Westfalia Service Training

Mechanical SeparationDivision

Westfalia SeparatorMineraloil Systems GmbHWestfalia Separator Mineraloil Systems GmbH

Service Training by Ronald Eschmann, Service Center Hamburg

- model designation- installation- bowl parts- single mode- series mode- running mode -02-- running mode -91-- running mode -01-- running mode -36-- running mode -96-- running mode -0196-- Displacement- potable water- syphons- centripetal pump

- Foundation- clutch, clutch shoes- gear oil- wear to gear- bottom bearing- misc.: OSA7, OSA20, OSB35- bowl unbalance- wear protection- refinery process / fuel problems- timing unit VESA, VESB, VESC- timing unit C7- alarm list- trouble shooting list


Westfalia SeparatorMineraloil Systems GmbH

30.06.2004 Ronald Eschmann, Service Dept., Hamburg 2

model designation of separators

e.g. OSA7-02-066




model designation of separators

OSA 7-02-066application: Mineral Oil

Separator with self-cleaning bowl

A-series of WS-Separators

size (efficiency) 7

bowl for clarification and separation with a disc stack

separator with single centripetal pump and discharge by gravity of the heavy component (water)

drive via centrifugal clutch, open frame, neck bearing standard or gas-tight; standard or EEx motor

hinged hood, either cast design with cast-on feed-and discharge line or welded design with welded-on

or screwed-on feed and discharge connections

flange-type motor (horizontal), type B5, with clutch




Diagram of installation

Fuel

Lube oil

Sludge

Bilge water

Stuffing box oil

HFO - Sludge tank LO - Sludge tank

Sludge tank

Settl.tank Service

tank




Diagram of installation: SINGLE MODE

Separator

throttle valve

pressure switch

feed valve

solenoid operating water

dirty oil feed

pre-strainer

feed pump

water discharges

inspection cover

control unit

motor starter

steam inlet

pre-heaterinstrument air

potable water

clean oil discharge

pre-set valve

solenoid f+d water




bowl: VARIZONE

clean oil discharge

dirty oil feed

dirty water discharges




bowl: disk stack

The disk stack consits a large number of conical disks situated on top of each other. Each disk is provided with spacers so that there are precisley defined narrow interspaces (very small radial sedimen-tation path). The solids will be collected on the upper wall of each inter-space. A smooth bottom disk surface is necessary to slide down the solids into bowl sludge holding space.




bowl: disk stack




Bowl: OSA7-02




bowl: OSA20 UNITROL

CS PSL




bowl: OSB35-02




Bowl: OSC4-02




bowl: OSC4 UNITROL

CS PSL




bowl: OSC30-91




bowl: OSD6-91




diagram of installation: SINGLE MODE

1: displacement water 2: operating water3: 3/2 way feed valve4: circulation valve5: water discharge valve 6: dirty oil feed7: feed return line8: clean oil discharge

36

7

8

pressure switch low (SMS)

pressure switch

ejection monitoring motor protection vibration monitor flow switch

temperature switch high / low conductivity sensor (WMS)

HFO: single / parallel mode: recommended with increased water content





return line of feed valve led back to settling tank

HFO





LO

return line of feed valve led back to oil sump




diagram of installation: SERIES MODE





HFO series mode: recommended with increased amount of solids in the feed




SERIES MODE of operation: HFO only

When running in series mode only the feed pump and pre-heater of the first stage (purifier) are in operation. An attached feedpump at the second stage (clarifier) must be disconnected from the horizontal shaft to avoid a run dry. If necessary the setpoint of TAL (temp. alarm low) needs to be lowered as well as the timer „alarm bridging time“ needs to be increased at the timing unit of second stage in order to avoid PAL (discharge pressure low) alarms.





series mode of operation: process and installation diagram




series mode with VESB-EC 1

FIRST STAGE: PURIFIERFunction keys to be pre-selected at timing unit type VESB-EC 1:

F2, F3 and F13

SECOND STAGE: CLARIFIERFunction keys to be pre-selected at timing unit type VESB-EC 1:

F2, F3, F4, F10 and F13

holes open in separating disc

holes closed in separating disc




series mode with VESB-EC 1

X1-Terminals 23 24 26 25 27 28 30 29 59 60 61 62 63 64 65 66

INPUTS - UNIT 2I 114I 113I 112I 111

VESB- Panel No. 2 O 1016

OUTPUTS -UNIT 2O 1015O 1014O 1013

X1-Terminals 59 60 61 62 63 64 65 66 23 24 26 25 27 28 30 29

OUTPUTS - UNIT 1O 1015O 1014O 1013 I 114I 113I 112I 111VESB- Panel

No. 1O 1016

INPUTS - UNIT 1

24 V

DC

fro

m u

nit

2

Feed

bac

k Si

gn

al

Seri

es M

od

e O

N

Seri

es M

od

e O

FF

Seri

es M

od

e FA

IL

24 V

DC

fro

m u

nit

1

Feed

bac

k Si

gn

al

Seri

es M

od

e O

N

Seri

es M

od

e O

FF

Seri

es M

od

e FA

IL




series mode with C7

FIRST STAGE: PURIFIERFunction keys to be pre-selected at timing unit type C7:

and

SECOND STAGE: CLARIFIERFunction keys to be pre-selected at timing unit type C7:

and






series mode with C7

Attention:

