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TECHNICAL DOCUMENTATION

TECHNISCHE DOKUMENTATION
GEA Westfalia Separator SeaWaterDistiller

EDITION / AUSGABE - 05.03.2019

CUSTOMER / KUNDE: Shanhaiguan New Shipbuilding Industry Co., Ltd.


WS-ORDER NO. / WS-BESTELL 1451848422
NR.:
PROJECT / PROJEKT: CT370-1

MODEL / MODELL: SWD 25-85-110

REVISION / REVISION: 00

engineering for a better world www.gea.com


1451848422 / 00 / 05.03.2019

Die Verfasser freuen sich immer über Kommentare und Ratschläge


diese Dokumentation betreffend. Sie können gesandt werden an

The authors are always for comments and suggestions for


improving the documentation. They can be sent to

© GEA Westfalia Separator Group GmbH

GEA Westfalia Separator Group GmbH


Werner-Habig-Str. 1, 59302 Oelde, Germany
Tel.: +49 2522 77-0, Fax +49 2522 77-2488
ws.info@gea.com, www.gea.com

GEA Westfalia Separator Group GmbH


1451848422 / 00 / 05.03.2019

CONTENTS / INHALT
COVER SHEET
DECKBLATT
1 SAFETY
SICHERHEIT
1.1 SAFETY INSTRUCTIONS FOR INSTALLATIONS 5
SICHERHEITSHINWEISE FUER ANLAGEN
1.2 QUALIFICATION PERSONNEL 21
QUALIFIKATION PERSONAL
1.3 SAFETY 29
SICHERHEIT
2 SYSTEM DESCRIPTION
SYSTEMBESCHREIBUNG
2.1 EVAPORATOR, COMPL.
VERDAMPFER VOLLST.
CHECKLIST # DATA RECORDS 59

3 DOCUMENTS RELATING TO ORDERS


PROJEKTBEZOGENE DOKUMENTE
3.1 GRAPHIC SYMBOLS 65
GRAFIKSYMBOLE
3.2 ORDER INFORMATION SPARE PARTS FOR INSTALLATIONS 79
BESTELLINFO ERSATZTEILE F. ANLAGEN
3.3 EQUIPMENT LIST 85
GERAETELISTE
3.4 DIMENSIONED DRAWING 91
AUFSTELLUNGSPLAN
3.5 DATA SHEET 93
PROZESSDATENBLATT
3.6 INSTALLATION DIAGRAM 95
INSTALLATIONSSCHEMA
4 CONTROL UNIT
STEUER- UND REGELEINRICHTUNG
4.1 INSTRUCTION MANUAL 97
BETRIEBSANLEITUNG
4.2 CIRCUIT DIAGRAM 213
STROMLAUFPLAN
GEA Westfalia Separator Group GmbH
1451848422 / 00 / 05.03.2019

5 PUMP
PUMPE
5.1 DISTILLATE PUMP
DESTILLATPUMPE
CM 273

CM-CME 303

5.2 CENTRIFUGAL PUMP, COMPL.


KREISELPUMPE VOLLST.
NSL 427

NSLH65_215_D02_62.90_60HZ 457

6 VALVES, FITTINGS, ASSEMBLY


VENTILE, ARMATUREN, ZUBEHÖR
6.1 BALL VALVE
KUGELHAHN
PD 461

6.2 PRESSURE GAUGE COCK


MANOMETERHAHN
G 1/4 465

6.3 NON-RETURN VALVE


RUECKSCHLAGVENTIL
IM-10-NRV 467

7 MEASUREMENT
MESSTECHNIK
7.1 PRESSURE GAUGE
DRUCKMESSGERAET
232.50 / 233.50 487

232.50 / 233.50 491

213.40 493

213.40 497

213.53 499

GEA Westfalia Separator Group GmbH


Safety precautions
for plants
No.: 9001

Edition: 0712

Designation: Safety precautions

engineering for a better world GEA Mechanical Equipment


2 9001 / 0712 / Safety precautions / 25.07.2012

ORIGINAL INSTRUCTION
Subject to modification!

The authors are always grateful for comments and suggestions for improving the
documentation. They can be sent to

GEA Mechanical Equipment


GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde, Germany
Tel.: +49 2522 77-0 · Fax +49 2522 77-2488
ws.info@geagroup.com,· www.westfalia-separator.com

GEA Westfalia Separator Group


9001 / 0712 / Safety precautions / 25.07.2012 3

For your safety


• Strictly adhere to instructions marked with this symbol.
This avoids damage to the plant or plant components.

• Take special care when carrying out operations marked with this
symbol -
otherwise danger to life.

Note: • This symbol is not a safety precaution but rather a reference to infor-
mation which help to better understand the plant components and the
processes.

• Observe the accident prevention regulations!


The local safety and accident prevention regulations apply uncondi-
tionally to the operation of the plant. The plant operator must ensure
compliance with these regulations.

• Follow the instructions in the manual.


Follow only the instructions given in this manual.
Repair and maintenance work that goes beyond the scope described
in this manual may not be carried out.

GEA Westfalia Separator Group


4 9001 / 0712 / Safety precautions / 25.07.2012

1 Safety precautions

1.1 Safety markings ....................................................................................... 5


1.1.1 Safety markings and their meaning ......................................................... 5
1.2 Performing work on a plant ...................................................................... 8
1.2.1 Demands on the operating and maintenance personnel ......................... 8
1.2.2 Spare part requirements .......................................................................... 9
1.2.3 Electrical installation ................................................................................ 9
1.2.4 Before start-up ....................................................................................... 10
1.2.5 Start-up .................................................................................................. 11
1.2.6 Shut-down and »Emergency-Off« ......................................................... 13

GEA Westfalia Separator Group


9001 / 0712 / Safety precautions / 25.07.2012 5

1.1 Safety markings


The safety markings (adhesives and metal plates) are attached to all plants, on
the hood and frame of the respective plant component in such a way that they
are clearly visible.
All safety markings on the plant, control system and plant components must al-
ways be in perfect condition.
• Clean dirty safety markings.
• Replace damaged safety markings.

1.1.1 Safety markings and their meaning


The following safety markings must be attached to the monitoring system as
adhesive labels:

Be sure to adhere to the plant


documentation!
• Every person who is assigned the
task of installing, operating, main-
taining and repairing the plant must
have read and understood the doc-
umentation.
• The documentation must be com-
plete kept near to the installation
and be readily accessible to the op-
erators. It must be available to the
operators at all times!
Fig. 1

Disconnect power prior to start-


ing work!
Risk of injury due to electrical voltage
and unintended start-up of the plant!

Before carrying out work on the


plant and electrical plant compo-
nents:
• Make sure the plant is at a standstill.
• Switch off all electrical appliances
via the main switch,
• Lock the installation to prevent it
Fig. 2 from being accidentally switched on.

GEA Westfalia Separator Group


6 9001 / 0712 / Safety precautions / 25.07.2012

Frequency converter operation!


• When setting the frequency convert-
er, do not exceed the admissible
speed (see nameplate)!

Note:
This adhesive plate is only used for
frequency converter operation.

Fig. 3

Warning of extreme surface


temperatures!

The surfaces of the plant components


can be hot!

Note:
This adhesive plate is only used for hot
operation.

Fig. 4

Danger due to electrical current!


Non-compliance with the protective
measures can result in serious dam-
age to persons or property.

Before working on electrical com-


ponents:
• Switch off all electrical appliances
via the main switch,
CAUTION:
The parts marked in this way can
carry voltage even when the main
Fig. 5 switch is off!

• Lock the installation to prevent it from being accidentally switched on.


• Take adequate preventive measures according to the national orovisions (in
Germany in accordance with the rules and regulations of the VDE (Verein
Deutscher Elektriker / Association of German Electrical Engineers) or EVU
(Europäische Vereinigung für Unfallforschung und Unfallanalyse / European
Association for Accident Research and Analysis) institutions.
• The work may only be carried out by competent persons (qualified technical
specialists).

GEA Westfalia Separator Group


9001 / 0712 / Safety precautions / 25.07.2012 7

Potential equalisation (protec-


tive-earth terminal)
The grounding protection is a measure
which, in the case of a malfunction,
leads off the touch voltage into the
earth.

Fig. 6

GEA Westfalia Separator Group


8 9001 / 0712 / Safety precautions / 25.07.2012

1.2 Performing work on a plant

The plant works reliably, provided that


it is operated and maintained in ac-
cordance with our operating instruc-
tions.

Fig. 7

Special attention must be given to:


• assembly
• electrical installation
• before start-up
• start-up
• shut-down
• maintenance and repair

1.2.1 Demands on the operating and maintenance personnel


Operating, maintaining or repairing the plant requires specialized knowledge!

CAUTION!
Operating, maintenance or repair work by unqualified or unauthorized
personnel can lead to operating, assembly and handling errors and severe
damage to persons and property.

Westfalia Separator accepts no liability for damage caused by unqualified


or unauthorized personnel!

For operation, maintenance and repair work, personnel may only be deployed
who
• have reached a minimum age of 18 years.
• are demonstrably familiar with the state-of-the-art through briefings and train-
ing.
• are adequately qualified for performing the work and checking it.
Electrical work may only be carried out by an authorized electrician!

The operator of the plant


• is responsible for the necessary skills and knowledge of the personnel.
• is responsible for briefing and training the personnel.
• must be sure that the personnel have read and understood the manuals nec-
essary to carry out their work.

GEA Westfalia Separator Group


9001 / 0712 / Safety precautions / 25.07.2012 9

Westfalia Separator offers a an extensive range of training and advanced train-


ing courses. You can obtain further information from Westfalia Separator or from
one of the authorized representatives.

1.2.2 Spare part requirements

• Use only genuine spare parts from Westfalia


Separator.
The use of non-genuine parts leads to:
– safety risks,
– less durability and availability,
– increased service requirement.
If a safety risk occurs when using non-original
spare parts, this may have legal consequences
Fig. 8 for the responsible persons. In such cases,
Westfalia Separator accepts no liability or war-
ranty claims.

1.2.3 Electrical installation

• Electrical work may only be car-


ried out by an authorized electri-
cian!
• The governing accident prevention
regulations apply for the electrical
appliances and installations.
• Special attention must be paid to the
installation guidelines of Westfalia
Separator.
• The frequency and voltage of the
power supply must correspond to
the machine specifications.
Fig. 9

• Carry out voltage equalization.


• Observe legal regulations; e.g. in the EU:
– Low-voltage guideline 73/23/EWG
– Electro-magnetic compatibility 89/336/EWG.
– Guidelines of the classification societies.

GEA Westfalia Separator Group


10 9001 / 0712 / Safety precautions / 25.07.2012

1.2.4 Before start-up

• Check that the lubrication and cool-


ing systems are serviceable.

Fig. 10

• Check whether the supervisory


equipment is operational and the
correct limit values are adjusted.
• When hoods, concentrate collectors
and vessels are pressurized, e.g. by
– inert gas blanketing,
– cooling,
– steam sterilization etc.
the pressures stated on the boiler
plate must not be exceeded.

Fig. 11

• Check that the product lines are set


to operation.
• Regularly check hoses for signs of
ageing.
• Check sight glasses for mechanical
damage.
• Damaged parts must be replaced
immediately by new or reconditioned
parts.

Fig. 12

GEA Westfalia Separator Group


9001 / 0712 / Safety precautions / 25.07.2012 11

1.2.5 Start-up

• Wear ear protection.

Fig. 13

In case of frequency converter


operation:
• Do not under any circumstances
manipulate the frequency converter
to exceed the permissible speed
(see nameplate).
• The plant may only be operated with
an independent device for speed
limiting.

Fig. 14

• Do not feed product which is catego-


rised as explosive.
• Do not operate the equipment in ex-
plosion-hazarded areas.

Note:
This is except for plants equipped for
operation in explosion-hazarded areas.

Fig. 15

GEA Westfalia Separator Group


12 9001 / 0712 / Safety precautions / 25.07.2012

• The plant may be fed with inflam-


mable product only when being in-
ert-gas blanketed.
• The oxygen level has to be kept be-
low limit of inflammability by means
of an appropriate inert gas.

Fig. 16

• When processing products harmful


to persons, observe the pertinent
safety regulations.
• Refer to the safety data sheet of the
product.
• Wear protective clothing.

Fig. 17

Only in case of hot operation:


• Product-contacting parts such as
– pipes and hoses,
– components,
– vessels
o
reach temperatures over 80 C
o
(176 F).

Fig. 18

GEA Westfalia Separator Group


9001 / 0712 / Safety precautions / 25.07.2012 13

1.2.6 Shut-down and »Emergency-Off«

• For shut-down refer to the chapter


"Operation".

Fig. 19

GEA Westfalia Separator Group


14 9001 / 0712 / Safety precautions / 25.07.2012

Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note

GEA Westfalia Separator Group


9001 / 0712 / Safety precautions / 25.07.2012 15

GEA Mechanical Equipment


GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde, Germany
Tel.: +49 2522 77-0 · Fax +49 2522 77-2488
ws.info@geagroup.com,· www.westfalia-separator.com
Qualification of staff
Edition: 0712

Designation: Qualification of staff

engineering for a better world GEA Mechanical Equipment


2 0712 / Qualification of staff

ORIGINAL INSTRUCTION
Subject to modification!

The authors are always grateful for comments and suggestions for improving the
documentation. They can be sent to

GEA Mechanical Equipment


GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde, Germany
Tel.: +49 2522 77-0 · Fax +49 2522 77-2488
ws.info@geagroup.com,· www.westfalia-separator.com

GEA Westfalia Separator Group


0712 / Qualification of staff 3

Qualification of staff

Work on / with separators requires special skills.


• Provide staff with special training / instruction for the following tasks:
– Operation,
– Maintenance,
– Repair.
• Clearly define responsibilities:
– Work performed by authorised persons only.

Type and source of danger:


Storage, transportation, erection, operation and maintenance of the sep-
arator / system by insufficiently trained staff.

Possible consequences of failure to observe:


Danger Incorrect operation, assembly and handling errors can cause serious damage,
injury / death.

Measures to prevent the danger:


– Use Westfalia Separator service.
– Take advantage of training opportunities.
– Read/follow operating manuals / operating instructions.

Westfalia Separator offers a comprehensive range of training measures.

The owner-operator is responsible for the training of staff.

NOTE

Contact Westfalia Separator or your nearest representative for more infor-


mation.
The owner-operator must select staff who, for example, fulfil the following re-
quirements:
• Minimum requirement:
– Read / understand the markings on the separator,
– Read / understand user instructions.
• Further requirements and skills:
– Basic general technical skills.
– Content of the operating manual / operating instruction.
– Measures for the prevention of accidents.
– Planning and implementation of installation.
– Securing of loads.
– Planning and implementation of start-up.
– Operation of the separator / system.
– Cleaning of the separator / system.
– Maintenance of the separator / system.
– Repair of the separator / system.
– Storage in case of extended periods of stoppage.

GEA Westfalia Separator Group


4 0712 / Qualification of staff

– Decommissioning of the separator / system.


– Disposal of operating material.
– Disposal of the separator / system.
• Other suitability:
– Only assign tasks to dependable persons.
– Minimum age of 18 years.
• Only employ persons undergoing training / apprenticeship under supervision.

The required skills and knowledge depend on the


tasks assigned.
NOTE

We reserve all rights to these documents. They may only be passed onto third parties after obtaining prior consent from Westfalia Separator Group GmbH.

GEA Westfalia Separator Group


0712 / Qualification of staff 5

GEA Westfalia Separator Group


6 0712 / Qualification of staff

Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note

GEA Westfalia Separator Group


0712 / Qualification of staff 7

GEA Mechanical Equipment


GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde, Germany
Tel.: +49 2522 77-0 · Fax +49 2522 77-2488
ws.info@geagroup.com,· www.westfalia-separator.com
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Safety Precautions and User Information


Machine and Skid Components

No.: 9953-9001-010
Version: 19.10.2016
About this document 9953-9001-010 / 19.10.16

ORIGINAL INSTALLATION GUIDELINES


Contents subject to modification!

The authors are always grateful for remarks and sugges-


tions for improving the documentation. These can be sent
to:

GEA Germany
GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1
59302 Oelde, Germany

Tel +49 2522 77-0 info@gea.com


Fax +49 2522 77-2950 gea.com

=== Ende der Liste für T extmar ke Titelseite ===

2 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 About this document

1 About this document 5

1.1 Sphere of application ................................................................................. 6


1.2 Qualification of the personnel .................................................................... 6
1.2.1 Operating personnel .................................................................................. 6
1.2.2 Service and repair personnel..................................................................... 6
1.3 Structure of the documentation ................................................................. 7
1.4 Symbols used ............................................................................................ 7
1.5 Structure of the safety references ............................................................. 7

2 Safety precautions 9

2.1 Intended use ............................................................................................ 10


2.2 Foreseeable use ...................................................................................... 10
2.3 Residual risk ............................................................................................ 11
2.4 Safety marking ......................................................................................... 12
2.5 Safety instructions for the personnel ....................................................... 12
2.6 Adjustments / commissioning .................................................................. 12
2.7 Maintenance and servicing ...................................................................... 12
2.8 Special types of hazard ........................................................................... 13
2.8.1 Electrical energy ...................................................................................... 13
2.8.2 Oils, fats and other chemical substances ................................................ 13

3 Description 15

3.1 Description and functional principles ....................................................... 16


3.2 Operating conditions ................................................................................ 16

4 Transport and storage 17

4.1 Transport ................................................................................................. 18


4.2 Storage .................................................................................................... 18

5 Assembly and installation 19

5.1 Measures to be taken prior to installation. ............................................... 20


5.2 Assembly ................................................................................................. 20
5.2.1 Fitting in the case of threaded connection ............................................... 20
5.2.2 Fitting in the case of a flanged connection .............................................. 20
5.3 Electrical connection ................................................................................ 21
5.4 Pneumatic connection ............................................................................. 21
5.5 Ex zone .................................................................................................... 21

6 Repair 23

6.1 Cleaning and care.................................................................................... 24


6.2 Maintenance ............................................................................................ 24
6.3 Repair ...................................................................................................... 24

GEA Westfalia Separator Group 3


About this document 9953-9001-010 / 19.10.16

7 Decommissioning 25

7.1 Machine disposal ..................................................................................... 26

8 Spare parts 27

8.1 Use only genuine spare parts. ................................................................. 28


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4 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 About this document

1 About this document

1.1 Sphere of application ................................................................................. 6


1.2 Qualification of the personnel .................................................................... 6
1.2.1 Operating personnel .................................................................................. 6
1.2.2 Service and repair personnel..................................................................... 6
1.3 Structure of the documentation ................................................................. 7
1.4 Symbols used ............................................................................................ 7
1.5 Structure of the safety references ............................................................. 7

GEA Westfalia Separator Group 5


About this document 9953-9001-010 / 19.10.16

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1.1 Sphere of application


These Safety precautions and User Information are an important aid to
• avoid risks,
• reduce repair costs and downtimes and
• prolong the lifecycle of components.
The term “component” will be used in singular although this document is applicable
to all components incorporated in the separators/plants.
To assure reliable information of the component, the safety precautions and user
information must be read and understood before carrying out the following work:
• Installation
• Transport, storage
• maintenance work (cleaning and care, maintenance, servicing, repair) and
• Disposal
For questions that cannot be solved with the aid of this documentation, please
check back with GEA Westfalia Separator Group.
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1.2 Qualification of the personnel


Using these safety and user instructions and direct handling of the component re-
quire specialist qualification of the staff. For identifying the qualification level GEA
Westfalia Separator Group uses the following standard terms:

1.2.1 Operating personnel


• Qualified staff have the necessary technical know-how and extensive experi-
ence enabling them to avoid the risks that can arise when handling electrical or
mechanical components. Knowledge of English is required.
• Trained staff are instructed or supervised by qualified staff to enable them to
avoid the risks that can arise when handling electrical or mechanical compo-
nents.
When installing, operating and testing the equipment, the staff has to adhere to the
safety rules applicable in the respective industry.

1.2.2 Service and repair personnel


Service and repair work require specialist knowledge and skills. Such work may be
carried out only by competent persons in terms of specialist knowledge and skills.
Documents in English are provided for this circle of persons. It is essential that this
circle of persons has an adequate command of English.
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6 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 About this document

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1.3 Structure of the documentation

WARNING Risk due to non-observance of the documentation

There is a threat of serious injuries if the instructions in all documents are not fol-
lowed.
 Refer to the instruction manuals for separators and/or start-up and shut-down
instructions for skids.
 Pay attention to the safety precautions and user instructions in machine and skid
documentation.
 Refer to the component manual.
 All safety precautions and warning instructions given in the documents have to
be adhered to.
 Access to the documentation must always be assured at the deployment site.

The documentation for components normally consists of:


• Instruction manuals for separators and/or start-up and shut-down instructions for
skids.
• Safety and user instructions on machine and plant documentation (this docu-
ment).
• Reference to component manual and / or technical datasheet of the component.
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1.4 Symbols used

This symbol gives information for better understanding the compo-


nent and its functions.

 The direction arrow marks work and/or operating steps. Keep to the order shown
from top to bottom.
• The bullet point marks lists.
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1.5 Structure of the safety references


The centrifuge has been designed and built so that it functions and can be operat-
ed safely. Reference will be made in this manual to further potential risks by using
warnings where appropriate.
A differentiation is made between hazards which result in damage to the centri-
fuge, plant components and environment and hazards which lead to possible or
probable injury or loss of life.

Signal words and their meaning

DANGER Denotes impending danger. If the preventive measures are not implemented, death
or serious injury will be the consequence.

WARNING Denotes a potentially dangerous situation. If the preventive measures are not im-
plemented, death or serious injury may be the consequence.

CAUTION Denotes a potentially dangerous situation. If the preventive measures are not im-
plemented, minor injury may be the consequence.

GEA Westfalia Separator Group 7


About this document 9953-9001-010 / 19.10.16

NOTICE Denotes a potentially damaging situation. If the preventive measures are not im-
plemented, the centrifuge or something else in its vicinity can get damaged.

Danger signals

This is the danger signal. It warns of injury risks.


 Comply with all measures marked with the danger signal to avoid injury or
death.

Structuring of the safety references according to the 5-point rule


1. Danger signals as a warning of injury risks.
2. Signal words signal the degree of risk.
3. The type and source of the hazard indicate from where the hazard origi-
nates.
4. Explanation of the hazard and consequences in the case of non-
compliance describe the threat and the consequences of human error.
5. Measures give instructions to avoid the hazard.

DANGER Type and source of the hazard

Explanation of the hazard and the consequences in the event of non-compliance.


 Measures to avert or minimise the hazard.

WARNING Type and source of the hazard

Explanation of the hazard and the consequences in the event of non-compliance.


 Measures to avert or minimise the hazard.

CAUTION Type and source of the hazard

Explanation of the hazard and the consequences in the event of non-compliance.


 Measures to avert or minimise the hazard.

NOTICE Type and source of the hazard

Explanation of the hazard and the consequences in the event of non-compliance.


