuel or lube oil treat ment

system is the centrifugal separator.

Effective treatment ensures that only clean oil enters

the drive unit. The wear on the injection system and

on components such as cylinders, cylinder liners and

the crankshaft of the diesel engine is minimized.

Main duties of centrifugal separators:

• Separation of solids

• Separation of water

Suitable types of centrifugal separators for

these duties:

• Self-cleaning separators with disc bowl

and automatic bowl ejection facility

• Manual cleaning separators with

solid-wall disc bowl

Centrifugal systems in power stations

Process Overview

8

Fuel oilconditioningsystem

Fuel oil treatment plant with centrifugal separator

Lube oil treatment plant with centrifugal separator

Sludge treatment plant with centrifugal separator

Waste water treatment plant with centrifugal separator

Service tank Lube oil tank

Settling tank Boiler plant

Utilities Utilities

Sludge Sludge

Pump system

Clean Oil Utilities

WaterConcentrated sludge

Disposale.g. incinerator

Waste oil tank

Utilities

Treated water

Pump system

Separated oil

Sludge

Waste oil tank

Storage tank

Pump system

Pump system

Pump system

Waste watersystem

9

Double Centripetal PumpSelf-cleaning separators

Features

• Automatic operation

• Continuous operating mode

• Self-cleaning effect of the bowl

without CIP system

• Highly concentrated solids

• High separation efficiency

• Can be used as clarifier and purifier

• Discharge of the light and heavy phase

under pressure by centripetal twin pump

• Low noise level

• Belt drive

Self-cleaning separators with disc bowl and

automatic solids ejection are used where the

percentage of solids in the oil is too high for manual

cleaning. They are used mainly for the clarification and

purification of fuel oils such as gas oil, diesel oil, crude

oil, heavy fuel oil and lube oil. The separated solids

slide down the underside of the disc into the solids

hold ing space. Self-cleaning separators eject solid

matter automatically while the separator is running.

This avoids shutting down the separator frequently

for cleaning. The clean oil and the sepa rated water

are conveyed to the discharge under pressure by a

centripetal twin pump.

Self-cleaning separators operate continuously. Solids

ejection occurs either by total or partial ejections or

in a combination of both. In case of total ejection and

combination of total and partial ejections, there is

additional self-clean ing of the disc stack.

Labour-intensive and costly measures to clean the

discs using CIP (cleaning in place with chemicals)

systems are not necessary. Optimum separation

efficiency over long operating times is ensured. Major

maintenance work is required only after 8000 to

16,000 operating hours.

10

Bowl cross section of a self-cleaning mineral oil separator with disc bowl

Solids discharge

Untreated oil feed

Treated oil discharge

Separated water discharge

Double centripetal pumpSealing and displacement water

11

Self-cleaning separators

GEA Westfalia Separator unitrol System – WMS / SMS in Single Stage

Modern fuel oil and lube oil treatment plants

from GEA Westfalia Separator Group provide easy

handling and optimum separating efficiency in

difficult situations.

The heart of these systems is a new gene ration

of self-cleaning mineral oil separators with

unitrol system. These separators operate without

regulating rings and can be applied for a wide range

of heavy fuel oils with a specific density up to

1.01 g / I as well as for a wide range of lube oils.

The essential features of these separators are both,

the continuous monitoring of the oil for water and

the continuous monitoring of the solids holding

space for optimum solids filling, in one stage.

Automatic monitoring means that regulating rings

are unnecessary and operating errors caused through

manual adjustment are eliminated.

The Water Monitoring System (WMS) ensures

reliable water separation. The water in the oil is

separated out and discharged. The Sludge Space

Monitoring System (SMS) checks the solids space

for separated foreign matter.

The oil is displaced prior to a bowl ejection. The

precisely defined displacement volume minimizes

oil losses.

A further innovative feature of these separators

is the bowl’s new hydraulic system (GEA Westfalia

Separator hydrostop). Extremely short ejection times

combined with maximized solid ejection ports pro-

vide highly concentrated solids. Further disposal

measures are simplified, disposal costs reduced

and environmental considerations fully taken into

account.

