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1/1507

TECHNICAL DOCUMENTATION
TECHNISCHE DOKUMENTATION
Energy compact Unit

EDITION / Ausgabe - 12.07.2018

CUSTOMER / KUNDE: 4501402654 MAN Diesel & Turbo SE


PROJECT / PROJEKT: 5303452 Chittagong
WS-ORDER NO. / WS-BESTELL
1.451.886.352
NO.:
3x ECU1 OSE 40 // Lube Oil Separator Module //
MODEL / MODELL:
Material: 11.63010-0288

engineering for a better world www.gea.com


2/1507

2 1.451.886.352 / 12.07.2018

Die Verfasser freuen sich immer über Kommentare und Ratschläge


diese Dokumentation betreffend. Sie können gesandt werden an

The authors are always grateful 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-Straße 1, 59302 Oelde, Germany


Phone: +49 2522 77-0, Fax: +49 2522 77-2488
ws.info@gea.com,· www.gea.com

GEA Westfalia Separator Group GmbH


3/1507

1.451.886.352 / 12.07.2018 3

CONTENTS / INHALT
COVER SHEET
DECKBLATT

1 SAFETY
SICHERHEIT
1.1 SAFETY PRECAUTIONS
SICHERHEITSHINWEISE
1.2 QUALIFICATION OPERATORS
QUALIFIKATION DES PERSONALS
1.3 SAFETY PRECAUTIONS AND USER INSTRUCTIONS FOR MACHINE
AND PLANT COMPONENTS
SICHERHEITS- UND BENUTZERHINWEISE ZU MASCHINEN- UND
ANLAGENKOMPONENTEN
1.4 DECLARATION OF INCORPORATION
EINBAUERKLAERUNG
1.5 DECLARATION OF INCORPORATION
EINBAUERKLAERUNG
1.6 DECLARATION OF INCORPORATION
EINBAUERKLAERUNG
1.7 CLEARANCE CERTIFICATE
NEGATIVBESCHEINIGUNG
2 SYSTEM DESCRIPTION
SYSTEMBESCHREIBUNG
2.1 INSTALLATION INSTRUCTIONS
INSTALLATIONSRICHTLINIEN
3 DOCUMENTS RELATING TO ORDERS
PROJEKTBEZOGENE DOKUMENTE
3.1 P1451886352-9937-DVL002
EQUIPMENT LIST
GERAETELISTE
3.2 P1451886352-9937-LAY002
DIMENSIONED DRAWING
AUFSTELLUNGSPLAN
3.3 P1451886352-9937-PDS002
DATA SHEET
PROZESSDATENBLATT
3.4 P1451886352-9937-PID002
INSTALLATION DIAGRAM
INSTALLATIONSSCHEMA
GRAFICAL SYMBOLS

GEA Westfalia Separator Group GmbH


4/1507

4 1.451.886.352 / 12.07.2018

GRAPHIKSYMBOLE
3.5 ORDER SHEET – SPARE PARTS
BESTELLSCHEIN - ERSATZTEILE
4 CONTROL UNIT
STEUER- UND REGELEINRICHTUNG
4.1 INSTRUCTION MANUAL
BETRIEBSANLEITUNG
4.2 CONTROL CABINET, COMPL.
STEUERSCHRANK VOLLST.
CIRCUIT DIAGRAM
STROMLAUFPLAN
5 CENTRIFUGE
ZENTRIFUGE
5.1 PARTS CATALOGUE
ERSATZTEILKATALOG
5.2 PARTS CATALOGUE
ERSATZTEILKATALOG
5.3 PARTS CATALOGUE
ERSATZTEILKATALOG
5.4 DATA SHEET
DATENBLATT
5.5 DATA SHEET
DATENBLATT
5.6 DATA SHEET
DATENBLATT
5.7 INSTRUCTION MANUAL
BETRIEBSANLEITUNG
6 PUMP
PUMPE
6.1 DIAPHRAGM PUMP
MEMBRANPUMPE
DM20/75 ANV-X
6.2 GEAR PUMP UNIT
ZAHNRADPUMPENAGGREGAT
KFF 2,5 - 200
7 FILTER
FILTER
7.1 STRAINER, COMPL.
SCHMUTZFAENGER VOLLST.
BR
8 HEAT EXCHANGER
WÄRMETAUSCHER
8.1 PLATE HEAT EXCHANGER

GEA Westfalia Separator Group GmbH


5/1507

1.451.886.352 / 12.07.2018 5

PLATTENWÄRMETAUSCHER
OC*
9 VALVES, FITTINGS, ASSEMBLY
VENTILE, ARMATUREN, ZUBEHÖR
9.1 3/2-WAY PISTON-TYPE CONTR.VALVE CPL
3/2-WEGE-KOLBENSTEUERVENTIL VOLLST.
DN25/PN16
9.2 THROUGH-WAY VALVE
DURCHGANGSVENTIL
FABA-LA
FABA-PLUS-SUPRA-LA
9.3 SPRING-LOADED SAFETY VALVE
FEDERSICHERHEITSVENTIL
67.961
9.4 THREE-WAY SOLENOID VALVE
DREIWEG-MAGNETVENTIL
330+331+332
9.5 SOLENOID-VALVE BLOCK, COMPLETE
MAGNETVENTILBLOCK VOLLST.
5281
9.6 CONTROL VALVE
STELLVENTIL
BR440-446
PREMIO-2.2KN
9.7 CONTROL VALVE
STELLVENTIL
STEVI-405-460
DP32-34
10 MEASUREMENT
MESSTECHNIK
10.1 STOP SWITCH
GRENZSCHALTER
LBFS
10.2 STEAM TRAP
KONDENSOMAT
FT14B
10.3 PROXIMITY SENSOR
NAEHERUNGSINITIATOR
NJ5-11-N-G
10.4 VIBRATION PICK-UP
SCHWINGUNGSAUFNEHMER
PCH1220
10.5 THERMOMETER
THERMOMETER
73/74/75

GEA Westfalia Separator Group GmbH


6/1507

6 1.451.886.352 / 12.07.2018

11 MOTOR
MOTOR
11.1 THREE-PHASE AC MOTOR
DREHSTROMMOTOR
11.2 GEAR PUMP UNIT
ZAHNRADPUMPENAGGREGAT

GEA Westfalia Separator Group GmbH


7/1507

1.451.886.352 / 12.07.2018 7

1 SAFETY
SICHERHEIT

1.1 SAFETY PRECAUTIONS


SICHERHEITSHINWEISE
1.2 QUALIFICATION OPERATORS
QUALIFIKATION DES PERSONALS
1.3 SAFETY PRECAUTIONS AND USER INSTRUCTIONS FOR MACHINE AND PLANT
COMPONENTS
SICHERHEITS- UND BENUTZERHINWEISE ZU MASCHINEN- UND
ANLAGENKOMPONENTEN
1.4 DECLARATION OF INCORPORATION
EINBAUERKLAERUNG
1.5 DECLARATION OF INCORPORATION
EINBAUERKLAERUNG
1.6 DECLARATION OF INCORPORATION
EINBAUERKLAERUNG
1.7 CLEARANCE CERTIFICATE
NEGATIVBESCHEINIGUNG

GEA Westfalia Separator Group GmbH


8/1507

8 1.451.886.352 / 12.07.2018

2 SYSTEM DESCRIPTION
SYSTEMBESCHREIBUNG

2.1 INSTALLATION INSTRUCTIONS


INSTALLATIONSRICHTLINIEN

GEA Westfalia Separator Group GmbH


9/1507

1.451.886.352 / 12.07.2018 9

3 DOCUMENTS RELATING TO ORDERS


PROJEKTBEZOGENE DOKUMENTE

3.1 P1451886352-9937-DVL002
EQUIPMENT LIST
GERAETELISTE
3.2 P1451886352-9937-LAY002
DIMENSIONED DRAWING
AUFSTELLUNGSPLAN
3.3 P1451886352-9937-PDS002
DATA SHEET
PROZESSDATENBLATT
3.4 P1451886352-9937-PID002
INSTALLATION DIAGRAM
INSTALLATIONSSCHEMA
GRAFICAL SYMBOLS
GRAPHIKSYMBOLE
3.5 ORDER SHEET – SPARE PARTS
BESTELLSCHEIN - ERSATZTEILE

GEA Westfalia Separator Group GmbH


10/1507

10 1.451.886.352 / 12.07.2018

4 CONTROL UNIT
STEUER- UND REGELEINRICHTUNG

4.1 INSTRUCTION MANUAL


BETRIEBSANLEITUNG
4.2 CONTROL CABINET, COMPL.
STEUERSCHRANK VOLLST.
CIRCUIT DIAGRAM
STROMLAUFPLAN

GEA Westfalia Separator Group GmbH


11/1507

1.451.886.352 / 12.07.2018 11

5 CENTRIFUGE
ZENTRIFUGE

5.1 PARTS CATALOGUE


ERSATZTEILKATALOG
5.2 PARTS CATALOGUE
ERSATZTEILKATALOG
5.3 PARTS CATALOGUE
ERSATZTEILKATALOG
5.4 DATA SHEET
DATENBLATT
5.5 DATA SHEET
DATENBLATT
5.6 DATA SHEET
DATENBLATT
5.7 INSTRUCTION MANUAL
BETRIEBSANLEITUNG