Not laying MPI-data cables parallelly to power cables

1 1 2 sc 1

Terminal strip HFO 1

Cable type:UNITRONIC-BUS-FD P L2/F.I.P1x2x0,25 mm2 + screen

Terminal strip HFO 2

1 2 sc

A B

onoff

HFO 1WMS-01-

MPI-interface / MPI - code 1/2 MPI-interface / MPI - code 3/4

A B

onoff

HFO 2SMS -36-




Separator type VARIZONE -02-

VARIZONE -02-: no UNITROL valves on the hood but a regulating ring; suitable for products with max. density of 0,991 kg/dm³ @ 15°C

OSC4




Separator type VARIZONE -02-, regulating ring

OSA20

Regulating ring (ringdam)

OSC15





OSC5-02-066

To choose the correct size of regulating ring, the density of the oil as well as the separation temperature must be given.

For example: density is given with 0,873 kg/dm³ @ 20°C. Separation temp: 70°C

The density of oil decreases linear with increased temperature. Find the intersection of the density line with the line of 70°C.

Find the thick curves (here green). The number in the field between two curves shows the correct regulating ring: Ø 70 mm.









OSC30

-91-: same working principle as VARIZONE -02-. Dirty water is not drained by gravity into the hood but discharged under pressure by means of a second centripetal pump





1 Dirty oil feed2 Clean oil discharge3 Filling / Displacement water4 Pressure switch (clean oil)5 Regulating ring6 Control unit7 Centripetal pump (dirty water)8 Centripetal pump (clean oil)9 Separating disk

10 Sludge holding space11 Dirty water discharge12 Operating water discharge13 Sludge discharge14 Operating water feed15 Solenoid valve block





dirty water discharge to frame drain

dirty oil feed

clean oil discharge

Two centripetal pumps





OSC30pressure switch in the dirty water discharge: PAH breakover water discharge









holes open !

All process parameters, timer adjustments, water flow rates, regulating ring diagram´s etc. of separator type -91- are identically with -02- design. Please note, the screw pins need´s to be removed from the lower centri-petal pump chamber cover when running mode VARIZONE -91-.





regulating ring

Efficient dewatering of water-contained oils is only possible when the bowl is correctly adjusted to the difference in densities between oil and water.

The inner diameter of the regulating ring can be determined from the diagram or by experiment. The general rule of thumb is:

- narrow regulating ring for heavy oil

- wide regulating ring for light oil





lower centripetal pump chamber cover

-UNITROL-holes closed

-VARIZONE-holes open





OSC30




Separator type UNITROL-WMS -01-

OSC50

Water Monitoring System: PURIFIER - FIRST STAGE

UNITROL-WMS: no ringdam; with conductivity sensor, circu-lation- and water discharge valve, suitable for products with max. density of 1,01 kg/dm³ @ 15°C





1: dirty oil feed2: clean oil discharge3: displacement

water feed

4: pressure indicator5: conductivity sensor6: pressure switch7: circulation valve8: water discharge

valve

9: sensing liquid flow10: sensing liquid pump11: control unit12: centripetal pump

(clean oil)13: separating disc14: dirty water discharge15: sludge holding space16: sludge discharge

17: operating water discharge

18: operating water feed

HFO

19

19: screw pin´s (holes open in separating disc !)p/n: 0019-9045-400





85

7

HFO

19

After the feed valve is open the WMS function is activated. The conductivity sensor (5) in the bypass line monitors the liquid concentration and leads off registered water by opening the water discharge valve (8). When running WMS -01- there is no need for filling water. To avoid emulsification, conductivity measurement is intermittent, i.e. the circulation valve (7) is closed via TIMER 15 for 60 seconds followed by opening of the circulation valve for 15 seconds via TIMER 16. Only during this time can the conductivity sensor register and discharge water until oil is detected again. Subsequently the measuring cycle is re-started.





„PURIFICATION“ means the separation of liquid mixtures which consists of two liquids, with simultaneous removal of the solidscontained in the liquids.„CLARIFICATION“ is the removal of solids from a liquid.






CS PSL

Separation: Circulation valve open, CS not activated

CS PSL

Water discharge: CS activated, water discharge valve open




WMS - measuring relais : type DNAR




WMS - measuring relais : type DNAR

set to: „100 Ω - 200 Ω“

turn clockwise to max.