During total ejections, preferred by GEA Westfalia

Separator Group, the disc stack is also cleaned. Work

and cost intensive measures for cleaning the disc

stack by CIP systems are not necessary; this ensures

optimum separating efficiency over a long period of

operation. Maintenance work is required only after

8000 to 16,000 operating hours.

Just a few basic models are sufficient to cover all

capacity ranges with the benefit of very economical

spare parts storing and servicing.

Features

• unitrol system in one stage WMS and SMS

• Treatment of fuel oils up to 1.01 kg / I

• Regulating rings are not required

• High separation efficiency even in

critical situations

• Automatic adjustment as

clarifier or purifier

• Automatic bowl ejection


• Continuous processing

• Self-cleaning effect of bowl

and disc stack by total ejection

• Versatility of application

• Safe operation

• Belt drive

• Low noise level

12

Sealing and displacement water

Untreated oil feed



Solids discharge

GEA Westfalia Separator unitrol system

13

Manual cleaning separators with solid-wall bowl and

single centripetal pump are today mostly used for the

treatment of diesel oil and lube oil in smaller power

stations.

They are suitable for clarifying or purifying oils with

a low solids content of up to 0.01 % by vol.

The clean oil is discharged from the bowl under

pres sure by means of a centripetal pump. The

separated solids slide down the underside of the disc

into the solids holding space which must be emptied

by hand periodically.

Bowl cross section of a manual cleaning mineral oil separator with pressure discharge of the clean oil by centripetal pump


Sealing water

Untreated oil feed



Manual Cleaning Separators

Features

• Suitable for both clarifying and purifying


• Solid design

• Versatility of application

• Low noise level

• Belt drive

14

Self-cleaning separators with disc bowl, single

centripetal pump and automatic solids ejection are

used where the percentage of solids in the oil is too

high for manual cleaning. These are used mainly for

the clarification and purification of fuel oils such as

gas oil, diesel oil and lube oil. Self-cleaning separators

discharge solid matter automatically while the separator

is running. This avoids shutting down the separator

frequently for cleaning.

Self-cleaning separators operate continuously. Solids

ejection occurs by total discharge with a self-cleaning

effect of the disc stack. Labour-intensive and costly

measures to clean the discs using CIP systems are not

necessary. Optimum separation efficiency over long

operating times is ensured.

The clean oil is conveyed to the discharge under

pressure by means of a centripetal pump. The separated

water flows under gravity via a regulating ring to the

discharge.

Bowl cross section of a self-cleaning mineral oil separator with solid wall disc bowl

Sealing and displacement water

Solids discharge

Operating water discharge

Untreated oil feed




Self-Cleaning Separators

Features

• Automatic operation

• Continuous operating mode

• Self-cleaning effect of the bowl

without CIP system


• High separation efficiency

• Can be used as clarifier and purifier

• Closed discharge of the light phase

under pressure by centripetal pump

• Low noise level

• Belt drive

15

It’s payback time

During the transportation from the refinery to the

power plant diesel oils are often conta minated with

sea water and other impurities. Centrifuges are essential

for the efficient control and removal of solids and

water from fuel oils in safety fuel oil treatment

systems; they will continue to be so in the future.

Efficient treatment protects the diesel engine from

wear of important components such as cylinder liners,

pistons, piston rings and the injection system. Big

cost savings because of less filter cleaning and less

replacements of filter inserts; no problems with bacteria

growth. The entire plant concept is completed with

the feeder unit.

Compact unit CU D2 for diesel oil treatment with self-cleaning separator OSD 2 without heater.

Schematic illustration of a diesel oil treatment system with manual cleaning separator without heater

Manual Cleaning SolutionsDiesel oil treatment

1

3

4

2

5

6

1 Untreated oil feed

2 Strainer

3 Manual cleaning separator

4 Separated water discharge

5 Feed pump

6 Treated oil discharge

16

Self-Cleaning Solutions

Schematic illustration for oil treatment system with self-cleaning separator without heater

2

3

5

4

1

6 7 8

9

10

1 Feed pump


3 Untreated oil return

4 Strainer

5 Operating water


7 Operating water discharge

8 Solids discharge

9 Self-cleaning separator


Manual Cleaning Solutions

17

Safety first

Increasingly crude oil is used in diesel engine power

plants, especially for crude oil pipeline projects.