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8 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Safety precautions

2 Safety precautions

2.1 Intended use ............................................................................................ 10


2.2 Foreseeable use ...................................................................................... 10
2.3 Residual risk ............................................................................................ 11
2.4 Safety marking ......................................................................................... 12
2.5 Safety instructions for the personnel ....................................................... 12
2.6 Adjustments / commissioning .................................................................. 12
2.7 Maintenance and servicing ...................................................................... 12
2.8 Special types of hazard ........................................................................... 13
2.8.1 Electrical energy ...................................................................................... 13
2.8.2 Oils, fats and other chemical substances ................................................ 13

GEA Westfalia Separator Group 9


Safety precautions 9953-9001-010 / 19.10.16

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The machine or skid components have been designed state-of-the-art and in ac-
cordance with the recognised safety regulations. However, when using the compo-
nent, risks may arise for the user or third party or the component or other assets
might get impaired if it is
• operated by persons who have not been trained or briefed,
• not used for the intended application,
• not correctly repaired or maintained.
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2.1 Intended use

The component is incorporated in machines and plants.


Precise details on the function of the component are found in the component man-
ufacturer’s manual.
The type of medium specified in the data sheet as well as the limit values for pres-
sure and temperature of the medium as per the specification must be complied
with at all times (see data sheet of the component manufacturer).
The specific values stated in the documents furnished with the component have to
be observed and adhered to.
Usage in an explosion-hazarded zone is not permitted. The only exception: this is
confirmed in the order or is in the manual or data sheet of the manufacturer.
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2.2 Foreseeable use


A different usage or a usage which goes beyond the scope is not in compliance
with the intended use. The operator of the machine/skid is exclusively liable for any
damage resulting from such usage. This applies likewise for unauthorized modifi-
cations.
Non-intended use is the use of
• materials with excessively high temperature,
• materials with excessively high pressure,
• materials with smouldering, burning or sticky particles.
• highly explosive and pasty materials,
• materials that act chemically with the materials of the component.
Changing the process conditions, operating conditions and environmental condi-
tions without the consent of the manufacturer are not in accordance with the in-
tended use.

WARNING Serious injury or death possible due to foreseeable misuse

Death or severe bodily injury to persons or damage to assets through disregarding


mechanical, chemical and electrical risks.
 The specific values stated in the documents furnished with the component have
to be observed and adhered to.
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10 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Safety precautions

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2.3 Residual risk


An element of risk will remain when using the components, even when strictly ad-
hering to all safety rules and regulations.
All persons working with the component must be familiar with this residual risk and
follow all instructions that prevent accidents or damage.

DANGER Danger to life through electric voltage

When working on live leads, there is a risk of electric shock. An electric shock
leads to serious injury or death.
 Work on electrical apparatus and/or on live component equipment must be per-
formed by qualified staff only.
 Disconnect the power to electrical equipment if necessary.
 Secure against unintentional switching back on.
 Attach a warning sign that prohibits switching on.

WARNING Serious injury due to non-use of personal protective gear

Fatal injuries due to non-use of personal protective gear!


 Make it compulsory for the maintenance personnel to wear personal protective
gear.
 Depending on the specific circumstances, wear safety shoes, protective gog-
gles, hearing protection etc.
 When surface temperatures of > 50 °C or < 0 °C (> 122 °F or < 32 °F) prevail,
wear temperature-resistant protective gloves when working on components.

Serious injury as a result of uncoordinated work in the area of the compo-


WARNING
nent
There is a threat of serious crushing, cuts and grazes as a result of uncoordinated
work in the area of the component.
 Be sure to work/move carefully in the area around the component.

Serious eye and/or skin injuries due to discharge of the medium under high
WARNING
pressure
Risk of burns when handling materials with abrasive or corrosive properties.
 Wear protective goggles or mask with eye protection to offset the risk of medium
spurting out.
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GEA Westfalia Separator Group 11


Safety precautions 9953-9001-010 / 19.10.16

2.4 Safety marking


The following markings (adhesive and metal plates) are fastened to the component
or its accessories:

Warning of dangerous voltage

The sign is attached to the electric terminal box.


The terminal box may only be opened by a qualified electrician.

Nameplate The nameplate contains specific component specifications.

All safety markings must always be in perfect condition.


 Clean dirty safety markings.
 Replace damaged safety markings.
 Note the safety marking.
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2.5 Safety instructions for the personnel


Use only components that are in perfect technical condition in accordance with
their intended use, paying attention to safety and hazard awareness and following
the instructions in the documentation.
Eliminate all faults immediately, especially those that can negatively impact safety!
Clearly define and comply with competencies for activities relating to operation and
maintenance. Only in this way can mistakes -- especially in risk situations - be
avoided.
Do not fit the component until all protective and safety devices are fitted and opera-
tional. Do not remove them during operation.
In the event of functional faults or safety-relevant changes in the operating behav-
iour , shut down and secure the separator or skid. Have faults eliminated by quali-
fied personnel immediately.
Discharge leakage from hazardous materials so that no risk arises for the operator
or the environment.
Do not touch damaged, cracked and, in particular, live components.
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2.6 Adjustments / commissioning


Through commissioning the component, the flow of medium can be changed or in-
terrupted. Prior to commissioning, make sure that possible adjustments cannot re-
sult in risks for persons or environment.
Check for correct functioning after each adjustment.
Implement suitable measures to avoid the crushing of limbs by moving actuators.
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2.7 Maintenance and servicing


When carrying out maintenance work, strictly adhere to all rules and regulations
applicable for handling the component or the medium (e.g. protective clothing, no
smoking).
Adhere to mandatory recurring tests and the intervals given in the documentation
for such tests and inspections.
Regularly check cables and hose connections, particularly on moving parts, for
damage and replace if necessary.
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12 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Safety precautions

2.8 Special types of hazard

2.8.1 Electrical energy


Never carry out work on live parts!
Do not modify constructional features in a way that impairs safety. Do not reduce
clearances and creepage distances through insulation.
Check the condition of cables on a regular basis and replace if necessary.

2.8.2 Oils, fats and other chemical substances


When handling oils, fats and other chemical substances, pay attention to and com-
ply with the valid regulations and safety data sheets issued by the manufacturers of
these substances regarding storage, handling, use and disposal!
First-aid measures after skin contact:
 Take off all contaminated pieces of clothing.
 Rinse off the skin thoroughly with water or take a shower.
 consult a doctor immediately.

First-aid measures after eye contact:


 Rinse out with plenty of water.
 consult a doctor immediately.
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GEA Westfalia Separator Group 13


Safety precautions 9953-9001-010 / 19.10.16

14 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Description

3 Description

3.1 Description and functional principles ....................................................... 16


3.2 Operating conditions ................................................................................ 16

GEA Westfalia Separator Group 15


Description 9953-9001-010 / 19.10.16

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3.1 Description and functional principles


The detailed description and functional principle of the respective component are
given in the corresponding component manual.
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3.2 Operating conditions


The housing and sealing materials are selected to suit the operating conditions.
The operating conditions have a major impact on the life of the component.
 Technical characteristics and the essential permissible limit values, especially
for pressure and temperature of the medium, are given in the manufacturer’s
manual.
 Care must be taken that the component is only used where the rating criteria
comply with the values stated on the nameplate. Proper and correct transport
and storage is essential.
 Faults arising from moving elements must be prevented by taking appropriate
measures.
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16 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Transport and storage

4 Transport and storage

4.1 Transport ................................................................................................. 18


4.2 Storage .................................................................................................... 18

GEA Westfalia Separator Group 17


Transport and storage 9953-9001-010 / 19.10.16

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4.1 Transport
The following conditions must be observed:

WARNING Danger through contact with substances hazardous to health

The component can come in contact with substances potentially harmful to health
during operation.
 De-contaminate the component prior to packing and/or transport.

• Use hoists to transport components that are too heavy to move by hand.
• Screw eye bolts or lugs into the component, attach properly to the hoist and then
transport the components.
• When using lifting straps, place them around the component, provide sharp-
edge protection if required, and watch for proper weight distribution.
• Protect the component against outside force during transport (impacts, vibra-
tions etc.).
• Protect the sealing surfaces of the connections against damage.
• Do not remove the corrosion protection layer.
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4.2 Storage
Protect the component against external impacts and contamination.
• Keep the storage room dry and dust-free.
• Avoid condensate formation.
• Protect connection openings against dirt.
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18 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Assembly and installation

5 Assembly and installation

5.1 Measures to be taken prior to installation. ............................................... 20


5.2 Assembly ................................................................................................. 20
5.2.1 Fitting in the case of threaded connection ............................................... 20
5.2.2 Fitting in the case of a flanged connection .............................................. 20
5.3 Electrical connection ................................................................................ 21
5.4 Pneumatic connection ............................................................................. 21
5.5 Ex zone .................................................................................................... 21

GEA Westfalia Separator Group 19


Assembly and installation 9953-9001-010 / 19.10.16

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• Refer to the component manual for specific information on the component.


• Before installation, read and follow the instructions in the chapter “Safety pre-
cautions”.
• Observe accident prevention regulations!
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5.1 Measures to be taken prior to installation.

CAUTION Injuries as a result of non-compliance with safety requirements

Transport and/or storage may result in damage to the packaging to the extent that
the component no longer meets the safety requirements.
 Check for potential damage prior to fitting.
 Do not fit a damaged component.

Before fitting, pay attention to the following:


 Check the piping and component for absolute cleanliness.
 Remove the protective caps from the caps only just before fitting.
 Do not damage the sealing surfaces or threads.
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5.2 Assembly
 Remove all the packaging parts directly before fitting.
 No dirt particles must be allowed to enter the component.
 When required, keep to the flow of direction shown on the component.

After fitting
 Perform a leakage and function test.
 Create the specified operating status.

5.2.1 Fitting in the case of threaded connection


 Use a suitable sealant.
 Lay the piping so that no flow of forces runs through the component.

5.2.2 Fitting in the case of a flanged connection


 Fit the specified screws. Use all flange bores provided.
 Fit suitable gaskets and center between flanges.
 Tighten the screws evenly and crosswise to avoid distortion. A pipe must under
no circumstances be pulled against the component.
 Pay attention to correct seating of the gaskets.
 Tighten the screws with the specified torque.
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20 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Assembly and installation

5.3 Electrical connection


For components with electrical accessories.

DANGER Danger to life through electric voltage

When working on live leads, there is a risk of electric shock. An electric shock
leads to serious injury or death.
 Work on electrical apparatus and/or on live component equipment must be per-
formed by qualified staff only.
 Disconnect the power to electrical equipment if necessary.
 Secure against unintentional switching back on.
 Attach a warning sign that prohibits switching on.
 Ground the component in accordance with the local regulations.
 Comply with the protective measures when connecting the component in ac-
cordance with the provisions of the responsible power company.
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5.4 Pneumatic connection


Actuate only with conditioned compressed air. Install a compressed air control unit
upstream if required.
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5.5 Ex zone
Usage in an explosion-hazarded zone is not permitted. The only exception: this is
confirmed in the order or is in the manual or technical data sheet of the manufac-
turer.
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GEA Westfalia Separator Group 21


Assembly and installation 9953-9001-010 / 19.10.16

22 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Repair

6 Repair

6.1 Cleaning and care.................................................................................... 24


6.2 Maintenance ............................................................................................ 24
6.3 Repair ...................................................................................................... 24

GEA Westfalia Separator Group 23


Repair 9953-9001-010 / 19.10.16

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This chapter is divided into the sections cleaning and care, maintenance and re-
pair.
 Before carrying out maintenance and repair, read and follow the instructions in
the chapter “Safety precautions”.
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6.1 Cleaning and care

NOTICE Damage to the component due to a dirt layer coating

Blockage of function openings. Reduction of heat dissipation.


 Arrange for efficient covering of the component when carrying out dirty work
near the separator or the plant (e.g. laying concrete, brickwork, painting, sand-
blasting).
 Clean the component regularly.

NOTICE Functional fault and damage to the component

There is a threat of damage to property due to improper cleaning.


 When cleaning with aqueous cleaning agents, pay attention to the type of pro-
tection of the electric components. In case of doubt, do not use it!
 Do not use aggressive detergents. The latter can attack metal and plastic sur-
faces as well hose connections.
 Never clean sensitive components with coarse brushes under strong mechanical
pressure.
 Functional
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6.2 Maintenance
 The maintenance intervals have to be re-determined (shortened) by the operator
according to prevailing operating conditions.
 Check or maintain the component for safety reasons. Note the following mini-
mum requirements:
- Regular check of the outer condition of the component and the accessories.
- Regular actuation so as not to impair the smoothness of action of all movable
parts through excessively long standstill times.
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6.3 Repair

NOTICE Material damage due to mechanical stressing of the components

Tread load, stress through connected pipes, excessively high ambient temperature
destroy the component.
 Fit without using force. Avoid stresses.
 No additional stress, e.g. tread load (use as unauthorized climbing aid).
 No welding and heat treatment.
 No tool machining (e.g. drilling).
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24 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Decommissioning

7 Decommissioning

7.1 Machine disposal ..................................................................................... 26

GEA Westfalia Separator Group 25


Decommissioning 9953-9001-010 / 19.10.16

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7.1 Machine disposal


When the machine has reached the end of its useful service life, the plant operator
is responsible for proper and correct disposal.
It is recommended to commission a company specialized in the disposal of ma-
chines or to obtain information from GEA Westfalia Separator service.
 Observe the local disposal regulations.
 Be sure to adhere to applicable environmental protection legislation.
 Have electrical connections disconnected by qualified personnel, e.g. electri-
cians.
IMPORTANT: Residual liquids in feed lines and utility lines can cause injury. Pro-
tective clothing must therefore be worn when dismantling lines.

WARNING Danger of acid and alkali burns

After cleaning, hot lye and acid residues can still be in the machine and the pipe-
lines. When working on the machine, contact with the lyes and acids can cause
burns.
 Wear acid-resistant safety gear, e.g. safety goggles, safety gloves, protective
overalls or protective suits.
 Take special care.
 Observe the plant operator's SOPs on handling acids and lyes as well as local
disposal regulations.
 Be sure to adhere to applicable environmental protection legislation.
 Drain residual liquids in feed lines and utility lines into suitable vessels and dis-
pose of them properly.
 Observe regulations on product contact.
 Dismantle feed lines and utility lines, clean superficial impurities caused by lubri-
cants or product with suitable media and dispose of separately.
 Dismantle all seals and non-metallic materials, clean them to remove lubricants
and dispose of them separately or recycle.
 Separate and sort metal parts and recycle them.
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26 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Spare parts

8 Spare parts

8.1 Use only genuine spare parts. ................................................................. 28

GEA Westfalia Separator Group 27


Spare parts 9953-9001-010 / 19.10.16

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8.1 Use only genuine spare parts.


All spare parts, wear parts and operating materials are originally packed by GEA
Westfalia Separator.

The original packing is provided with the


marking shown.

Fig. 1

WARNING Danger due to defective spare parts

Non-original or unauthorized parts or supplies endanger the personnel working on


the machine.
Non-genuine or non-approved spare parts or operating materials reduce the avail-
ability of the machine.
 Use only genuine spare parts from GEA Westfalia Separator to assure the oper-
ating safety and optimum availability of the machine.
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28 GEA Westfalia Separator Group


9953-9001-010 / 19.10.16 Spare parts

=== Ende der Liste für T extmar ke Inhalt ===

GEA Westfalia Separator Group 29


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We live our values.


Excellence • Passion • Integrity • Responsibility • GEA-versity

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.

GEA Germany
GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1 Tel +49 2522 77-0 info@gea.com
59302 Oelde, Germany
=== Ende der Liste für T extmar ke Ruec ks eite ===
Fax +49 2522 77-2950 gea.com
Checklist – data records

Page 1
Checklist – data records
Subject to modification!

GEA Westfalia Separator Systems GmbH reserves the right to modifications


without notice.

The authors will always be grateful for any comments on possible errors and
faults and for suggestions to improve this documentation. They can be sent to
GEA Westfalia Separator Systems GmbH
Werner-Habig-Str. 1
D-59302 Oelde

Copies of this documentation can be obtained from our local agencies.

© GEA Westfalia Separator

Page 2
Checklist – data records
Sea Water Distiller
Checklist for SWD pre-commissioning
(as additional information to the Installation and Operation manual)
Yard:
Hull number:

1. SWD - installation checked

- SWD is fixed on deck (screwed)


- no declination
- sufficient working space for maintenance / repair works
(e.g. opening of hood, control panel)
- threshold / drain below distiller

2. Pipe / hose connections

- All pipes are connected according to PID (screwed and sealed correctly)
seawater inlet
seawater outlet
heating water inlet
heating water outlet
distillate outlet

- Thermometers installed near to SWD connection


heating water inlet
g water outlet
heating

- Flaps installed near to SWD connection


seawater inlet
heating water inlet
heating water outlet

- Hoses not damaged / hose clamps fixed


1" distillate
1/2" distillate rejection
1/2" non condensable gases

3. Electrical connection

- Power cable is connected to control panel


- Seawater pump cable is connected to control panel
- Alarm contact is connected to ship system
- Internal cabling is not damaged
solenoid valve
distillate pump
conductivity measuring cell

4. Seawater pump

- Power cable is fixed (coming from SWD control panel)


- Seawater pump is mounted below water line and near to sea chest
- Pressure gauges installed at suction and discharge side
- Mesh size of seawater strainer <=2 mm

5. Chemical

- Anti Scaling chemical is availabel for sea trial

date, name, signature


ACCEPTANCE CERTIFICATE FOR SEAWATER DISTILLER

Yard: Ships Engineer


Hull number: SWD serial Number:
WSST order: Year of built:

Tag Nr. Description Unit typical Date 2 Date 3

10-9-001 Feedwater bar g (**)


11-9-001 Seawater to ejector bar g min. 3,3
11-9-002 Seawater to ejector °C max. 42
12-9-001 Distillate salinity ppm <10
12-9-002 Distillate pressure bar g max. 1,5
12-9-003 Distillate Water clock start counter
12-9-003 Distillate Water clock end counter
Distillate (per 24 h) t/d
84-9-001 Chemical dosing l/h 1,25
87-9-001 Evaporator housing bar g max. -0,85
87-9-002 Evaporator housing °C max. 54
Alarm A1 Destillat Leitfähigkeit hoch ppm >10 = active
Alarm A2 Sensorüberwachung ppm <0.5= active
If available Seawater to SWD °C max. 32
If available Heating water inlet °C
If available Heating water outlet °C
If available Ejector back pressure bar g max. 0,6
If available Seawater pump suction bar g min. -0,3 (*)
If available Seawater pump discharge (*)
Level in sight glass empty/full/half half
(*) not self priming, 5,0 bar Pump head
(**) SWD pressure
10 -0,6 bar g
15 -0,1 bar g
20 0,6 bar g
25 1,4 bar g
30 2,4 bar g

Remarks:

During the today´s test run was proved that the delivered goods did reached the specified
performance parameters as defined in the contract. Defects as per the punchlist above have to
be cured within a reasonable time. Such defects do not hinder the acceptance as per today. The
warranty periode starts to run today.

Acknowledgement / Signatures

Customer End User Service Engineer Date


DATA REPORT FOR SEAWATER DISTILLER

Yard: Ships Engineer


Hull number: SWD serial Number:
WSST order: Year of built:

Tag Nr. Description Unit typical Date 2 Date 3

10-9-001 Feedwater bar g (**)


11-9-001 Seawater to ejector bar g min. 3,3
11-9-002 Seawater to ejector °C max. 42
12-9-001 Distillate salinity ppm <10
12-9-002 Distillate pressure bar g max. 1,5
12-9-003 Distillate Water clock start counter
12-9-003 Distillate Water clock end counter
Distillate (per 24 h) t/d
84-9-001 Chemical dosing l/h 1,25
87-9-001 Evaporator housing bar g max. -0,85
87-9-002 Evaporator housing °C max. 54
Alarm A1 Destillat Leitfähigkeit hoch ppm >10 = active
Alarm A2 Sensorüberwachung ppm <0.5= active
If available Seawater to SWD °C max. 32
If available Heating water inlet °C
If available Heating water outlet °C
If available Ejector back pressure bar g max. 0,6
If available Seawater pump suction bar g min. -0,3 (*)
If available Seawater pump discharge (*)
Level in sight glass empty/full/half half
(*) not self priming, 5,0 bar Pump head
(**) SWD pressure
10 -0,6 bar g
15 -0,1 bar g
20 0,6 bar g
25 1,4 bar g
30 2,4 bar g
Remarks:
GRAFICAL SYMBOLS ACCORDING TO DIN ISO 10628-2 (DIN EN 62424)
GRAPHISCHE SYMBOLE IN ANLEHNUNG AN DIN ISO 10628-2 (DIN EN 62424)

GEA EQUIPMENT HEATER AND COOLING EQUIPMENT PUMPS / PUMPEN SEPARATION EQUIPMENT MIXING AND MILLING EQUIPMENT
WÄRMEAUSTAUSCHER ABSCHEIDER MISCHER UND MÜHLE

DEFOAMING PUMP PUMP (GENERAL)


STATIC MIXER
ENTSCHÄUMUNGSPUMPE PLATE HEAT EXCHANGER PUMPE (GENEREL) DOUBLE BASKET FILTER
STATISCHER MISCHER
PLATTENWÄRMEAUSTAUSCHER DOPPELTER KORBFILTER
SEPARATOR
BELT DRIVE
FINISCHER CENTRIFUGAL PUMP
DYNAMIC MIXER
NACHWÄSCHER KREISELPUMPE
DYNAMISCHER MISCHER
CONVEYING
TUBE BUNDLE HEAT EXCHANGER
FLOUR MIXER ROHRBÜNDELWÄRMEAUSTAUSCHER DIAPHRAGM PUMP FÖRDERUNG
MEMBRANPUMPE MALAXEUR
MEHLMISCHER
SCREW CONVEYOR MALAXEUR
SCHNECKENFÖRDERER PHI_INSERTPOINT

SEPARATOR ECCENTRIC SCREW PUMP


GEAR DRIVE VESSELS / BEHÄLTER WASSERKÜHLER EXZENTERSCHNECKENPUMPE AGITATOR
CONVEYOR BELT
WATER COOLER RÜHRWERK
FÖRDERBAND

PISTON PUMP AGITATOR


VESSEL BASIC SYMBOL
BEHÄLTER BASIS SYMBOL
KOLBENPUMPE CONVEYOR BELT RÜHRWERK
FÖRDERBAND
AIR COOLER
LUFTKÜHLER
DISPLACEMENT PUMP
VERDRÄNGUNGSPUMPE MILL
SEPARATOR MÜHLE
DIRECT DRIVE COMPRESSING
VERDICHTER
CONICAL BOTTOM VESSEL VACUUM PUMP
STEAM / WATER COIL
BEHÄLTER MIT KONISCHEM BODEN VAKUUMPUMPE
DAMPF / WASSER ROHRSCHLANGE
COMPRESSOR
VERDICHTER
STEAM JET INJECTOR
STRAHLPUMPE
HEAT EXCHANGER VENTILATOR
WÄRMEAUSTAUSCHER VENTILATOR
DOME ROOF VESSEL
SEPARATOR BEHÄLTER MIT DOMDACH GEAR PUMP
INTEGRATED DIRECT DRIVE ZAHNRADPUMPE
M