GEA Westfalia Separator Group GmbH


12/1507

12 1.451.886.352 / 12.07.2018

6 PUMP
PUMPE

6.1 DIAPHRAGM PUMP


MEMBRANPUMPE
DM20/75 ANV-X
6.2 GEAR PUMP UNIT
ZAHNRADPUMPENAGGREGAT
KFF 2,5 - 200

GEA Westfalia Separator Group GmbH


13/1507

1.451.886.352 / 12.07.2018 13

7 FILTER
FILTER

7.1 STRAINER, COMPL.


SCHMUTZFAENGER VOLLST.
BR

GEA Westfalia Separator Group GmbH


14/1507

14 1.451.886.352 / 12.07.2018

8 HEAT EXCHANGER
WÄRMETAUSCHER

8.1 PLATE HEAT EXCHANGER


PLATTENWÄRMETAUSCHER
OC*

GEA Westfalia Separator Group GmbH


15/1507

1.451.886.352 / 12.07.2018 15

9 VALVES, FITTINGS, ASSEMBLY


VENTILE, ARMATUREN, ZUBEHÖR

9.1 3/2-WAY PISTON-TYPE CONTR.VALVE CPL


3/2-WEGE-KOLBENSTEUERVENTIL VOLLST.
DN25/PN16
9.2 THROUGH-WAY VALVE
DURCHGANGSVENTIL
FABA-LA
FABA-PLUS-SUPRA-LA
9.3 SPRING-LOADED SAFETY VALVE
FEDERSICHERHEITSVENTIL
67.961
9.4 THREE-WAY SOLENOID VALVE
DREIWEG-MAGNETVENTIL
330+331+332
9.5 SOLENOID-VALVE BLOCK, COMPLETE
MAGNETVENTILBLOCK VOLLST.
5281
9.6 CONTROL VALVE
STELLVENTIL
BR440-446
PREMIO-2.2KN
9.7 CONTROL VALVE
STELLVENTIL
STEVI-405-460
DP32-34

GEA Westfalia Separator Group GmbH


16/1507

16 1.451.886.352 / 12.07.2018

10 MEASUREMENT
MESSTECHNIK

10.1 STOP SWITCH


GRENZSCHALTER
LBFS
10.2 STEAM TRAP
KONDENSOMAT
FT14B
10.3 PROXIMITY SENSOR
NAEHERUNGSINITIATOR
NJ5-11-N-G
10.4 VIBRATION PICK-UP
SCHWINGUNGSAUFNEHMER
PCH1220
10.5 THERMOMETER
THERMOMETER
73/74/75

GEA Westfalia Separator Group GmbH


17/1507

1.451.886.352 / 12.07.2018 17

11 MOTOR
MOTOR

11.1 THREE-PHASE AC MOTOR


DREHSTROMMOTOR
11.2 GEAR PUMP UNIT
ZAHNRADPUMPENAGGREGAT

GEA Westfalia Separator Group GmbH


18/1507

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 Westfalia Separator Group GmbH

Werner-Habig-Straße 1, 59302 Oelde, Germany


Phone: +49 2522 77-0, Fax: +49 2522 77-2488
ws.info@gea.com,· www.gea.com
19/1507

Safety precautions
for plants
No.: 9001

Edition: 0712

Designation: Safety precautions

engineering for a better world GEA Mechanical Equipment


20/1507

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


21/1507

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


22/1507

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


23/1507

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


24/1507

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


25/1507

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


26/1507

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


27/1507

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


28/1507

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


29/1507

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


30/1507

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


31/1507

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


32/1507

14 9001 / 0712 / Safety precautions / 25.07.2012

Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note

GEA Westfalia Separator Group


33/1507

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
34/1507

Qualification of staff
Edition: 0712

Designation: Qualification of staff

engineering for a better world GEA Mechanical Equipment


35/1507

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


36/1507

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


37/1507

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


38/1507

0712 / Qualification of staff 5

GEA Westfalia Separator Group


39/1507

6 0712 / Qualification of staff

Note
Notes
Notizen
Anotaciones
Для записей
Muistiinpanot
Σημειώσεις
Notater
Notes
Note

GEA Westfalia Separator Group


40/1507

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
41/1507

Pos : 1.2 /BA/Standard/00_Titel_R üc ks eite/D ec kblatt_CD _2016_Ins tall ationsric htlini en @ 34\mod_1465543921873_18.doc x @ 1343889 @ @ 1

Safety Precautions and User Information


Machine and Skid Components

No.: 9953-9001-010
Version: 19.10.2016
42/1507

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


43/1507

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

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7 Decommissioning 25

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

8 Spare parts 27

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


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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

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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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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.

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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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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

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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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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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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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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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3 Description

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


3.2 Operating conditions ................................................................................ 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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4 Transport and storage

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


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

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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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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

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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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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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6 Repair

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


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

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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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7 Decommissioning

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

GEA Westfalia Separator Group 25


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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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8 Spare parts

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

GEA Westfalia Separator Group 27


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

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

GEA Mechanical Equipment

Klaus Dittert
Health, Safety and Environment

Phone +49 2522 77-2670


Fax +49 2522 77-32670
klaus.dittert@geagroup.com

March 7, 2012

REACH – EU directive (1907/2006): Registration, Evaluation, Authorisation and Restriction of Chemicals

Dear Sir or Madam,

GEA Westfalia Separator fulfills its obligations under the REACH project in the capacity of a downstream user.
The company is neither manufacturer nor importer of the chemicals delivered.

There is no extra registration under REACH required!

As a suppler / handler, GEA Westfalia Separator has to make sure that the intended use of the substances in
question were duly considered by the registrants (suppliers) and that all information (e.g. safety data sheet) are
handed to its customers.
The relevant information system has been installed!

The REACH procedure was inspected in cooperation with TÜV Rheinland BioTech GmbH / Germany, and the
suppliers have been notified by GEA Westfalia Separator accordingly.

With best regards,

Klaus Dittert

Health, Safety and Environment

GEA Westfalia Separator Group GmbH


Werner-Habig-Straße 1, 59302 Oelde, Germany
Tel. +49 2522 77-0, Fax +49 2522 77-2488, www.westfalia-separator.com, www.geaquipment.com
Registered office: Oelde, Registered at the local court of Münster, HR B 7223, VAT-No. DE 812 459 899
Management: Markus Hüllmann (Chairman), Bernd Huber, Jörg Timmermann
Deutsche Bank AG, Bielefeld (BLZ 480 700 20) 066922600, SWIFT: DEUT DE 3 B, IBAN DE72 4807 0020 0066 9226 00
Commerzbank AG, Bielefeld (BLZ 480 800 20) 0213384200, SWIFT: DRES DE FF 480, IBAN DE13 4808 0020 0213 3842 00
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Installation instructions
Separator

No.: 2058-9601-020
Version: 0716
76/1507

About this document 2058-9600-020 / 22.08.16

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 e-mail@gea.com


Fax +49 2522 77-2950 gea.com

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

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2058-9600-020 / 22.08.16 About this document

1 About this document 7

1.1 Sphere of application ................................................................................. 8


1.2 Other applicable documents ...................................................................... 8
1.3 Structure of the safety references ............................................................. 8

2 Safety precautions 11

2.1 Materials .................................................................................................. 12

3 Transport and storage 13

3.1 Safety during transport ............................................................................ 14


3.2 Transport in the transport packaging ....................................................... 14
3.2.1 Transport with the aid of a hoist .............................................................. 14
3.2.1 Transport with fork-lift trucks ................................................................... 15
3.3 Transporting the separator ...................................................................... 15
3.4 Storage after delivery .............................................................................. 20
3.4.1 Separator ................................................................................................. 20
3.4.2 Control cabinet......................................................................................... 20
3.5 Preservation measures on site ................................................................ 21

4 Installation 23

4.1 Installation ................................................................................................ 24

5 Separator 27

5.1 Space requirement for the separator ....................................................... 28


5.2 Bowl weights ............................................................................................ 30
5.3 Hoist specifications for separators ........................................................... 30
5.4 Ventilating the separator room ................................................................ 31
5.5 Foundations ............................................................................................. 32
5.6 Installing the separators .......................................................................... 34
5.6.1 Separators …SD 2 and …TC 2, 3 ........................................................... 34
5.6.2 Separators …SD 6, 18, 35, 60 – …SE 5, 10, 20, 40, 80, 120 –
…TC 5, 10, 20, 40, 80 ............................................................................. 34
5.7 Screw torques .......................................................................................... 36
5.7.1 Screw torques in Newton meters (Nm) ................................................... 36
5.7.2 Screw tightening torques in inch-pound (inlb) ......................................... 36
5.8 Fastening the foundation frame (shipboard operation) ........................... 37
5.8.1 Installing the separator (shipboard operation) ......................................... 38
5.9 Vibrations ................................................................................................. 39
5.10 Feed and discharge lines on the separator ............................................. 40
5.10.1 Feed and discharge lines ........................................................................ 40
5.10.2 Operating, filling and displacement water lines ....................................... 41

6 Operating, filling and displacement water 43

6.1 Operating, filling and displacement water discharge lines ...................... 44


6.2 Water quality ............................................................................................ 44

GEA Westfalia Separator Group 3


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6.3 Supply pressure and temperature ........................................................... 44


6.3.1 Operating, filling and displacement water lines ....................................... 45
6.4 Rating the water lines .............................................................................. 46
6.5 Water quantity.......................................................................................... 48

7 Compressed air 49

7.1 Compressed air quality ............................................................................ 50


7.2 Configuration of the compressed air line (per separator) ........................ 50

8 Product line 51

8.1 General .................................................................................................... 52


8.2 Pipe cross-sections ................................................................................. 52
8.2.1 Selection diagram .................................................................................... 53
8.3 Piping network ......................................................................................... 54
8.4 Product feed pump .................................................................................. 56
8.4.1 Pressure line ............................................................................................ 56
8.5 Strainers and pre-strainers ...................................................................... 57
8.6 Plate heat exchangers and tubular heat exchangers .............................. 58
8.6.1 Steam-heated plate heat exchanger with PI controller............................ 59
8.6.2 Steam-heated tubular heat exchanger with PI controller ........................ 60
8.6.3 Thermal oil-heated plate heat exchanger with PI controller .................... 61
8.6.4 Thermal oil-heated tubular heat exchanger with PI controller ................. 62
8.7 Soldered plate heat exchanger................................................................ 63
8.8 Safety valve ............................................................................................. 64

9 Solids tank 65

9.1 Solids tank ............................................................................................... 66


9.2 Solids tank ventilation .............................................................................. 66
9.2.1 Solids tank venting .................................................................................. 68
9.2.2 Set-up of the solids tank venting ............................................................. 69
9.3 Solids discharge lines .............................................................................. 70
9.3.1 Solids discharge lines with shut-off flap .................................................. 71
9.3.2 Standard installation of shut-off flaps ...................................................... 72
9.4 Operating and dirty water discharge lines ............................................... 73