WS part number: 0005-3929-000 (220 VDC) 0005-3929-010 (110 VDC)

old version until 1996




WMS - measuring relais : type RM-3 LA1

WS part number: 0005-3929-020 (since summer 1996)

function: the time from that the conductivity sensor is detecting water until water is being discharged

R-sector: the full scale adjustment: 50 kΩ

R-value Ω: to be adjusted to approx. 20 means the actual setpoint has been adjus-ted to 20 kΩ. When do the „fine tuning“ at site (adding water manually) please check the switch back from „water discharge“ to „purification“. The setpoint needs to be decreased in case the program does not switch back to „purification“

Time value s: value of delay time: 1 sec




WMS - measuring relais : type RM-3 LA1




WMS - measuring relais : type RM-4 LA3 2MW

WS part number: 0005-3929-030; since summer 2003

time delay adjustment: set to 1 sec

sensitivity adjustment: set to 40 % of full scale, to be balanced at site. The setpoint is to be reduced in case the WMS does not switch back from “water discharge“ to “circulation“.

sensivitiy range / delay function selection:set to 50 sensivity range: 0 - 50 kΩfunction: ON-delay (the time from detecting water to water discharge)

empty / fill selection: set to empty




replacement DNAR by RM3 / RM4

terminal DNAR RM3 / RM4

11 15

12 16

14 18

O B2

M B1

A1 A1

A2 A2




WMS: conductivity sensor 0005-1347-000

1 housing 0005-1347-0102 isolating piece 0005-1347-0203 cover 0005-1347-0304 hex head screw 0019-6842-4005 sensor 0005-1347-1006 threaded piece 0019-0576-6007 gasket (2 pcs) 0007-2507-7508 gasket (2 pcs) 0007-1866-8309 cable head 0005-0637-000

10 cable 0005-0400-00811 plug 0019-0644-60012 plug 0019-1492-000












Separator type UNITROL -SMS -36-

OSC50

Sludge Monitoring System: CLARIFIER - SECOND STAGE

UNITROL-SMS -36-: no ring-dam; pressure switch and circu-lation valve in use, running in second stage when running in series mode only, HFO clarifier





14: dirty water discharge

1: dirty oil feed2: clean oil discharge3: displacement

water feed

4: pressure indicator5: conductivity sensor6: pressure switch7: circulation valve8: water discharge

valve

9: sensing liquid flow10: sensing liquid pump11: control unit12: centripetal pump

(clean oil)13: separating disc

15: sludge holding space16: sludge discharge



HFO

19

19: screw pin´s (holes closed in separating disc !)p/n: 0019-9045-400





6

7

HFO

19

A small amount of sensing liquid is diverted via the separating disc (13). It is conveyed by the sensing liquid pump (10), the circulation valve (7) to the pressure switch (6) and recycled back into the feed. If the sensing liquid intake becomes blocked due to water or solid accumulation in the sludge holding space (15) the pressure switch sends a pulse to the control unit. The automatic solids ejection program for both first stages is triggered (so called „self thinker“). The pressure switch is working as PSL. The circulation valve is open over the whole period of time of separation.





A clarifier is not able to discharge water continiously just by de-sludgings only. The system of WMS -01- and SMS -36- are identically. To rebuild the separator from WMS into SMS just close the holes in the separating disc by means of two screw pins and re-adjust the timing unit.






Separation:circulation valve open, sensing liquid pressure above the setpoint of pressure switch

CS PSL CS PSL

Separation: circulation valve open, sludge holding space filled up with solids, sensing liquid pressure dropped below setpoint

CS PSL

Ejection: on both stages triggered by the „self thinker“, feed valve closed .





OSC50

Sludge Monitoring Systemfor Lube oil

UNITROL-SMS-96-: no ringdam; pressure switch and circulation valve in use, designed for LO only; same working principles as SMS-36-, holes open in sep. disc.





CS PSL

Separation: sensing liquid pressure above the setpoint

CS PSL

Separation: sludge holding space filled up with water and solids, sensing liquid pressure dropped below setpoint, ejection triggered

PSLCS

Filling: no pressure at the PSL, CS not in use, holes in separating disc open, bowl partially pre-filled





1: dirty oil feed

2: clean oil discharge

3: displacement water feed

4: pressure indicator

5: conductivity sensor

6: pressure switch

7: circulation valve

8: water discharge valve

9: sensing liquid flow

10: sensing liquid pump

11: control unit

12: centripetal pump (clean oil)

13: separating disc

14: dirty water discharge

15: sludge holding space

16: sludge discharge



19

LO

19: screw pin´s (holes open in separating disc !)p/n: 0019-9045-400





6

719

LO

A small amount of sensing liquid is diverted via the holes in the separating disc (13). It is conveyed by the sensing liquid pump (10), the circulation valve (7) to the pressure switch (6) and recycled back into the feed. If the sensing liquid intake becomes blocked due to water or solid accumulation in the sludge holding space (15) the pressure switch sends a pulse to the control unit. The automatic solids ejection program is triggered (so called „self thinker“). The pressure switch is working as PSL. Before feed valve is open the bowl is partially filled with water. This is not to create a water seal but will improve the clarification (discharge of solids from the oil).





When running with UNITROL SMS -96- the flowrate of filling- and displacement water must not exceed 0,1 l/s. To achieve this reduced flowrate a orifice plate of bore 3,0 mm need´s to be installed in the filling- and displacement water assy.





LO: Separator type UNITROL-WMS+SMS -0196-

UNITROL-WMS+SMS: no ring-dam; conductivity sensor, circu-lation- and water discharge valve as well as pressure switch in use. For LO only.

Water Monitoring System + Sludge Monitoring System




Separator type UNITROL WMS+SMS -0196-

CS PSL

After the ejection the bowl is empty. Sliding piston as well as annular piston are in sealing position.