SPIRAL HEATER
SCREW PUMP
SPIRALWÄRMETAUSCHER MOTOR / MOTOR
SCHRAUBENSPINDELPUMPE
HORIZONTAL VESSEL
BEHÄLTER HORIZONTAL
DECANTER ELECTRIC MOTOR
M ELEKTROMOTOR
GREASE PUMP
TUBULAR PREHEATER
FETTSCHMIERPUMPE Processing functions for (N) actuators - motors
BALANCE TANK RÖHRENVORWÄRMER
AUSGLEICHSBEHÄLTER Verarbeitungsfunktionen für (N) Aktoren - Motoren
NS On / Off
An/ Aus
ROTARY BRUSH STRAINER CYCLONE FC normal overload For small loads
DREHBÜRSTENSIEB ZYKLON NCN
FU Normal Overload Bei geringen Belastungen
350 mm

TUBULAR PREHEATER NCH FC high overload Preset


RÖHRENVORWÄRMER FU High Overload Voreinstellung
OPERATING WATER SIPHON
STEUERWASSERSIPHON
350 mm

ELECTRIC PREHEATER
ELEKTROVORWÄRMER
Aktualisierung der Symbole D. Bregenhorn
H Updating the symbols 04.05.2018
SETTLING VESSEL
ABSETZBEHÄLTER Revision Revisionsbeschreibung Rev.-Datum Rev.-Name
Revision Description of Revision Rev.-Date Rev.-Name
Datum Name Beschreibung Zeichnungs.-Nr.
Date Name Description Drawing-No.

gez.
created 05.05.2015 2323VE GEA Group
D-59302 Oelde
GRAPHICAL SYMBOLS 9901-8104-300
Copyright reserved Blatt / Blätter Format
letzte Änderung We reserve all rights on this drawing Sheet / Sheets Size
last modified 05.07.2017 BREG Für diese Zeichnung behalten GRAPHISCHE SYMBOLE 1/7 A2
wir uns alle Rechte vor.
SYMBOLS AND CODE LETTERS FOR MSR ACCORDING TO DIN EN 62424 - CATEGORY
BILDZEICHEN UND KENNBUCHSTABEN FÜR MSR IN ANLEHNUNG AN DIN EN 62424 - KATEGORIE

Code letter /
Kenn- Application Verwendung
buchstabe
Analysis Analyse PCE CATEGORY PCE PROCESSING (NEXT LETTER)
A
PCE KATEGORIE PCE VERARBEITUNGSFUNKTION (FOLGEBUCHSTABEN)
Burner control, Brennersteuerung,
B flame monitoring Flammenüberwachung A ANALYSIS
Freely usable ANALYSE
C Frei verwendbar
N S T AH PART OF MCC OR PLC B BURNER CONTROL/ FLAME DETECTION
D Density Dichte xxx-9-xxx/M1 xxx-9-xxx FUNKTION IN DER STEUERUNG BRENNERSTEUERUNG/ FLAMMENÜBERWACHUNG
E Electrical voltage Elektrische Spannung D DENSITY
DICHTE
F Flow rate Durchfluss TE LOCAL MEASURING ELEMENT E ELECTRICAL VOLTAGE
G Distance, length, position Abstand, Länge, Stellung
M xxx-9-xxx/B1 LOKALER MESSAUFNEHMER ELEKTRISCHE SPANNUNG
F FLOW
Manual input, DURCHFLUSS
H Handeingabe, Handgriff
manual intervention G DISTANCE, LENGHT, POSITION, STRETCHING
WEG, LÄNGE, POSITION, AUSDEHNUNG
I Electrical current Elektrischer Strom
H MANUAL
J Electrical output Elektrische Leistung MANUELL

K Time-based functions Zeitbasierte Funktionen MEASURING AND CONTROL EXAMPLES I CURRENT


ELEKTRISCHER STROM
MESS - UND REGELUNGSBEISPIELE
L Filling level Füllstand J POWER
LEISTUNG
M Humidity Feuchte 0 - xx m³/h 0 - xx bar K TIME
ZEIT


Regulating member FI PI

N Stellglied ( Motor) ■
(motor) xxx-9-xxx xxx-9-xxx
L LEVEL
NIVEAU
0 Optical measurement Optische Messung xxx-9-xxx/B1
xxx-9-xxx/B1 DN M MOISTURE
DN FEUCHTIGKEIT
P Pressure Druck
N ACTUATOR (MOTOR)
Q Quantity or number Menge oder Anzahl 0 - xx m³/h STELLGLIED (MOTOR)

R Radiation variables Strahlungsgrößen


FICALAH
O OPTICAL
xxx-9-xxx OPTISCH

S
Speed, speed of rotation, Geschwindigkeit, Drehzahl, GSH/GSL FIT P PRESSURE
frequency Frequenz YC1 xxx-9-xxx/B1 DRUCK

T Temperature Temperatur Q QUANTITY


xxx-7-xxx DN MENGE, ZÄHLER
U Do not use Nicht benutzen DN
NO R RADIATION QUANTITY
0 - xx bar
STRAHLUNGSMENGE
V Vibration, oscillation Vibratin, Schwingung PAL S SPEED, rpm, FREQUENCY
xxx-9-xxx GESCHWINDIGKEIT, rpm, FREQUENZ
W Weight, mass Gewicht, Masse
PIS T TEMPERATURE
X Other variables *1 Sonstige Größen *1 xxx-9-xxx/B1
TEMPERATUR
Regulating member DN V VIBRATION
Y Stellglied (Ventil) VIBRATION
(valve)
W WEIGHT, MASS
Z Freely usable Frei verwendbar GEWICHT, MASSE
Y ACTUATOR (VALVE)
STELLGLIED (VENTIL)
LOCAL DISPLAY RELEVANT TO GMP

LOKALE ANZEIGE GMP RELEVANT

CENTRAL CONTROL CENTER RELEVANT TO SAFETY


ZENTRALER LEITSTAND
▲ SICHERHEITSRELEVANT
H Aktualisierung der Symbole
Updating the symbols 04.05.2018 D. Bregenhorn

Revision Revisionsbeschreibung Rev.-Datum Rev.-Name


Revision Description of Revision Rev.-Date Rev.-Name
LOCAL CONTROL PANEL
LOKALER STEUERSCHRANK ■ RELEVANT TO QUALITY
QUALITÄTSRELEVANT
Datum
Date
Name
Name
Beschreibung
Description
Zeichnungs.-Nr.
Drawing-No.

gez.
created 05.05.2015 2323VE GEA Group
D-59302 Oelde
GRAPHICAL SYMBOLS 9901-8104-300
Copyright reserved Blatt / Blätter Format
letzte Änderung We reserve all rights on this drawing Sheet / Sheets Size
last modified 26.03.2018 BREG Für diese Zeichnung behalten GRAPHISCHE SYMBOLE 2/7 A2
wir uns alle Rechte vor.
SYMBOLS AND CODE LETTERS FOR MSR ACCORDING TO DIN EN 62424 - PROCESS
BILDZEICHEN UND KENNBUCHSTABEN FÜR MSR IN ANLEHNUNG AN DIN EN 62424 - PROZESS

Kenn- Appplication Verwendung


buchstabe
A Alarm, message Alarm, Meldung PCE CATEGORY PCE PROCESSING (NEXT LETTER)
PCE KATEGORIE PCE VERARBEITUNGSFUNKTION (FOLGEBUCHSTABEN)
B Limit, restriction Beschränkung, Eingrenzung
A ALARM/ NOTIFICATION
C Control Regelung ALARM/ MELDUNG
D Difference Differenz N S T AH PART OF MCC OR PLC B LIMITATION / DEFINING
xxx-9-xxx/M1 xxx-9-xxx FUNKTION IN DER STEUERUNG BESCHRÄNKUNG/ EINGRENZUNG
E Element Element
C CONTROLLER
Ratio Verhältnis REGLER
F
TE LOCAL MEASURING ELEMENT DIFFERENCE
G Not applicable Nicht anwendbar M xxx-9-xxx/B1 LOKALER MESSAUFNEHMER
D
DIFFERENZ
Top limit value, oberer Grenzwert, E ELEMENT
H on, open ELEMENT
an, offen
Analogue display Analoganzeige F PROPORTION
I PROPORTION
J Not applicable Nicht anwendbar H UPPER LIMIT/ ON/ OPEN
OBERER GRENZWERT/ AN/ OFFEN
K Not applicable Nicht anwendbar MEASURING AND CONTROL EXAMPLES I INDICATION
Bottom limit value, unterer Grenzwert, MESS - UND REGELUNGSBEISPIELE ANZEIGE
L aus, geschlossen LOWER LIMIT/ OFF / CLOSED
off, closed L
UNTERER GRENZWERT/ AUS/ GESCHLOSSEN
M Not applicable Nicht anwendbar 0 - xx m³/h 0 - xx bar
O LOCAL OR PCS STATUS OF BINARY SIGNALS


FI PI
N Not applicable Nicht anwendbar ▲ LOKALE ODER PCS STATUSANZEIGE VON BINÄRSIGNALEN
xxx-9-xxx xxx-9-xxx ■
lokale oder Q SUMMARY
Local or PCS status xxx-9-xxx/B1 SUMME
0 PCS Statusanzeige xxx-9-xxx/B1 DN
display of binary signals RECORDED VALUE
von Binärsignalen DN R
AUFGEZEICHNETER WERT
P Not applicable Nicht anwendbar 0 - xx m³/h S BINARY CONTROL FUNCTION OR SWITCHING FUNCTION
FICALAH BINÄRE STEUERUNGSFUNKTION ODER SCHALTFUNKTION
Q Integral, sum Integral, Summe
T TRANSMITTER
xxx-9-xxx

R Recorded value Aufgezeichneter Wert GSH/GSL FIT TRANSMITTER


YC1
Y CALCULATOR FUNCTION
xxx-9-xxx/B1
Binary control function Binäre Steuerfunktionen RECHENFUNKTION
S or switching function oder Schaltfunktion xxx-7-xxx DN BINARY CONTROL FUNCTION OR SWITCHING FUNCTION
(not relevant to safety) (nicht sicherheitsrelevant) DN
NO Z (RELEVANT SAFETY)
0 - xx bar BINÄRE STEUERUNGSFUNKTION ODER SCHALTFUNKTION
T Transmitter Transmitter PAL (SICHERHEITSRELEVANT)
xxx-9-xxx
U Not applicable Nicht anwendbar
PIS
V Not applicable Nicht anwendbar xxx-9-xxx/B1
DN
W Not applicable Nicht anwendbar

X *1 *1

Y Calculating function Rechnerfunktion


Binary control function Binäre Steuerfunktionen Aktualisierung der Symbole
H 04.05.2018 D. Bregenhorn
Z or switching function oder Schaltfunktion Updating the symbols

( relevant to safety) (sicherheitsrelevant) Revision


Revision
Revisionsbeschreibung
Description of Revision
Rev.-Datum
Rev.-Date
Rev.-Name
Rev.-Name
Datum Name Beschreibung Zeichnungs.-Nr.
Date Name Description Drawing-No.

gez.
created 05.05.2015 2323VE GEA Group
D-59302 Oelde
GRAPHICAL SYMBOLS 9901-8104-300
Copyright reserved Blatt / Blätter Format
letzte Änderung We reserve all rights on this drawing Sheet / Sheets Size
last modified 26.03.2018 BREG Für diese Zeichnung behalten GRAPHISCHE SYMBOLE 3/7 A2
wir uns alle Rechte vor.
ACCESSORIEST LIST
Example/ Beispiel: 1 60 - 3 - 001 / M1
LEVEL 4 / EBENE 4 ANHÄNGE
Accessory tag: 1 letter / Zubehör: 1 Buchstabe
Count number: 1 digit / Zählnummer: 1 Zahl LEVEL 4 / EBENE 4

LEVEL 3 / EBENE 3 MEASURING INSTRUMENTS


B1
COMPONENT TAGGING Component tag: 1 digit / Komponentennummer: 1 Zahl
MESSGERÄTE
Count number: 3 digits / Zählnummer: 3 Zahlen MOTOR
KOMPONENTENBESCHREIBUNG M1
MOTOR
LEVEL 2 / EBENE 2 ILUMINATION
L1
Subsection: 2 digits / Untersektion: 2 Zahlen BELEUCHTUNG

LEVEL 1 / EBENE 1 GSH / GSL LIMIT SWITCHES


GRENZSCHALTER
Section: 1 digit / Sektion: 1 Zahl
YS1 PILOT VALVES - OPEN / CLOSE
STEUERVENTILE - AUF / ZU

YC1 REGULATING VALVES


STELLARMATUR GEREGELT

YD DIRECT ACTUATED SOLEVOID VALVE


DIREKT GESTEUERTES MAGNETVENTIL
Example/ Beispiel: FAT - 160 PL004 - D4404S52 - WI40 HTe
LEVEL 6 / EBENE 6
Heat tracing specification: 3 letters
Begleitheizungsspezifikation: 3 Buchstaben

LEVEL 5 / EBENE 5
Insulation specification / Isolierspezifikation
Insulation type: 2 letters / Isoliertyp: 2 Buchstaben
Insulation thickness in mm: 2 digits / Isolierstärke in mm: 2 Zahlen

LEVEL 4 / EBENE 4
PIPING DESCRIPTION Piping specification / Rohrleitungsspezifikation
Standard: letter(s) / Norm: Buchstabe(n)
ROHRLEITUNGSBESCHREIBUNG Material: digits / Material: Zahlen
Connection type: letter(s) / Anschlussart: Buchstabe(n)
Seal material: digits / Dichtungswerkstoff: Zahlen
Note: project-specific (large projects)
Hinweis: projektspezifisch (Großprojekte) LEVEL 3 / EBENE 3
Pipe line number: PL + 3 digits
Rohrleitungsnummer: PL + 3 Zahlen

LEVEL 2 / EBENE 2
Section + subsection number: 3 digits
Sektion + Untersektion Nummer: 3 Zahlen

LEVEL 1 / EBENE 1
Product short code: 2 to 4 letters
Medium Kurzzeichen: 2 bis 4 Buchstaben

Aktualisierung der Symbole D. Bregenhorn


H Updating the symbols 04.05.2018

Revision Revisionsbeschreibung Rev.-Datum Rev.-Name


Revision Description of Revision Rev.-Date Rev.-Name
Datum Name Beschreibung Zeichnungs.-Nr.
Date Name Description Drawing-No.

gez.
created 05.05.2015 2323VE GEA Group
D-59302 Oelde
GRAPHICAL SYMBOLS 9901-8104-300
Copyright reserved Blatt / Blätter Format
letzte Änderung We reserve all rights on this drawing Sheet / Sheets Size
last modified 03.05.2018 BREG Für diese Zeichnung behalten GRAPHISCHE SYMBOLE 4/7 A2
wir uns alle Rechte vor.
GRAFICAL SYMBOLS - PIPE FITTINS, VALVES
GRAPHISCHE SYMBOLE - LEITUNGSFITTINGE, ARMATUREN

Actuator, manually operated (secured)

Actuator with rotating system, general


Stellantrieb mit rotierendem System,
Stellantrieb, handbetätigt (gesichert)

Stellantrieb mit Elektromagnet


Stellantrieb mit schrägen Sitz

Stellantrieb mit Elektromotor


Actuator, manually operated

Actuator with electromagnet


PIPE FITTINGS

Stellantrieb mit Schwimmer


Actuator with electric motor

Stellantrieb mit Membrane


Actuator with slanted seat
Valves with safety function Non return fittings

Stellantrieb, handbetätigt

Actuator with diaphragm


Rückschlagarmaturen LEITUNGSFITTINGE

Stellantrieb mit Kolben


Armaturen mit Sicherheitsfunktionen

Stellantrieb mit Feder


Actuator with spring
Actuator with piston

Stellantrieb mit Lift

Actuator with float


Non return fitting

Actuator with lift


Safety valve Rückschlagarmatur
Sicherheitsventil COMPENSATOR

allgemein
KOMPENSATOR
Non return valve
Safety valve Rückschlagventil HOSE
Sicherheitsventil
Valves symbols Non-return flap SCHLAUCH
Symbole Armaturen M Rückschlagklappe
DIRT STRAINER
Double check valve SCHMUTZFÄNGER
Shut-off fitting (general) M Doppelrückschlagventil
Needle valve RESTRICTION ORIFICE
Absperrarmatur (allgemein)
Nadelventil
BLENDE
Gate valve M Needle valve
SIGHT GLASS
Absperrschieber Nadelventil
SCHAUGLAS
Shut-off valve M
GERADE

Absperrventil SIGHT GLASS WITH LIGHT


Pressure valves SCHAUGLAS MIT BELEUCHTUNG
Druckventile
Shut-off flap M
IN-LINE HOUSING
Absperrklappe
PI IN-LINE GEHÄUSE

Stopcock M
Self acting back-pressure regulator
Absperrhahn Constant-pressure valve PULSATION DAMPER
internal sensing
Konstantdruckventil
PI Selbsttätiges Druckminderventil PULSATIONSDÄMPFER
Diaphragm valve M
Membranventil
STEAM TRAP
KONDENSATABSCHEIDER
Control valve M
Regelventil
PI FUNNEL
Pressure reducer with strainer TRICHTER
Pinch valve
Quetschventil Druckminderventil mit Filter
SPRAY BALL
ECK

Angle shut-off fitting PI SPRÜHKOPF


Pressure reducer with strainer and oiler
Absperrarmatur in Eckform
Druckminderventil mit Filter und Öler TRAP
ABSCHEIDER
Three-way shut-off fitting
PI
Dreiwegearmatur AIR FILTER
Maintenance unit
Wartungseinheit LUFTFILTER
Three-way shut-off valve
DREIWEG

Absperr-Dreiwegeventil OIL FILTER


ÖLFILTER
Three-way stopcock
Safety position
Dreiwegehahn
Sicherheitsposition DIFFERENTIAL METERING PISTON
T - Shut-off valve DOSIERKOLBEN
T - Absperrventil
NO NORMALLY OPEN STRAINER
T - Diaphragm valve FEDERÖFFNEND FILTER
T - Membranventil xxx-7-xxx xxx-7-xxx
DN DN

xxx-7-xxx
NC NORMALLY CLOSED
= NO

DN
NC
DISTRIBUTER UNIT
MULTI-

FEDERSCHLIESSEND
PORT

MULTIPORT VERTEILER
MULTIPORT = INDIFFERENT

Aktualisierung der Symbole D. Bregenhorn


H Updating the symbols 04.05.2018

Revision Revisionsbeschreibung Rev.-Datum Rev.-Name


Revision Description of Revision Rev.-Date Rev.-Name
Datum Name Beschreibung Zeichnungs.-Nr.
Date Name Description Drawing-No.

gez.
created 05.05.2015 2323VE GEA Group
D-59302 Oelde
GRAPHICAL SYMBOLS 9901-8104-300
Copyright reserved Blatt / Blätter Format
letzte Änderung We reserve all rights on this drawing Sheet / Sheets Size
last modified 26.04.2018 BREG Für diese Zeichnung behalten GRAPHISCHE SYMBOLE 5/7 A2
wir uns alle Rechte vor.
GRAFICAL SYMBOLS - PIPE, PIPE FITTINGS, LABELS, BREAK IDENTIFIERS
GRAPHISCHE SYMBOLE - ROHRLEITUNG, LEITUNGSFITTINGE, BESCHRIFTUNG, TRENNSTELLEN

PIPE SYMBOLS PIPE FITTINGS BREAK IDENTIFIERS


ROHRLEITUNGSSYMBOLE LEITUNGSFITTINGE TRENNSTELLEN

PROCESS MAIN PIPE


FLANGE SET CHANGE IN PIPE LINE ID NUMBER
PROZESS HAUPTLEITUNG
FLANSCHPAAR LEITUNGSNUMMERNWECHSEL

SECONDARY PROCESS PIPE / UTILITIES PIPE


PROZESS NEBENLEITUNG TRI CLAMP
... ...
TRI CLAMP CHANGE IN PIPING CLASS
CROSSING OF PIPES ROHRKLASSENÄNDERUNG
LEITUNGSKREUZUNGEN SCREW COUPLING
VERSCHRAUBUNG
CONNECTION OF PIPES
BLIND FLANGE L ...
LEITUNGSANSCHLUSS SCOPE OF SUPPLY
BLINDFLANSCH
LIEFERGRENZE
CONCENTRIC / EXCENTRIC REDUCER
HOSE CONNECTION
KONZENTRISCHE / EXZENTRISCHE REDUZIERUNGEN
SCHLAUCHVERBINDUNG
... ...
INSTRUMENT AIR / COMPRESSED AIR SCOPE OF SUPPLY
INSTRUMENTENLUFT / DRUCKLUFT SLEEVE LIEFERGRENZE
MUFFE
NITROGEN
STICKSTOFF CONNECTOR
L ... L = GEA WS Supplied and controlled
STUTZEN
INSTRUMENTATION SIGNAL GEA WS liefert und steuert
INSTRUMENTIERUNG SIGNAL P = GEA WS supplied, Customer controlled
INJECTION NOZZEL
GEA WS liefert, Kunde steuert
FLOW DIRECTION SPRITZDÜSE  
... ...
FLUSSRICHTUNG C = Customer supplied, GEA WS controlled
Kunde liefert, GEA WS steuert
2%
SLOPE INDICATOR  
S = Customer supplied and controlled
PHI_INSERTPOINT PHI_INSERTPOINT

GEFÄLLE Kunde liefert und steuert

LIMITS W = --- (freely definable in project)


GRENZEN (im Projekt frei definierbar)

± 0m REFERENCE SYMBOL FOR LEVEL INDICATION


HÖHENANGABE

BOTTOM
BODEN

ISOLATION
ISOLIERUNG

Aktualisierung der Symbole D. Bregenhorn


H Updating the symbols 04.05.2018

Revision Revisionsbeschreibung Rev.-Datum Rev.-Name


Revision Description of Revision Rev.-Date Rev.-Name
Datum Name Beschreibung Zeichnungs.-Nr.
Date Name Description Drawing-No.

gez.
created 05.05.2015 2323VE GEA Group
D-59302 Oelde
GRAPHICAL SYMBOLS 9901-8104-300
Copyright reserved Blatt / Blätter Format
letzte Änderung We reserve all rights on this drawing Sheet / Sheets Size
last modified 30.01.2018 BREG Für diese Zeichnung behalten GRAPHISCHE SYMBOLE 6/7 A2
wir uns alle Rechte vor.
GRAFICAL SYMBOLS - MEDIUM CONSUMPTION, CROSS REFERENCE
GRAPHISCHE SYMBOLE - MEDIENVERBRAUCH, QUERVERWEIS

