Untitled 1

5838 GEEP Contract
Rehabilitation of HCO Treatment Plant

Power Station: Al Quds
Centrifugal separator type OSD60 / WSD60
Section:
Fuel Oil Treatment Systems for
Gas Turbine Power Plants
GEA Westfalia Separator Group GmbH

Customer Needs
To protect the gas turbine, fuel contaminated with sea water

and impurities needs being treated by a FOTS
Fuel Oil Transportation

and Handling
Oil Refinery Protect your

Site Storage Gas Turbine!!
Fuel Oil
Treatment
Refinery Fuel Oil Storage System
Customer Benefits
GEA Westfalia Separator’s centrifugal technology minimizes the risk of

hot gas path temperature corrosion on the turbine blades to a minimum
Traces like sodium and potassium create hot

temperature corrosion.
These water-soluble salts will be absorbed

into the water phase and separated out.

Customer Benefit
With a GEA WS Group’s fuel oil treatment system the Life Cycle Costs of
a GT can be reduced
Increasing of service life of turbine

blade by 50 – 70%
Necessary general overhauling of
gas turbine at intervals of only 8-12
years (instead of 5-7 years)
50% reduction of operation costs
for downstream equipment
With the reduction of the efficiency
loss by installing a FOTS the
generated capacity of the GT is
increased by 5% at supply of same
Corrosion on a turbine blade
fuel quantity

Customer Benefit
The water and sediment content in the fuel is drastically reduced

at the discharge of our fuel oil treatment system
Separation results: benefit:
Optimum salt reduction of

Water content will be reduced Na and K down to < 0.1 ppm.
to less than 200 ppm in the
treated oil Reduction of the risk of
bacteria growth in the tank.
Big cost savings for down-

The separated oil is practically stream equipment like:
free from metal particles > 3 - Filter cleaning / filter inserts
micron and heavy non-metallic - less sealing wear
particles > 5 micron. - less maintenance of other
equipment like pumps,
nozzles

Product Overview
GEA WS Group scope of supply and scope of services
Fuel Oil Treatment Lube Oil Treatment Environment Oil Management

• Distillate • Steam Turbine Lube Oil • Waste Water treatment • Pumping
• Naphtha / NGL • Gas Turbine Lube Oil • Sludge concentration • Heating
• Crude Oil • Generator Lube Oil • Cooling
• Heavy Fuel oil • Filtration
• Selection
Automatic Process Ready-To-Connect Complete Solutions • Dosing
Control Modules • Analysing
Oil-Fired Gas Turbine Steam Turbine Power Nuclear Power Plant* Hydro Power Plants*
Power Plants Plants*
* Lube Oil Treatment System

Diesel Oil Treatment Systems
Main characteristics of a diesel oil treatment system
Normally heating is not required (depending on site conditions).

Dilution water could be added up to 1% of the fuel flow.
Dosing of chemicals is not required.
Reduction of Na+K down to 0.1 ppm.
Oily waste water and oily sludge can be separated.
70% to 80% of GEA WS installations are treating diesel oil.

In many cases diesel oil is only stand-by fuel.
If only one fuel storage tank is available, the FOTS
can be installed in by-pass mode.

A diesel oil treatment system is the most simple installation
OILY WASTE
WATER
WATER
FI PAH
DPISH TRANSFER
PUMP
UNTREATED
FUEL
P
PIALH FI
TREATED
FUEL
SLUDGE
CHANNEL
LSHH
SLUDGE
PUMP LSH
SLUDGE CENTRIFUGAL
OUTLET LSL
SEPARATOR
(OILY)

distillate treatment system with OSD 60-01-036 in a

power plant with LM 6000 gas turbines

distillate treatment system with 6 units CP6:

36 x OSC 50-01-066, total treatment capacity 1.080 m³/h.
Muara Tawar power plant in Jakarta - Indonesia

Crude Oil Treatment Systems
Main characteristics of a crude oil treatment system
Crude oils have many different chemical compositions.