CS PSL

FILLING: the bowl will be filled with water timer controlled. The signal of the pressure switch will override the timer.





CS PSL

SEPARATION: the upper centripetal pump is acting as a gravity disk. Dirty water will be discharged continiously.

CS PSL

HIGH WATER: Alarm will be given once that a certain amount of water is being discharged (Timer controlled)





CS PSL CS PSL

SMS mode: after the WMS mode is over by timer the SMS mode is activated. Water will be added timer controlled.

SMS mode: Both valves are closed. No signal of the pressure switch means: sludge holding space is filled up.





CS PSL

SMS mode: Ejections will be triggered timer controlled. The signal of the pressure switch will override the timer (T20)

CS PSL

BREAKOVER: Alarm will be given when the water seal has been lost however: Signal from the PSL but no signal from the CS.




non-self-cleaning type: solid wall bowl

Type OTBType OTA Type OTC




Separator type UNITROL -DISPLACEMENT-

CS PSL

Separation: sludge hol-ding space filled up with solids, sensing liquid pressure dropped below setpoint

Displacement: Filling + Displacement and circulation valve open, clean oil displaced to the clean oil discharge

CS PSL CS PSL

Ejection: on both stages triggered by the „self thinker“, oil losses minimized




Potable water

condensate as well as desillate is not permissible




Potable water




Potable water




Potable water




water discharges: syphons

If no syphon is installed, the frame drain as well as the dirty water discharge must always be submerged below the minimum tank level so as to produce a liquid seal.




water discharges: syphons

If a syphon is installed, submerging of the water discharges is not required because a liquid seal is already present. The dimension „h min“ for defining the syphon lenght is specified in the table.




centripetal pump

lower centripetal pumpupper centripetal pump




centripetal pump




OSA, OSB, OSC: Foundation

Vibrations from the vessel / ship structure into the separator skid must be reduced as good as possible (rubber cushion, cap springs, flexible hoses, stiff foundation etc.)




OSA, OSB, OSC: Foundation

wrong !

wrong ! Tighten the lower nut lightly by hand. Use an open-end wrench to tighten the nut by a further turn. Then check the tightened nut with the upper nut by counterholding.




Foundation




foundation / max. vibration limit

max. vibration limit at installation surface with stopped separator




OSD: Foundation

0021-3308-7500021-3309-750




OSD: Foundation

OSD 6 / OSD 18

pos. 340: 2058-1467-000

pos. 350: 0021-3308-750

OSD 35 / OSD 60

pos. 390: 2057-1467-000

pos. 400: 0021-3309-750




clutch, clutch shoes




fitting of clutch shoes

for OSC15 (belt drive only)




clutch driver, clutch shoes OSA, OSB, OSC

For all gear driven separators




OSD: clutch, cluch shoes

One friction pad for all OSD type of separators




clutch drive: permissable wear holding slit




gear oil - oil level in gear box

Check oil level daily. Check whether the oil bath contains water (milky colouring) or product (HFO - dark colouring). If so change immediatly.

OTC2OTC3




gear oil CLP100




gear oil CLP220




gear oil ISO-VG 220




gear oil ISO-VG 68

For belt driven separators only.




synthetic gear oil, running in procedure

list of approved oils:MOBIL SHC 630SHELL Delima HT 220CASTROL Alphasyn T 220CASTROL Alphasyn HG 220BP Enersyn HTX 220ESSO Teresso SHP 220ELF (Lub Marine) EPONA SA 220FINA Gearan 220

The gear must be run in with mineral lube oil for approx. 1500 - 1750 running hours. The running-in marks must be clearly visible on each tooth of worm wheel.b = min. 1,5 - 2,5 mm for OSC4, OSC5, ESC4, OTA7, OTB9, OTA14 etc.b = min. 2,0 - 3,0 mm for OSA20, OSB/C30, OSA/B35, OTA18/30, OSC50 etc.All approved oils are in accordance with ISO-VG 220 and on poly-alpha-olefin basis (WS p/n: 0015-0018-200). In case of very high ambient temperature gear oil of ISO-VG 320 is recommended for OSA20, OSB/C30, OSA/B35, OTA18/30 and OSC50. The remaining viscosity @ 100 °C is approx. 30 cSt [mm²/s].

For OSC15 (flat belt drive !) synthetic gear oil of ISO-VG 68 is recommended.




synthetic gear oil, running in procedure




wear to gear

The gear parts (both worm wheel as well as vertical spindle need´s to be replaced incase the tip of tooth worn out to 1/2 to dimension “h”.

The gear parts (both worm wheel as well as vertical spindle need´s to be replaced incase the base of the tooth shows sign of wear.




bottom bearing

OSC50

- both bearings may only be replaced together (same maker) !- the bottom bearings may only be loaded axially in one direction !- fit both bearings so that the outside narrow rim faces upwards to the bowl !- incorrect fitting will decrease service life dramatically (crash) !- heat bearings and protection ring to approx. 80 °C before fitting




bottom bearing : sherical plain bearing

This joint is not a crack but necessary to fit the inner ring in the factory. There is no special instruction how to install the bearing.