MEDIUM CONSUMPTION CONNECTION TABLE


MEDIENVERBRAUCH ANSCHLUSSTABELLE

DRAWING CONNECTOR
MEDIUM ZEICHNUNGSANSCHLUSS
CONNECTION TABLE / ANSCHLUSSTABELLE
MEDIUM
Product feed
Produktzulauf
Pos. Description / Benennung DN / INCH Execution
PRESSURE
DRUCK 3 bar 30 °C 11 11 Product feed 50 SHOULDERED CONNECTOR BUNDSTUTZEN
15 m3/h POSITION Produktzulauf DIN 11864-BS-A-53x1.5-1.4404- H3
FLOW RATE
POSITION 12 Discharge stand. milk 65 SHOULDERED CONNECTOR BUNDSTUTZEN
FÖRDERSTROM
TEMPERATURE Ablauf stand. Milch DIN 11864-BS-A-70x2.0-1.4404- H3
TEMPERATUR CONNECTION POINT FOR TABLE
13 Discharge surplus cream 40 SHOULDERED CONNECTOR BUNDSTUTZEN
ANSCHLUSSPUNKT FÜR TABELLE
Ablauf Überschußrahm DIN 11864-BS-A-41x1.5-1.4404- H3
14 CIP 25 SHOULDERED CONNECTOR BUNDSTUTZEN
CIP DIN 11864-BS-A-29x1.5-1.4404- H3
15 Cream to homogenizer 40 BLIND FERRULE BLIND-BUNDSTUTZEN
DRAWING CONNECTOR Rahm zum Homogenisator DIN 11864-1-A-RA-DN40-1.4435
ZEICHNUNGSANSCHLUSS 16 Cream from homogenizer 50 BLIND FERRULE BLIND-BUNDSTUTZEN
MEDIUM Rahm vom Homogenisator DIN 11864-1-A-RA-DN50-1.4435
MEDIUM
Product feed 17 Raw milk feed 50 SHOULDERED CONNECTOR BUNDSTUTZEN
PRESSURE Produktzulauf 11 Rohmilch Zulauf DIN 11864-BS-A-53x1.5-1.4404- H3
DRUCK 3 bar POSITION 18 Discharge skim milk 50 SHOULDERED CONNECTOR BUNDSTUTZEN
15 m3/h POSITION Ablauf Magermilch DIN 11864-BS-A-53x1.5-1.4404- H3
FLOW RATE 30 °C
19 Discharge cream 25 SHOULDERED CONNECTOR BUNDSTUTZEN
FÖRDERSTROM CONNECTION POINT FOR TABLE Ablauf Rahm DIN 11864-BS-A-29x1.5-1.4404- H3
ANSCHLUSSPUNKT FÜR TABELLE
TEMPERATURE
TEMPERATUR

POSITION MEDIUM NOMINAL DIAMETER TYPE OF CONNECTION


POSITION MEDIUM NENNWEITE ANSCHLUSSESART

CROSS REFERENCE
QUERVERWEIS

MEDIUM
MEDIUM
Product feed
FUNCTION Produktzulauf DRAWING CONNECTOR
FUNKTON Q001 ZEICHNUNGSANSCHLUSS
PID002.A1
P&ID NO. SQUARE
P&ID NR. QUADRAT

MEDIUM
MEDIUM
Product feed DRAWING CONNECTOR
FUNCTION Produktzulauf ZEICHNUNGSANSCHLUSS Aktualisierung der Symbole
H Updating the symbols 04.05.2018 D. Bregenhorn
FUNKTON Q001
PID002.A1 Revision Revisionsbeschreibung Rev.-Datum Rev.-Name
P&ID NO. SQUARE Revision Description of Revision Rev.-Date Rev.-Name
P&ID NR. QUADRAT Datum Name Beschreibung Zeichnungs.-Nr.
Date Name Description Drawing-No.

gez.
created 05.05.2015 2323VE GEA Group
D-59302 Oelde
GRAPHICAL SYMBOLS 9901-8104-300
Copyright reserved Blatt / Blätter Format
letzte Änderung We reserve all rights on this drawing Sheet / Sheets Size
last modified 27.03.2018 BREG Für diese Zeichnung behalten GRAPHISCHE SYMBOLE 7/7 A2
wir uns alle Rechte vor.
GEA Service
Ordering of replacement parts and other consumable items for centrifuge-specific GEA
systems.

For all questions concerning technical support, the ordering of replacement parts or to
request on-site support for your systems please contact your nearest GEA agent.

IF YOU DO NOT HAVE THE CONTACT DETAILS TO HAND, YOU CAN ACCESS
THEM QUICKLY AND CONVENIENTLY AT:

gea.com/Service

If you do not have access to the internet please call our German head office in Oelde and
ask for the contact details for your location:

Tel.:+49 2522 77 – 0

To speed up your request and to ensure that we deliver the right parts please include the
following information:

- For model designation and serial number of the equipment please refer to the nameplate
- Number of parts required
- Part numbers and designations as per parts list
- Your enquiry / order number
- Preferred delivery date (from GEA works)
- Your company address
• Your complete company name or customer number
• Your invoice address (if it differs from the delivery address)
• Your delivery address

THE GEA SERVICE PHILOSOPHY


Our integrated approach to service partnership ensures long-term business success – for our
customers and for GEA.
We work alongside our customers as a partner and support you over the whole life cycle of
your system as well as that of the particular equipment.
From tailored installation and commissioning to professional maintenance that guarantees a
smooth production run, from proactive process improvement to continuing customer service
–we are always on the spot to maximise the safety, performance and reliability of our
customers’ systems.

Fig. 1:GEA Service – Four levels for lasting success

The service products


FIELD SERVICE
Our customers expect that as a service provider, GEA will have the necessary expertise
and experience to carry out all the maintenance measures needed for a specific machine
or process. Service activities have to be supplied globally, regardless of which local
market our customers are active in and where the value-added process takes place.
We are always close at hand and can provide you with advice and practical support
within Germany, 24 hours a day, 365 days a year.

REPLACEMENT PARTS
Original GEA replacement parts provide reliability and protect your investment.
Our high quality replacement parts will keep your operation running with maximum efficiency.
Original replacement parts are manufactured to the highest quality standards. Moreover, the
advance identification of critical parts, short delivery periods and constant availability will
ensure the safe and reliable operation of your plant.

We can give you the assurance of:


• Tested high standard of processing and delivery quality:
• The development of new machinery and hence the further development of spare
parts
• Maximum operational security for your equipment
• Permanent and partly very long-term availability of parts
• Optimised logistics processes and locations of our logistics centres
• Short delivery periods

REPAIRS – CORRECTIVE MAINTENANCE


The GEA repair service is always close at hand.
We not only carry out repairs all over the world, but also optimisation measures individually
tailored to your GEA equipment using state-of -the-art technology.
We can guarantee you:
• The same care, precision and responsibility as we exercise in the manufacture of
GEA equipment
• Certification to DIN EN ISO 9001
• Original spare parts
• Attractive upgrade options
• Proven safety, quality and performance

RENTAL AND EXCHANGE COMPONENTS


GEA constantly endeavours to maintain the safety and availability of your systems at the
highest possible level. To do this, we can offer rental bowls and a trade-in and part exchange
service, so that downtimes can be reduced to the absolute minimum. In addition to bowls and
screws, various other exchange components are available for centrifuges.

UPGRADES / MODERNISATION / OPTIMISATION


Our proactive service concept includes ongoing identification and introduction of possible
optimisations of processes and systems.
Do your systems require an upgrade or modernisation as a result of market conditions or
new regulations? We will support you on the path to energy savings, cost reductions,
capacity adjustments and enhanced security. We will provide you with our expertise and
latest innovations in order to implement precisely the optimisations that you require.
Our global consultancy and certification framework is part of the GEA service philosophy and
will be of benefit to you all over the world..
We can guarantee you:
• A longer service life
• Lower capital expenditure compared to purchasing new equipment
• A reduction in production costs
• The maintenance of individual safety standards with qualified information on industrial
safety with corresponding specialist machine safety audits.
• Reliability and optimal benefit-cost ratio

PREVENTIVE MAINTENANCE
Our GEA PerformancePlus service concept takes an intelligent and economic approach to
ensuring plant availability and security.
The availability of historic and actual measurement data provides you and also GEA with a
detailed insight into the status of the plant. This enables a forward-looking introduction of
corrective, and in particular, planned measures.
We can guarantee:
• The planning of optimal service intervals
• Concise status information
• Minimum unplanned downtimes
• Enhanced plant security
• Optimised plant availability

PERFORMANCE AGREEMENTS
Even the best plant is worthless without the right service.GEA provides an approach for
preventing expensive cost traps.
Our service packages, individually tailored to your requirements, place particular emphasis
on plant availability, security and cost controls. Let the GEA experts take over the inspection,
maintenance and status control of your plant.
Our service modules can be adapted to changes in production conditions in all life cycle
phases without additional costs.
We can guarantee:
• A high level of plant availability
• A reduction in downtimes
• Optimised plant operation
• Maximum planning security
• Short response times

TRAINING
Our qualified staff will train your employees on site in one of our excellently equipped training
centres.
GEA training modules are tailored to your individual requirements. Our experienced
engineers offer comprehensive practical training, impart process expertise and raise
awareness in your employees of plant status to ensure safe, professional plant operation
from the outset.
We can guarantee:
• Optimal plant efficiency
• High availability and reliability
• Highly qualified personnel
• Awareness of plant status
• Motivation

USED MACHINES – FACTORY-REFURBISHED PLANT


Used GEA systems are efficient, reliable and are rapidly installed in situ where they still have
many years of operation ahead of them.
Because the systems were manufactured by GEA, we have the technical expertise to
guarantee their efficient and safe operation.
We can guarantee:
• Factory-refurbished systems
• Service for refurbished systems
• Shorter delivery periods than for new systems
• Excellent price-performance ratio
• The expertise of the manufacturer
• Safety, quality, performance and guarantee

SERVICE CONSULTANCY
Service consultancy is an essential stage in the optimisation and adaptation of operating
processes. Even in this area we have set ourselves the goal of fulfilling the requirements of
our clients with a market-leading service through the use of the latest technology – so that
you can provide your customers with superb products. That is why we bring all the necessary
tools and latest technical know-how together with our experience to bear on the problem
analysis, assessments and complex solutions to problems, in order to jointly overcome the
challenges.
Customer: SHANHAIGUAN SHIPBUILDING Project-/Order-No.: 30054723 / 1881848422
INDUSTRY CO.,LTD
Location: CT370-1 Project-title: SWD
GEA Westfalia Separator
Equipment List

Order-No.: 1881848422

Project - title: SWD

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Date: 19.10.2017 Dept.: 8833

Type: SWD Corr. Drawing: P1881848422-9913-PID000 Belongs to:

Repl for: --- Repl. by: --- Std. checked: ---

Explanations:
Priority(A): Procurement (B): Scope of supply (C):
N = Obligatory M = Must be obtained from Westfalia L = Scope of supply by WS
E = Recommended K = May be obtained from Westfalia S = Supplied by client
P = Possible Z = Supplied by client F = to be removed
U = --- V = --- W = loose supply

Created Date: 19.10.2017 Checked Date: 19.10.2017 Approved Date: Document No.: Revison: Page:

By: CT73 By: CT26 By: P1881848422-9913-DVL000 1/5

Copyright. © All rights reserved


Customer: SHANHAIGUAN SHIPBUILDING Project-/Order-No.: 30054723 / 1881848422
INDUSTRY CO.,LTD
Location: CT370-1 Project-title: SWD
GEA Westfalia Separator
Equipment List
ID Quantity Description Size/Type Power Comments Part-No. A B C
Usage Nominal Bore PID Code

10-3-001 1 Pcs Sea water pump 2022-9983-230 N M W


DN80/65
10-7-001 1 Pcs Feedwater valve 0018-8118-400 N M L
DN25
10-7-002 1 Pcs Ball cock for pressure gauge 0018-8241-400 N M L
1/4"
10-7-003 1 Pcs Orifice 2022-2021-010 N M L
1"
10-7-004 1 Pcs Ball cock for pressure gauge 0018-8241-400 N M W
1/4"
10-7-005 1 Pcs Ball cock for pressure gauge 0018-8241-400 N M W
1/4"
10-9-001 1 Pcs Pressure gauge PI 0001-1433-400 N M L

10-9-003 1 Pcs Pressure gauge PI 0001-1433-400 N M W

10-9-004 1 Pcs Pressure gauge PI 0001-0304-400 N M W

11-3-001 1 Pcs Ejector pump 2022-9200-030 N M L


DN80/80/100
11-7-001 1 Pcs Ball cock for pressure gauge 0018-8241-400 N M L
1/4"
11-7-002 1 Pcs Non return valve 0018-8132-600 N M L
DN80
11-9-001 1 Pcs Pressure gauge PI 0001-0304-400 N M L

Created Date: 19.10.2017 Checked Date: 19.10.2017 Approved Date: Document No.: Revison: Page:

By: CT73 By: CT26 By: P1881848422-9913-DVL000 2/5

Copyright. © All rights reserved


Customer: SHANHAIGUAN SHIPBUILDING Project-/Order-No.: 30054723 / 1881848422
INDUSTRY CO.,LTD
Location: CT370-1 Project-title: SWD
GEA Westfalia Separator
Equipment List
ID Quantity Description Size/Type Power Comments Part-No. A B C
Usage Nominal Bore PID Code

11-9-002 1 Pcs Thermometer TI 0001-1647-400 N M L

12-3-001 1 Pcs Distillate pump 2022-2252-020 N M L


1"
12-7-001 1 Pcs 3-way ball cock N M L
1/4"
12-7-002 1 Pcs Ball cock 2022-8977-100 N M L
3/4"
12-7-003 1 Pcs Non return / overflow valve 2022-8977-080 N M L
3/4"
12-7-004 1 Pcs 2/2- way Solenoid valve 2022-8977-110 N M L
1/2"
12-7-005 1 Pcs Non return valve 2022-8977-120 N M L
G1/2"
12-7-008 1 Pcs 3-way ball cock N M L
3/4"
12-8-001 1 Pcs Distillate suction hose 0018-8001-818 N M L
DN32
12-9-001 1 Pcs Conductivity measuring cell QISA 2022-2912-000 N M L

12-9-002 1 Pcs Pressure gauge PI 0001-1433-600 N M L

12-9-003 1 Pcs Water clock FQ 2022-8977-070 N M L

83-7-001 1 Pcs Non return valve 0018-8125-400 N M L


G1/2"

Created Date: 19.10.2017 Checked Date: 19.10.2017 Approved Date: Document No.: Revison: Page:

By: CT73 By: CT26 By: P1881848422-9913-DVL000 3/5

Copyright. © All rights reserved


Customer: SHANHAIGUAN SHIPBUILDING Project-/Order-No.: 30054723 / 1881848422
INDUSTRY CO.,LTD
Location: CT370-1 Project-title: SWD
GEA Westfalia Separator
Equipment List
ID Quantity Description Size/Type Power Comments Part-No. A B C
Usage Nominal Bore PID Code

83-8-001 1 Pcs Hose for non-condensable gases 0018-8002-818 N M L


1/2"
84-2-001 1 Pcs Chemical dosing tank 0003-0750-800 N M L

84-7-001 1 Pcs Ball cock 0018-8241-400 N M L


1/4"
84-7-002 1 Pcs Needle valve 0001-1665-700 N M L
1/4"
84-7-003 1 Pcs Non return valve 0018-6588-300 N M L
G1/4"
84-8-001 1 Pcs Hose for chemical dosing 2022-1176-008 N M L
3/8"
84-9-001 1 Pcs Flow indicator FI 0001-1665-700 N M L

87-1-001 1 Pcs Evaporator housing 2022-1165-010 N M L

87-7-001 1 Pcs Ball cock for pressure gauge 0018-7958-630 N M L


1/4"
87-7-002 1 Pcs Ball cock 4086-0010-074 N M L
1/4"
87-7-003 1 Pcs Non return / overflow valve 0018-8125-600 N M L
1 1/2"
87-9-001 1 Pcs Pressure gauge PI 0001-0529-600 N M L

87-9-002 1 Pcs Thermometer TI 0001-1489-280 N M L

Created Date: 19.10.2017 Checked Date: 19.10.2017 Approved Date: Document No.: Revison: Page:

By: CT73 By: CT26 By: P1881848422-9913-DVL000 4/5

Copyright. © All rights reserved


Customer: SHANHAIGUAN SHIPBUILDING Project-/Order-No.: 30054723 / 1881848422
INDUSTRY CO.,LTD
Location: CT370-1 Project-title: SWD
GEA Westfalia Separator
Equipment List
ID Quantity Description Size/Type Power Comments Part-No. A B C
Usage Nominal Bore PID Code

Created Date: 19.10.2017 Checked Date: 19.10.2017 Approved Date: Document No.: Revison: Page:

By: CT73 By: CT26 By: P1881848422-9913-DVL000 5/5

Copyright. © All rights reserved


GEA Westfalia Separator Group GmbH

P
Costumer:
WS Order No.:
Hull No.:
Drawing No.:
Sea Water Desalinator: Project No.: 30054723

1 x Distillate capacity : 25 m3/24h


2 x Residual salt content : 4 ppm NaCl
3 x Heat requirement : 762(*) kW (at 32°C seawater)
Heat requirement
4 x Heating water flow : 50,4 m3/h
5 x Pressure drop of jacket water : 0,25 - 0,5 bar
6 Heating steam flow : t/h (at 32°C seawater)
Heating steam flow : t/h (at 10°C seawater)
7 x Heating water temperature in / out : 85 / 72(*) °C
8 Heating steam pressure : bar abs
9 x Sea water flow : 62,3 m3/h
10 xx Sea water temperature in / out : 32 / 42 °C
x Pumps
1x Distillate Pump
x Discharge rate : 1,25 m3/h
x Total head : 30 mWC
x Power supply : 3x 440 / 60 V / Hz
x Power installed : 1,1 (**) kW
x Current (in operation / start) : 1,9 / 13,3 A
x Motor type : squirrel, direct on line
x Motor protection class : IP 55
x Insulation class : F, B (55°C)
x Casing : Stainless Steel 1.4401
x Impeller : Stainless Steel 1.4401
x Shaft : Stainless Steel 1.4401
x Seal Type : Mechanical Seal
2x Combined Sea Cooling Water / Ejector Pump (non self priming)
x Discharge rate : 62,3 m3/h
x Total head : 50.0 mWC
x Power supply : 3x 440 / 60 V / Hz
x Power installed : 17,3 (**) kW
x Current (in operation / start) : 27,5 /220 A
x Motor type : 160M squirrel, direct on line
x Motor protection class : IP 55
x Insulation class : F, B (45°C)
x Casing : Cast bronze
x Impeller : Cast bronze
x Shaft : Stainless Steel
x Seal Type : Mechanical Seal

(*) at seawater temperature of 32 °C (**) at 45 °C ambient temperature


Pos : 2 /BA/Standar d/00_Titel_R üc ks eite/D ec kblatt_CD _2016 @ 33\mod_1462957704414_18.doc x @ 1327579 @ @ 1

Instruction manual
Fresh water generator
Type: SWD 10,15,20,25,30

No.: 2022-9001-060
Version: 04.07.16
About this document 2022-9001-060 / 22.03.17

ORIGINAL INSTRUCTION MANUAL


Contents subject to modification!

The authors are always grateful for remarks and sugges-


tions for improving the documentation. These can be sent
to:

GEA Germany
GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1
59302 Oelde, Germany

Tel +49 2522 77-0 e-mail@gea.com


Fax +49 2522 77-2950 gea.com

=== Ende der Liste für T extmar ke Titelseite ===

2 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 About this document

1 About this document 7

1.1 Scope of application .................................................................................. 8


1.2 Other applicable documents ...................................................................... 8
1.3 Structure of safety notices ......................................................................... 8
1.4 Target groups ............................................................................................ 9
1.4.1 Operator ................................................................................................... 10
1.4.2 Skilled worker .......................................................................................... 10
1.4.3 Trained specialist ..................................................................................... 10
1.5 Additional documentation ........................................................................ 10
1.6 Service offers ........................................................................................... 11
1.6.1 Training .................................................................................................... 11

2 Safety precautions 13

2.1 Intended use ............................................................................................ 14


2.2 Reasonably foreseeable misuse ............................................................. 14
2.3 Qualification of the personnel .................................................................. 15
2.4 Responsibility of the plant operator ......................................................... 15
2.5 Hazards from products and operating materials ..................................... 16
2.6 Modifications to the system ..................................................................... 16
2.7 Requirements for spare parts and operating materials ........................... 17

3 Description 19

3.1 Safety information .................................................................................... 20


3.1.1 Safety devices ......................................................................................... 20
3.1.2 Safety markings on the system ............................................................... 21
3.1.3 Personal safety gear ................................................................................ 21
3.1.4 Avoid hazards caused by vibrations or shocks ....................................... 23
3.2 Description of the system ........................................................................ 24
3.2.1 General function of a fresh water generator ............................................ 24
3.3 Overview image of the fresh water generator ......................................... 26
3.4 Controller ................................................................................................. 26
3.4.1 Control cabinet design ............................................................................. 26
3.4.2 Front view of the control cabinet.............................................................. 27
3.4.3 Salinity indicator....................................................................................... 28

4 Technical data 29

4.1 Technical specifications ........................................................................... 30


4.1.1 Technical data fresh water generator ...................................................... 30
4.1.2 Technical data salinity indicator ............................................................... 30
4.1.3 Technical data conductivity measuring cell ............................................. 30
4.2 Regular temperature and pressure values .............................................. 31
4.2.1 Regular values fresh water generator ..................................................... 31

5 Transport and storage 33

5.1 Safety information .................................................................................... 34


5.1.1 Safety during transport ............................................................................ 34
5.1.2 Hazards from ambient temperatures ....................................................... 34

GEA Westfalia Separator Group 3


About this document 2022-9001-060 / 22.03.17

5.1.3 Using load suspension equipment safely ................................................ 34


5.2 Using lifting eye bolts or lifting eye nuts as load handling devices .......... 36
5.3 Transporting the system .......................................................................... 37
5.4 System storage ........................................................................................ 39
5.5 Storing and handling electrical equipment .............................................. 39

6 Assembly and installation 41

6.1 Safety information .................................................................................... 42


6.1.1 Avoiding risks during assembly and installation ...................................... 42
6.1.2 Foundation risk ........................................................................................ 42
6.2 Requirements for the installation location ............................................... 42
6.3 Space requirements for the fresh water generator .................................. 45
6.4 Attach the foundation plate for the installation ........................................ 46
6.5 Connecting the control unit ...................................................................... 47
6.5.1 Electrical installation (land-based operation) ........................................... 47
6.5.2 Connecting external voltages .................................................................. 47
6.6 Connect equipotential bonding for pumps ............................................... 47
6.7 Connect equipotential bonding for foundation plate ................................ 48
6.8 Dimensioning and connecting the feed and discharge lines ................... 49
6.8.1 Dimensioning the piping .......................................................................... 49
6.8.2 Connecting hot water pipes ..................................................................... 50
6.8.3 Connecting the seawater pipes ............................................................... 51
6.8.4 Distillate ................................................................................................... 52
6.8.5 Overflow opening ..................................................................................... 52
6.8.6 Dosing tank filling pipe ............................................................................. 52
6.9 Installing the seawater pump ................................................................... 52
6.9.1 General .................................................................................................... 52
6.9.2 Pressures ................................................................................................. 53
6.10 Assembling the evaporator stack (lower plate stack) .............................. 53
6.11 Assembling the condenser stack (upper plate stack) .............................. 56