The crude oil is delivered to the power plant in a

pre-cleaned and degassed condition. However, after

the pre-cleaning the fuel quality is still too poor to be

burnt in a diesel engine.

The viscosity ranges from diesel oil to heavy fuel oil.

As crude oil contains wax which is getting liquid only

at a temperature of min. 50°C, the separating temperature

is between 60° C and 98° C. Due to the low flash point,

the system must be equipped with explosion protection.

Plant Concepts with a SystemCrude oil treatment

Crude oil treatment unit with control panel for hazardous area installation

Centrifuges are essential for the efficient control and

removal of solids and water from fuel oils in fuel oil

safety treatment systems; they will continue to be so

in the future.

Crude oil fuels from different sources must be purified

efficiently. This treatment protects the diesel engine

from wear of important components such as cylinder

liners, pistons, piston rings and the injection system.

The whole plant concept for crude oil treatment is

rounded off with ViscoBoosterUnits.

18

Process Overview

Under normal circumstances, GEA Westfalia Separa-

tor Group recommends single-stage treatment for

crude oils.

The high efficiency of separation in a single stage

process ensures low wear of the engine. The high

reliability and long service intervals ensure low operating

costs and continuous, unattended automatic operation

for months. The stand-by centrifuge can be saved for

occasional use in abnormal conditions – during

increased solids loading for example.

All equipment with electrical components are useable

for Ex zone 2 (Category 3) Explosion Group II A or B,

Temperature Class T3 in accordance to ATEX EG-RL94/9.

Purging / flushing for the separator is integrated.

1

2

3

4

5

6

7

10

11

12 14 15

16

13

8

9

1 Regulating valve

2 Strainer

3 Steam

4 Pre-heater

5 Condensate

6 Steam trap


8 Feed pump

9 Strainer

10 Operating water




14 Purging / flushing

15 Solids discharge


Single stage treatment plant for fuel oil with

separator

19

Heavy fuel oil treatment

Protect your engine

Owing to its low price, residual oil is widely available

on the international market. During combustion

however, impurities cause corrosion and deposits.

Depending on the application, treatment systems are

available both for high-grade and low-grade fuels.

When rating the throughput capacity of the plant,

the following fuel oil data are of central importance:

• Viscosity (cSt)

• Density (kg/l)

• Solids and liquid impurities (%)

The results of a research programme confirm optimum

treatment even of fuel oils with viscosities up to

1650 cSt/50°C and densities up to 1.01 kg/l (15°C).

Centrifuges are essential for the efficient control and

removal of solids and water from fuel oils in fuel oil

safety treatment systems; they will continue to be so

in the future.

Low-grade fuels from different refining processes such

as atmospheric or vacuum distillation as well as

from conversion plants such as catalytic cracker or

visbreaker process must also be purified efficiently.

This treatment protects the diesel engine from wear of

important components such as cylinder liners, pistons,

piston rings and the injection system. The whole plant

concept for heavy fuel oil treatment is rounded off

with ViscoBoosterUnits.

Plant Concepts with a System

Energy Compact Unit 2 with two separators type OSD 35 for HFO treatment

20

Process Overview

Under normal circumstances, GEA Westfalia Separator

Group recommends single-stage treatment for heavy

fuel oils.

The high efficiency of separation in a single-stage

process ensures low wear of the engine. The high

reliability and long service intervals ensure low

operating costs and continuous, unattended automatic

operation for months. The stand-by centrifuge can be

saved for occasional use in abnormal conditions – during

increased solids loading for example.