Crude oils are separated into:
- Light crude oil (light Arabian crude)
- Heavy crude oil
Heating is required above wax melting point (min. 60°C /140°F).
Dilution water can be added up to 1% of the fuel flow.
To optimize the desalting process for crude oil chemical dosing
(demulsifier) is requested.
Na+K can be reduced down to 0.3 ppm.

If flash point is below handling temperature and/or customer declares
the area as hazardous, explosion-proof design is required.

All crude oils have something in common:
Similarities Special treatment
Low flash-point Explosion-proof design is mandatory
Purging with nitrogen or fresh air if the

separating temperature is at least not
Build-up of explosive vapors
min. 15°C below the flash point of the
product
Separation temperature must be in any

High wax content case higher than the wax melting point,
i.e. 60°C

A crude oil treatment system for light crude oil as single-stage system
OILY WASTE
WATER
WATER
DEMULSIFIER M
LI
FI PAL
LAL
PAL
DEMULSIFIER PISTON
BUFFER TANK DOSING
PI M
PUMP
DPISH HEAT TC
EXCHANGER
UNTREATED
FUEL
TRANSFER OIL PRE-
P
PUMP HEATER
FI
PIALH
TREATED
FUEL
SLUDGE
CHANNEL
LSHH
SLUDGE
PUMP LSH
CENTRIFUGAL
OILY
LSL SEPARATOR
SLUDGE

A crude oil treatment system for light crude oil as single-stage system
Heat exchanger
Untreated oil feed

Pre-heater
Treated oil
discharge
Demulsifier
Dilution water
Separated water
discharge
Solids Self-cleaning Operating

discharge separator water

Light Arabian crude oil treatment system with 3 OSC 50-01-536/60

Al Jouf gas turbine power plant in Saudi Arabia

Light
LightArabian
Arabiancrude
crudeoiloiltreatment
treatmentsystem
systemwith
with3 5OSC
OSE50-01-536/60
80-01-537
WadiAlAlJouf
Dawaser
gas turbine
gas turbine
power
power
plantplant
in Saudi
in Saudi
Arabia
Arabia

Heavy Fuel Oil and
Heavy Crude Oil Treatment Systems
Main characteristics of a heavy fuel oil (HFO) and

a heavy crude oil (HCO) treatment system
HFO and HCO have many different chemical compositions.

Heating of HFO and HCO is required up to 98°C (208,4°F).
Regarding the high content of salts a two-stage washing system is
required.
Wash Water shall be added up to 10% of the fuel flow.
Wash water heating is requested.
For optimizing the desalting process chemical dosing (demulsifier) is
requested.
Na+K can be reduced down to 0.3 ppm.
If flash point is below handling temperature and/or customer declares
the area as hazardous, explosion-proof design (especially for HCO)
is required.
Heavy Fuel Oil and
HFO/HCO treatment system as two-stage counter current washing

system

Heavy Fuel Oil and
HFO treatment system with 8 OSC 50-01-036/60

Shenzhen Yuhu gas turbine power plant in China

Heavy Fuel Oil and
HFO and HCO treatment system with 4 OSC 50-01-336/60

in total 8 lines - Baiji gas turbine power plant in Iraq

Extended Products
Westfalia´s full range of extended products:

Waste water treatment and sludge concentration
- Waste water treatment with our waste water centrifuges
- Sludge concentration with our decanters
- Combination of both as complete system
Pump stations (*can be offered without fuel oil treatment system)
- Unloading pump skids*
- Forwarding pump skids*
- Water booster pump skids
Chemical dosing systems (can be offered without fuel oil treatment system)
- Inhibititor dosing skids
Complete system solutions

- Control system incl. communication with the DCS system
- Equipment installation in container
- Heating systems
- Filtration and selection skid for HFO/HCO and light crude oil
- Laboratory equipment
- Engineering and delivery of interconnecting pipe work and cabeling
Waste Water Treatment Systems
Waste water treatment systems with GEA WS Group centrifuges

are preferrably used for diesel oil treatment systems
Oily waste water

from our fuel oil
Treatment De-oiled water  15 ppm
treatment centrifuges
with WSC
centrifuge
Oily sludge
for disposal Collecting
channel