7 Settings 59

7.1 Dosing chemicals..................................................................................... 60

8 Commissioning 61

8.1 Safety information .................................................................................... 62


8.2 Safety during commissioning................................................................... 62
8.3 Commissioning the system ...................................................................... 62
8.4 Commissioning check list ........................................................................ 63
8.5 Checking the rotational direction of the pumps ....................................... 65
8.6 Carrying out a vacuum test...................................................................... 65
8.7 Refilling the evaporator stack .................................................................. 66
8.7.1 Filling the chemical dosing tank............................................................... 67

9 Operation 69

9.1 Safety information .................................................................................... 70


9.1.1 Preventing hazards before starting up .................................................... 70
9.1.2 Avoiding hazards during operation .......................................................... 70
9.2 Monitoring operation ................................................................................ 70
9.3 Starting up the system ............................................................................. 70
9.3.1 Setting the supply water pressure ........................................................... 71
9.4 Switching on the distillate pump .............................................................. 72
9.5 Determining the distillate flow rate........................................................... 74

4 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 About this document

9.6 Adjusting the chemical dosage ................................................................ 75


9.7 Checking the supply water flow rate ........................................................ 75
9.8 Checking the seawater level .................................................................... 76
9.9 Checking the temperature and pressure values ...................................... 76
9.10 Stopping the system ................................................................................ 77
9.11 Water meter bypass (optional) ................................................................ 78
9.12 Using the filling pipe dosing tank (optional) ............................................. 78

10 Trouble shooting 79

10.1 Safety information .................................................................................... 80


10.2 Avoiding hazards during malfunctions ..................................................... 80
10.3 Troubleshooting ....................................................................................... 81
10.4 Alarms and warnings ............................................................................... 83

11 Maintenance 85

11.1 Safety information .................................................................................... 86


11.2 Preventing hazards through regular maintenance .................................. 86
11.3 Maintenance schedule ............................................................................. 88
11.4 Maintenance work SWD .......................................................................... 91
11.4.1 Chemical dosage ..................................................................................... 91
11.4.2 Dosing valve ............................................................................................ 91
11.4.3 Replacing the sacrificial anode ................................................................ 91
11.4.4 Cleaning the wire mesh mist eliminator ................................................... 91
11.4.5 Cleaning the lamellar mist eliminator....................................................... 92
11.4.6 Cleaning the conductivity measuring cell ................................................ 92
11.4.7 Checking and cleaning the ejector nozzles ............................................. 92
11.4.8 Cleaning the evaporator plates................................................................ 92
11.4.9 Cleaning the condenser plates ................................................................ 93

12 Repair 95

12.1 Safety information .................................................................................... 96


12.1.1 Preventing hazards in the case of repair work ........................................ 96
12.1.2 Hazards from electricity ........................................................................... 96
12.1.3 Hazards from mechanical energy ............................................................ 96

13 Decommissioning 97

13.1 Safety information .................................................................................... 98


13.1.1 Avoiding hazards on disposal .................................................................. 98

14 Spare parts 99

14.1 Original spare parts ............................................................................... 100


14.2 Notes on ordering spare parts ............................................................... 100
14.3 Spare parts ............................................................................................ 102
14.3.1 Evaporator ............................................................................................. 102
14.3.2 Tank ....................................................................................................... 104
14.3.3 Tandem ejector pump general information ............................................ 105
14.3.4 Ejector pump SWD 10 ........................................................................... 106
14.3.5 Ejector pump SWD 15/20 ...................................................................... 107
14.3.6 Ejector pump SWD 30 ........................................................................... 108
14.3.7 Dosing device ........................................................................................ 109

GEA Westfalia Separator Group 5


About this document 2022-9001-060 / 22.03.17

14.3.8 Distillate block ........................................................................................ 110


14.3.9 Condenser stack .................................................................................... 111
14.3.10 Evaporator stack .................................................................................... 112
14.3.11 Heating water unit (optional).................................................................. 113
14.3.12 Steam injection module (optional) ......................................................... 114
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6 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 About this document

1 About this document

1.1 Scope of application .................................................................................. 8


1.2 Other applicable documents ...................................................................... 8
1.3 Structure of safety notices ......................................................................... 8
1.4 Target groups ............................................................................................ 9
1.4.1 Operator ................................................................................................... 10
1.4.2 Skilled worker .......................................................................................... 10
1.4.3 Trained specialist ..................................................................................... 10
1.5 Additional documentation ........................................................................ 10
1.6 Service offers ........................................................................................... 11
1.6.1 Training .................................................................................................... 11

GEA Westfalia Separator Group 7


About this document 2022-9001-060 / 22.03.17

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1.1 Scope of application


This document applies for all persons who work with or on the compact unit. It ap-
plies to the plant operator as a basis for compiling standard operating procedures
(SOP) for conduct at the compact unit workplace.
Pos : 7 /BA/Standar d/01_Zu_dies em_Dokument/Mitgeltende_Dokumente/Mitgeltende_D okumente_SWD @ 11\mod_1393931932755_18.doc x @ 676010 @ 2 @ 1

1.2 Other applicable documents


The following documents contained in the plant documentation apply in addition to
this instruction manual:
• Safety information for the system
• Project-related documents
• Set of drawings
• Data sheets
• Plans and lists
• P&ID (Piping and Instrumentation Diagram)
• Documentation on the system controller
• Instruction manuals for components of other manufacturers, such as motors, fil-
ters, pumps, valves, and fittings of the measuring technology.

Pertinent standards and regulations:


• DIN 10217 Tubes
• DIN 2576 Flanges
• PN10 Nominal pressure
• NEN Electrical systems
• IP54 Degree of protection
• IMO G8

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1.3 Structure of safety notices


The installation has been designed and built so that it functions and can be operat-
ed safely. This manual will refer to further potential risks by using warning notices
at the relevant points.
A differentiation is made between hazards which result in damage to the plants,
plant components and environment and hazards which lead to possible or probable
injury or loss of life.
Signal words and their meaning

DANGER Denotes impending danger. If the preventive measures are not implemented, death
or serious injury will be the consequence.

WARNING Denotes a potentially dangerous situation. If the preventive measures are not im-
plemented, death or serious injury may be the consequence.

CAUTION Denotes a potentially dangerous situation. If the preventive measures are not im-
plemented, minor injury may be the consequence.

8 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 About this document

NOTICE Denotes a potentially damaging situation. If the preventive measures are not im-
plemented, the system or something else in its vicinity can get damaged.

Danger signals

This is the danger signal. It warns of injury risks.


 Comply with all measures marked with the danger signal to avoid injury or
death.

Structuring of the safety references according to the 5-point rule


1. Danger signals as a warning of injury risks.
2. Signal words signal the degree of risk.
3. The type and source of the hazard indicate from where the hazard origi-
nates.
4. Explanation of the hazard and consequences in the case of non-
compliance describe the threat and the consequences of human error.
5. Measures give instructions to avoid the hazard.

DANGER Type and source of hazard

Explanation of the hazard and the consequences in the event of non-compliance.


 Measures to avert or minimise the hazard.

WARNING Type and source of hazard

Explanation of the hazard and the consequences in the event of non-compliance.


 Measures to avert or minimise the hazard.

CAUTION Type and source of hazard

Explanation of the hazard and the consequences in the event of non-compliance.


 Measures to avert or minimise the hazard.

NOTICE Type and source of hazard

Explanation of the hazard and the consequences in the event of non-compliance.

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1.4 Target groups


The target groups for this documentation are all persons involved in installing, as-
sembling, operating, maintaining and repairing the compact unit.
What work may be carried out by what target group depends on the qualification of
the personnel and on the type of work.
In the tables in the chapters Troubleshooting and Maintenance the responsible
target group as well as the operation is specified.
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GEA Westfalia Separator Group 9


About this document 2022-9001-060 / 22.03.17

1.4.1 Operator
Abbreviation: Op
The operator is employed by the customer and has been briefed in the following
operations:
• Starting and shutting down the machine.
• Monitoring the machine and process (e.g. by means of indicators).
• Execution of easy re-lubrication and cleaning operations.
When given specific directions, the operator is able to carry out simple modifica-
tions to the process, e.g.:
• Adjusting temperatures, pressures and throughput capacities.
• Dosing additives.
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1.4.2 Skilled worker


Abbreviation: Skilled
The skilled worker is normally employed by the customer and has been briefed in
the following areas:
• Performing easy assembly work
• Performing routine maintenance work or servicing
• Limited settings and parametrization on the components and control system
The skilled worker has basic technical knowledge. The basic knowledge corre-
sponds to a technical apprenticeship (mechanical or electrical).
The skilled worker is selected and deployed by the employer (plant operator).
GEA Westfalia Separator will carry out the briefing only in specific technical fea-
tures that are part of the supply schedule and and will indicate potential hazards.
This briefing is no substitute for an apprenticeship.
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1.4.3 Trained specialist


Abbreviation: Tspec
The trained specialist normally belongs to the service team of GEA Westfalia Sep-
arator Group.
In exceptional cases, skilled workers employed by the customer can obtain a cor-
responding qualification by attending training courses held by GEA Westfalia Sepa-
rator Group.
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1.5 Additional documentation


Request further information and technical documentation from the following places:
• Directly from GEA Westfalia Separator in Oelde.
• From the nearest representative of GEA Westfalia Separator.
• Per Internet under: gea.com
• Vie e-mail at: wsinfo@gea.com
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2022-9001-060 / 22.03.17 About this document

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1.6 Service offers

1.6.1 Training
GEA Westfalia Separator regularly holds training courses for customer employees.
Training content is aimed at the customer's operating and service staff who work
with the installation. The operator must know how the installation functions.
Trained operators assure the operating safety of the system.
Many different applications require competent process engineering know-how. On-
ly adequately trained employees in service ensure a high quality standard. This re-
quires ongoing further training.
The demands on the qualification of the service staff are growing increasingly.
GEA Westfalia Separator consequently offers a qualification model and training
concept.
Contact the following addresses for training courses for operating and service staff:
• info.learningcenter@gea.com

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GEA Westfalia Separator Group 11


About this document 2022-9001-060 / 22.03.17

12 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Safety precautions

2 Safety precautions

2.1 Intended use ............................................................................................ 14


2.2 Reasonably foreseeable misuse ............................................................. 14
2.3 Qualification of the personnel .................................................................. 15
2.4 Responsibility of the plant operator ......................................................... 15
2.5 Hazards from products and operating materials ..................................... 16
2.6 Modifications to the system ..................................................................... 16
2.7 Requirements for spare parts and operating materials ........................... 17

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2.1 Intended use


The fresh water generator (Sea Water Distiller, SWD) is used to desalinate salt wa-
ter or seawater. This takes place through vacuum distillation.
The distillate can be used for washing, personal hygiene, in the kitchen and as
technical water.
The distillate can also be used as drinking water if the missing minerals and vital
ingredients typical of drinking water are supplied to the organism through other
foods. In addition, the drinking water must be sterilized.
The system is intended exclusively for commercial operation. It is technically de-
signed according to the mode of operation contractually agreed upon with the
manufacturer.
It is intended for the following use:
• Heat absorption for evaporation through an external heat source, for example,
through the exhaust heat of a diesel engine or the drive motor of a ship.
• Evaporation of the sea water to evaporator plates during vacuum in the housing.
• Separating of the salt water in the mist eliminator.
• Condensation of the vapour in the sea water-cooled condenser.
• Recycling of the concentrated brine into the sea and creation of a vacuum with a
tandem ejector pump.
• Sterilization of the distillate with UV disinfection system if it is also used as drink-
ing water (optional).
• Hardening filter for the distillate if it is also used as drinking water (optional).
• The fresh water generator may only be operated after proper installation and
commissioning by an expert. The safety regulations applicable at the local site
must be complied with.
• The water treatment system may only be operated if all components have been
installed correctly. Safety systems must not be removed, bypassed, or rendered
non-functional in any other way. The system may only be used for the applica-
tions indicated above.
• Intended use also includes compliance with the specifications in this instruction
manual and with safety regulations applicable at the particular local site as well
as performance of periodic maintenance work; see section “Maintenance”.

For information on process conditions, operating conditions, and environmental


conditions, see:
• System nameplate
• Technical specifications
The following requirements must be met to ensure safe operation of the system at
all times:
• Use only genuine spare parts and genuine operating materials.
• Comply with limits.
• Do not change or expand the system.
• Use the system only for its intended purpose.
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2.2 Reasonably foreseeable misuse


The manual contains instructions for the intended use. Any operation of the system
that does not fall under the intended use constitutes unintended use and is consid-
ered to be misuse.

14 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Safety precautions

Reasonably foreseeable misuse includes:


• Use of unsuitable spare parts
• Use of impermissible operating materials
• Exceeding of defined limits
• Modifying or expanding the system
• Changing the process conditions, operating conditions and environmental condi-
tions without the consent of the manufacturer.
• Non-wearing of the prescribed personal protective gear.
Any misuse of the system may cause bodily injury and property damage.
 Use the system only as intended.
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2.3 Qualification of the personnel


Special expertise is required for working on and with the system. The qualification
of the personnel with this expertise is an important requirement for the operational
reliability. The requirements in respect of qualification levels are set out in the
chapter "About this document / Target groups". They depend on the tasks as-
signed.
Faulty operation, assembly and handling errors can result in danger to life and limb
as well as causing severe damage to property.
The plant operator must implement measures for the qualification of its personnel:
 Assign only reliable individuals to work on the system.
 Allow only authorized personnel to work on the system.
 Give special training and briefings to the personnel for the tasks assigned.
 Clearly define responsibilities.
 Make sure that the authorized persons have read and understood the safety in-
formation before beginning work.
 Make sure that the authorized persons have read and understood all sections of
the instruction manual required for their work before beginning work.
 Give special briefings to persons who cannot read, and monitor their work.
 Persons still undergoing training may only be deployed under supervision.
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2.4 Responsibility of the plant operator


The operation of a system is subject to rules and regulations for occupational
health and safety.
The order of the rules and regulations listed below is not a reflection of their priori-
ty. The list lays no claim to completeness:
• Regulations relating to safety and health (accident prevention regulations) based
on Article 118a of the treaty establishing the EEC, e.g., Directive 89/655/EEC
and follow-up versions or corresponding national regulations issued by the coun-
try of operation.
• Regular check of safety devices
• Compliance with the Machinery Directive 2006/42/EC or corresponding national
regulations issued by the country of operation when working within the responsi-
bility as manufacturer.
• Compliance with the German Equipment and Product Safety Act or correspond-
ing national regulations issued by the country of operation when working within
the responsibility of the manufacturer.

GEA Westfalia Separator Group 15


Safety precautions 2022-9001-060 / 22.03.17

Only for systems designed according to ATEX and that are used in potentially ex-
plosive areas:
• Compliance with regulations governing health protection and safety of employ-
ees in hazardous areas, e.g., Directive 1999/92/EC or corresponding national
regulations issued by the country of operation.
• Compliance with ATEX Directive 94/9/EC, EMC Directive 89/336/EC, Low-
Voltage Directive 73/23/EC or corresponding national regulations issued by the
country of operation when working within the responsibility of the manufacturer.

The plant operator is responsible for complying with the rules and regulations for
assigned persons working safely and with awareness of the hazards. These inclu-
de the following measures:
 Ensuring that the statutory and other binding regulations on safety, accident pre-
vention and occupational safety are known and complied with.
 Assigning only qualified and authorised staff with technical understanding and
fundamental technical knowledge and skills to work on the control unit.
 Clearly defining and communicating responsibilities for tasks.
 Operating the system only in perfectly functional condition in line with the in-
tended use. For the intended use, refer to the section Intended use.
 Checking all safety devices for proper functioning before each startup.
 Having the system checked regularly by qualified persons for its operational reli-
ability. Check the operating condition of the system at least once annually.
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2.5 Hazards from products and operating materials


Hazardous materials are all materials that, on physical contact, represent a hazard
for the persons operating in the environment of the system.
Systems that have been purpose-built for operation with hazardous materials are
marked with safety stickers.
Hazards resulting from the following product characteristics and operating materi-
als are known from product observation:
• Hot products
• Cold products
• Hazardous, chemically critical products
• Hazardous, biologically critical products
• Cleaning agents
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2.6 Modifications to the system


Modifications to the system are not permitted. They represent an unintended use
and endanger the operational reliability of the system. This may cause bodily injury
and property damage.
 When modifications to the system are necessary, e.g., due to new operational
sequences, contact GEA Westfalia Separator.
 Clarify the planning and the measures for the modifications to the system with
GEA Westfalia Separator.
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16 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Safety precautions

2.7 Requirements for spare parts and operating materials


Spare parts, wear parts, and operating materials can cause bodily injury and prop-
erty damage if they do not meet the requirements.
Genuine spare parts and operating materials from GEA Westfalia Separator meet
all requirements for operational reliability of the system.
 Use only genuine spare parts.
 Use only genuine operating materials.
 Use the spare parts catalogue that was supplied.
 See the chapter "Spare parts" for ordering spare parts and operating materials.
 Comply with limits.
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Safety precautions 2022-9001-060 / 22.03.17

18 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Description

3 Description

3.1 Safety information .................................................................................... 20


3.1.1 Safety devices ......................................................................................... 20
3.1.2 Safety markings on the system ............................................................... 21
3.1.3 Personal safety gear ................................................................................ 21
3.1.4 Avoid hazards caused by vibrations or shocks ....................................... 23
3.2 Description of the system ........................................................................ 24
3.2.1 General function of a fresh water generator ............................................ 24
3.3 Overview image of the fresh water generator ......................................... 26
3.4 Controller ................................................................................................. 26
3.4.1 Control cabinet design ............................................................................. 26
3.4.2 Front view of the control cabinet.............................................................. 27
3.4.3 Salinity indicator....................................................................................... 28

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Description 2022-9001-060 / 22.03.17

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3.1 Safety information


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3.1.1 Safety devices


EMERGENCY STOP button
The Emergency Stop shutdown achieves functional safety in the event of an emer-
gency or hazardous situation. It ensures that processes are stopped and all moving
parts are brought to a standstill as quickly as possible.
The system and all auxiliary equipment are not de-energised by the Emergency
Stop shutdown. All components remain functional even when the system is at a
standstill. The voltage must be disconnected manually.
An EMERGENCY STOP shutdown can be initiated manually or occur automatical-
ly.

EMERGENCY STOP buttons are located


on the control cabinet. Exact information
on the position of the EMERGENCY
STOP buttons can be found in the elec-
trical documentation.

The control cabinet is installed according


to the specifications of the plant operator.
Therefore the position of the
EMERGENCY STOP button can be
found in the SOP of the plant operator.

Fig. 1

Main switch

Precise information on the position of the


main switch on the cabinet is given in the
electrical documentation.

The control cabinet is installed according


to the specifications of the plant operator.
The position of the cabinet with the main
switch must therefore be obtained from
the instruction manual of the operator.

Fig. 2

Electrical safety and electromagnetic compatibility


Electrical safety of the fresh water generator has been tested during the manufac-
turing process in the factory.
Work on the system may affect the electrical safety and thus necessitates a new
electrical protective measure (ELSI). A specialist can recognize errors caused by
the old and new ELSI at an early stage and thus increase the operational safety.

Maintenance work
Only qualified personnel are permitted to perform maintenance work. The system
must be switched off and disconnected from the mains before work is performed
on it.

20 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Description

NOTE:
It is recommended to install a coaming (sill, border) under the water-bearing parts
of the system with connection to the bilge. This permits controlled draining of dis-
charged water during maintenance and service jobs.

Effects on the environment and public health


According to the risk assessment the installation and operation of the fresh water
generator do not pose any identifiable risks to the ship, the crew or other persons
of concern and/or parties.

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3.1.2 Safety markings on the system


The following safety markings can be found on the system:
Safety markings on system

Heavy duty power (400/440 V)

Connection for earthing/equipotential earthing

Warning

Warning of dangerous voltage

System is OFF

System is ON

Fragile

This Side Up

Store in dry place

Inlet and outlet

Action prohibited

Important information
Potential equalization

Correct disposal

Before conducting maintenance work on the system make


sure to read the operating instructions, switch off the main
switch and secure it against restarting.

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3.1.3 Personal safety gear


To avoid death or bodily injury, the prescribed personal safety equipment must be
worn when operating the system or performing maintenance work or repairs on the
system.

GEA Westfalia Separator Group 21


Description 2022-9001-060 / 22.03.17

The personal safety equipment conforms to:


• Locally applicable accident prevention regulations
• Instruction manual of the operator or employer
• Instructions in the safety information in this instruction manual
Anyone who works with or on the system is responsible for ensuring that the per-
sonal safety equipment is worn and that it is in proper condition.
 Replace damaged safety equipment with new equipment.
Clean dirty safety equipment.

Wear hearing protection!

 Wear hearing protection when


working in a loud environment!

The noise level of a system may


exceed 85dB (A).

Fig. 1 S67

Wear protective goggles!

 Wear protective goggles when


working on pipes and fittings.

Possible residues of caustic liquids in


valves and pipes and piping systems
not relieved from pressure.

Fig. 2 S102

22 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Description

Wear protective gloves!

 Wear protective gloves when


working on hot or cold surfaces of
separator and piping.

Possible temperature ranges: -10 to


+80 °C and 14 to 176 °F.

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Fig. 3 S103
3.1.4 Avoid hazards caused by vibrations or shocks
In dynamic loads, there is a fundamental distinction between vibrations and
shocks. From a physical standpoint, these two phenomena are similar. However,
they are distinguished because they have different effects.
Vibrations occur at periodic intervals. Many of these phenomena are generally
known, such as vibrations that are caused by motors and ship motions on sea
waves.
Shocks are rare - usually one-time - events that result, for example, from an impact
or when an object is dropped or falls over. This includes bumps, blows, and an im-
pact caused by manoeuvring.
During installation of the system, it must be ensured that vibrations or shocks can-
not be transmitted to the system.
For dimensioning of suitable bases and pedestals, the individual operating weights
of the modules specified in the respective dimension drawings must be taken into
account.

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3.2 Description of the system


General
As a supplier of system technology for the engine room, GEA Westfalia provides
innovative treatment systems for the water on board, including fresh water genera-
tion for converting seawater into fresh water.