1

2

3 7

10

8

5 6

4 9

11

12 14

15

13

1 Regulating valve

2 Strainer

3 Steam

4 Pre-heater

5 Condensate

6 Steam trap


8 Feed pump

9 Strainer

10 Operating water




14 Solids discharge


Single-stage treatment plant for fuel oil with separator incl.

unitrol system

21

GEA Westfalia Separator lifecyclebenefit® During application lube oils are exposed to

continuous contamination. Foreign matter such as

abrasives, dust, condensate and decomposition products

deposit in the lube oil sump. Furthermore, acids

contained in the oil and foreign matter from catalysts

can lead to premature aging.

In case of diesel engines, particularly trunk piston

engines, combustion residue and unused fuel find

their way into the crankcase compartment, especially

with partial load operation. Sulphurous residues

and cleavage products of the fuel condensate form

acid water with the water vapour produced during

combustion in the cylinder. All this culminates in

damage of bearings, pistons and cylinders.

Centrifugal separation is the most common method

of lube oil treatment. The separator is located in a

by-pass loop within the lube oil treatment system.

Plant Concepts for Efficient OperationLube oil treatment

Schematic illustration of a lube oil treatment plant with manual cleaning separator

1

2

3

4

5

1 Feed pump


3 Strainer

4 Pre-heater




6

22

Process Overview

Self-cleaning mineral oil centrifuges are mainly used

for the purification and dewatering of lube oils,

especially if there is a requirement for 24-hour

unattended operation. Lube oil cleaning reduces

wear and prolongs the life of the lube oil.

The whole range of centrifuges is available for efficient

and reliable treatment of lube oil.

All fuel and lube oil treatment centrifuges from

GEA Westfalia Separator Group have identical design

features allowing the use of common components.

This simplifies store management and maintenance

immensely.

Schematic illustration of a lube oil treatment plant with self-cleaning separator

1

2

3

4

5

6 13

12

11

9

10

8

7

1 Feed pump


3 Strainer

4 Pre-heater

5 Operating water


7 Regulating valve

8 Steam

9 Condensate

10 Steam trap



13 Solids discharge

23

Sludge treatment

Save natural resources

The trend towards burning higher viscosity and

higher density fuel oils, together with an increasingly

common usage of residuals, means that the amount

of sludge being created from both, fuel and lube oil

systems, is increasing.

The sludge is pumped from the sludge tank by an

eccentric screw pump and is fed via a heater to the

centrifugal separator. The sludge components of

water, oil and solids are separated by centrifugal force.

The recovered oil and water is discharged under pressure

by centripetal pumps.

The concentrated sludge is discharged intermittently

via the sludge transfer unit into a heated sedimentation

tank where final concentration takes place. Excess

water and oil is allowed to overflow back to the

sludge tank. The concentrated sludge is pumped from

the unit automatically by a solids discharge pump

controlled by a level switch.

A microprocessor-based control cabinet super vises

and controls the complete concentration process.

System Concepts for the Future

1

2

4

5

6

8

7

10

11

9

12

13

14

15

16

17

18

3

1 Regulating valve

2 Steam

3 Pre-heater

4 Condensate

5 Steam trap

6 Feed of oil sludge mixture

7 Feed pump

8 Filter

9 Operating water


11 Vibration monitoring


13 Sludge concentration unit

14 Oily water

15 Concentrated sludge

16 Sludge transfer unit

17 Centrifugal separator


24

System Concepts for the Future

Approximately 2.5 % of a power plant´s fuel

consumption remains as an unwanted by-product in

the form of an oily water sludge mixture.

With increasing environmental awareness as well as

strict regulations and controls, most operators dispose

of this sludge by incineration or by shoreside

disposal using contract companies. In either case

sludge disposal is becoming an expensive problem for

the op erators today.

The GEA Westfalia Separator Group sludge treatment

plant incorporating a specially designed centrifugal

separator is capable of reducing the volume of sludge

for disposal by up to 90%. In addition, fuel oil is

recovered for re-use and recovered lubricating oil can

be used as boiler fuel.