Sludge Concentration Systems
Sludge concentration systems with GEA WS Group decanters

are preferrably used for HFO/HCO and big diesel and crude oil treatment
systems
Oily sludge
from fuel oil
treatment skid Buffer
tank
Recovered oily
water back to
untreated tank Sludge
concentration
with decanter Concentrated Sludge
for disposal
Two-phase decanter:
CD 205 300 l/h Trolley for
collection

Sludge Concentration Decanter
The main components of every decanter are the housing with the
discharge chutes and hood, the rotor which consists of the bowl and
scroll, the product feed line and the drive.
bowl
scroll
housing
drive
feed pipe

Sludge Concentration Decanter
main motor
housing
feed
end face
cover with
bowl
bearing
clarified liquid
end face
cover with
bowl
bearing
solids bowl and scroll
secondary
motor

Unloading Pump Skids
The unloading pump skids are necessary in nearly all power plants
in order to feed the oil safely from the trucks into the storage tank
DPAH
PI FAL PI PAL FAL
Oil from Oil to the

the Truck Storage Tank
An unloading station consists of:

• Strainer for pump protection
• Self-priming unloading pump
• Degaser
• Flow meter and flow counter
Design criteria
• Capacity
• Requested discharge pressure
Forwarding Pump Skids
The forwarding pump skids feed the treated oil under specified
conditions to the high pressure pumps in front of the GT
Min. Flow DPAH

Circulation
PI PIALH
back to
Storage Tank
PI PIALH
From Treated Oil Treated Oil

Storage Tank to Gas Turbine
To quote a forwarding pump skid we need:

• Inlet pressure conditions
• Outlet pressure requirements
• Pump capacity
• Design philosophy like 1 x 100%, 2 x 100% or 3 x 50%
Water Booster Pump Skids
The water booster unit is needed if customer provided

a too low water pressure to operate our centrifuge skids safely
PI/PAL
Water Accumulator
PI PI PI/PHL PI/PHL
PI/PAL
To Fuel Oil Treatment Skid
The design of a water booster pump skid:

• Number and type of installed centrifugal
separators on the FOTP
• Inlet pressure conditions
• Design philosophy like 1 x 100% or 2 x 100%

Chemical Dosing Systems
In case there are higher contents of oil-soluble trace elements like

vanadium, lead, nickel, etc. we provide an inhibitor dosing system
Oil-soluble elements If content is above Dosing of inhibitor

cannot be separated GT-specification is recommended
TO
GAS
TURBINE
LI
PISTON M
DOSING PAL PI
LAL
PUMP
INHIBITOR
BUFFER
PISTON M
TANK
DOSING
PUMP
FI
Important: - Inhibitor type must be approved by GT manufacturer.

- Exact dosing rate must be approved by GT manufacturer.
Control System, Motor Control Center, workstation
The control cabinet consists of main power incoming, motor starters,

PLC system & HMI (human machine interface means for process-
operations visualizations). The cabinet is also designed as free-standing
solution

The control cabinet consists of main power incoming, motor starters,

PLC system & HMI (human machine interface means for process-
operations visualizations). The cabinet is also designed as free-standing
solution

A “corner solution” is possible and perfect to be installed into so-called

„container housings“. This corner solution is limited to a maximum of
12-15 separator motor starters including auxiliaries like pumps, etc.
A touch screen as HMI
for process control and
operation visualizations
of the whole process will
be displayed by using
graphics at the screen.