10 Electrical installation 75

10.1 Installing control cabinets ........................................................................ 76


10.1.1 Installation site and operation .................................................................. 76
10.1.2 Control cabinet D10 ................................................................................. 77
10.1.3 Control cabinet E40 ................................................................................. 79
10.1.4 Assembly example for control cabinets ................................................... 81
10.1.5 Electrical connection ................................................................................ 81
10.1.6 Type of protection .................................................................................... 82
10.1.7 External voltages ..................................................................................... 82
10.1.8 Shipboard operation ................................................................................ 82
10.1.9 Onshore operation ................................................................................... 83
10.2 EMC-compliant installation ...................................................................... 83
10.3 Solenoid valves........................................................................................ 84
10.3.1 Solenoid valve block ................................................................................ 84
10.3.2 Sensor block ............................................................................................ 85
10.3.3 Terminal box ............................................................................................ 86
10.4 Double thermometer PT 100 ................................................................... 87
10.5 Electric motors and sensors .................................................................... 88

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10.6 Execution of the lectrical installation........................................................ 89


10.6.1 Voltage equalization of the separator ...................................................... 89
10.6.2 Equipotential bonding of the electric heater ............................................ 90
10.6.3 Equipotential bonding of the foundation plate ......................................... 91
10.6.4 Equipotential bonding of the control cabinet ........................................... 92
10.7 Electric motors procured by the customer ............................................... 93

11 Spare parts 95

11.1 Use only genuine spare parts. ................................................................. 96


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Note
注释
Noter
Notas
Notes
‫وتالحظ‬
Notater
Notatki
Notizen
Notities
Бележки
Pastabos
Märkmed
Σημειώσεις
Anotaciones
Для записей
Muistiinpanot

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1 About this document

1.1 Sphere of application ................................................................................. 8


1.2 Other applicable documents ...................................................................... 8
1.3 Structure of the safety references ............................................................. 8

GEA Westfalia Separator Group 7


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1.1 Sphere of application


This document represents an integral part of the contract when procuring separator
installations and is part of the complete documentation. The document describes
the specifications for the design, manufacture and implementation of separator
systems.
For the plant operator, this document is considered to be a basis for planning and
executing the installation of separator installations.

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1.2 Other applicable documents


 P&ID (Piping & Instrumentation Diagram)
 Installation diagram and equipment list
 Dimensioned drawing
Information on space requirement for operation and maintenance, minimum
clearance from walls/pillars or other machines
 Centrifuge operating manual
 Control unit manual
 Instruction manuals for components from other manufacturers such as motors
and valves.
 Further order-specific documents if relevant.

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1.3 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.

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.

8 GEA Westfalia Separator Group


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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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Note
注释
Noter
Notas
Notes
‫وتالحظ‬
Notater
Notatki
Notizen
Notities
Бележки
Pastabos
Märkmed
Σημειώσεις
Anotaciones
Для записей
Muistiinpanot

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2 Safety precautions

2.1 Materials .................................................................................................. 12

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2.1 Materials
 All components are functional and of the best possible materials in terms of suit-
ability for the application.

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3 Transport and storage

3.1 Safety during transport ............................................................................ 14


3.2 Transport in the transport packaging ....................................................... 14
3.2.1 Transport with the aid of a hoist .............................................................. 14
3.2.1 Transport with fork-lift trucks ................................................................... 15
3.3 Transporting the separator ...................................................................... 15
3.4 Storage after delivery .............................................................................. 20
3.4.1 Separator ................................................................................................. 20
3.4.2 Control cabinet......................................................................................... 20
3.5 Preservation measures on site ................................................................ 21

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3.1 Safety during transport


When the centrifuge is transported with hoists and fork-lift trucks, hazards can oc-
cur. Risk of injury and material damage are a threat when unqualified persons are
deployed and unsuitable or damaged lifting gear is used.
Therefore, pay attention to the following points during transportation:
 Assign only qualified personnel with the task of transporting the centrifuge.
 Use approved and intact lifting gear and hoists for transportation.
 Use only suitable hoists with adequate lifting capacity.
- For the weight of the centrifuge, refer to the separator manual, chapter "Tech-
nical Data / Weights".

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3.2 Transport in the transport packaging

3.2.1 Transport with the aid of a hoist

 Always secure the goods to be trans-


ported in a suitable way against slip-
ping and tilting.
 When transporting the centrifuge in the
transport packaging, use only suitable
vehicles or suitable cranes.
 Ensure an even pressure distribution
on the bottom panel.

Fig. 1

Packaging example: Centrifuge with belt


drive

Fig. 2

14 GEA Westfalia Separator Group


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3.2.1 Transport with fork-lift trucks

 Remove side walls, filling material and


all loose parts.
 Use the bottom panel of the transport
packaging as a pallet for transporting
the centrifuge with a fork-lift truck.
 Ensure an even pressure distribution
on the bottom panel.

Fig. 3

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3.3 Transporting the separator

WARNING Danger of injury due to overturning of the separator during transport

Separators and their transport packaging can cause injuries through impacts and
crushing and tilting or slipping.
 Transport only by briefed and assigned persons.
 Pay attention to separator weight specifications (see separator manual, chapter
"Technical Data".
 Comply with the instructions for safe transportation.
 Secure separators adequately against slipping and tilting.
 Refer to the chapter "Transport" in the separator manual for suitable suspension
points and correct fastening methods.

 Remove the bowl from the frame be-


fore transporting the separator.

IMPORTANT: The separator is normally


delivered without installed bowl.
An exception to this rule are the separa-
tors…SD 2, …TC 2 and …TC 3. They
are delivered and transported with fitted
bowl.

Fig. 4

The examples below show how the transport ropes must be attached to the differ-
ent frames (see Fig. 5 – Fig. 14):

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Separators…SD 6 and 18, …SE 5, 10 and 20, …TC 5, 10 and 20

 Unscrew screw plug (1) from the lower


section of the frame.

Fig. 5

 Screw double nipple (1) into the hole in


the frame.

Fig. 6

 IMPORTANT: Do not use the horizon-


tally screwed-in eye bolts of the motor
to suspend the separator.
 Hang in the transport ropes.
- Do not damage any machine com-
ponents when fastening the
transport ropes.
- Swing the transport ropes around
the machine A and the double nip-
ple and hang it in the load hook of
the hoist.
- Prevent the frame from overturning:
Place part of the rope around the
load hook in such a way that the
frame is lifted horizontally (see de-
tail).
- Make sure that the transport ropes
cannot slip.
- Ensure even load distribution.

Fig. 7

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Separators …SD 35, …SE 40, …TC 40

 Unscrew screw plug (1) from the lower


section of the frame.

Fig. 8

 Screw two eye bolts (1) into the upper


section of the frame.
 Screw double nipple (1) into the hole in
the frame.

Fig. 9

 IMPORTANT: Do not use the horizon-


tally screwed-in eye bolts of the motor
to suspend the separator.
 Hang in the transport ropes.
- Do not damage any machine com-
ponents when fastening the
transport ropes.
- Thread shackle (1) through the eye
bolts.
- Arrange the transport ropes around
the double nipple (2), pull through
the two shackles (1) and hang into
the load hook of the hoist.
- Prevent the frame from overturning:
Place part of the rope around the
load hook in such a way that the
frame is lifted horizontally (see de-
tail).
- Make sure that the transport ropes
cannot slip.
- Ensure even load distribution.

Fig. 10

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Separators …SD 60, …SE 80 and …TC 80

 Screw two eye bolts (1) into the upper


section of the frame.
 Screw two eye bolts (2) with fitted
washers (3) into the intermediate
flange / holes in the frame.

Fig. 11

 IMPORTANT: Do not use the horizon-


tally screwed-in eye bolts of the motor
to suspend the separator.
 Hang in the transport ropes.
- Do not damage any machine com-
ponents when fastening the
transport ropes.
- Thread shackle (4) through the eye
bolts (1) and (2).
- Pull the transport ropes through the
four shackles and hang in the load
hook of the hoist.
- Prevent the frame from overturning:
Place part of the rope around the
load hook in such a way that the
frame is lifted horizontally (see de-
tail).
- Make sure that the transport ropes
cannot slip.
- Ensure even load distribution.

Fig. 12

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Separator …SE 120

 Screw two eye bolts (1) (M 12) tightly


into the upper part of the frame.
 Screw two eye bolts (2) (M 20) tightly
into the intermediate flange / holes in
the frame.

Fig. 13

 IMPORTANT: Do not use the horizon-


tally screwed-in eye bolts of the motor
to suspend the separator.
 Hang in the transport ropes.
- Do not damage any machine com-
ponents when fastening the
transport ropes.
- Thread shackle (4) through the eye
bolts (1) and (2).
- Pull the transport ropes through the
four shackles and hang in the load
hook of the hoist.
- Prevent the frame from overturning:
Place part of the rope around the
load hook in such a way that the
frame is lifted horizontally (see de-
tail).
- Make sure that the transport ropes
cannot slip.
- Ensure even load distribution.

Fig. 14

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3.4 Storage after delivery


 The original transport packaging must not be stored in the open.
 All parts must be stored in their original transport packaging in a suitable place
until commissioning.
 IMPORTANT: When stored under proper conditions, all separator parts are ad-
equately protected for maximum one year. A storage duration longer than 12
months is only possible after prior consultation with the manufacturer.

Pay attention to the following notes on storage and transport packaging:

 Handle delicate goods with care.

 Protect the goods against moisture and humidity.

 Protect the goods against heat.

 Pay attention when erecting the goods.

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3.4.1 Separator
 If the separator is not installed immediately after delivery, it must be stored in the
original transport packaging.
 The storage location must be a closed, dry room.
o o
 The storage temperature must not be lower than 5 C (41 F) and must not ex-
o o
ceed 50 C (122 F).
 A storage duration longer than 12 months is only possible after prior consultation
with the manufacturer.
- If the machine is in storage for longer than 12 months, the maintenance inter-
vals specified in the separator manual must be adhered to.