Economical Advantages –Ecological Merits

0

20

40

60

80

100

120

Feed Oil outlet Water outlet

Solids

Water

Oil

Sludge treatment system ESD 18 with self-cleaning centrifugal separator to

reduce the disposal costs

Separation results sludge treatment

Sample taken from

Portion

Benefits

• Saves up to 90% disposal costs

• Recovers valuable fuel oil

• Unburdens the waste water

system from oil residues

• Protects our sensitive power ecosystem

25

Protect the Environment –Self-Cleaning Centrifugal System

Waste water treatment system WSD 18


in many conventional plants under practical opera-

tion conditions anyway. The further we can reduce

this value, the greater the benefit for our environ-

ment. Waste water is a mixture of the following

constituents:

• Cooling water leakages

• Fuel and lube oil leaks

• Drainages from settling and sludge tanks

• Effluent from various cleaning processes

The product (i.e. oily water without excessive emul-

sion) is sucked up from the oily water tank and fed by

the feed pump through the filter and pre -heater via

the feed valve to the separator. During the start-up or

ejection program it is led back into the oily water tank.

The product flows from above into the centre of the

separator bowl. The heavy water phase is separated

from the finest oil particles and then conveyed under

pressure by a centripetal pump to the discharge.

Water is the source of life

The treatment of waste water is strictly controlled by

national and international laws.

Waste water may only be discharged after prior

de-oiling with specially approved treatment systems.

The maximum oil content must not exceed 15 ppm. The

limit has even been reduced to 10 ppm in some areas.

Our water must stay clean

Water is the source of all life on earth. The environment

is the habitat of all life and therefore needs our special

protection. Indeed we have a responsibility to future

generations who have the same right on a rich nature

as we do.

15 ppm is too much

Oily water may only be discharged if the oil content

in the effluent is below 15 ppm. 15 parts of oil to one

million parts of water seems small but GEA Westfalia

Separator Group believes this is still too high. More-

over, practice has shown that this value is not attained

26

Protect the Environment –Self-Cleaning Centrifugal System

The separated impurities accumulated in the sludge

space are discharged into the sludge tank periodically.

The treated water discharge is monitored by an oil

content meter and discharged into the environment.

If the oil content exceeds 15 or 10 ppm the water is

recirculated into the oily water tank. If an oil content

of ≤ 10 ppm is required, our treatment systems are

generally fitted with an absorption filter that can be

connected to ensure that the required result is

achieved.

1 Steam

2 Condensate

3 Automatic filter

4 Heater

5 Untreated waste water return

6 Pre-de-oiled waste water feed

7 Operating water


9 Emulsion breaker

10 Solids discharge

11 Recovered waste oil


13 Absorption filter

14 Treated waste water return

15 Treated water discharge

16 Oil monitor

Centrifugal waste water treatment with self-cleaning separator in

combination with absorption filter and emulsion breaker

1

2

3

4

5

6

7

8 10

9

11 14

13

16

15

12

27


GEA Westfalia Separator minimaXx® –Manual Cleaning Centrifugal System

Protect the environment

The waste water treatment system will be supplied as

a ’Compact Unit’ (CU). The CU consists of four main

components:

• minimaXx® separator

• Pump / Prefilter

• Absorption filter

• Control unit

All the components are small and lightweight to make

them easy for transporting and fitting into the engine

room. The components are installed on a common base

frame. The modular concept can be incorporated into

an existing system.

28

1 Pre-de-oiled waste water feed

2 Pre-filter

3 Waste oil collection tank

4 Treated waste water return

5 Feed pump


7 Treated water discharge

8 Oil monitor

9 Absorption filter

The clever solution

The waste water treatment system with the

minimaXx® separator type WTC was specially

designed for small capacities.

The product (i.e. oily water without excessive emulsion)

is fed by the feed pump into the centre of the separator

bowl. Within the rotating bowl, the product is

separated into heavy and light phase.

The heavy water phase is separated from the finest

oil droplets and dirt particles and then conveyed

under pressure by the centripetal pump to the

discharge. If the oil concentration on the clean

water outlet of the centrifuge exceeds 15 ppm the

water is led through an absorption filter. The lighter

oil phase flows to the centre of the bowl and is

discharged by gravity.

The separated sludge is collected in the solids holding

space and must be removed by hand.

An intelligent control and monitoring system assures

problem-free, round-the-clock unmanned operation.