At this application the HMI (human machine interface) is a personal

computer monitor, keyboard and a printer. Not only process controlling
can be done but also programme modifications
Data bus connection

to the S7 unit

Auxiliary Skids
GEA WS Group can deliver the wide range of skids

from unloading up to selection skid in front of the gas turbine
Heating systems
(mostly needed for crude oil and HFO/HCO)
Requested to heat up the fuel oil to increase
the viscosity before feed to the GT.
Filtration and/or selection skid for

HFO/HCO and light crude oil
On this module a fine filter is installed
(manual cleaning or automatic backflushing),
a change-over valve (diesel oil/HFO-HCO)
and mostly a flow meter.
Laboratory equipment (offline)

- RDE AES Spectrometer
- Water-in-oil measurement
- Oil-in-water measurement
- Density, viscosity ….
Engineering and Delivery of
Interconnecting Pipe Work and Cabling
In case of bigger installations GEA WS can provide the engineering and

the bulk material for the required pipe work and cabeling to connect all
skids
auxiliary skid
fuel oil treatment skids
waste water treatment skid
control unit and customer

laboratory take-over
equipment point
Engineering incl.:
• all drawings
• calculation
• bill of material
Baghdad South heavy fuel oil treatment system

imprint
Author: Ronald Eschmann

Company: GEA Westfalia Separator Group GmbH, Germany
Department: Customer Training
Release date: 01-Mar-2016
Revision number: 1
Target group: MoE staff, Iraq, Maintenance and Operation
Supervisor working at Power Plant Al Quds
Method: compiled in .pptx, converted to .pdf
File name: Fuel Oil Treatment Systems for Gas Turbine Power
Plants
© 2016 GEA Mechanical Equipment. All rights reserved. External sources are indicated.

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5838 GEEP Contract

Rehabilitation of HCO Treatment Plant

GEA Westfalia Separator Group GmbH

To protect the gas turbine, fuel contaminated with sea water

Fuel Oil Transportation

Oil Refinery Protect your

GEA Westfalia Separator’s centrifugal technology minimizes the risk of

Traces like sodium and potassium create hot

These water-soluble salts will be absorbed

GEA Westfalia Separator Group GmbH

Increasing of service life of turbine

GEA Westfalia Separator Group GmbH

The water and sediment content in the fuel is drastically reduced

Separation results: benefit:

Optimum salt reduction of

Big cost savings for down-

GEA Westfalia Separator Group GmbH

GEA WS Group scope of supply and scope of services

Fuel Oil Treatment Lube Oil Treatment Environment Oil Management

GEA Westfalia Separator Group GmbH

Main characteristics of a diesel oil treatment system

Normally heating is not required (depending on site conditions).

70% to 80% of GEA WS installations are treating diesel oil.

GEA Westfalia Separator Group GmbH

A diesel oil treatment system is the most simple installation

GEA Westfalia Separator Group GmbH

distillate treatment system with OSD 60-01-036 in a

GEA Westfalia Separator Group GmbH

distillate treatment system with 6 units CP6:

GEA Westfalia Separator Group GmbH

Main characteristics of a crude oil treatment system

Crude oils have many different chemical compositions.

Na+K can be reduced down to 0.3 ppm.

GEA Westfalia Separator Group GmbH

All crude oils have something in common:

Similarities Special treatment

Low flash-point Explosion-proof design is mandatory

Purging with nitrogen or fresh air if the

Separation temperature must be in any

GEA Westfalia Separator Group GmbH

GEA Westfalia Separator Group GmbH

Untreated oil feed

Solids Self-cleaning Operating

GEA Westfalia Separator Group GmbH

Light Arabian crude oil treatment system with 3 OSC 50-01-536/60

GEA Westfalia Separator Group GmbH

GEA Westfalia Separator Group GmbH

Main characteristics of a heavy fuel oil (HFO) and

HFO and HCO have many different chemical compositions.

HFO/HCO treatment system as two-stage counter current washing

GEA Westfalia Separator Group GmbH

HFO treatment system with 8 OSC 50-01-036/60

GEA Westfalia Separator Group GmbH

HFO and HCO treatment system with 4 OSC 50-01-336/60

GEA Westfalia Separator Group GmbH

Westfalia´s full range of extended products:

Complete system solutions

Waste water treatment systems with GEA WS Group centrifuges

Oily waste water

GEA Westfalia Separator Group GmbH

Sludge concentration systems with GEA WS Group decanters

GEA Westfalia Separator Group GmbH

GEA Westfalia Separator Group GmbH

GEA Westfalia Separator Group GmbH