3.2.1 General function of a fresh water generator

Fig. 3 General functional diagram of a fresh water generator

1 Heat exchanger
2 Heating water
3 Distillate
4 Housing
4.1 Condenser
4.2 Mist eliminator
4.3 Evaporator
5 Brine
6 Supply water
7 Non-condensable gases
8 Seawater
9 Condensation
10 Steam cleaner
11 Steam
12 Circulation pump
13 Motor cooling water

24 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Description

Function description fresh water generator


The fresh water generator works according to the principle of vacuum distillation.
The waste heat from the main drive motor of the ship functions as a heating medi-
um for evaporation. Evaporation takes place in the evaporator stack, which is in-
stalled in the bottom part of the housing. Part of the supplied water evaporates due
to high vacuum that prevails in the interior of the housing.
The generated steam passes through a wire mesh mist eliminator, which separates
the salt droplets. Condensation takes place in the condenser stack in the upper
part of the housing. The condenser is sea water cooled. The latent heat of conden-
sation is discharged into the sea water. The condensation temperature and the
evaporation temperature is dependent on the temperature of the seawater.
A small portion of the heated sea water is used as supply water for the evaporator
stack.
The majority is used as a driving medium for the tandem ejector pump. The tan-
dem ejector pump has two functions: Extraction of the excess water (the so-called
brine) from the housing and to generate the vacuum by discharging the non-
condensable gases.
The distillate quality (salinity) is monitored by the control cabinet. If the salt content
is above the setpoint (2-10 ppm), the distillate passes through a solenoid valve
back into the evaporator.

The system "SWD" consists of the following components:


• 1 Housing with condenser, evaporator and mist eliminator
• 1 Control cabinet, mounted on the right or left
• Dosing tank for chemicals, installed
• Distillate pump
• Thermometer and pressure gauge set
• Check valve set
• Supply water valve
• Solenoid valve
• Water meter
• Conductivity measuring cell and salinity indicator

In addition, a heating module can be used with a heat exchanger (optional). The
heat can be generated from steam, hot water or thermal oil depending on the local
conditions.

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Description 2022-9001-060 / 22.03.17

3.3 Overview image of the fresh water generator

Fig. 4 Overview drawing fresh water generator

Caption 1 Heating water inlet


2 Sea water outlet
3 Distillate outlet (standard) with water meter bypass (optional)
4 Heating water outlet
5 Sea water inlet
6 Distillate pump
7 Dosing tank

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3.4 Controller
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3.4.1 Control cabinet design


The control cabinet is the same for all fresh water generator types. It can be
mounted on the right or left side of the system.
The salinity indicator is installed in the door of the control cabinet ready for connec-
tion.

26 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Description

3.4.2 Front view of the control cabinet

Fig. 1 Control elements on the control cabinet

Caption 1 Salinity indicator


2 Operating hour meter seawater pump
3 "Alarm" signal light
4 Control buttons distillate pump
5 Main switch
6 Control buttons seawater pump
7 Power supply indicator
8 Seawater pump ammeter

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Description 2022-9001-060 / 22.03.17

3.4.3 Salinity indicator


The device is in the working level after the power is switched on and is preset at
delivery.

Fig. 2

Caption 1 Actual value display


2 Field for additional text
3 Unit display
4 Parameter button
5 Setting button downward
6 Setting button upward
7 Activated alarm outputs display
Only the current salinity in the unit per ppm is displayed. Two alarm outputs are ac-
tivated. "Alarm salinity too high" appears if the upper alarm threshold is exceeded.
"Alarm sensor error" appears if the lower alarm threshold is not reached.

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2022-9001-060 / 22.03.17 Technical data

4 Technical data

4.1 Technical specifications ........................................................................... 30


4.1.1 Technical data fresh water generator ...................................................... 30
4.1.2 Technical data salinity indicator ............................................................... 30
4.1.3 Technical data conductivity measuring cell ............................................. 30
4.2 Regular temperature and pressure values .............................................. 31
4.2.1 Regular values fresh water generator ..................................................... 31

GEA Westfalia Separator Group 29


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4.1 Technical specifications


Subject to change!
The order-related process data are indicated on the operating data sheet which is
part of the documentation.

4.1.1 Technical data fresh water generator

Fresh water generator

SWD 10 SWD 15 SWD 20 SWD 25 SWD 30


Capacity [t/d] 10 15 20 25 30
Heating water tem- [°C] 70-90
perature
Connections:
Seawater inflow [DN] 65
Seawater drain [DN] 65 80 80 100 100
Heating water inflow [DN] 65
Heating water drain [DN] 65
Distillate [inch] G¾
Weight
Empty weight [kg (lb)] 600 (1323) 617 (1360) 626 (1380) 642 (1415) 651 (1435)
Working weight [kg (lb)] 640 (1411) 676 (1490) 706 (1556) 742 (1636) 771 (1700)

4.1.2 Technical data salinity indicator

Conductivity measuring device

Type LF 9648
Dimensions DIN 96x48 mm
Power consumption Max. 3.5 VA
Working temperature min. -10 °C max. 55 °C
Measurement range temperature min. -50 °C max. 200 °C

4.1.3 Technical data conductivity measuring cell

Conductivity measuring device

Type LF 2603
Working temperature min. 0 °C max. 60 °C

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4.2 Regular temperature and pressure values


The following temperature and pressure values indicate a normal operation.

4.2.1 Regular values fresh water generator

Seawater

Supply temperature 0-32 °C


Temperature differential condenser 10-13 °C
Pressure loss condenser max. 0.5 bar

Heating water

Supply temperature 80-90 °C


Temperature difference evaporator 10-15 °C
Pressure loss evaporator max. 0.5 bar
Example: SWD 15-85 means 15 t/d at 85°C heating water

Evaporator

Temperature 40 – 55 °C (seawater 0 – 32 °C)


Pressure -0.9 – -0.85 bar (seawater 0 – 32 °C)

Distillate

Pressure 1.0 – 2.5 bar

Tandem ejector
pump
SWD Ejector pump inlet pressure Ejector pump-backpressure
11-9-001 [bar g] [bar g]

min. max. min. max.


10 3.3 4.1 0.2 0.6
15 3.4 4.2 0.2 0.6
20 3.5 4.3 0.2 0.6
25 3.5 4.3 0.2 0.6
30 3.5 4.3 0.2 0.6

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32 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Transport and storage

5 Transport and storage

5.1 Safety information .................................................................................... 34


5.1.1 Safety during transport ............................................................................ 34
5.1.2 Hazards from ambient temperatures ....................................................... 34
5.1.3 Using load suspension equipment safely ................................................ 34
5.2 Using lifting eye bolts or lifting eye nuts as load handling devices .......... 36
5.3 Transporting the system .......................................................................... 37
5.4 System storage ........................................................................................ 39
5.5 Storing and handling electrical equipment .............................................. 39

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5.1 Safety information


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5.1.1 Safety during transport


When the system is transported with hoists and fork-lift trucks, hazards can occur.
There is a risk of injury and material damage if unqualified personnel or unsuitable
or damaged load suspension equipment are used.
Therefore, pay attention to the following points during transport:
 Use only qualified personnel to transport the system.
 Use approved and undamaged load suspension equipment for transport.
 Use only suitable load suspension equipment with adequate lifting capacity.
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5.1.2 Hazards from ambient temperatures


The system has lines and tanks that are filled with water. The system can be dam-
aged as a result of frost or high temperatures.
 To avoid damage, take measures to prevent frost action during transport and
storage.
 Do not install or store the system next to objects with strong heat radiation.
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5.1.3 Using load suspension equipment safely


The working load limit of the slings depends on the method of use. They may be
used only in accordance with their intended use. Unintended use may cause the
slings to tear or break. There is a risk of death or bodily injury and material dam-
age.
For the reduction of the working load limit in individual cases, see the manufactur-
er's specifications.
GEA Westfalia Separator recommends the use of round slings made of synthetic
fibres.

Observe the following points when using load suspension equipment:


• Inspect the slings for damage before each use.
• Do not use damaged or incomplete load suspension equipment or slings.
• Use slings only in the way approved by the manufacturer.
• Never load the slings beyond their maximum working load limit (WLL). The WLL
specification is located on the sling label.
• Conduct periodic training for the slingers and the individuals who are assigned to
perform transport work.
• Use only the load fastening points specified in the documentation.
• Use only suitable ground conveyors and hoisting equipment with adequate lifting
capacity.
• Pack and secure the load before transport in accordance with the Cargo
Transport Unit transport guidelines.
• Observe all regional regulations and laws governing transport and transport se-
curing.

Load suspension equipment for transport of system


Ground conveyors and hoisting equipment for transporting the system to the instal-
lation site must be provided by the operator.

34 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Transport and storage

Hoisting equipment, e.g., crane, needed to remove or install filters, UV reactors,


and other heavy components must be provided by the operator.

Load suspension equipment for repair of system


Load suspension devices and slings needed for disassembling certain components
of the system are included in the special tools supplied. In accordance with their in-
tended use, they must not be used for other lifting work. Slings include, for exam-
ple, the chain suspension gear, and the load-suspension devices include the lifting
eye nuts and eyebolts.

Use slings safely; observe the following points for this:


• Use only slings with an identification tag.

The identification tag on the sling


shows the following data:
- CE mark
- Manufacturer
- Year of manufacture
- Part number
- Application
- Maximum load
- Own weight

Fig. 1 Example of an identification tag

• Use slings only as described in this instruction manual.


• Observe the permitted loading limit.
• Check slings for visible damage before each use.
• Use only slings that are in perfect condition.
• Do not carry out repairs to slings.
• Send damaged slings to the manufacturer.
• Always screw in threaded rods as far as they will go.
• Tighten all nuts fully.
• Tighten all screws fully.
• Do not walk under suspended loads.
• Inspect slings regularly, see Maintenance schedule.
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5.2 Using lifting eye bolts or lifting eye nuts as load handling devices
Incorrect use of lifting eye bolts or lifting eye nuts during transport can lead to seri-
ous accidents, e.g. due to overload.

WARNING Deformed lifting eye bolts or lifting eye nuts due to overload!

Danger to life and limb through falling loads when lifting eye bolts or lifting eye nuts
break!
Observe the following points to avoid accidents:
• The pertinent standards and guidelines of the national associations in the coun-
try of origin on the operation of load handling devices in lifting mode
• Only trained specialists are authorized to mount lifting eye bolts or lifting eye
nuts.

 Mount lifting eye bolts or lifting eye


nuts only as illustrated.
 Screw in lifting eye bolts or lifting eye
nuts completely.
 Attach load handling devices as verti-
cally as possible, e.g. chains.
– Pull max. 45° diagonally.
– Modes of assembly other than those
shown are not admissible, e.g. lat-
eral pull.

Fig. 2
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5.3 Transporting the system

Fig. 3 Example of seaworthy packaging for GEA Westfalia Separator systems.

 Use lifting equipment, e.g., a crane, to


transport the transport packaging.

Fig. 4

GEA Westfalia Separator Group 37


Transport and storage 2022-9001-060 / 22.03.17

 Sling the transport packaging with


cables and attach to the load hook of
the crane.

CAUTION!
Wind one cable section around the hook
twice to prevent the cables from slipping.

Fig. 5 Proper mounting on the load hook

WARNING Risk of injury from falling loads.

Risk of injury and property damage can occur if unsuitable or damaged hoists,
slings and lifting equipment are used.
 Use only suitable lifting accessories capable of bearing the load. Refer to the
"Technical data" section for the system weights.
 Safely install and use lifting accessories; see "Safe assembly and use of eye-
bolts and eye nuts".

 Only transport the unpacked system


on the four lugs which are specified,
see example.
 During transportation, always ensure
that slings are not attached to or run
around the control cabinet, pipes and
mechanical units. This would result in
damage to the components or the lift-
ing gear.
 Make sure that transportation is car-
ried as per the GEA Westfalia Separa-
tor guidelines.

Fig. 6 Transport of fresh water generator


without packaging
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5.4 System storage


Suitable means must be employed to protect the system if it is not put into opera-
tion immediately after installation.
• Do not remove the original packaging or the protective film on the system.
• All parts such as tools and spare parts must be stored in their original packaging
at a suitable location until commissioning.
• To ensure the packaging is not damaged store the system in dry rooms protect-
ed from the weather at 10 to 30° C (50-86° F) and make sure the relative humidi-
ty of less than 70%.
• Do not expose system to aggressive gases, dust, dew and pollution.
• Make sure to consult GEA Westfalia Separator if the system must be stored for
more than 1 month.
• IMPORTANT: Outdoor storage is not permitted!

NOTE: Improper storage will void the manufacturer's warranty.


same storage conditions apply to the hot water unit (if applicable) as for the fresh
water generator.

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5.5 Storing and handling electrical equipment


If the installation has to be put into interim storage because the set-up location is
not yet prepared, note the points below.
• Do not remove original packaging and protective film.
• Store the electrical equipment at 5 to 50 °C (41 - 122 °F) in dry, weatherproof
rooms to prevent the packaging from getting damaged. Outdoor storage is not
permitted.
• Cover window coverings and displays on control cabinets with protective film un-
til commissioning.
• Only set up desk-top monitors or control units and control consoles with IP 54
protection in dry or air-conditioned rooms.
• Do not allow any dust or aggressive atmospheres in the environment of the elec-
trical equipment.
• Connect control cabinet heating (optional) to a third-party power supply and
switch on before commissioning the installation to prevent damage.
• Do not remove cable entry base plates in free-standing cabinets and consoles.
• If dust has got in, blow out the control cabinet with dry air prior to commission-
ing.
• Remove desiccant bags only after switching on the controller. The desiccant is
effective for about one year.
• The ambient temperature must not exceed 45 °C (113 °F) and relative humidity
must be < 70 %.

Note!
Incorrect storage and handling will lead to loss of warranty.

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40 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Assembly and installation

6 Assembly and installation

6.1 Safety information .................................................................................... 42


6.1.1 Avoiding risks during assembly and installation ...................................... 42
6.1.2 Foundation risk ........................................................................................ 42
6.2 Requirements for the installation location ............................................... 42
6.3 Space requirements for the fresh water generator .................................. 45
6.4 Attach the foundation plate for the installation ........................................ 46
6.5 Connecting the control unit ...................................................................... 47
6.5.1 Electrical installation (land-based operation) ........................................... 47
6.5.2 Connecting external voltages .................................................................. 47
6.6 Connect equipotential bonding for pumps ............................................... 47
6.7 Connect equipotential bonding for foundation plate ................................ 48
6.8 Dimensioning and connecting the feed and discharge lines ................... 49
6.8.1 Dimensioning the piping .......................................................................... 49
6.8.2 Connecting hot water pipes ..................................................................... 50
6.8.3 Connecting the seawater pipes ............................................................... 51
6.8.4 Distillate ................................................................................................... 52
6.8.5 Overflow opening ..................................................................................... 52
6.8.6 Dosing tank filling pipe ............................................................................. 52
6.9 Installing the seawater pump ................................................................... 52
6.9.1 General .................................................................................................... 52
6.9.2 Pressures ................................................................................................. 53
6.10 Assembling the evaporator stack (lower plate stack) .............................. 53
6.11 Assembling the condenser stack (upper plate stack) .............................. 56

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6.1 Safety information


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6.1.1 Avoiding risks during assembly and installation


Assembly and installation involve risks if they are not carried out professionally or
not in accordance with these installation diagrams and installation instructions. The
owner/operator is responsible for executing and checking installation work and for
its safety.
Pay attention to the points below during assembly and installation.
• Special regulations issued by classification bodies or other authorised bodies
must be observed.
• Install the installation at the installation site in accordance with the installation
diagrams.
• Do not install controls more than 2300 mm above the floor.
• Provide an adequate space around the installation from adjacent installations in
order to ensure accessibility for operation, maintenance and repair, see dimen-
sions sheet.
• For rating piping, refer to the specifications in the P&ID (Piping and Instrumenta-
tion Diagram) in the installation diagram and in the datasheets.
• Connect all feed and discharge lines flexibly to the installation by means of U-
shaped conduits or compensators.
• Tensile strain on pipelines is not permitted. All pipe joints are rated without tak-
ing tensile forces into account.
• Support fixed pipelines and fittings securely in order to reduce vibration or
movement.
• Arrange contact points/supports so that pipes react flexibly to changing tempera-
tures without creating stresses.
• Pipelines may not be used for supporting distributors or appliances. The excep-
tion are small parts designed for the purpose which have to be fitted on the
manufacturer's recommendation, e.g. thermometers, pressure gauges, etc.
• For more details, see the mechanical or electrical drawings. Installation, i.e. me-
chanical and electrical connection to the ship's connections, must be performed
by authorized personnel.

Fastening material
Unsuitable fastening material puts structural calculations and the operating safety
of the installation at risk. This can lead to damage to the installation.
 Use the specified fastening material supplied. This is rated for the installation
foundation plate and the base.
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6.1.2 Foundation risk


The base for assembly or the suspension design must be stable, otherwise the in-
stallation may be severely damaged by vibrations or falling.

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6.2 Requirements for the installation location


Requirement for the base and the installation position
• Installation location according to GL for CE/EMC: Zone 2
• The base must comply with the requirements. See load information and dimen-
sions in the installation diagram, technical specifications, and dimensioned draw-
ing.

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• The base must be designed in such a way that no high vibrations are transferred
from the environment to the system.
• Provide sufficient room for maintenance work. See dimensioned drawing and in-
stallation diagram.

Requirements for load suspension equipment


• Use hoisting equipment and ground conveyors having the required lifting capaci-
ty.
• Use permissible and adequately dimensioned slings. Compare the specifications
on the slings with those from the dimensioned drawing and data sheet.

Requirement for the environment of the system


• Ensure the ventilation of the system.
• Do not install system components directly in front of steam pipes, condensers,
discharge pipes, or hot air outlets of other machines or in the direct proximity of
corrosive vapours.
• Ambient temperature must be within the range of 5° C to 45° C. The order-
specific permissible ambient temperatures can be found in the “Data sheet” ac-
cording to EN 12547 or in section “Technical specifications”.
• The maximum permissible humidity is 50% at 40° C and a 90% at 20° C.

Requirements for protective devices


• Protective devices designed according to DIN EN ISO 13857.
• Access to danger areas prevented through suitable measures.

Requirements for the electrical system


• Operator panel of the conductivity measuring device may not be exposed to di-
rect sun radiation; overheating must be prevented.
• Supply voltage for the controller must conform to the specifications on the
nameplate in the cabinet.
• Do not install the cabinets near heat sources. Sufficient clearance for free ac-
cess of at least 1 m must be provided. In addition, a clearance of at least 0.5 m
for cooling must be provided in front of the air filters of the cabinets.
• Complete opening of the cabinet doors must be possible so that the door inter-
locking can engage.
• Pushbuttons, switches, and control electronics must not be installed or operated
in an environment with excessively high air humidity or with moisture from con-
densate.
• In order for the temperature within the system to be kept constant after commis-
sioning, the system should remain switched on even when it is in idle state.

Requirement for fitting accessories and materials


• All seals between flanges must be made of polymer, preferably EPDM or NBR
(SH70), to protect the stainless steel surface from crevice corrosion. Seals made
of absorbent material, such as Klingersil seals, must be avoided without excep-
tion!

GEA Westfalia Separator Group 43


Assembly and installation 2022-9001-060 / 22.03.17

Requirements for personnel:


• Only authorized personnel are permitted to carry out the mechanical and electri-
cal installation, including connection of the system to the energy supply of the
ship.
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6.3 Space requirements for the fresh water generator


Sufficient space must be kept clear around the fresh water generator for operation,
maintenance, and repair.
Observe the following when installing the system:
• Only seawater pipes, hot water pipes, steam pipes, condensate pipes and distil-
late pipes for the fresh water generator may be installed in the operating area
around the system.
Refer to the table below for the clearances between the fresh water generator and
other installed equipment.

Fig. 7 Space requirements for the fresh water generator

Table for defining the operating area around the system


Dimensions in mm
System type A B C D E
SWD 477 600 800 1000 1423

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6.4 Attach the foundation plate for the installation


Example for installing an installation on board ship.

If it can be guaranteed that no vibrations


will be transmitted to the installation, the
steel plate can also be welded directly to
the steel structure of the platform or of
the ship.

Z = foundation

Fig. 8

Note the points below when welding on


the steel plate.
• Weld seams should be 100 mm long.
• The distance between weld seams
should be approx. 350 mm.
• If required, the foundation plate can
also be welded all the way round.

Fig. 9

Example for installing an installation on land and on a concrete foundation.

Note the points below when attaching the


steel plate to concrete.
• The foundation plate can be bolted
directly to the foundation provided.
 Use only the fastening material sup-
plied.

Fig. 10

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6.5 Connecting the control unit


IMPORTANT: The installation electrical equipment must be carried out by qualified
personnel.
The controller is already installed on the fresh water generator. All internal electri-
cal devices (solenoid valve, conductivity measuring cell and distillate pump) are
connected to the controller.
The power supply and the seawater pump must be connected to the controller. The
circulation pump for the heating water unit (if present) must also be connected to
the controller.
 Please observe the circuit diagram and the motor specifications sheet.
Terminals for potential-free contacts are installed in the fresh water generator for
monitoring purposes. The contacts must be connected to the ship alarm system
depending on the specifications of the shipyard.
 Check mains voltage and frequency.
 Do not install the switch cabinet in an overly humid environment.
 Observe the permissible installation and operation data:

Permissible tolerance of the system's local ambient data

Voltage fluctuations +/- 10 % of the mains voltage


Frequency fluctuations +/-2% of the mains frequency
Ambient temperatures +5 to +45 °C (41 to 113 °F)
Air humidity Max. 50 % at 40 C (104 F)
Max. 90 % at 20 C (68 F)
Transport temperatures -25 to +55° C (-13 to 131 °F)

NOTE: Improper installation will result in loss of warranty.

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6.5.1 Electrical installation (land-based operation)


Observe the following for the electrical installation in land-based operation:
• In general, use unarmoured oil-resistant flexible (Ölflex) cables, or mechanically
robust rubber cable ("NSSHÖU") for outside installation
• Use commercially available cable glands.
• The control cable and power cable must be routed separately without exception.
• Cable entries with plastic or metal glands are permissible
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6.5.2 Connecting external voltages


The potential-free contacts of the output modules carry external voltage even when
the main switch is off.
These are recognizable from the orange wiring inside them and can be used in ex-
ternal control systems up to 250 V AC.
A cross-section of 1.5 mm² Cu is adequate for interlock and signalling cables.

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6.6 Connect equipotential bonding for pumps


Equipotential bonding for the pumps on the installation is always effected via the
equipotential bonding connection of the electric motor for the pumps.

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Note!
If there is no protective earth incorporated in multi-core cables (e.g. in the ar-
moured marine cable), the drive motor for the pumps must also be integrated in
equipotential bonding.
The cross-section of the equipotential bonding cable (yellow-and-green insulation)
depends on the largest external cable connected to the consumer in question, see
Table 1 in EN 60 204-1.
GEA Westfalia Separator uses the following cable cross-section for equipotential
bonding:
10 mm²< S < 25 mm² Cu
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6.7 Connect equipotential bonding for foundation plate

The foundation plate or foundation trough


must be fitted with a marked connector
bolt for equipotential bonding by the cus-
tomer.

Fig. 11

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6.8 Dimensioning and connecting the feed and discharge lines


IMPORTANT: All piping must be cleaned and connected to the distiller. Only
thereafter may other settings be carried out. Otherwise, contamination may occur
and interference caused.

6.8.1 Dimensioning the piping

Fig. 12 Dimensioning diagram for piping

Q Flow

v Flow velocity

DN Nominal diameter of pipe

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6.8.2 Connecting hot water pipes

CAUTION Damage to the rubber liner is possible.