It also ensures that only water with an oil content

lower than 15 ppm is released into the environment.

A pre-heater is recommended if the waste water con-

tains oils of a higher viscosity.

3

6

2

5

41 7

9

8

29

Safety first

With the ViscoBoosterUnits, GEA Westfalia

Separator Group offers a complete, compatible system

for a safe and economic fuel oil treatment from the

service tank to the engine.

ViscoBoosterUnits are supplied as package systems.

They are designed for 24-hour unattended operation.

Efficient operation of power station diesel engines

requires optimum fuel supply. This key condition is

accomplished by the ViscoBoosterUnits de veloped by

GEA Westfalia Separator Group for fuel conditioning.

This unit consists of a treatment system that meets the

fuel requirements between the clean oil tank and injection

system for the diesel engine in terms of the required

injection viscosity and temperature. Supply and booster

pumps are provided for a stable system pressure.

The modules are designed for the different en gines as

well as to the required injection viscosity (approx.

10 – 24 cSt) and corresponding tem perature (approx.

135 – 150°C).

To be able to ensure a high plant availability and

to achieve the high plant capacities, several diesel

generators are frequently in stalled in power stations.

We recommend splitting the classical “Energy Unit”

into a “Feeder Unit” and, depending on the number

of engines, into several “Booster Units”.

GEA Westfalia Separator Group has developed the right

systems for this task.

VBU – GEA Westfalia Separator ViscoBoosterUnit: Complete System Between Service Tank and EngineFuel oil conditioning system

Benefits

• Easy adjustment to the engines in

operation

• Higher availability of the complete

insta lla tion

• Simple switch-over to

HFO / MDO for each engine

• Easy adjustment if the system is

upgraded later

30

VBU (divided module)

VBU for power plant application

Features

• Compact, robust design

• Good operability

• Automatic viscosity control

• Automated control system via control

cabinet with redundant power supply

• Automatic, compressed-air controlled

filter system for particle separation

• Low weight

• Easy installation

• Low maintenance costs

1 HFO

2 MDO

3 Feeder pump

4 Strainer

5 Stand-by

6 Pressure control valve

7 Fuel to day tank

8 Fuel from engine

9 Automatic backflushing filter

10 Flow-meter

11 Mixing / Degassing tank

12 Degassing valve

13 Booster pump

14 Stand-by

15 Regulating valve

16 Steam trap

17 Steam or thermal oil

18 Pre-heater

19 Stand-by

20 Condensate or thermal oil

21 Viscosity sensor

22 Fuel to engine

22

2117

18

19

20

16

14

13

1512

7

83

4

52

6

9

1

10

11

31

Automatic Process Control –More Safety, More Comfort

The E40 control unit is specifically designed for

the eagleclass. Even the most complex separator and

system applications are controlled with precision.

The E40 control unit performs process and control

functions over and above those of the D10. To

facilitate understanding, operating states, current

process values, faults and changes in system status

are shown by a change in color in the color display.

Machine or system-specific display screens with

assigned touch keys reduce the possibility of

operating faults even further. MMC cards function as

program memory; the lifetime data of the systems

can be read out by technical staff for interval or

preventive maintenance purposes.

As an option, the control unit can be patched into the

worldwide web using the Sm@rt Client server

function of the panel and the integrated Ethernet

port. Sm@rt Client allows remote servicing to be

effected quickly and simply. The machine can be

operated and observed from any workstation within

the customer’s network.

Program control

The control unit controls the program automatically

as well as monitoring the separator completely. In

addition to all the electrical components on the sepa-

rator itself, it is also possible to incorporate in the

control and monitoring system the peripherals

required for a customer’s specific application.

Keys F1 – F4 Soft keypad, screen dependent

Keys 1 – 0 Function keypad with fixed allocation

Status LEDs

Touch display with backlighting and 4 lines

Easy handling by

Micro Memory Card

which stores setting

and history data for

D10 and E40.