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3.4.2 Control cabinet


IMPORTANT: Improper storage discharges the manufacturer or supplier from the
warranty obligation.
 If the control cabinet is not installed immediately after delivery, it must be stored
in the original transport packaging in a protected place.
 The control cabinet must not come in contact with dusty and corrosive atmos-
phere.
 The storage location must be a closed, dry room.

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 The control cabinet may not be exposed to foreign heat sources (e.g. direct sun-
light, heater fans etc.).

Additional requirements to be met by the place of storage

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)

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3.5 Preservation measures on site

After installation until commissioning


 The spindle and drive chamber are lubricated at the factory. This affords them
protection for 12 months.
 After this time (12 months) has elapsed, it must be checked at 12 month inter-
vals whether all roller bearings and the spindle are adequately lubricated.
 Required lubricants:
- Shell Oil S.7294 (SAE 30/SAE 50) for roller bearings and spindle
- Roller bearing grease for the spindle cone.

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Note
注释
Noter
Notas
Notes
‫وتالحظ‬
Notater
Notatki
Notizen
Notities
Бележки
Pastabos
Märkmed
Σημειώσεις
Anotaciones
Для записей
Muistiinpanot

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4 Installation

4.1 Installation ................................................................................................ 24

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4.1 Installation

Fig. 15 Installation example

1 Separator
2 Separator foundation
3 Control unit
4 Control cabinet
5 Preheater
6 Solids tank
7 Vent on solids tank
8 Crane
9 Cleaning table
10 Supply air
11 Vent

 The prevailing regulations and standards of classification societies or other au-


thorized bodies must be complied with.
 All lubricating points and the drive housing of the separator must be easily ac-
cessible without having to remove pipes or gratings.
 All operating elements must be within easy reach of the operator and at an ap-
propriate height.
 Operating elements must not be mounted higher than 1800 mm above the work-
ing platform.
 All devices must be arranged so that they do not cramp the working area and so
that they can be safely serviced and operated.
 All fixed pipes and fittings must be securely attached in order to minimize vibra-
tions and movements.
 Contact points and supports must be attached in such a way that pipes can still
move in the event of temperature variations without causing stresses in the
lines.
 Pipes and pipe joints must be accessible for maintenance.
 Pipes may not be used to support electric distributors or devices.

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 These installation guidelines do not apply for small, specially manufactured


components whose durability, accessibility and operation are not impacted.
These components must be mounted in accordance with the recommendations
of the manufacturer.
 No galvanized parts may be fitted in product-carrying lines (e.g. heavy oil, diesel
oil, steam lines and thermal oil lines). This does not apply when type-tested pipe
connections are attached to pipe trace heaters.
 Y strainers must be preferably attached horizontally, whereby the filter element
must face downwards or to the side (turned through 90°).
If this is not possible for space reasons, the strainer can be installed vertically
with a flow from top to bottom. In this case, make sure that the filter element can
be removed.

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Note
注释
Noter
Notas
Notes
‫وتالحظ‬
Notater
Notatki
Notizen
Notities
Бележки
Pastabos
Märkmed
Σημειώσεις
Anotaciones
Для записей
Muistiinpanot

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5 Separator

5.1 Space requirement for the separator ....................................................... 28


5.2 Bowl weights ............................................................................................ 30
5.3 Hoist specifications for separators ........................................................... 30
5.4 Ventilating the separator room ................................................................ 31
5.5 Foundations ............................................................................................. 32
5.6 Installing the separators .......................................................................... 34
5.6.1 Separators …SD 2 and …TC 2, 3 ........................................................... 34
5.6.2 Separators …SD 6, 18, 35, 60 – …SE 5, 10, 20, 40, 80, 120 –
…TC 5, 10, 20, 40, 80 ............................................................................. 34
5.7 Screw torques .......................................................................................... 36
5.7.1 Screw torques in Newton meters (Nm) ................................................... 36
5.7.2 Screw tightening torques in inch-pound (inlb) ......................................... 36
5.8 Fastening the foundation frame (shipboard operation) ........................... 37
5.8.1 Installing the separator (shipboard operation) ......................................... 38
5.9 Vibrations ................................................................................................. 39
5.10 Feed and discharge lines on the separator ............................................. 40
5.10.1 Feed and discharge lines ........................................................................ 40
5.10.2 Operating, filling and displacement water lines ....................................... 41

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5.1 Space requirement for the separator


 IMPORTANT: Apart from the feed and discharge pipes of the separator, no
pipes may be laid in the operating area.
 it must be ensured that the separator is readily accessible from all sides.
 Minimum clearance to walls of buildings and other machines must be observed.
- All machine parts must be readily accessible for maintenance and repair work.
- For removing and fitting the drive motor F and the bowl G.
 In the case of an installed foundation, pay attention to the actual overall height
E including the height of the foundation frame.
- refer to the installation plan in the order-specific final documentation.

Front view and top view of the separator.

 See the following table to determine


the operating area (shaded).

Fig. 16

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Operating range for separators

Dimensions in mm
Separator
A B C D E F G H X Y Z
…SD 2 100 100 500 100 750 100 250 280 500 425 700
…SD 6 150 150 750 400 1500 175 350 550 900 550 900
…SD 18 150 150 750 400 1700 175 425 640 1050 575 1025
…SD 35 200 150 750 300 2100 250 600 850 1325 750 1300
…SD 60 200 150 750 525 2150 225 700 1020 1650 875 1550
…SE 5 150 150 500 275 1200 175 326 375 790 460 770
…SE 10 150 150 750 400 1500 175 350 550 900 550 900
…SE 20 150 150 750 400 1700 175 425 640 1050 575 1025
…SE 40 200 150 750 300 2100 250 600 850 1325 750 1300
…SE 80 200 150 750 525 2150 225 700 1020 1650 875 1550
…SE 120 200 200 750 250 2750 200 850 1040 1800 1200 1950
…TC 2 100 100 500 100 750 100 250 250 500 300 575
…TC 3 100 100 500 100 750 100 250 250 500 300 575
…TC 5 150 150 500 300 1500 175 326 360 650 350 875
…TC 10 150 150 750 300 1600 175 350 550 700 500 1000
…TC 20 150 150 750 300 1700 175 425 640 825 550 1150
…TC 40 200 150 750 300 2100 250 600 850 1050 625 1350
…TC 80 200 150 750 300 2250 225 700 1020 1650 775 1700

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5.2 Bowl weights

Hoist rating specifications

Fig. 17

Bowl weight
Separator b h
(kg)
...SD 2 200 195 10
...SD 6 255 270 45
...SD 18 300 320 75
...SD 35 425 420 190
...SD 60 540 530 360
...SE 5 220 225 30
...SE 10 260 270 50
...SE 20 315 315 65
...SE 40 440 450 205
...SE 80 560 570 400
...SE 120 660 645 660
...TC 5 220 215 25
...TC 10 265 260 40
...TC 20 315 310 55
...TC 40 440 435 140
...TC 80 560 560 240

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5.3 Hoist specifications for separators


 The hoisting equipment must be mobile or swivel-type.
 The hoist be rated to enable the following:
- Vertical removal and fitting of the bowl (see chapter “Space requirement for
the separator", table - dimensions E).
- Horizontal removal and fitting of the drive motor (see chapter “Space require-
ment for the separator", table - dimensions G).

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5.4 Ventilating the separator room


 Pay attention to the correct attachment of the air intake and exhaust lines.
- Efficient aeration and deaeration of the separator room.
- No vacuum in the air intake lines and air exhaust lines.
o
- Do not exceed the permitted room temperature (normally max. 45 C
o
(113 F) ).

IMPORTANT:
 Dimensioning of the electrical devices is crucial in this connection.
 If the permissible temperatures are exceeded, special action must be taken. The
maintenance intervals and measures may have to be adapted accordingly.

Installation example of a ventilation sys-


tem

Fig. 18

1 Supply air
2 Vent

Approximate values on air exchange

-1
For small, closed separator rooms 30 – 50 h
-1
For large separator rooms 15 – 20 h
-1
For engine rooms (beside main or auxiliary engines) 50 – 70 h

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Air volume (pressed out of the separator frame)

Air volume
Separator
(m³/h)
...SD 2 10
...SD 6 35
...SD 18 45
...SD 35 55
...SD 60 75
...SE 5 10
...SE 10 40
...SE 20 50
...SE 40 60
...SE 80 80
...SE 120 150
...TC 2 10
...TC 3 10
...TC 5 10
...TC 10 10
...TC 20 50
...TC 40 60
...TC 80 80
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5.5 Foundations
 To avoid the influence of foreign vibrations, foundations and foundation frames
for separators which have contact with other foundations must not exceed the
specified vibration values (see chapter "Vibrations").
IMPORTANT: If the foundation frame does not have an appropriate rigidity and
bending strength, this can result in loss of warranty.

Installation example for a foundation


frame

Fig. 19

1 Foundation frame

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 The foundation frames must be de-


signed so that dimensions a and b in
the table below are adhered to.
 When other parts are used, the mo-
ment of resistance of the U-sections
may not be below the value stipulated
in DIN 1026.
 The foundation frame must have a
rigidity with a maximum permitted de-
flection of 1:1000.
 The separator feet must be fastened at
the neutral axis of the foundation
frame.
Fig. 20

Dimensioning of the foundation frame

Dimensions in mm
Separator
a b
...SD 2 80 45
...SD 6 140 60
...SD 18 140 60
...SD 35 180 70
...SD 60 180 70
...SE 5 140 60
...SE 10 140 60
...SE 20 140 60
...SE 40 180 70
...SE 80 180 70
...SE 120 220 80
...TC 2 80 45
...TC 3 80 45
...TC 5 80 45
...TC 10 140 60
...TC 20 140 60
...TC 40 180 70
...TC 80 180 70

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5.6 Installing the separators


The following chapters will show how the different separators are installed.

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5.6.1 Separators …SD 2 and …TC 2, 3

Assembly of the separators on a steel


foundation room with the aid of rubber-
metal cushions.

Fig. 21

 Screw rubber-metal cushions (4) into


foundation frame (5).
 Screw studs (2) into rubber-metal
cushions (4).
- Torque: 30 Nm
 Place plate (3) over the studs.
 Position the separator on the plate (3)
and bolt tight using hexagon nuts (1).