OSB35 - modified hydraulic system

1 x 0007-1892-750 385/405x10

2 x 0007-1674-750 393,1/407,1x7

new previous




OSB 35: hard metal ring of sliding piston

Y

OSB35

The sealing surface of the sliding piston can be remachined several times when worn (up to 1,5 mm in total) before replacement of sliding piston becomes nescessary. When re-machining, make sure that the shoulder on diameter „X“ is at least 1.0 mm. When in doubt check dimension „Y“ of which must be at least 21.0 mm

Remachine the sealing surface as soon as possible as there are sligh-test traces of erosion (of 0.2 - 0.3 mm depth). After the re-machining the polaymid gasket in the bowl top needs to be replaced. Rebalancing of bowl is not necessary.

Guide values for re-machining:Tool: carbide-tipped tool of M30 or K20Speed: 10 - 12 rpmDepth of cut: max. 0.15 mmRate of feed: max. 0.1 mm/rev




OSB 35: correction of bowl height




OSA20 - modified hydraulic system

2 x 0007-1851-750 304,2/318,2x7

1 x 0007-1851-750 304,2/318,2x7

new previous

2040-9958-000 2178-9959-000




OSA20 - threaded ring 2178-6627-010

In some cases the threaded ring pos. 308 cannot be loosened. To take off the ring by means of a lathe please use carbide-tipped tool and about 40 to 70 m/min. Control the thread of the bowl bottom and the leading surface regarding marks. Smooth the surface. CAUTION: the threaded ring can be loosen during cut off.




OSA 20 - hard metal ring of sliding piston

OSA20

Guide values for re-machining:

Tool: carbide-tipped tool of M30 or K20Speed: 10 - 12 rpmDepth of cut: max. 0.15 mmRate of feed: max. 0.1 mm/rev

The sealing surface of the sliding piston can be re-machined several times when worn (up to 1,0 mm in total) before replacement of sliding piston becomes nescessary. When remachining, make sure that the shoulder on diameter „X“ is at least 1.5 mm. Remachine the sealing surface as soon as possible as there are slightest traces of erosion (of 0.2 - 0.3 mm depth). After the remachining the polaymid gasket in the bowl top needs to be replaced. Rebalancing of bowl is not necessary.




OSA 20 - frame venting

In order to improve the frame venting a pipe should beinstalled in the frame drain as shown above.




hard metal ring of sliding piston OSA7

The sealing surface of sliding piston can be re-machined several times when worn (up to 1,0 mm in total) before replacement of sliding piston becomes nescessary. When re-machining, make sure that the shoulder on diameter „X“ is at least 1.5 mm.

Re-machine the sealing surface as soon as possible as there are sligh-test traces of erosion (of 0.2 - 0.3 mm depth). After the re-machining the polaymid gasket in the bowl top needs to be replaced.

Re-balancing of bowl is not necessary

Guide values for re-machining:Tool: carbide-tipped tool of M30 or K20Speed: 10 - 12 rpmDepth of cut: max. 0.15 mmRate of feed: max. 0.1 mm/rev

OSA7




bowl: Table of bowl height´s

type X [mm] Y [mm] 50 Hz [rpm] 60 Hz [rpm]OSC4 54-56 * 9980 10030OSC5 54-56 * 9980 10030OSA7 80-82 1,50 8520 8510OSC15 37-39 * 9960 / 10240 11490 / 11470OSA20 120-122 2,00 7500 7500OSC30 16-18 2,00 7500 7500OSB35 38-40 2,00 6440 6540OSC50 -old- 43-45 2,00 6500 6500OSC50 -new- 34-36 2,00 6500 6500 *: height not adjustable

Yadjustment of bowl height:- unscrew bottom bearing cap (3)- remove gasket (1)- Adjust the bowl height by turning bottom bearing

threaded piece (2). A full turn will raise or lower the bowl by the dimension Y.

bowl is too high: turn anti-clockwisebowl is too low: turn clockwise




separator bowl - unbalance

when having trouble with unbalance of bowl please check if:

- all “0“ marks are in-line and all locking devices are in perfect condition

- the disc stack pressure has been lost (blind disk or disk to be added)

- any damages / erosion / corrosion / cavitation are to be noticed

- the bowl has been re-assembled completely (missing parts ?)

- all bowl parts are arranged in fixed positions to one onother

- bowl part´s from different bowl has been mixed




separator bowl - unbalance

The bowl need´s to be exchanged when the bowl top or bowl bottom has been damaged. These bowl parts cannot be replaced without re-balancing of complete bowl because of the positions of balancing area.




bowl: taper seat of bowl bottom / spindle

The conical seat of bowl bottom and worm spindle must be absolutely dry when assembling the bowl.




separator bowl: chrome layer peeling

The sliding surfaces of bowl are protected with a crome layer to prevent bowl parts from seizing during the run-ning-in phase. This crome layer is necessary during the first few hundret running hours only and may peel off. The scope and location of this peeling can differ from bowl to bowl. The product, the operating mode and the number of ejections etc. can influence the overall picture. There is no effect on the separation efficiency, maintenance schedule and service life of bowl.




separator bowl OSA, OSB - wear protection

Bowls type OSA and OSB are equipped with wear protection against erosion when running with HFO: wear liner, wear inserts and hard metal ring. Please never run bowl without wear protection with HFO or any other abrasive product (sludge, palmoil etc.)