D10 withtext display

Control units

32

1 Motorstarter box

Motorstarter separator

Motorstarter feed pump

2 OMB 220

Overflow monitoring box

Water seal broken alarm

3 Control unit MC-1



Flow monitoring FAH

4 Control unit CC-1



Flow monitoring FAH

Temperature monitoring TAL / TAH

Preheater interlocking

5 Control unit CD-1

Control and monitoring system for

self-cleaning minimaXx® separator.



Flow monitoring FAH

Flow monitoring FAL

Clean oil outlet

Temperature monitoring TAL / TAH

Preheater interlocking

Sludge pump control

D10

GEA Westfalia Separator minimaXx® – Process Control for Every Requirement

1 2

3

5

4

33

Flexible systems

Energy Compact Units – Solutions for the Modern Power Plant

GEA Westfalia Separator Group‘s design engineers

have integrated flexibility into all their products.

Single-, Double- and Triple-Energy Compact Units

(ECU) with optimum layout to meet power plant

requirements are available as standard modules.

ECU 1

ECU 2

ECU 3

34

Energy Compact Units – Solutions for the Modern Power Plant

The Economical Solution

Customer benefits

All systems:

• Are installed, piped and electrically wired,

ready for operation on rigid,

stable foundation frames

• Are completely checked and tested

• Require small installation costs

• Are of very compact design, small volume and

weight (less transportation costs)

• Can be started up immediately

• Are very easy to operate

35

Various additional systems and equipment

Your Powerful Partner for Complete Systems

GEA Westfalia Separator Group pro vides various

systems tailor-made to customers‘ needs.

Modern module design ready for installation.

System intergration into the power plant concept.

Engineering and total system design. All available

from GEA Westfalia Separator Group.

Desalting module for fuel oil washing

Container enclosure for complete modules

Fuel oil unloading module

Heat recovery module

Module supply

• Fuel oil unloading module

• Fuel oil transfer module

• Heat recovery module

• Desalting module for fuel oil

• Additive dosing module

• Water booster module

• Air compressor module

• Container enclosure for complete modules

36

Your Powerful Partner for Complete Systems

Additive dosing module Air compressor module

Fuel oil transfer module

Water booster module

37

Process cooling systems

PHE – Plate Heat Exchanger

PHEs are used for cooling purposes, e.g. mainly for

central, lube oil, jacket water circuits, as well as for

auxiliaries, charge air, etc.

A wide range of flexible plate configurations are

offered to cover all heat exchange applications. Suitable

materials like titanium, different grades of stainless

steel, etc. are available.

Features

• High heat transmission coefficient

• Optimised heat transfer surfaces

• Compact design

• Low life cycle costs

• Simple inspection and maintenance

• Low liquid content

• Glued and glueless gaskets

38

1

2

4

5

6

37

8

9

10

11

12

13

14

1 From main engine

2 To main engine

3 Circulation pump

4 From main engine

5 To main engine

6 Circulation pump

7 Auxiliaries

8 Charge air cooler

9 Lube oil cooler

10 Cooling water pump

11 Cooling water

12 LT – central cooler

13 HT – central cooler

14 Cooling water

39

Water desalination system

FWG – Fresh Water Generator

Independent generation of fresh water by single

stage evaporation technology.

Sea water is fed through the condenser, where it

absorbs the latent heat of the condensing vapour.

Some sea water is used as feed water for the evaporator

whilst the remaining brine and non-condensible

gases are discharged using a combined ejector. In

the evaporator the sea water is heated up to the

saturation temperature corresponding to the

vacuum maintained by the ejector, and part of it

is evaporated.

The evaporator generally utilizes the waste heat from

the main diesel engine jacket water, however, other

heating media may also be used (e.g. steam, thermal oil).

The vapour produced passes through the demister

located in the upper casing to remove trapped droplets

of water and is led to the condenser. The distillate

is drawn from the condenser by the distillate pump

and discharged through the salinity measuring unit.

Depending on the residual salt content of the distillate,

it is either led to the distillate tank or, if the maximum

allowable residual salt content is exceeded, back to

the evaporator.

All parts in contact with sea water are made of

corrosion-resistant materials (CuNi, stainless steel).

The plates are made of titanium.