Fig. 22

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5.6.2 Separators …SD 6, 18, 35, 60 – …SE 5, 10, 20, 40, 80, 120 – …TC 5, 10,
20, 40, 80

 Align separator (1) with feet (2) and


plates (3) on foundation frame (4).
 Tack plates (3) in position.
 Loosen hex head screws (5).
 Raise the separator with feet, see
chapter "Transporting the separator".
 Weld plates (3) to foundation frame
(4).
 Position the separator on the plates (3)
and bolt tight using hex head screws
(5).
 Tighten the hex head screws (6) firmly
(the torques are specified in the table
Fig. 23 below).

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Hex head screw Torque


Separator
(6) (Nm)
...SD 6
M 12 52
...SD 18
...SD 35
M 16 100
...SD 60
...SE 5
...SE 10 M 12 52
...SE 20
...SE 40
M 16 100
...SE 80
...SE 120 M 20 200
...TC 5
...TC 10 M 12 52
...TC 20
...TC 40
M 16 120
...TC 80
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5.7 Screw torques


The torques apply for the following conditions:
 Metric screws with coarse-pitch threads.
- Hex head screws according to DIN EN ISO 4014
- Allen screws according to DIN EN ISO 4762
 Through holes according to DIN ISO 20273 (medium).
 Greased screws (total minimum coefficient of friction = 0.10).
 Torque wrench with a scatter (tolerance) of 10 %.
 Material combinations:
- Steel-steel
- Stainless steel-stainless steel.
IMPORTANT: Screws whose torque deviates from this table are marked with the
required torque in the manual.

5.7.1 Screw torques in Newton meters (Nm)

Super
A2-70 A2-80 Hastelloy
Strength class 8.8 10.9 12.9 Duplex
A4-70 A4-80 2.4819
1.4501
Yield stress/yield strength 640 450
940 1100 600 550 360
in N/mm² 660 250
Parameter Torque in Nm
M4 2.6 3.9 4.5 1.9 2.5 1.9 1.5
M5 5.2 7.6 8.9 3.6 4.8 3.6 2.9
M6 9.0 13.2 15.4 6.3 8.4 6.3 5.0
M8 21.6 31.8 37.2 15.2 20.2 15.2 12.1
M 10 43.0 63.0 73.0 30.0 40.0 30.0 24.0
M 12 73.0 108.0 126.0 52.0 69.0 52.0 42.0
M 14 117.0 172.0 201.0 82.0 109.0 82.0 65.0
M 16 180.0 264.0 309.0 126.0 168.0 126.0 100.0
M 18 259.0 369.0 432.0 177.0
M 20 363.0 517.0 605.0 248.0
M 22 495.0 704.0 824.0 187.0
M 24 625.0 890.0 1041.0 237.0
M 30 1246.0 1795.0 2077.0 472.0
M 36 2164.0 3082.0 3607.0

Screws made of Super Duplex 1.4501 are treated like A4-70 screws while neglect-
ing the higher yield stress.
In the case of screws larger than M 16, an individual drop in strength due to the
degree of deformation of the screw raw material and the thread rolling procedure
must be taken into account.
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5.7.2 Screw tightening torques in inch-pound (inlb)


The following formula is used to convert the torques (Ma) from “Nm“ to “inlb“:

Mainlb = MaNm x 8.85

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Example:

Mainlb = Wanted (screw tightening torques in “inch-pound”)


MaNm = 50 (screw tightening torques in “Newtonmeter“)
Mainlb = 50 Nm x 8.85

Mainlb = 442.5 inlb

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5.8 Fastening the foundation frame (shipboard operation)

 The foundation frame (2) can be di-


rectly welded onto the steel structure
(1).

Fig. 24

The detail view X shows an example for


welding the foundation frame to the steel
structure.

Fig. 25

X Fillet weld

Example 1
 The weld seams must be 100 mm long.
 The distance between the weld seams must be approx. 350 mm.
That means that three weld seams with a length of 100 mm stretch for a distance
of one metre.

Example 2
 The foundation frame can also be welded all the way round.

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5.8.1 Installing the separator (shipboard operation)

 The supports (1) must be attached


beneath the separator feet.
 The dimensional specifications a and b
for the clearance of the supports (1)
must be observed (see figure and ta-
ble below).
 The position of the separator feet can
be seen in the chapter "Space re-
quirement for the separator".

Fig. 26

Dimensional specifications a and b for


the clearance of the supports of the re-
spective separator.

Fig. 27

Dimension "a" Dimension "b"


Separator
[mm] [mm]
...SD 2 452 237
...SD 6 350 220
...SD 18 425 270
...SD 35 555 380
...SD 60 700 460
...SE 5 326 220
...SE 10 350 220
...SE 20 425 270
...SE 40 555 380
...SE 80 700 460
...SE 120 850 620
...TC 2 452 237
...TC 3 452 237
...TC 5 326 220
...TC 10 350 220
...TC 20 425 270
...TC 40 555 380
...TC 80 700 460
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5.9 Vibrations

Fig. 28

Tolerable vibration Limits for Vibro 2


Permissible vibra- Limits for Vibro 1
values at the sepa- with installed vibra-
tion value at the with installed vibra-
Separator rator contact area tion sensor (3)
reference point (2) tion sensor (3)
(footprint) [1] (mm/s)
(mm/s) (mm/s)
max. (mm/s)
...SD 2 2.0 4.5 4.5 7.0
...SD 6 2.0 4.5 4.5 7.0
...SD 18 2.0 4.5 4.5 7.0
...SD 35 2.0 4.5 4.5 7.0
...SD 60 2.0 4.5 4.5 7.0
...SE 5 2.0 4.5 4.5 7.0
...SE 10 2.0 4.5 4.5 7.0
...SE 20 2.0 4.5 4.5 7.0
...SE 40 2.0 4.5 4.5 7.0
...SE 80 2.0 4.5 4.5 7.0
...SE 120 2.0 4.5 4.5 7.0
...TC 2 2.0 4.5 4.5 7.0
...TC 3 2.0 4.5 4.5 7.0
...TC 5 2.0 4.5 4.5 7.0
...TC 10 2.0 4.5 4.5 7.0
...TC 20 2.0 4.5 4.5 7.0
...TC 40 2.0 4.5 4.5 7.0
...TC 80 2.0 4.5 4.5 7.0
(1) Measured at separator standstill and normal ship operation.
(2) Measured when separators are running.
(3) The vibration sensor is fitted in this area.

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5.10 Feed and discharge lines on the separator


The general configuration of the piping network is described in the following chap-
ters:

5.10.1 Feed and discharge lines


 The feed and discharge lines must be laid in conformity with the guidelines of
GEA Westfalia Separator or the specifications of the classification societies.

WARNING Danger due to defective spare parts or operating materials

Non-original or unauthorized parts or operating materials endanger the personnel


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

 The lines must be flushed before commissioning to protect the valves and units.
 The following lines must be connected to hoses or compensators to prevent vi-
brations:
- Product feed line and product discharge line
- Operating, filling and displacement water lines
- Solids discharge
- Dirty water discharge line
- Frame drain
Special requirements apply for shockproof separators.
 The connection dimensions of the feed and discharge lines are given in the or-
der-specific dimensioned drawing.

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 hoses and protective sleeves for cables:

Protective sleeve for cables

 IMPORTANT: Avoid abrasion.


- Fit protective sleeve (1) along the
full length of the cable harness (con-
tact points to the machine).
- Adapt the length of the protective
sleeve (1).

Fig. 29

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Corrugated hose with braiding

 IMPORTANT: Do not twist corrugated


hose.
- Fit corrugated hose without torsion.

Fig. 30

 IMPORTANT: Do not over-bend cor-


rugated hose.
- Fit corrugated hose as shown.
- Fit a pipe bend to divert if neces-
sary.

Fig. 31

 IMPORTANT: Do not kink corrugated


hose.
 Remove all corrugated hoses for ser-
vicing work (before removing the
hood).

Fig. 32

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5.10.2 Operating, filling and displacement water lines

 The water lines must be laid so that


they can be drained completely at the
lowest point without having to be dis-
mantled.
 Y-strainers are fitted horizontally at the
factory, whereby the filter elements (1)
face downwards.
 The solenoid valves for operating,
filling and displacement water to the
separator are fitted so that the hose
between the separator and solenoid
valves cannot drain.

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Fig. 33

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6 Operating, filling and displacement water

6.1 Operating, filling and displacement water discharge lines ...................... 44


6.2 Water quality ............................................................................................ 44
6.3 Supply pressure and temperature ........................................................... 44
6.3.1 Operating, filling and displacement water lines ....................................... 45
6.4 Rating the water lines .............................................................................. 46
6.5 Water quantity.......................................................................................... 48

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6.1 Operating, filling and displacement water discharge lines


 Operating, filling and displacement water discharge lines may not be led into
public sewage systems, draining ditches and waters.
- Comply with environmental protection legislation.
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6.2 Water quality


 IMPORTANT: When desalinated water or condensate is used, corrosion must
be reckoned with.
 The use of boiler feed water is not permitted.
 land water is not recommended since its degree of hardness is normally too
high.
 The water must be as pure as possible and meet the following standards:

Hardness
- up to 55 °C (131 °F) separating temperature < 12° dH
- above 55 °C (131 °F) separating temperature < 6° dH
The different hardness values are linked by the following relationships:
1° dH = 1.79° fH = 1.25° eH = 17.9 ppm CaCO3
pH 6.5 – 7.5
Chloride ions < 100 mg/l
Suspended matter max. 10 mg/l
Particle size max. 50 µm
dH = German hardness | fH = French hardness | eH = English hardness

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6.3 Supply pressure and temperature

Fig. 34

IMPORTANT: The pressure downstream of the water pressure reducer must


be set to 0.25 Mpa (2.5 bar) when the operating water valve is open.

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 Refer to the dimensioned drawing of the separator.