Refinery process




cat fines




Residual Marine fuel standards

ISO, BSI, CIMAC




Incompatibility of Fuels





Sludge of an asphalt nature may be produced if fuels from different refineries are mixed and this sludge may cause serious trouble. If this happens the fuels are said to be incompatibile. Such disruptions first become evident in the centrifuge in the form of excessive amounts of sludge separating out. Asphalt sludge may also clog the pipes, pre-heater and filter and collect in the tanks. Changing the temperature of the oil has virtually no effect on the formation of sediment. The reason is that the more intensive refining process and particularly the use of the visbreaker, produces a higher content of aspahltenes. Many of these large molecules are at the limit of their solubility in the parent oil (are in a labile state). It is ensured that the above disorders do not occur in refineries by appropriate management of the process and by admixing selected components (e.g. cracked gas oil to act as a low-viscosity component). If however a heavy oil of this kind is mixed with a fuel with a lower capacity for dissolved asphaltenes, then the asphaltenes precipitate. Instability of this nature exists even when for example admixed component isa paraffin-base destillate.








Stability of Fuels

Occationally layers of low and high-viscosity oil occure which have nothing to do with stability but are due to inadequate blending of the components. This may cause an oil overflow to the dirty water discharge.

The chemical stability of a residual oil decreases the more deficient the carbon molecules is in the hydrogen atoms which would be needed to occupy all its free valences. Therefore it is easy for external influences to bring about a change in the chemical make-up of the molecules. This danger is thus accentuated with the fairly hydrogen-deficinet residues from cracking plants (catalytic crackers and visbreakers).

The residues in question oxidise by absorbing oxygen from the atmosphere and as a result of polymerisation (linking) of molecules they form fairly large structures which precipitate as sludge. The tendency to oxidise increases with the content of unsaturated hydrocarbons, of which there is a particularly high concentration in residues from cracking. The tendency also increases sharply as temperature rises. For this reason feed tanks should not be heated very much above the pump temperature.




Precipitation of Paraffin (wax) / Spot test

It must be remembered that fuel oils may contain components of aparaffine nature. Paraffins in the narrower sense are usually understood to be those members of a homologues series of saturated straight-chain hydrocarbons which exits as a solid phase at room temperature. So long as the fuel oil is kept at an appropriate temperature, the paraffines remain in solution but as their solubility decreases as temperature drops, paraffin components may separate out in solid form if the fuel oil cools down. The temperature at which the precipitation of the paraffinbegins depends on the mean molecular weight of the fuel oil and also on the amount of paraffins present and their melting points. As the majority of fractions of this kind are cracked off in cracking plants, the precipitation of paraffins is more frequently encountered with residues from pure destillation.

A small amount of the phase flowing out on the water side is heated to approximately 100 °C and a spot placed on a filter paper. If a nucleus collects, then what is involved is the precipitation of asphaltenes or the separating out of products of oxidation and if not then it is the precipitation of paraffins.




fuel problem: contamination with chemical´s





pittings / cavitations at the sensing liquid pump (HFO)





5 barCS 5 barCS 3 bar





pittings / cavitations at the sensing liquid pump (HFO)




electrical equipment -general layout plan




Diagram of installation: SINGLE MODE

Separator

control unit

feed valve pre-heater

solenoid filling/ displacement water

Motor starter

pressure switch

solenoid operating water




Timing unit type VESA

timing unit type VESA installed 1980 - 1990

Voll Elektronische Steuerung A- Typ





timing unit type VESA installed 1980 - 1990

Voll Elektronische Steuerung A- Typ





















d1: Waiting

d2: Displacement

d3: Ejection

d4: Speed recovery time

d5: Filling

d6: Bridging time after ejection

d7: Alarm delay time

d8: Ejection monitoring time

digital adjuster at the rear side of VESA




Timing unit type VESB

timing unit type VESB installed 1990 - 1999

Voll Elektronische Steuerung B- Typ












PLC100/1WS-part number : 0005-4050-260PLC100/2 WS-part number : 0005-4050-270PLC100/3 WS-part number : 0005-4050-280PLC100/4 WS-part number : 0005-4050-290





Timing unit type VESB: PLC100

1: control unit PLC 1002: LED off / input status3: LED on / output status4: Cursor up5: Cursor down6: Output range7: Input range8: Counter range9: Timer range

10: Copy program11: Status text12: display13: Operation LED (control unit READY)14: numeric key´s15: Enter key16: Specific call-up in preselected mode17: Function key´s: F0 - TEST




Timing unit type VESB: PLC100, function keys

gives access to key F10 to F16SHIFT

freeF16

diesel oil operation: alarm TAL suppressedF15

freeF14

series operation – ONF13

free (displacement with product)F12

freeF11

self-thinker control – ONF10

alarm acknowledgementF6

diagnostics: help functionF5

clarifier operation: step FILLING suppressedF4

flushingF3

displacementF2

program START with ejectionF1

program STOP with ejectionF0




Timing unit type VESB: PLC100

PLC100 without EPROM

PLC100: 16 inputs, 8 + 8 outputs, maker: SCHLEICHER




Timing unit type VESB: replacing PLC100

PLC100/1 can be replaced by PLC100/1 or PLC100/3.PLC100/2 can be replaced by PLC100/2 or PLC100/4.