On request GEA Westfalia Separator Group can also

supply Multi Flash Water Generators in a range from

100 – 3000 t/d.

Process overview

Sea water Jacket water

Fresh water

Fresh water

Fresh watergenerator

40

FWG – Fresh Water Generator

Thermal oil / hot water heated

Single Stage Evaporating System

Benefits

• Compact

• Easy operating, fully automatically controlled

• Reliable

• Low weight

• Low maintenance costs

• Integrated anti-scaling system

• Corrosion resistant materials

• High performance

1 Heat exchanger

2 Jacket water

3 Circulation pump

4 Steam heated

5 Steam

6 Steam jet liquid pump

7 Condensate

8 Sea water

9 Distillate

10 Heating water

11 Jacket water heated

12 Circulation pump

13 Feed water

14 Brine

15 Brine

16 Demister

1

8

9

10

11

12

13

14

15

16

2

3

45

6

7

41

Safety first: this is precisely what the service concept

serv&care stands for.

Shipowners not only benefit from traditional

services such as inspection, maintenance, original

spare parts and repair work provided by the original

manufacturer; they also benefit from proactive

solutions which avoid risk, e. g. online and offline

monitoring with GEA Westfalia Separator wewatch®.

These preventive services are the best pre-condition

for a smooth operation.

Enhanced process efficiency also follows from

maximum operating reliability and machine

availability. Accompanying modernization or

upgrading to state-of-the-art technology also offer

the option of boosting performance as required.

serv&care – Proactive Service for Optimum Reliability on Board

The proactive, risk-free services of serv&care optimize operatingreliability and permanent availability of the drive systems.

Training provided on site or in the modern training

centre of GEA Westfalia Separator Group ensures that

the plant operator’s employees receive training in the

proper handling of the high-tech installations. This

provides additional safety.

Authorized workshops worldwide

And if problems occasionally occur or if a spare part

is required at short notice, the specialists are able

to attend to the ships quickly. This is ensured by a

global network with more than 50 sales and service

companies. Authorized workshops are able to service

every location in the world at short notice.

42

In addition to traditional services such as maintenance or repair, serv&care also provides solutions which avoid risk and with which the installation availability can be proactively assured.

serv&care accordingly makes for maximum operating

reliability, machine availability, process efficiency

and budget security. And these benefits are

provided throughout the entire life cycle of the

entire installation.

Service from the original manufacturer:

• Service engineers quickly on site

• Extensive service network

• Risk avoidance through service provided

by the original manufacturer

• Proactive solutions

• Upgrading to boost performance

• Crew training

serv care

43

The

info

rmat

ion

cont

aine

d in

thi

s br

ochu

re m

erel

y se

rves

as

a no

n-bi

ndin

g de

scrip

tion

of o

ur p

rodu

cts

and

is w

ithou

t gu

aran

tee.

Bin

ding

info

rmat

ion,

in p

artic

ular

rel

atin

g to

cap

acity

dat

a an

d su

itabi

lity

for

spec

ific

appl

icat

ions

, can

onl

y be

pro

vide

d w

ithin

the

fra

mew

ork

of c

oncr

ete

inqu

iries

. Prin

ted

on c

hlor

ine-

free

ble

ache

d pa

per

· Prin

ted

in G

erm

any

· Sub

ject

to

mod

ifica

tion

· Wes

tfal

ia®, W

estf

alia

Sep

arat

or ®, l

ifecy

cleb

enef

it®

, m

inim

aXx®

and

wew

atch

® a

re r

egis

tere

d tr

adem

arks

of

GEA

Mec

hani

cal E

quip

men

t G

mbH

. B_

EN-1

2-10

-000

2 EN

GEA Mechanical Equipment

GEA Westfalia Separator Group GmbH

Werner-Habig-Straße 1, 59302 Oelde, GermanyPhone: +49 2522 77-0, Fax: +49 2522 77-1778www.gea.com

GEA Group is a global engineering company with multi-billion euro sales and operations in more than

50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and

process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity

Documents

Diesel%20engine%20power%20plant en tcm11 19484