 The supply pressure and the temperature for the operating, filling and dis-
placement water must meet the following specifications:

Supply pressure 0.3 – 1.0 MPa (3 – 10 bar)


Temperature min. 10 °C (50 °F)
max. 85 °C (185 °F)

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6.3.1 Operating, filling and displacement water lines

 The water lines must be laid so that


they can be drained completely at the
lowest point without having to be dis-
mantled.
 Y-strainers are fitted horizontally at the
factory, whereby the filter elements (1)
face downwards.
 The solenoid valves for operating,
filling and displacement water to the
separator are fitted so that the hose
between the separator and solenoid
valves cannot drain.
Fig. 35

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6.4 Rating the water lines


 Manifolds must be dimensioned in such a way that the separators are always
supplied with an adequate water volume to ensure smooth operation.
 The manifolds must be laid in such a way as to enable fitting and removing the
solenoid valves and filters,

 In the case of a separator, the mani-


fold must have the same nominal width
as the separator feed lines.
 The nominal width R is given in the
following table.

Fig. 36 1 Separator

Fig. 37 2 Separators

With two separators:


IMPORTANT: When two separators request water simultaneously, the water sup-
ply can be dimensioned as for one separator.
 The manifold must have a nominal width S (see following table).
 The feed lines to the separator must have a nominal diameter R (see the follow-
ing table).

With three and more separators


 The manifold must have a nominal width of DN 32.
 The feed lines to the separator must have a nominal diameter R (see the follow-
ing table).

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Nominal diameter (DN)


Separator Manifold Feed line
S R
...SD 2 25 20
...SD 6 25 20
...SD 18 25 20
...SD 35 32 20
...SD 60 32 20
...SE 5 25 20
...SE 10 25 20
...SE 20 25 20
...SE 40 32 20
...SE 80 32 20
...SE 120 32 20
...TC 2 25 20
...TC 3 25 20
...TC 5 25 20
...TC 10 25 20
...TC 20 25 20
...TC 40 32 20
...TC 80 32 20

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6.5 Water quantity


The following water quantities are required for precise program control with simul-
taneous actuation of the solenoid valves.

Solenoid valve Total con- Total con-


V2 V2 V3 sumption sumption
per cycle per cycle
Filling water Displace- Operating
Separator without
ment water water * filling wa-
ter
l/s l/s l/s l (approximate)
...SD 2 0.25 0.25 0.25 2 1.5
...SD 6 0.1 0.1 0.5 3 2
...SD 18 0.1 0.1 0.8 5 3.5
...SD 35 0.1 0.1 0.8 10 6.5
...SD 60 0.1 0.1 0.8 23 13
...SE 5 0.1 0.1 0.5 1.6 1.1
...SE 10 0.1 0.1 0.5 2.3 1.5
...SE 20 0.1 0.1 0.5 3.2 2.0
...SE 40 0.1 0.1 0.8 11.6 7.6
...SE 80 0.1 0.1 0.8 25.4 15.4
...SE 120 0.5 0.5 1.0 46 31
...TC 2 0.1 0.1 - 1.5 0.8
...TC 3 0.1 0.1 - 2.4 1.2
...TC 5 0.1 0.1 - 2.9 1.3
...TC 10 0.1 0.1 - 4.5 2.0
...TC 20 0.1 0.1 - 6.6 3.1
...TC 40 0.1 0.1 - 17.7 9.0
...TC 80 0.1 0.1 - 42.6 21.0
* Ejection cycle =  (filling water + displacement water + operating water)

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7 Compressed air

7.1 Compressed air quality ............................................................................ 50


7.2 Configuration of the compressed air line (per separator) ........................ 50

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7.1 Compressed air quality


 The compressed air must be free from impurities and dry.
- Comply with all pertinent national and international regulations.

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7.2 Configuration of the compressed air line (per separator)

Fig. 38 Example of a separator

1 Pressure reducer

 IMPORTANT: The standard scope of delivery for separators does not in-
clude a compressed air control assembly.
 When other pneumatic components are operated, the corresponding in-
structions on air quality and air purity must be followed.

Pressure of compressed air supply and compressed air consumption

Permitted supply pressure 0.3 – 1.0 MPa (3 – 10 bar)


Supply pressure 0.3 MPa (3 bar)
downstream of the pressure reducer (1)
Max. compressed air consumption (per separa- 3
0.01 Nm /h
tor)

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8 Product line

8.1 General .................................................................................................... 52


8.2 Pipe cross-sections ................................................................................. 52
8.2.1 Selection diagram .................................................................................... 53
8.3 Piping network ......................................................................................... 54
8.4 Product feed pump .................................................................................. 56
8.4.1 Pressure line ............................................................................................ 56
8.5 Strainers and pre-strainers ...................................................................... 57
8.6 Plate heat exchangers and tubular heat exchangers .............................. 58
8.6.1 Steam-heated plate heat exchanger with PI controller............................ 59
8.6.2 Steam-heated tubular heat exchanger with PI controller ........................ 60
8.6.3 Thermal oil-heated plate heat exchanger with PI controller .................... 61
8.6.4 Thermal oil-heated tubular heat exchanger with PI controller ................. 62
8.7 Soldered plate heat exchanger................................................................ 63
8.8 Safety valve ............................................................................................. 64

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8.1 General
 Pay special attention to the chapter "Installation"!
 The suction lines must be as short as possible to avoid pressure losses.
 When dimensioning the suction line, it must be ensured that the total pressure
loss in the suction line does not exceed the maximum suction head of the pump.
 The pipes must be installed at an adequate distance from the electronic compo-
nents.
 IMPORTANT: Liquid seals (siphons) in the pipes must be avoided. The liquid
must be able to flow off freely.
 When different products, e.g. diesel oil and heavy oil, are fed to the separator, it
must be ensured that the respective product feed lines are not interchanged.

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8.2 Pipe cross-sections


 All pipes, valves, fittings and instruments must be laid so that an insulation of 40
mm is possible.
 The dimensions of the pipes are given in the corresponding dimensioned draw-
ing.
 The pipes can be selected using the diagram below. The specifications in the
dimensioned drawing have priority.
 The pipe resistances must be kept as low as possible.
 Under consideration of the total pressure losses the flow velocities must be:
- between 0.5 m/s and < 1 m/s in suction lines
- between 1 m/s and 3 m/s in pressure lines

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8.2.1 Selection diagram

Fig. 39

Q Flow

v Velocity in m/s

Example:
3
A flow rate of 5 m /h produces a velocity of 1.2 m/s with a nominal width of 40.

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8.3 Piping network


IMPORTANT: A return line into the suction side of the pump is not allowed.

Fig. 40 Lubrication oil schematic

1 Lube oil tank

 When separating lube oil, the return line of the 3/2-way valve can be led into the
product discharge line of the separator.

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Fig. 41 Diesel oil schematic

1 Diesel oil tank


2 Service tank
3 Heat exchanger (option)
 When separating diesel oil, the return line of the 3/2-way valve must be led into
the DO tank (1).

Fig. 42 Lubrication oil schematic

1 Settling tank
2 Service tank
 When separating heavy oil, the return line of the 3/2-way valve must be led into
the settling tank (1).

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8.4 Product feed pump

Product feed pump


- Gear pump Max. 0.04 MPa (0.4 bar)
- Worm pump Max. 0.05 MPa (0.5 bar)
Required pressure head approx. 0.3 MPa (3 bar)
Viscosity of the oil to be conveyed < 1 000 cSt
Feed pressure in the suction line Max. 0.05 MPa (0.5 bar)

IMPORTANT:
 The total pressure loss in the pipe must not exceed the maximum suction height
of the pump.
 The viscosity of the oil to be conveyed must be kept below the specified value, if
necessary by means of preheating and trace heating.
 To protect the preheater against overheating, a pump post-running time must be
programmed for the pump units and the product preheating.

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8.4.1 Pressure line


 When dimensioning the pressure line, it must be ensured that the total pressure
loss in the pipes does not exceed the maximum pressure head of the pump.
 The pressure line from the product feed pump via the orifice plate, the pre-
heater and the 3/2-way valve to the separator must be kept as short as possible.

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8.5 Strainers and pre-strainers


 The strainers and pre-strainers are fitted in the suction line of the feed pump to
protect it from coarse impurities.
 During installation, special attention must be paid to the fitting position, see
chapter "Installation".

 Use only strainers with the following


characteristics:

Fig. 43

Nominal width Filter element (1)


(DN) Mesh width
mm mm
15 – 50 1.00
65 – 80 1.25
> 100 1.60

 Use only pre-strainers with a mesh


width of the filter element (1) of 0.63
mm.

Fig. 44

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8.6 Plate heat exchangers and tubular heat exchangers


 The heat exchanger must be installed so that no heat is given off to the control
cabinet.
 IMPORTANT: To avoid accidents during venting due to releasing hot vapours
and liquids, the discharge lines of the vent valves must be laid at minimum floor
height.
 The discharge line of the safety valve must be laid so that there is no accident
risk when the safety valve responds due to overpressure.
 The discharge line must be laid so that it can always be monitored. It must not
be concealed by pipes, valves or other components.
 Steam traps
– must be attached horizontally between two connections.
– may not be insulated to assure correct operation.
– must be installed in such a way that the condensate can discharge without
backpressure.
 At least one proportional-integral controller must be used for the heat exchang-
ers.
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The following installation examples are set out in the next chapters:
 Steam-heated plate heat exchanger with PI controller
 Steam-heated tubular heat exchanger with PI controller
 Thermal oil-heated plate heat exchanger with PI controller
 Thermal-oil-heated tubular heat exchanger with PI controller

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8.6.1 Steam-heated plate heat exchanger with PI controller

Fig. 45

A Oil inlet
B Oil outlet
C Steam inlet
D Condensate outlet
0.1 Spring safety valve
1.0 Plate heat exchangers
1.1 Resistance thermometer (PT 100)
2.1 Strainer
2.2 Control valve
2.3 Ball float condensate trap

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8.6.2 Steam-heated tubular heat exchanger with PI controller

Fig. 46

A Oil inlet
B Oil outlet
C Steam inlet
D Condensate outlet
0.1 Spring safety valve
1.0 Plate heat exchangers
1.1 Resistance thermometer (PT 100)
2.1 Strainer
2.2 Control valve
2.3 Ball float condensate trap

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8.6.3 Thermal oil-heated plate heat exchanger with PI controller

Fig. 47

A Oil inlet
B Oil outlet
C Thermal oil inlet
D Thermal oil outlet
0.1 Spring safety valve
1.0 Plate heat exchangers
1.1 Resistance thermometer (PT 100)
2.1 Control valve

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8.6.4 Thermal oil-heated tubular heat exchanger with PI controller

Fig. 48

A Oil inlet
B Oil outlet
C Thermal oil inlet
D Thermal oil outlet
0.1 Spring safety valve
1.0 Tubular heat exchanger
1.1 Resistance thermometer (PT 100)
2.1 Control valve

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8.7 Soldered plate heat exchanger

IMPORTANT:
 Deformations, distortion or any other kind of stress of the soldered connecting
points must be prevented.
 The pipes must be securely in place.