Damage to the rubber liner may be caused if too much torque is applied when the
flange is tightened.
 Tighten the flanges on the housing of the system with a max. of 25 Nm of
torque.

 Connect the inlet and outlet pipes of the heating water according to the dimen-
sion drawing on fresh water generator.

Regular temperature and pressure values

Temperature max. 95 °C
Pressure max. 4.0 bar

 Install the thermometers and valves close to the inlets and outlets of the fresh
water generator.
 Install the pressure gauge close to the inlets and outlets of the fresh water gen-
erator.
 Do not exceed flow rates of 2.5 m/s to prevent the loss of pressure in the water
circuit pipes.

Minimum required pipe diameter

Flow rate [m³/h] Minimum diameter [mm] at a flow


rate of 2.5 m/s
25 59
30 65
35 70
40 75
45 80
50 84
55 88
60 92
65 96

Flow rates

SWD 80 °C 85 °C 90 °C
Capacity [t/d] Flow rate [m³/h] Flow rate [m³/h] Flow rate [m³/h]
10 26.2 20.2 17.5
15 39.3 30.2 26.2
20 52.4 40.3 34.9
25 62.3 50.4 43.6
30 65.1 60.1 52.1

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NOTE: Depending on the distance and type of piping larger pipe diameters may be
required.

6.8.3 Connecting the seawater pipes


The sea box is constructed to minimize the risk of sand, dirt and other contami-
nants in the seawater.
The piping for the seawater are constructed to minimize the loss of pressure.

CAUTION Damage to the rubber liner is possible.

Damage to the rubber liner may be caused if too much torque is applied when the
flange is tightened.
 Tighten the flanges on the housing of the system with a max. of 25 Nm of
torque.

 Install the inlet and outlet pipes of the seawater according to the dimension
drawing on fresh water generator.

Sea water inlet


Regular temperature and pressure values

Temperature max. 32 °C
Pressure min. 4.0 bar max. 6.0 bar
 Install the thermometers and pressure gauges near the inlet.

Sea water outlet


The brine (slightly concentrated seawater) and the seawater are discharged via the
seawater drain.
 Install the pressure gauge near the outlet.
 Install a straight pipe (500 mm) on the water outlet for the non-condensable
gases, otherwise the capacity of the tandem jet pump will be reduced.
NOTE: A non-return function should be integrated in the outlet valve.

Seawater filter
 Install a seawater filter with a 1.0 - 2.0 mm wide mesh in the seawater supply
line before the fresh water generator.
 Check pressure loss on the seawater filter in order to calculate the seawater
pump head.

Feed pressure
The capacity of tandem ejector pump is reduced if the feed pressure of the sea-
water is insufficient. This also leads to inadequate extraction of brine from the dis-
tiller.
Flow rates of 2.5 m/s should not be exceeded in order to prevent the loss of pres-
sure losses in the seawater pipes.
 Check the seawater pipes if there is a loss of pressure.
- Important: In the worst case scenario the fresh water generator will not oper-
ate if the supply pressure to the tandem ejector pump is not sufficient.

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Assembly and installation 2022-9001-060 / 22.03.17

Minimum pipe diameters

SWD Seawater flow rate [m³/h] Minimum diameter [mm] at a flow


rate of 2.5 m/s
10 25.2 60
15 37.8 73
20 50.4 84
25 62.3 94
30 64.6 96

NOTE: Contact your local GEA Westfalia Separator office for longer pipelines (>
5m) or differences in height (> 5m).

6.8.4 Distillate
The distillate produced is discharged via the distillate pump.
The distillate is routed back into the evaporator if the conductivity of the distillate is
too high.
Max distillate backpressure: 1.5 bar

6.8.5 Overflow opening


The evaporator housing may become completely filled with water if a malfunction
occurs. The overflow valve opens if the internal pressure of the housing exceeds
0.1 bar g.
Max. seawater temperature: 55 C

6.8.6 Dosing tank filling pipe


The chemical dosing tank must be filled with water and the chemicals to prevent
boiler scaling once a day.
 See Chapter "Using the filling pipe dosing tank (optional)".

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6.9 Installing the seawater pump

6.9.1 General
The seawater pump is delivered separately. The motor starter is integrated in the
controller for the fresh water generator.
 Connect the motor for the seawater pump to the controller for the fresh water
generator.

The following points must be observed when installing the seawater pump:
• Observe operating instructions of the manufacturer of the pump.
• The pump must be easy to access for maintenance and repairs.
• The pump is not self-priming.

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• Pump is arranged horizontally or vertically.


• Pressure gauges must be installed on the suction and pressure connections.
• A seawater filter must be installed on the outlet side of the pump.

6.9.2 Pressures
Inlet pressure
The seawater pump is not self-priming. The minimum inlet pressure during opera-
tion is 0.3 bar g. Pressure loss on the inlet side must be minimized.

Outlet pressure
The outlet pressure depends on the pump head (WS standard 50 m).

Pump
The seawater pressure at the inlet of the fresh water generator must be at least 3.8
bar. The calculations are based on the assumption that the height difference with
the fresh water generator is 5 m. A 0.2 bar pressure loss in the pipes is provided
for in the calculation.
IMPORTANT: If the distance is greater or the pressure loss is higher, please con-
tact your local GEA Westfalia Separator office.

Minimum pipe diameters

SWD Seawater flow rate [m³/h] Minimum diameter [mm] at a flow


rate of 2.5 m/s
10 25.2 60
15 37.8 73
20 50.4 84
25 62.3 94
30 64.6 96

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6.10 Assembling the evaporator stack (lower plate stack)

CAUTION The plates may be damaged if overtightened.

Over-tightening of the plate stack will lead to irreversible damage to the plates.
 Make sure the dimension of the plate stack remains below the tolerance limit of -
3% when tightening.

Thickness per plate 3.9 mm


Assembly dimension tole- +-3 %
rance
Thickness of the pressure 20 mm
plate

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The evaporator stack consists of a certain number of plates including seals. There
are four different types of plates in the evaporator stack:
• Starting plate including starting seal
• Plate including EC seal (the seal is closed)
• Plate including EO seal (the seal is open on top)
• End plate including ECO seal
The number of plates depends on the type of fresh water generator and can be
found in the following table.

Number of plates depending SWD type


Item Plate design Part No. 10-80 15-80 20-80 25-80 30-80
1 Starting plate, borehole 2022-2467-000 1 1 1 1 1
2 Plate including EO seal 2022-2467-010 16 24 33 41 50
3 Plate including EC seal, borehole 2022-2467-020 16 24 33 41 50
4 End plate including ECO seal 2022-2467-030 1 1 1 1 1

Assembly dimension in mm 133 195 265 328 398


Tolerance +-3% in mm 4 6 8 10 12
Assembly dimension including pressure plate 153 215 285 348 418

Number of plates depending SWD type


Item Plate design Part No. 10-85 15-85 20-85 25-85 30-85
1 Starting plate, borehole 2022-2467-000 1 1 1 1 1
2 Plate including EO seal 2022-2467-010 14 21 29 36 44
3 Plate including EC seal, borehole 2022-2467-020 14 21 29 36 44
4 End plate including ECO seal 2022-2467-030 1 1 1 1 1

Assembly dimension in mm 117 172 234 289 351


Tolerance +-3% in mm 4 5 7 9 11
Assembly dimension including pressure plate 137 192 254 309 371

Number of plates depending SWD type


Item Plate design Part No. 10-90 15-90 20-90 25-90 30-90
1 Starting plate, borehole 2022-2467-000 1 1 1 1 1
2 Plate including EO seal 2022-2467-010 12 19 26 33 39
3 Plate including EC seal, borehole 2022-2467-020 12 19 26 33 39
4 End plate including ECO seal 2022-2467-030 1 1 1 1 1

Assembly dimension in mm 101 156 211 265 312


Tolerance +-3% in mm 3 5 6 8 9
Assembly dimension including pressure plate 121 176 231 285 332

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Fig. 13

 Install the starting plate including starting seal (1).


 Install plate including EO seal (2).
 Install plate including EC seal (3).
 Alternately install plates with an EO seal and an EC seal until the correct number
of plates is reached.
 Install end plate including ECO seal (4).
 Install pressure plate (5).
IMPORTANT:
- First lubricate the threaded rods with GEA assembly grease.
- Tighten the nuts crosswise and evenly so that the plates do not tilt.
IMPORTANT:
• The plates must always be reduced in pairs if their number must be reduced.
The assembly dimension must be reduced by 3.9 mm per plate.
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6.11 Assembling the condenser stack (upper plate stack)

CAUTION The plates may be damaged if overtightened.

Over-tightening of the plate stack will lead to irreversible damage to the plates.
 Make sure the dimension of the plate stack remains below the tolerance limit of -
3% when tightening.

Thickness per plate 3.9 mm


Tolerance at dimension (A) +-3 %
Thickness of the pressure 20 mm
plate

The condenser stack consists of a certain number of plates including seals. There
are four different types of plates in the condenser stack:
• Starting plate including starting seal
• Plate including CC seal (the seal is closed)
• Plate including CO seal (the seal is open on top)
• End plate including CO seal
The number of plates depends on the type of fresh water generator and can be
found in the following table.

Number of plates depending SWD type


Item Plate design Part No. 10-80 15-80 20-80 25-80 30-80
1 Starting plate including starting 2022-2467-100 1 1 1 1 1
seal
2 Plate including CC seal 2022-2467-110 17 25 34 42 51
3 Plate including CO seal 2022-2467-120 16 24 33 41 50
4 End plate including CO seal 2022-2467-130 1 1 1 1 1

Assembly dimension in mm 137 199 269 332 402


Tolerance +-3% in mm 4 6 8 10 12
Assembly dimension including pressure plate 157 219 289 352 422

Number of plates depending SWD type


Item Plate design Part No. 10-85 15-85 20-85 25-85 30-85
1 Starting plate including starting 2022-2467-100 1 1 1 1 1
seal
2 Plate including CC seal 2022-2467-110 15 22 30 37 45
3 Plate including CO seal 2022-2467-120 14 21 29 36 44
4 End plate including CO seal 2022-2467-130 1 1 1 1 1

Assembly dimension in mm 121 176 238 293 355


Tolerance +-3% in mm 4 5 7 9 11
Assembly dimension including pressure plate 141 196 258 313 375

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Number of plates depending SWD type


Item Plate design Part No. 10-90 15-90 20-90 25-90 30-90
1 Starting plate including starting 2022-2467-100 1 1 1 1 1
seal
2 Plate including CC seal 2022-2467-110 13 20 27 34 40
3 Plate including CO seal 2022-2467-120 12 19 26 33 39
4 End plate including CO seal 2022-2467-130 1 1 1 1 1

Assembly dimension in mm 105 160 215 269 316


Tolerance +-3% in mm 3 5 6 8 9
Assembly dimension including pressure plate 125 180 235 289 336

Fig. 14

 Install the starting plate including starting seal (1).


 Install plate including CC seal (2).
 Install plate including CO seal (3).
 Alternately install plates with an CC seal and an CO seal until the correct num-
ber of plates is reached.
 Install end plate including CO seal (4).

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 Install pressure plate (5).


IMPORTANT:
- First lubricate the threaded rods with GEA assembly grease.
- Tighten the nuts crosswise and evenly so that the plates do not tilt.
IMPORTANT:
• The plates must always be reduced in pairs if their number must be reduced.
The assembly dimension must be reduced by 3.9 mm per plate.
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7 Settings

7.1 Dosing chemicals..................................................................................... 60

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7.1 Dosing chemicals


A deposit inhibitor is added to the supply water to prevent the formation of boiler
scale on the evaporator plates.
IMPORTANT: Make sure the dose is correct since dosage that is too low will de-
crease the distillation output due to boiler scaling.
The dosing tank must be filled once a day.

CAUTION Danger of irritation to the skin or eyes

Irritation may occur upon contact of chemicals with the skin or eyes.
 Avoid contact of the chemicals with the skin and eyes.
 Wear protective gloves and protective goggles.

 Fill the dosing tank (1) with 0.25 to 0.5


litres of the chemical.
- Follow manufacturer's instructions.
Familiar products are e.g. Vaptreat
or Maxivap Plus.
 Fill the dosing tank with water (approx.
30 litres).
 Set the flow rate of 1.25 l/h on the
dosing valve (2).

Fig. 15

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8 Commissioning

8.1 Safety information .................................................................................... 62


8.2 Safety during commissioning................................................................... 62
8.3 Commissioning the system ...................................................................... 62
8.4 Commissioning check list ........................................................................ 63
8.5 Checking the rotational direction of the pumps ....................................... 65
8.6 Carrying out a vacuum test...................................................................... 65
8.7 Refilling the evaporator stack .................................................................. 66
8.7.1 Filling the chemical dosing tank............................................................... 67

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8.1 Safety information


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8.2 Safety during commissioning


The commissioning of the system after setup and installation may only be per-
formed by specialists from GEA Westfalia Separator or authorized service partners.
Non-professional execution of commissioning by unsuitable personnel can endan-
ger personnel and property.
Observe the following points during commissioning:
• Assign only trained and authorized specialist with the task of commissioning.
• The operation of the flaps and valves on the ship related equipment is only al-
lowed with the permission of the crew.
• Eliminate faults during commissioning immediately, e.g. leaky pipe joints.
• Check the function of all safety and protective devices, identify faults and elimi-
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nate them immediately.
8.3 Commissioning the system
Prior to commissioning, ensure that the SWD is properly installed, secured in place
and connected. In addition, individual components must be checked for proper
functioning.
NOTE: The operation of the flaps/valves on the ship related equipment is only al-
lowed with the permission of the crew.
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8.4 Commissioning check list


Operator: Trained specialist
• Before initial commissioning the system
• When re-starting after repairs and a long standstill period

Documents
The instruction manual is available.
Data sheet according to EN 12547 is available.
Spare parts list is available.
Operating instructions for optional additional equipment are available.
P&ID is available.
Order-specific dimensioned drawing is available.

Installation
The fresh water generator is installed on the deck (bolted or welded).
The fresh water generator is not installed in an inclined position.
Enough space for service and repair work is available (e.g. for opening the cover or to en-
sure accessibility to controller).
A coaming which is connected to the bilge is installed under the distillation unit.
A chemical deposit inhibitor is available for testing at sea.
Safety stickers are complete, attached properly and are clean and legible.
The thermometers are mounted close to the fresh water generator.
Heating water from the main motor cooling circuit is correct.
Flap (motor cooling water) are installed close to the fresh water generator.
The mesh width of the seawater filter is less than or equal to 2 mm.

Pipe/hose connections
All connections are carried out in accordance with P & ID.
All connections are fixed and screwed down tight according to specifications.
Hoses are intact.
Hose clamps are tightened securely.

Electrical connections
The solenoid valve cable (12-7-004) is not damaged.
The conductivity measuring cell cable (19-9-001) is not damaged.
The distillate pump cable (12-3-001) is not damaged.
The power supply is connected according to specifications.
All incoming cables are attached in the correct terminal and the terminals are tightened
securely.
The seawater pump cable is connected to the control panel.
Electrical connections for fittings are connected according to specifications.

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Pumps
The seawater pump is properly installed and secured in place.
The distillate pump is properly installed and secured in place.
Pressure gauges are located both on the suction and on the pressure side of the seawater
pump.

Electric motors of the pumps


Transportation locking device has been removed (if fitted).
Connection values on the motor nameplate match the specifications on the system name-
plate and the connection values of the local power supply.
Electrical connection has been executed professionally.
The rotational direction of the pump motors is correct.
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8.5 Checking the rotational direction of the pumps


The rotational direction of the seawater pump and the distillate pump must be
checked before the pumps are put into operation. The rotational direction is indi-
cated by arrows on the pump.

CAUTION Damage to the device if allowed to run dry for too long

The seals on the pump may be damaged if the pump is switched on for too long.
 Only run the pump for a short time.

IMPORTANT: The distillate pump has a restart lock. This prevents dry running in
the water pump fails and consequential damage of the seal.
 Make sure that the water pump is already operating before switching on the dis-
tillate pump.
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8.6 Carrying out a vacuum test


IMPORTANT: The operation of the flaps and valves on the ship related equipment
is only allowed with the permission of the crew.
 Open all flaps and valves in the seawater piping system (ship-related system) on
the inlet and outlet of the fresh water generator.

 Close the vacuum relief valve on the


pressure gauge (1).
 Switch on the seawater pump at the
switch cabinet.
 Check the ejector pump inlet pressure
on the pressure gauge (2) and ejector
pump backpressure (in the overboard
line) for correct values according to the
following table.

Fig. 16

Pressure specifications for the tandem ejector pump

Ejector pump-backpressure Ejector pump backpressure


[bar g] [bar g]
SWD
Min Max Min Max

10 3.3 4.1 0.2 0.6

15 3.4 4.2 0.2 0.6

20 3.5 4.3 0.2 0.6

25 3.5 4.3 0.2 0.6

30 3.5 4.3 0.2 0.6

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CAUTION Erosion hazard due to low ejector pump backpressure

Decrease the ejector pump output if the ejector pump back pressure is less than
0.2 bar. This can lead to overflow of the evaporator housing. Erosion may occur on
the discharge nozzles as a result of cavitation.
 Increase the backpressure if possible by not fully opening the overboard valve or
by installing a diaphragm.
IMPORTANT: Backpressure in the ejector pump outlet line that exceeds more than
0.6 bar can lead to a reduction of ejector output and overflowing of the evaporator.
 Check overboard line and if possible reduce the backpressure by further open-
ing the overboard valve.

The supply water valve (2) remains


closed and no supply water flows into the
evaporator.
 Switch off the seawater pump after
approx. 2 minutes if the pressure in the
evaporator housing is stable and less
than -0.9 bar.
 Check the pressure increase in the
evaporator housing for an additional 5
minutes.
- The pressure can be read from the
pressure gauge (1).

Fig. 17 If the pressure exceeds 50 mbar then this


increase in pressure indicates a vacuum
leak.
 Localize the error source.
 Correct the error immediately.

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8.7 Refilling the evaporator stack

WARNING Risk of injury from burns.

Hot system components and piping can cause severe burns.


 Do not touch the hot water pipes or the housing with your hands.
 Wear protective gloves.

IMPORTANT: The operation of the flaps and valves on the ship related equipment
is only allowed with the permission of the crew.
 Open the valves on the pipes of the heating water inlet and the heating water
outlet slowly.
- IMPORTANT: Make sure to open valves slowly. A sudden drop in pressure
could result in the failure of hot water system.
 Open the vent (e.g. on the thermometer or the pressure gauges in the motor-
cooling water pipe system).
 Close the valves after the hot water system (pipes and evaporator stack) is
completely filled.
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8.7.1 Filling the chemical dosing tank


 Fill the dosing tank with water and suitable chemicals to prevent the formation of
boiler scale, see Chapter "Settings dosing chemicals).
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9 Operation

9.1 Safety information .................................................................................... 70


9.1.1 Preventing hazards before starting up .................................................... 70
9.1.2 Avoiding hazards during operation .......................................................... 70
9.2 Monitoring operation ................................................................................ 70
9.3 Starting up the system ............................................................................. 70
9.3.1 Setting the supply water pressure ........................................................... 71
9.4 Switching on the distillate pump .............................................................. 72
9.5 Determining the distillate flow rate........................................................... 74
9.6 Adjusting the chemical dosage ................................................................ 75
9.7 Checking the supply water flow rate ........................................................ 75
9.8 Checking the seawater level .................................................................... 76
9.9 Checking the temperature and pressure values ...................................... 76
9.10 Stopping the system ................................................................................ 77
9.11 Water meter bypass (optional) ................................................................ 78
9.12 Using the filling pipe dosing tank (optional) ............................................. 78

GEA Westfalia Separator Group 69


Operation 2022-9001-060 / 22.03.17

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9.1 Safety information


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9.1.1 Preventing hazards before starting up


Only start up the installation if there are no defects which could endanger safe op-
eration.
The owner/operator is responsible for ensuring that necessary checks are covered
and performed with care.
Cover the points below before starting up the installation each time:
• visual inspection to see whether installation has obvious damage.
• check connections and pipelines for leaks.
• check setting parameters and rating data.
• eliminate any faults found before starting up the installation.
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9.1.2 Avoiding hazards during operation


Operating the system can pose risks if the operator does not operate the system in
accordance with its intended use.
The operator is responsible for ensuring that necessary checks are done carefully
and that suitable personnel are deployed.
The following must be observed:
• Comply with the operating instructions.
• Operate the system only when no defects are present that conflict with safe op-
eration.
• Operate the system only in accordance with its intended use and the agreed-
upon process conditions.
• Operate the system only in accordance with the data specified on the name-
plates and in the datasheet.

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• Use only qualified personnel, see "Qualification of personnel".
9.2 Monitoring operation
Observe the following points for operational monitoring and daily inspection round:
• Check the valve positions for the selected mode of operation.
• Listen for unusual noises from pumps.
• Check pressures.
• Check the pipe connections and tubes for leaks.
• Check for vibrations.
• Check the flow rate performance.
• Check personnel-occupied areas of the system for cleanliness.

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• Notify service personnel in the event of alarm signals, damage, or anomalies.
9.3 Starting up the system

WARNING Risk of injury from burns.

Hot system components and piping can cause severe burns.


 Do not touch the hot water pipes or the housing with your hands.
 Wear protective gloves.

70 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Operation

IMPORTANT: The operation of the flaps/valves on the ship related equipment is


only allowed with the permission of the crew.
 Open valves in the distillate piping upstream of the tank.
- The evaporator may not be operated near the coast. The minimum distance
from the coast is 30 nautical miles.
 Close the vacuum relief valve (1).
 Switch on the seawater pump.

 Wait until the start-up vacuum of -0.9


bar is reached, see pressure gauge on
the vacuum relief valve (1).

Fig. 18
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9.3.1 Setting the supply water pressure

WARNING Risk of injury from burns.

Hot system components and piping can cause severe burns.


 Do not touch the hot water pipes or the housing with your hands.
 Wear protective gloves.

 Adjust supply water pressure with the


supply water valve (2) according to the
following table.
- The supply water pressure can be
read off on pressure gauge 1.

Fig. 19

SWD Pressure to orifice plate [bar g]


(10-9-001)
10 -0.6
15 -0.1
20 0.6
25 1.4
30 2.4

GEA Westfalia Separator Group 71


Operation 2022-9001-060 / 22.03.17

IMPORTANT:
• Insufficient supply water flow leads to boiler scale formation on the evaporator
plates and reduces the distillation output.
• Excessive supply water flow leads to an overflow on the evaporator housing.

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9.4 Switching on the distillate pump

WARNING Risk of injury from burns.

Hot system components and piping can cause severe burns.


 Do not touch the hot water pipes or the housing with your hands.
 Wear protective gloves.

IMPORTANT: The operation of the flaps and valves on the ship related equipment
is only allowed with the permission of the crew.