1. Please make a note of the original settings of all timer and counter2. Please switch off the main switch and plug off all plug connectors as

well as the EPROM (please never plug off EPROM while contolcabinet is energized)

3. Replace the PLC100 and plug in the connectors and (new) EPROM(check both fuses and the output of the 24 V power supply: must be24 VDC steady otherwise the power supply is damaged)

4. Switch on the main switch and press following keys:“STATUS” then “#” then “TEST”

5. Enter the password: “02522” and finally press the “ENTER”-key6. Press the “COPY”-key, then “ENTER” and “STATUS” again.7. Now you can change the present timer and counter setting`s to the

original one´s. To do this please press the "TIMER" key. By meansof the cursor key´s you can scroll trough the timer list and changethe settings . To call up the timer please press the "ENTER" key.




Timing unit type VESB: Password PLC100

To download the soft-ware from the EPROM into the CPU by means of the COPY function as well as to change the timer settings in the timer list, the password protection needs to be lifted. Please follow the procedure.

Please note: the EPROM must not returned to WS in case the PLC 100 is gone.




VESB function key´s - HFO series mode -01-36-

First stage: WMS -01-: VESB-EC-1, with DISPLACEMENT and FLUSHING. Please pre-select function key F2 for DISPLACEMENT, F3 for FLUSHING and F13 to activate the series mode.

Second stage: SMS -36-: VESB-EC-1, with DISPLACEMENT and FLUSHING. Please pre-select function key F2 for DISPLACEMENT, F3 for FLUSHING, F4 for CLARIFIER OPERATION, F10 to activate the SMS and F13 to activate the series mode.




Timing unit type VESC

Voll Elektronische Steuerung C- Typ

timing unit type VESC installed 1995 - 1999
















Timing unit type VESC, check of PSU card





Timing unit type VESC , check of PSU card

R13

four pin socket





R13 burned

rear side of PSU card





R13 new







power supply unit, part number: 0005-4097-100

VESC-1-W (8155-0202-050)to be installed on the wall

VESC-1-S (8155-0202-060)to be installed inside control cabinet.





EPROM; software: 0005-2045-100








EPROM; software: 0005-2045-100




Timing unit type C7

0005-4050-300 C7-623 (A) 0005-4050-310 C7-626 (A) 0005-4050-320 C7-626 (A) DP 0005-4050-340 C7-623 (P) 0005-4050-350 C7-626 (P) 0005-4050-360 C7-626 (P) DP

UD700: 0005-4040-190 (software update)

C7-623 C7-626

timing unit type SIEMENS C7 installed from 2000




Timing Unit type C7-626





















Display

Status /fault indicator

Function key System key´s

Softkey´s

Softkey´s




Timing Unit type C7- softkeys

ALARMS: Picture-dependent function key as per display. On the PROCESS page you can use this key to call up and view alarm message buffer.

OPERATION: Pressing this key takes you from any display page to the main menue (PROCESS page - this is the graphic process picture)

UP and DOWN: Keys are normally used in the display to access the next / previous level. Other functions are picture-dependent and are shown in the display.





SEPARATOR PROGRAM OFF

This key stops the separating program, closes the feed valve in separation mode and empties the bowl. On the OSC separators two total ejections are triggered automatically.

SEPARATOR PROGRAM ON

This key starts the separating program. When the ejection program has run the feed valve is openend. The ejection monitoring system is suppressed after pressing this key because there is no de-sludging when the bowl is empty (on C-type of separators only)





WMS 01: WATER MONITORING SYSTEM UNITROL-HFO: single or parallel mode of operation, first stage in series mode

SMS 36: SLUDGE MONITORING SYSTEM UNITROL-HFO: second stage in series mode

SMS 96: SLUDGE MONITORING SYSTEM UNITROL-LO

SERIES MODE for UNITROL-HFO only.




Timing Unit type C7- function keys

The LED in the key´s shows the actual status:permanent lighting: OPERATIONslow flashing: FAULT from motor protectionrapid flashing: winding up time or delay to stop time

No other function.




Timing Unit type C7- function keys

PARTIAL EJECTION: OSC type of separators allow partial ejections. To do this, pre-select the number of partial ejections on Counter C01 to be triggered before the total ejection and the press the key PARTIAL.

HEATER RELAESE: Press this key only if an EXTERNAL FEEDPUMP is fitted. An optional heating system will be relaesed which is then process-dependently controlled.




C7 display: contrast, background illumination

626

The contrast at C7 623 is adjusted by pressing the SHIFT and +/- key.