Fastening plate heat exchangers:


 Prepare an assembly plate support
and bolt it to the foundation.
 Fasten assembly plate (50) with
screws (70) and nuts (80) to the as-
sembly plate support.
 The assembly plate must be installed
vertically relative to the pipe axis.
 IMPORTANT: The assembly plate
must not be welded to the support.
 Fasten heat exchanger with gaskets
(40), counterflanges (30), lock washers
(20) and screws (10) to the assembly
plate.
 Attach the pipes to the counterflanges
by tack-welding.
 Dismantle the heat exchanger and
gaskets.
 Completely weld the pipes to the coun-
terflanges.
 Finally, re-assemble the parts as per
instruction.

Fig. 49

A A The illustrated channel steel must be provided by the shipyard.


B Recommendation: U-section in accordance with DIN 1026-1-50.

Allen Lock Counter- Assembly Hex head Hexagon


Gasket
Type screw washer flange plate screw nut
(10) (20) (30) (40) (50) (70) (80)
ISO 4017 – ISO 3032 –
ISO 4762 – DIN127 – B10 1 in - 32.92 x 3.53 352 x 125 x 12
M 12 x 40 M 12
B 10 M 10 x 45 (16 x) SAE3000PSI (8 x) (1 x)
(2 x) (2 x)
(16 x) (4 x)

ISO 4762 - DIN127 – B12 5.08 cm - 56.74 x 3.53 563 x 290 x 12 ISO 4017 – ISO 3032 –
M 12 x 55 (16 x) SAE3000PSI (8 x) (1 x) M 12 x 40 M 12
B 45 (16 x) (4 x) (2 x) (2 x)

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8.8 Safety valve

Safety valve in vertical fitting position

Fig. 50

 IMPORTANT: Do not use galvanized


components and hoses.
 The safety valve outlet should be led
via a funnel (1).
 A discharge line is welded to the fun-
nel (1) through which the medium is
discharged.

Fig. 51

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9 Solids tank

9.1 Solids tank ............................................................................................... 66


9.2 Solids tank ventilation .............................................................................. 66
9.2.1 Solids tank venting .................................................................................. 68
9.2.2 Set-up of the solids tank venting ............................................................. 69
9.3 Solids discharge lines .............................................................................. 70
9.3.1 Solids discharge lines with shut-off flap .................................................. 71
9.3.2 Standard installation of shut-off flaps ...................................................... 72
9.4 Operating and dirty water discharge lines ............................................... 73

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9.1 Solids tank


IMPORTANT: This chapter does not apply for the sludge transfer units (STU) on
Compact Units (CU or ECU).

 There should always be separate sol-


ids tanks (also called sludge tanks) for
the lube oil and fuel systems.
 A tank heating system (3) must be
installed depending on the viscosity
and ambient temperature respectively.
 The general designs and constructions
are subject to the valid regulations.

Fig. 52

1 Monitoring
2 Ventilation
3 Tank heating
4 Utilizable volume

Minimum volume of the solids tank


Volume Maximum usable volume
Separator
(l) (%)
...SD 2 80 60
...SD 6 200 60
...SD 18 200 60
...SD 35 300 60
...SD 60 300 60
...SE 5 80 60
...SE 10 200 60
...SE 20 200 60
...SE 40 300 60
...SE 80 300 60
...SE 120 450 60

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9.2 Solids tank ventilation


The following criteria must be taken into consideration when ventilating the tank:
 Installation in accordance with the guidelines of the classification societies
 Controlled discharge of oil and water vapours
 An uncontrolled discharge of the solids (e.g. sludge) must be avoided.
 The vent lines of the solids tank must be laid so that a suction effect is created.
This suction effect must be strong enough to ensure that the air generated by
the running separator can be led off under all operating conditions (see chapter
"Venting the separator room").
The volume of air generated during each bowl ejection must additionally be tak-
en into account.

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Bowl volume
Volume
Separator
(l)
...SD 2 1
...SD 6 1.5
...SD 18 3
...SD 35 8
...SD 60 21
...SE 5 1
...SE 10 2
...SE 20 3.6
...SE 40 10
...SE 80 23
...SE 120 42

 Vent lines may not be laid horizontally.


o
They must have a slope of at least 5 .

 When laying vent lines, avoid water


pockets.

Fig. 53

 All possible bends in the vent lines


must be arranged stepwise.

Fig. 54
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9.2.1 Solids tank venting


 IMPORTANT: Connect the solid tank vent to the on-board venting system only.

Separators
 If one or more separators are connected to a solids tank, the nominal sizes DN
from the following table must be used.

Separators Solids tank venting


per solids DN in mm
tank ...SD 2 ...SD 6 ...SD 18 ...SD 35 ...SD 60
1 50 80 80 125 125
2 50 100 100 150 150
3 80 125 125 150 150

...SE 5 ...SE 10 ...SE 20 ...SE 40 ...SE 80 ...SE 120


1 50 80 80 125 125 125
2 50 100 100 150 150 150
3 80 125 125 150 150 150

 When combining separator models at a solids tank, the total number of all sepa-
rators must be used as a basis and the nominal width DN of the largest model
must be used.

Compact Units (CU or ECU)


 If one or several compact units with sludge transfer units (STU) are connected to
the venting system, the standard tank vents of the STU in accordance with the
following table must be used.

Separators Solids tank venting


per solids DN in mm
tank CUD 2 CUD 6 CUD 18 CUD 35 CUD 60
1 50 80 80 125 125
2 50 100 100 150 150
3 80 125 125 150 150

CUE 5 CUE 10 CUE 20 CUE 40 CUE 80 CUE 120


1 50 80 80 125 125 125
2 50 100 100 150 150 150
3 80 125 125 150 150 150

 When combining different compact unit models at a manifold, the total number of
all separators ( Cu or ECU) must be used as a basis and the nominal width of
the largest model must be used.
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9.2.2 Set-up of the solids tank venting


The nominal width DN is specified in the table above (see chapter "Solids tank
venting").

. Solids tank with one separator

Fig. 55

Solids tank with several separators

Fig. 56

Solids tank with surge plates


A solids tank with surge plates is required
if the movements of the ship cause a
malfunction in the level monitoring.
 If surge plates are used, each individ-
ual section must be vented.
 The vent lines must be joined.

Fig. 57

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9.3 Solids discharge lines

 IMPORTANT: This piping arrange-


ment is not permissible.

Fig. 58

 The solid discharge lines must, if pos-


sible, always be vertical.
 The solids discharge line must always
end 50 – 100 mm below the tank top.
 The solid discharge line must never be
located below the maximum level in
the solids tank.
 The maximum level in the solids tank
must be monitored with the aid of a
level switch.
 The pipeline network of the solids dis-
charge lines must be attached without
reduction and with compensators.
Fig. 59
 The length of 2 m may not be exceed-
ed without trace heating.

 If there is a deviation from the vertical


arrangement, an angle of 45° must not
be exceeded.

Fig. 60

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9.3.1 Solids discharge lines with shut-off flap

Fig. 61

 A shut-off valve (4) in the solids discharge line (1) prevents vapours from enter-
ing a stationary separator while another separator is operating.
 If more than one separator is used for a solids tank, a shut-off flap (4) must be
installed in the solids discharge line (1).
GEA Westfalia Separator recommends monitoring the shut-off flap (4) by means
of a limit switch. It prevents the separator from being switched on when the shut-
off flap is closed.
 When several separators or compact units (CU or ECU) are connected to a vent
manifold, a shut-off flap (4) must be installed in the solids discharge line (1). Al-
ternatively, the shut-off flap (4) can also be fitted in the respective line of the sol-
ids tank vent (3) of compact unit (CU or ECU).
 GEA Westfalia Separator recommends monitoring the shut-off flap (4) by means
of a limit switch. It prevents the separator from being switched on when the shut-
off flap is closed.
 Shut-off flaps (4) are not included in the standard supply schedule of GEA West-
falia Separator. They can, however, be delivered by GEA Westfalia Separator.
 Centri-Packs kids or modules delivered with a solids tank from GEA Westfalia
Separator and equipped with more than one separator are always delivered with
shut-off flaps.
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9.3.2 Standard installation of shut-off flaps

...SD- and ...SE separators

Fig. 62

1 Solids tank discharge line


2 Hood and frame drain
3 Solids tank venting
4 Shut-off flap

 IMPORTANT: The shut-off flaps must be open during separator operation.


 The discharge lines (1) and (2) must be installed as shown in the illustration be-
low.

Shut-off flap
 The solids discharge line must always
end below the solids tank cover.
 For the dimension X see chapter "Sol-
ids discharge lines", first figure.

Fig. 63

1 Shut-off flap
2 Flange
3 Pipe
4 Hose (is delivered with the separator)
5 Solids tank cover
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9.4 Operating and dirty water discharge lines


 IMPORTANT: Operating and dirty water discharges may not be led into public
sewage systems, draining ditches and waters.
- Comply with environmental protection legislation.
 The discharge lines for operating and waste water can be conveyed into a sepa-
rate tank for oily water.
 The pipeline network for the operating and waste water must be attached verti-
cally, without reduction and with vibration compensators. There is no upper
length limit.