Fig. 20
1 Sight glass
2 Distillate pump
3 Water meter
4 Pressure retention valve setting
5 Transparent distillate hose

 Check seawater level in the evaporator housing through the sight glass (1).
- IMPORTANT: The sight glass may not be completely filled.
 Slowly open the valves in the pipes for the heating water inlet and the heating
water outlet for fresh water generator.
- IMPORTANT: Make sure to open valves slowly. A sudden drop in pressure
could result in the failure of hot water system.
 Switch on the distillate pump (2) if distillate can be seen in the distillate-suction
hose (5).

72 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Operation

The distillate conductivity is generally above the alarm setpoint in the first few
minutes. The distillate is fed back into the evaporator. The water meter is not run-
ning.
 Adjust the backpressure on pressure retention valve (4) once the water meter is
running and the distillate conductivity is below the alarm setpoint the distillate.
- Distillate backpressure during 50 Hz operation: 1.5 bar
- Distillate backpressure during 60 Hz operation: 2.5 bar
 The level of distillate in the distillate suction hose (5) must be 20 - 50 cm above
the pump inflow level.
- The distillate back pressure must be reduced if the level is more than 50 cm.

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GEA Westfalia Separator Group 73


Operation 2022-9001-060 / 22.03.17

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9.5 Determining the distillate flow rate

 Determine the distillate flow rate over a


1 minute period (l/min) with the water
meter (3).
 Check if the per minute distillate flow
rate that was determined corresponds
with the nominal output indicated in the
table below.

Fig. 21

Distillate flow rate nominal output

SWD Flow rate per minute in litres Flow rate per day in litres
Type
10 6.9 10 000
15 10.4 15 000
20 13.9 20 000
25 17.4 25 000
30 20.8 30 000

WARNING Risk of injury from burns.

Hot system components and piping can cause severe burns.


 Do not touch the hot water pipes or the housing with your hands.
 Wear protective gloves.

 Adjust the heating water flow rate as follows if the distillate flow rate deviates
from the nominal output:
- Reduce the heating water flow rate to evaporator housing if the value is
greater than the nominal output. If the distillate flow rate is too high it can lead
to boiler scale formation on the evaporator.
- Increase the heating water flow rate to the evaporator if the value is less than
the nominal output.
 IMPORTANT: Recheck the distillate backpressure after adjusting the heating
water flow rate, see Chapter "Operation / switching on the distillate pump".

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74 GEA Westfalia Separator Group


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9.6 Adjusting the chemical dosage

Fig. 22

 Adjust the chemical dosage to 1.25 l/h on the dosing valve (2).
 Open the valve (1) at the injection point.
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9.7 Checking the supply water flow rate

WARNING Risk of injury from burns.

Hot system components and piping can cause severe burns.


 Do not touch the hot water pipes or the housing with your hands.
 Wear protective gloves.

 Check supply water flow rate on the


pressure gauge (1), see Chapter "Op-
eration / adjusting the supply water
pressure".
- IMPORTANT: If the supply water
flow rate is too low the risk of
boiler scale formation on the
evaporator plates increases and
distillation output is reduced.

Fig. 23

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GEA Westfalia Separator Group 75


Operation 2022-9001-060 / 22.03.17

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9.8 Checking the seawater level

 Check seawater level in the evaporator


housing through the sight glass (1).
- IMPORTANT: The sight glass may
not be completely filled.

Fig. 24
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9.9 Checking the temperature and pressure values


The following temperature and pressure values indicate normal operation and must
be checked regularly to ensure safe operation of the system.

WARNING Risk of injury from burns.

Hot system components and piping can cause severe burns.


 Do not touch the hot water pipes or the housing with your hands.
 Wear protective gloves.

Seawater

Supply temperature 0 – 32 C

Temperature differential conden- 10 °– 13 °C


ser

Pressure loss condenser Max. 0.5 bar

Heating water

Supply temperature See technical data sheet.


- Example: SWD 15-85 means 15t/d at
85 C

Temperature difference evapora- 10 – 15 °C


tor

Pressure loss condenser Max. 0.5 bar

Evaporator

Pressure -0.9 – -0.85 bar

Temperature 40 – 55 °C

Distillate

Pressure 1.0 – 2.5 bar

76 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Operation

Tandem ejector pump

Ejector pump inlet pressure 11-9- Ejector pump backpressure


001 [bar g] [bar g]
SWD
Min Max Min Max

10 3.3 4.1 0.2 0.6

15 3.4 4.2 0.2 0.6

20 3.5 4.3 0.2 0.6

25 3.5 4.3 0.2 0.6

30 3.5 4.3 0.2 0.6

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9.10 Stopping the system

WARNING Risk of injury from burns.

Hot system components and piping can cause severe burns.


 Do not touch the hot water pipes or the housing with your hands.
 Wear protective gloves.

IMPORTANT: The operation of the flaps and valves on the ship related equipment
is only allowed with the permission of the crew.

 Slowly close the valves in the pipes for


the heating water inlet and the heating
water outlet for the evaporator.
- IMPORTANT: Too rapid closing of
the valves can lead to an increase
in the temperature in the heating
water system and its subsequent
failure.
 Allow the system to cool down (ap-
prox. 1 minute).
 Close the supply water valve (2).

Fig. 25

CAUTION Standstill corrosion in the evaporator housing through liquid residue.

There is a risk of standstill corrosion if the liquid is not completely drained from the
evaporator housing.
 Empty the evaporator housing completely (approx. 1 minute) after closing the
supply water valve (2).

 Switch off the seawater pump.


 Close the valves in the seawater piping system.
 Open the vacuum relief valve on the pressure gauge (1).
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GEA Westfalia Separator Group 77


Operation 2022-9001-060 / 22.03.17

9.11 Water meter bypass (optional)


The fresh water generator can be equipped with a water meter bypass if requested
by the customer.
The water meter bypass consists of a 3-way ball valve (2) and a second connec-
tion for the distillate block.

The shut-off valve (1) must be closed and


the handle of the 3-way ball valve (2)
must be turned 90° in order to bypass the
water meter.

Fig. 26

The shut-off valve (1) prevents the distillate from flowing through the water meter.
The distillate then flows instead through the upper drainage connection (3) on the
distillate block. Turning the ball valve (2) (L-configuration) closes the connection to
the water meter and the connection to the upper drainage connection of the distil-
late block is opened.

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9.12 Using the filling pipe dosing tank (optional)


The fresh water generator is equipped with a filling pipe for the dosing tank if re-
quested by the customer. This filling pipe (3) is connected to the back of the distil-
late block.

 Turn valve (2) by 90° to fill the dosing


tank.
The pressure gauge (1) is not in opera-
tion during the filling process.

Fig. 27 Distillate block

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78 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Trouble shooting

10 Trouble shooting

10.1 Safety information .................................................................................... 80


10.2 Avoiding hazards during malfunctions ..................................................... 80
10.3 Troubleshooting ....................................................................................... 81
10.4 Alarms and warnings ............................................................................... 83

GEA Westfalia Separator Group 79


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10.1 Safety information


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10.2 Avoiding hazards during malfunctions


Malfunctions on the installation and its components can lead to reduced production
output or to failure of the installation, impair the operational safety of the ship and
incur additional costs for the owner/operator - for example, additional demurrage
charges for ships. If troubleshooting is not carried out by professionals and is
rushed, there is a considerable risk of mistakes. Errors during troubleshooting can
lead to accidents endangering life as well as to material damage.
Observe the points below when troubleshooting.
• Determine the source of the fault and inform the responsible person on site if
appropriate. Carry out troubleshooting and remedy faults with care.
• Troubleshooting work may only be carried out by authorized personnel.
• Ensure that no-one is put at risk by the troubleshooting.
• Observe local standard operating procedures (SOPs) governing repairs to the
installation and wear the specified safety gear.
• Cordon off the working area and hang up a warning sign.
• Remove unauthorized persons from the area of the malfunction.
• Prior to any troubleshooting work, switch off the main switches and secure them
against being switched back on.
• Before starting the installation back up again, ensure that all components have
been fully fitted and all connections are tight.
• Refit all safety devices after carrying out maintenance and repair work on instal-
lations.
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10.3 Troubleshooting

Fault Possible cause Action Operator


Excessive distillate production  Check the display of the Skilled
(overproduction). water meter to make sure
the value is correct.
The seawater level in the evapo-  Check the seawater level Skilled
rator housing is too high. through the sight glass.
- The sight glass may not
be completely filled.
 Check the supply water
pressure to make sure the
value is correct.
 Check the ejector pump
backpressure.
- Max. 0.6 bar.
Salinity in the distillate is Contaminated seawater.  Check the seawater in the Skilled
too high evaporator housing for
foaming through the sight
glass.
 Increase the chemical
dosage (if anti-foam com-
pound is included).
The mist eliminator is not in  Check the mist eliminator Skilled
proper position. for correct position.
 Correct the position if nec-
essary.
Rolling motion of the ship.  Reduce the distillate pro- Skilled
duction.
 Reduce the supply of heat
energy.

Defective rubber insert on the  Make sure the rubber in- Skilled
motor-cooling water inlet or mo- sert is seated properly.
tor cooling water outlet. - The rubber insert is held
Defective rubber insert on the in place by the titanium Skilled
seawater inlet or freshwater plates from the inside
Water leakage between
outlet. and by the seating be-
painted steel plate and
tween the flanges from
stainless steel housing.
the outside.
 Replace the rubber insert if
necessary.
 Make sure the rubber in-
sert is applied crease-free.

Op = Operator / Spec = Specialist / Tspec = Trained specialist

GEA Westfalia Separator Group 81


Trouble shooting 2022-9001-060 / 22.03.17

Heating water temperature is too  Observe the SWD name- Skilled


low. plate.
- For example, SWD 20-
80 means 80° C heating
water.
Heating water flow rate is too  Check the heating water Skilled
low. temperature difference on
the inlet and outlet of the
evaporator (value during
normal operation: 10 –
15 °C).
Evaporator plates are clogged  Check the evaporator Skilled
with boiler scale. plates (lower plate stack).
Solenoid valve (open without  Check the return hose. Skilled
current) is defective, and the  Replace the coil.
distillate is returned the evapora-
tor housing.
Distillation output too low Distillate backpressure is too  Check the distillate level in Skilled
high. the suction hose to the dis-
tillate pump (filling level
during normal operation:
20 – 50 cm)
 Check the pressure gauge
on the distillate pump.
 Adjust the overflow valve.
 Open the water meter
valve all the way.
Temperature in the evaporator  Check distillate level in the Skilled
housing is too high (max. 55 ° C) hose.
and condensation is disrupted.  Reduce the distillate back-
pressure.
 Check evaporator for vac-
uum leaks.
 Carry out a vacuum test,
see Chapter "Commission-
ing / vacuum test".

Ejector pump output not OK.  Check the inlet. Skilled


 Check the ejector pump
backpressure.
Ejector nozzle eroded or  Check the ejector nozzle. Skilled
clogged.
Plate seal in the evaporator  Inspect the plate stack with Skilled
Seawater level in the hous- stack defective. the cover open and when
ing too high. the motor coolant is flow-
ing.
Plate seal in the condenser plate  Inspect the plate stack with Skilled
stack defective. the cover open and when
Seawater is flowing.
 Close the supply water
valve.

Op = Operator / Spec = Specialist / Tspec = Trained specialist


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10.4 Alarms and warnings


The following potential free contacts for alarms and operating messages are pre-
sent on the SWD switch cabinet.

Alarms and operating


messages
Item Meaning
X1 Seawater pump is running
K1 Seawater pump malfunction
Q3 Distillate pump is running
K2 Distillate pump malfunction
K4 High salinity
K6 Collective alarm
K3 HWU circulation pump malfunction
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GEA Westfalia Separator Group 83


Trouble shooting 2022-9001-060 / 22.03.17

84 GEA Westfalia Separator Group


2022-9001-060 / 22.03.17 Maintenance

11 Maintenance

11.1 Safety information .................................................................................... 86


11.2 Preventing hazards through regular maintenance .................................. 86
11.3 Maintenance schedule ............................................................................. 88
11.3.1 After/during initial commissioning and daily ............................................ 89
11.3.2 Every 4 months ........................................................................................ 89
11.3.3 Every 6 months ........................................................................................ 89
11.3.4 Annually ................................................................................................... 89
11.3.5 In case of major maintenance work and when required .......................... 90
11.4 Maintenance work SWD .......................................................................... 91
11.4.1 Chemical dosage ..................................................................................... 91
11.4.2 Dosing valve ............................................................................................ 91
11.4.3 Replacing the sacrificial anode ................................................................ 91
11.4.4 Cleaning the wire mesh mist eliminator ................................................... 91
11.4.5 Cleaning the lamellar mist eliminator....................................................... 92
11.4.6 Cleaning the conductivity measuring cell ................................................ 92
11.4.7 Checking and cleaning the ejector nozzles ............................................. 92
11.4.8 Cleaning the evaporator plates................................................................ 92
11.4.9 Cleaning the condenser plates ................................................................ 93

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11.1 Safety information


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11.2 Preventing hazards through regular maintenance


Regular maintenance of the system is crucial in terms of service life, safety and
operating readiness. Failure to carry out regular maintenance will result in in-
creased wear, poorer outputs and higher energy consumption. Increased wear re-
duces the robustness of the components and the availability of the system and can
cause damage to the system. This damage may create hazards for personnel and
damage to property.
Observe the following with regard to maintenance:
• Observe the specified maintenance intervals even if the operating hours have
not been reached.
• For the purpose of keeping to the maintenance intervals specified in the mainte-
nance schedule, read off the total number of operating hours on the operating
hour counter in the control cabinet.
• The maintenance intervals apply to standard applications. In the case of in-
creased load caused by special operating conditions, shorten the service inter-
vals in agreement with GEA Westfalia Separator Service.
• Check safety-relevant components regularly. See “Maintenance schedule”.
Safety-relevant and highly stressed system components include, for example,
the pumps and filters.
• If a check reveals a fault, correct the fault and put the system back into opera-
tion.
• If a check reveals damage, replace the damaged elements immediately with
genuine spare parts from GEA Westfalia Separator.
• Persons with pacemakers may not carry out work on pumps with magnetic sys-
tem couplings.
• If problems arise during maintenance work, consult with GEA Westfalia Separa-
tor or make use of our training offers. Refer to “Qualification of personnel” and
“Service and training” in section “About this document”.
• When servicing plant components, refer to the manuals of the manufacturers of
the components.
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86 GEA Westfalia Separator Group


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GEA Westfalia Separator Group 87


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11.3 Maintenance schedule

Fig. 28 Positions for maintenance work on fresh water generator

88 GEA Westfalia Separator Group


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11.3.1 After/during initial commissioning and daily

Machine compo-
Item Action Target group
nent
 Check the system for leaks, loose parts, unusual noise or Skilled
1 System
irregularities.

2 Chemical dosage  Refill chemicals. Skilled

Heating water unit  Check heating water unit for leaks and loose or damaged Skilled
3
(optional) parts.

11.3.2 Every 4 months

Machine compo-
Item Action Target group
nent
 Check sacrificial anode. Skilled
4 Sacrificial anode
 Replace the sacrificial anode at 60% consumption.

11.3.3 Every 6 months

Machine compo-
Item Action Target group
nent
 Check the wire mesh mist eliminator. Skilled
Wire mesh mist
5  Clean the wire mesh mist eliminator if the salinity in the distil-
eliminator
late has increased or scaling is present in the boiler.
 Check the lamellar mist eliminator. Skilled
Lamellar mist elimi-  Clean lamellar mist eliminator and rinse with clear water if
6
nator salinity has increased in the distillate or boiler scaling is pre-
sent.
 Check the conductivity measuring cell Skilled
Conductivity mea-
7  Clean the conductivity measuring cell with a cloth or soft
suring cell
brush if a layer of deposit has formed on the surface.
Heat exchanger for Skilled
heating water unit  Make sure the mounting is secure.
(optional)

9 Seawater pump  Visual inspection of the slide-ring packing Skilled

Circulation pump Skilled


(only for unit with  Visual inspection of the slide-ring packing
heating water unit)

11.3.4 Annually

Machine compo-
Item Action Target group
nent
Ejector nozzles  Check the ejector nozzles. Skilled
10
 Replace the nozzles if they are damaged due to erosion.
Steam-jet air ejec- Skilled
 Check the steam-jet air ejectors.
tor (only on unit
 Replace the nozzles if they are damaged due to cavitation.
with steam injector

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module)
Evaporator plates  Check the evaporator plates. Skilled
11  Clean evaporator plates with acid if distillation output has
dropped.
Condenser plates  Check the condenser plates. Skilled
12  Rinse condenser plates with clear water if the pressure con-
tinues to drop.

11.3.5 In case of major maintenance work and when required

Machine compo-
Item Action Target group
nent
 Check the settings on the salinity display: Tspec
13 Control unit

The system must be visually inspected daily for leaks or loose parts.
The time intervals stated in the maintenance schedule are only guidelines for a
visual inspection. Maintenance is required if the criteria are already met.

Legend of the target groups:


• Op = Operator
• Skilled = Skilled worker
• Tspec = Trained specialist

For a description of the required knowledge and skills of the respective personnel,
see "Target groups" in section "About this document".
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11.4 Maintenance work SWD

11.4.1 Chemical dosage


The dosing tank with the chemical boiler scale inhibitor must be replenished daily,
see Chapter "Operation / adjusting the chemical dosage".

11.4.2 Dosing valve


The dosing valve (needle valve) must be cleaned if the level of liquid in the water
tank does not change within 24 hours.

 Remove the measuring glass (1).


 Remove the doing hose (4) from the
valve.
 Open needle valve (2) and clean the
valve with compressed air.
 After the valve is cleaned, close the
valve, attach the hose and reinstall the
measuring glass.

Fig. 29

11.4.3 Replacing the sacrificial anode


The sacrificial must be replaced by a new one if more than 60% of it is consumed.
Otherwise a portion of the old anode may fall into the brine piping and block the
ejector nozzles.

11.4.4 Cleaning the wire mesh mist eliminator

WARNING Risk of injury through exposure to acid

The wire mesh mist eliminator must be cleaned with acid. The improper use of acid
can cause injuries to the face or hands.
 Wear protective goggles and protective gloves.
 Dispose of the acid in accordance with the local regulations after it is used.
 Store residual acid according to local operating instructions.

 Open the cover.


 Remove the mounting for the wire mesh to remove and take out the wire mesh.
 Place the wire mesh in an acid bath (e.g. SAFACID) to remove salt and lime
crystals, see the instructions of the acid manufacturer.

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11.4.5 Cleaning the lamellar mist eliminator


 Open the cover.
 Remove the mounting for the wire mesh to remove and take out the wire mesh.
 After removing the steel sheet in the door, the lamella can be pulled out like
drawers.
 Rinse the lamella material with clear and warm water until all salt and lime crys-
tals are removed.

11.4.6 Cleaning the conductivity measuring cell


The conductivity signal may fail if the sensor is not clean.

CAUTION Damage to the measuring cell from using improper tools.

The conductivity measuring cell is very sensitive and can be destroyed if screwed
in with tools.
 Screw the measuring cell in only by hand.
 Replace the measuring cell if damaged.

 Disconnect cable connector.


 Remove the measuring cell.
 Clean the sensor with water and a soft cloth.

11.4.7 Checking and cleaning the ejector nozzles


The ejector pump nozzles wear out during operation depending on the quality of
water and the content of abrasive solids. Nozzles must be visually inspected for
eroded areas. If there is a severe erosion the ejector pump cannot remove the
brine from the distillation system. The ejector must be taken out of the distillation
system before the nozzles can be inspected. The first nozzle can be inspected
through the sea water inlet connection. The mixer nozzle can be inspected after
the mixing duct is removed.

 Clean the ejector nozzles with a cloth or brush.

11.4.8 Cleaning the evaporator plates


To formation of boiler scale on the evaporator plates is inevitable during operation.
The sedimentation process can be minimized but not be completely eliminated with
the right dosage of a deposit inhibitor and the correct flow rate of supply water. De-
posits reduce the area of heat transfer on the plates and the distillate output de-
creases accordingly.
 Open the door and remove the pressure plate from the plate stack (the socket
wrench is located on the frame of the fresh water generator).
Important:
- First lubricate the threaded rods with GEA assembly grease.
- Loosen the nuts crosswise and evenly so that the plates do not tilt.

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WARNING Risk of injury through exposure to acid

The evaporator plates must be cleaned with acid. The improper use of acid can
cause injuries to the face or hands.
 Wear protective goggles and protective gloves.
 Dispose of the acid in accordance with the local regulations after it is used.
 Neutralize or store residual acid according to local operating instructions.

 Remove the plates and place them into an acid bath until free of all crystals.
 Store the starting plate and the end plate separately.
Important:
 Rinse the plates with clear water after treating them with acid.

Note:
See Chapter "Assembling the evaporator stack" for the assembly and mounting
dimensions of the plate stack.
The starting plate is the first plate in the stack.
Important: Pay attention to the position of the borehole.

CAUTION Leaks through incorrect installation.

The plate seal must be positioned properly on the plate, otherwise leakage will oc-
cur.
 Make sure that the plate seal is assembled properly.

The plate stack ends with the end plate.


 Insert the pressure plate.
Important:
- Tighten the nuts crosswise and evenly so that the plates do not tilt.

11.4.9 Cleaning the condenser plates


The condenser plate stack acts as a filter. Organic material is held between the
plates. Fouling occurs at high ambient temperatures when the system is not run-
ning. This blocks the transfer of heat and loss of pressure increases.
 Open the door.
 Remove the pressure plate from the plate stack (the socket wrench is located
on the frame of the fresh water generator).
Important:
- First lubricate the threaded rods with GEA assembly grease.
- Loosen the nuts crosswise and evenly so that the plates do not tilt.
 Remove the plates.
 Store the starting plate and the end plate separately.
 Clean the plates with water and a brush until all organic materials are removed.

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Note:
See Chapter "Assembling the condenser stack" for the assembly and mounting di-
mensions of the plate stack.
The starting plate is the first plate in the stack.

CAUTION Leaks through incorrect installation.

The plate seal must be positioned properly on the plate, otherwise leakage will oc-
cur.
 Make sure that the plate seal is assembled properly.

The plate stack ends with the end plate.


 Insert the pressure plate.
Important:
- Tighten the nuts crosswise and evenly so that the plates do not tilt.

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12 Repair

12.1 Safety information .................................................................................... 96


12.1.1 Preventing hazards in the case of repair work ........................................ 96
12.1.2 Hazards from electricity ........................................................................... 96
12.1.3 Hazards from mechanical energy ............................................................ 96

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12.1 Safety information


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12.1.1 Preventing hazards in the case of repair work


Safety and availability of the system are dependent on proper carrying-out of re-
pairs.
Repairs may only be carried out by persons qualified to perform these activities,
e.g., technicians from GEA Westfalia Separator and personnel trained and author-
ized (certified) by GEA Westfalia Separator.

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12.1.2 Hazards from electricity


The following must be observed for handling of electricity when performing repairs:
• Observe the values for the power supply specified on the system.
• Perform only repair work that is described in the manual.
• Do not touch electrical components with wet hands!
• Before working on electrical components, switch off the power supply and se-