623




Timing Unit type C7- system keyboard




C7 control cabinet, inside view

Use only approved shielded cables for wiring the analog in - and outputs as well as the IM, V.24 and MPI interfaces




C7 control cabinet, inside view




C7: view from rear, interfaces

1: IM port2: Analog inputs3: Analog outputs4: AUX digital inputs5: Serial interface V.246: Digital inputs (top)7: Digital outputs (bottom)8: DI/DO 24 VDC power supply




C7 series mode: first and second stage

MPI-plug: 0005-1408-000




C7 series mode: first, second, third stage




C7: alarm list

no. description001 motor protection separator-motor PTC002 clean oil discharge pressure low PAL003 clean oil discharge pressure high PAH004 breakover water discharge FSH005 temperatur low TSL006 temperatur high TSH007 ejection monitoring system ISL008 sludgetank level high high LSHH009 free010 motor protection feed pump PTC011 motor protection sludge pump PTC012 vibro stage 1 NAH013 vibro stage 2 NAHH014 series mode failure015 minimum sep. time not o.k.016 free017 WMS alarm- high water content




C7: error messages

alarm 001: MOTOR-PROTECTION

Temp. > max. °CMotor shut off

Help informations:Please check:> fuses in starter> Thermistor relais> clutch> correct numbers of clutch shoes> brake> motor current




C7: error messages

alarm 002: PAL-CLEANOIL-OUTLET

pressure < setpointSeparation stop

Help informations:Please check:> adjusting of back pressure> flow-rate feedpump> hydraulic function> leaking of hydraulic liquid> clutch of feedpump> condition of pre-strainers




C7: error messages

alarm 003: PAH-CLEANOIL-OUTLET

pressure > 3,0 barSeparation stop

Help informations:Please check:> valve / position in cleanoil outlet pipes> adjusting of back pressure> flow rate> oil temperature-setting> setpoint of frequency converter




C7: error messages

alarm 004: FAH-WATER-OUTLET

Flow too highSeparation stop

Help informations:Please check:> adjustment of back pressure> flow rate feedpump> adjusting of setpoint> leaking of hydraulic liquid




C7: error messages

alarm 005: TAL-PRODUCT-FEED

Temp. min: < SetpointSeparation stop

Help informations:Please check:> Temp. setting of Analog / Input> Temp. indicator in feedline> function of heating system




C7: error messages

alarm 006: TAH-PRODUCT-FEED

Temp. max: > SetpointSeparation stop

Help informations:Please check:> Temp. setting of Analog / Input> Temp. indicator in feedline> function of heating system




C7: error messages

alarm 007: EJECTION MONITOR

current < SetpointSeparation stop

Help informations:Please check:> Ejection current> Setpoint of ejection monitor> Amount of operating water> clutch shoes> function of bowl




C7: error messages

alarm 008: LSHH- SLUDGETANK

level-highSeparation stop

Help informations:Please check:> Function of sludge pump> Function of level switch / wiring> Handvalve position> clutch shoes> system / leakages




C7: error messages

alarm 010: FEED-PUMP

Motor-protection pump out of order

Help informations:Please check:> Fuses / breaker in motorstarter> Function of pump> Function of motor> Motor temperature> Nominal current




C7: error messages

alarm 011: SLUDGE-PUMP

Motor-protection pump out of order

Help informations:Please check:> Fuses / breaker in motorstarter> Function of pump> Function of motor> Motor temperature> Nominal current




C7: error messages

alarm 012: VIBRATION STAGE 1

Vibration > 4,5 mm/s start ejection program

Help informations:Please check:> operation water system> bowl hydraulic> sludge outlet> vibration monitor> correct bowl assembly> setpoint stage 1




C7: error messages

alarm 013: VIBRATION STAGE 2

Vibration > 7,0 mm/s Motor switch off

Help informations:Please check:> operation water system> bowl hydraulic> sludge outlet> vibration monitor> correct bowl assembly> setpoint stage 2




C7: error messages

alarm 014: SERIES MODE FAILURE

connection / pre-set failure

Help informations:Please check:> key „SERIES 1<=>2“ on both timing units> MPI-cables / plugs on both timing units> Both separators in „Ready for operation“




C7: error messages

alarm 015: MIN. SEPARATION TIME < 10 min

high water content

Help informations:Please check:> water content in dirty oil feed> Leakage of water valve> control holes in separation disk HFO / LO




C7: error messages

alarm 017: WMS - alarm high water content

WMS-SYSTEM NOT OKhigh water during Timer 22

Help informations:Please check:> WMS-signal> settings of measuring relais> function of WMS> function of water discharge valve




C7: error messages

alarm 018: Water seal broken during Timer 35

SMS- FUNCTION NOT OK

Help informations:Please check:> function of SMS pressure switch> amount of filling water> product feed




C7: error messages

alarm 019: PSL pressure switch monitoring

Clean oil outlet pressure

Help informations:Please check:> adjusting of back pressure> flowrate feedpump> bowl closing> hydraulic function> leaking of hydraulic liquid> clutch of feed pump




C7: error messages

alarm 020: Bowl monitoring

Closing water impulse T06

Help informations:Please check:> adjustment of closing water impulse> operating water pressure> clutch shoes> function of bowl




C7: error messages

alarm 021: Separator off

Separator off function active T39(no ACK after alarm raised)

Help informations:Please check:> Separator off function active > Separator shut down after T39 elapsed




Service Training

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Documents

Westfalia Service Training