Separators ...SD, ...SE and OTC

 The water discharge must be im-


mersed
(longitudinal / transverse inclination)
 The dimension h is:
- min. 50 mm for shipboard operation,
- min. 20 mm for onshore operation,

Fig. 64

1 Hood and frame drain


2 Solids tank discharge line
3 Solids tank venting

 If a siphon is installed, the frame drain


does not have to be immersed to un-
der the minimum fill level, as a liquid
seal is ensured.
 Dimensions h1 and h2 are given in the
table below.

Fig. 65

1 Hood and frame drain


2 Solids tank discharge line
3 Solids tank venting
4 Siphon for hood and frame drain
5 Solids tank discharge line

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Siphon length (mm)


Separator
h1 h2
...SD 6
200 150
...SD 18
...SD 35
300 200
...SD 60
...SE 5
...SE 10 200 150
...SE 20
...SE 40 200
...SE 80 300
250
...SE 120
…TC 2 - -
…TC 3 - -
…TC 5 - -
…TC 10 - -
…TC 20 - -

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10 Electrical installation

10.1 Installing control cabinets ........................................................................ 76


10.1.1 Installation site and operation .................................................................. 76
10.1.2 Control cabinet D10 ................................................................................. 77
10.1.3 Control cabinet E40 ................................................................................. 79
10.1.4 Assembly example for control cabinets ................................................... 81
10.1.5 Electrical connection ................................................................................ 81
10.1.6 Type of protection .................................................................................... 82
10.1.7 External voltages ..................................................................................... 82
10.1.8 Shipboard operation ................................................................................ 82
10.1.9 Onshore operation ................................................................................... 83
10.2 EMC-compliant installation ...................................................................... 83
10.3 Solenoid valves........................................................................................ 84
10.3.1 Solenoid valve block ................................................................................ 84
10.3.2 Sensor block ............................................................................................ 85
10.3.3 Terminal box ............................................................................................ 86
10.4 Double thermometer PT 100 ................................................................... 87
10.5 Electric motors and sensors .................................................................... 88
10.6 Execution of the lectrical installation........................................................ 89
10.6.1 Voltage equalization of the separator ...................................................... 89
10.6.2 Equipotential bonding of the electric heater ............................................ 90
10.6.3 Equipotential bonding of the foundation plate ......................................... 91
10.6.4 Equipotential bonding of the control cabinet ........................................... 92
10.7 Electric motors procured by the customer ............................................... 93

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10.1 Installing control cabinets


 Control cabinets may only contain electrical components, assemblies or systems
specified in the circuit diagram.
 Incorrect and improper installation discharges the supplier from his warranty ob-
ligation.

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10.1.1 Installation site and operation


 The control cabinets may not be installed in the open.
 Select the installation site so that
- the control cabinet does not come in contact with dust and corrosive atmos-
phere.
- the control cabinet is not installed in an excessively moist or damp environ-
ment.
- the sun does not shine on the control panel or the displays since this would
make operation and monitoring more difficult.
- heating up of the controls is avoided.

 If necessary, check screwed connections and plug-in connections for reliable


contact.
 Connect the thermostat-controlled control cabinet heating to an external energy
source and switch on to avoid damage.
 The control cabinet heating must be switched on before the temperature drops
below the dew point.
Dewing can occur during the night which is not good for the electrical compo-
nents.
 Check that the mains voltage and frequency correspond to the connection data
of the control system (see nameplate).

Permissible installation and operation data:

Voltage fluctuations +/- 10 % of the mains voltage


Frequency fluctuations +/- 2 % of the mains frequency
o o
Ambient temperatures + 5 to + 45 C (41 to 113 F)
o o
Air humidity max. 50 % at 40 C (104 F)
o o
max. 90 % at 20 C (68 F)
Installation height up to 1000 m above sea level
o o
Transport temperatures – 25 to + 55 C (–13 to 131 F)
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10.1.2 Control cabinet D10

Control cabinet configuration (front


view)

Fig. 66

1 Interlock
2 Control unit
3 OFF/ON keys for separator
4 OFF/ON keys for product feed pump
5 Manual switches for optional function
6 Main switch

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Control cabinet configuration (inner


view)
14

13 2

9 5

12 8

11

10

Fig. 67

1 Isolator amplifier for analog output (option)


2 WMS relay (WMS = Water Content Monitoring System), if applicable
3 Full motor protection module
4 Interface relay
5 Auxiliary contactor
6 Main contactor
7 Current transformer
8 Power supply for PLC and valves
9 Connection strip
10 Control transformer for heating and air (option)
11 Main switch
12 Control voltage transformer (option)
13 Motor protection switch
14 Safety cut out
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10.1.3 Control cabinet E40

Control cabinet configuration (front


view)

Fig. 68

1 Interlock
2 Control unit E40
3 OFF/ON keys for separator
4 OFF/ON keys for product feed pump
5 MANUAL/0/AUTOMATIC selector switch for solids pump (option)
6 Main switch

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Control cabinet configuration (inner


view)

Fig. 69

1 Door locking devices (180°)


2 CPU / expansion modules
3 Power supply unit (24 V DC)
4 Switch amplifier (optional)
5 Interface relay
6 Duct for wiring
7 Terminal strip
8 Motor starter
9 Contactor
10 Motor protection switch
11 Safety cutout
12 Control transformer (option)
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10.1.4 Assembly example for control cabinets

Fig. 70

1 Gasket (10.5 x 23 x 5)
2 Threaded bolt (M 8) (embedded in the wall)
3 Washer
4 Rear panel of the control cabinet
5 Washer
6 Wall

 The control cabinet


- must be allocated to the respective separator by means of a code.
- must be mounted on a frame or a wall in the vicinity of the separator.
 It must be possible to open the control cabinet door wide so that the door fas-
tener can lock in place.
 Select the installation site so that
- the control cabinet can be easily operated and monitored.
- an ambient temperature of 50 °C (122 °F) is not exceeded. If necessary, en-
sure that an adequate supply of fresh air is present.
 If the control cabinet is mounted on a wall, a wall clearance of 20 mm must be
observed to achieve a vibration-free fastening arrangement.
 Although the buttons and switches as well as the electronic control unit are pro-
tected against moisture by the protective foil and door seal, the control cabinet
may nevertheless not be installed in an excessively damp and moist environ-
ment.
 IMPORTANT: To keep the temperature constant inside the control unit after
starting, the main switch should remain switched on even when the separator is
at a standstill.

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10.1.5 Electrical connection


 The control system is designed for the connection voltage specified on the
nameplate in the control cabinet.
 In the case of a version without motor starter, the rated connection voltage is
115 VAC or 230 VAC, which must be protected by a 6-A slow blow fuse.

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10.1.6 Type of protection


 Type of protection IP 54 applies as a minimum for control cabinets set up in the
vicinity of the separator or skid.
 Cable ducts, fans or other openings made afterwards must comply with the said
type of protection as a minimum requirement.

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10.1.7 External voltages


 The deenergized contacts of the output modules
- carry foreign voltage (even if the main switch is off!).
- can be determined by the orange cable.
- can be used up to 250 VAC for external control systems.
2
 A cross-section of 1.5 mm Cu is appropriate for all control lines and interlocking
lines.
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10.1.8 Shipboard operation


 The standard control cabinets are equipped with halogen-free, oil-resistant plas-
tic.
 Only cables of type "MGCH“ conforming to DIN 89158.
 All cables must meet the test requirements for the spread of fire when bundling
cables in accordance with IEC 60332-3 or IEEE 45-18.13.
 All cable materials must be halogen-free in accordance with IEC 60754-1 and
must not generate toxic gases in accordance with IEC 60754 and no corrosive
gases in accordance with IEC 60754-2.
 All cables must be approved by the responsible classification society.
 Insulation resistance 0.6/1KV
 Standard: Nexans MPRX 0.6/1kV
 Connecting and control cables can be laid jointly without clearance
 IMPORTANT: In the case of HFO separators in series operation, the signal ex-
change between the control cabinets must be in accordance with the circuit dia-
gram (see chapter "Electromagnetically compatible installation").

Cable glands for shipboard installation

Female Cable outer Grounding device +


Cable gland
thread Ø (mm) Design of the inner parts

M 16 x 1,5 4 – 11 M 24 x 1,5
M 20 x 1,5 8 – 13 M 24 x 1,5
M 25 x 1,5 11 – 17 M 36 x 1,5
M 32 x 1,5 15 – 21 M 36 x 1,5
M 40 x 1,5 19 – 28 M 36 x 1,5

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10.1.9 Onshore operation


 The local regulations and guidelines of the plant operator must be complied with.
 "Ölflex" cables are normally used and "NSSHÖU" for outer installation.
 Commercially available cable glands can be used.
 Separate cable routing must be used for connecting and control lines.
 Cable entries with plastic or metal glands are permitted.

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10.2 EMC-compliant installation


 The control cabinet is designed to meet requirements for electromagnetic com-
patibility (EMC).
 The following must be taken into consideration for EMC-compliant electrical in-
stallation:
- Grounding straps
- Equipotential bonding
- Shielding of cables
- Separate cable routing
- Use of cut-off elements in the case of inductance
 In the case of HFO series operation, procedure must be in accordance with the
circuit diagram below.

Fig. 71

A Switch ON
B Control cabinet HFO No. 1
C Control cabinet HFO No. 2
D Connecting terminals
F Cable type
E Customer shipboard installation

 IMPORTANT: use only data cable UNITRONIC-BUS-FD P L2/F.I.P


2
(1 x 2 x 0.25 mm + screen).

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 IMPORTANT: Do not lay data cables directly next to connecting cables since
this can cause problems with the electromagnetic compatibility.
 Pay attention to the different software statuses of the control system.
- 1. Unit has the MPI addresses 1 / 2
- 2. Unit has the MPI addresses 3 / 4
- 3. Unit has the MPI addresses 5 / 6
 Faulty or broken cable connections are displayed with error code no. 551.
- Check all connections.
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10.3 Solenoid valves


Only original solenoid valves with integrated suppressor diodes and protection
against battery discharge in the connection head may be used for the filling, dis-
placement and operating water lines (see chapter "Use only original spare parts").

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10.3.1 Solenoid valve block

This diagram shows an original valve


block which is used in filling, displace-
ment and operating water lines.

Fig. 72

Connections:

Fig. 73

A Connecting terminal + 24 V DC
B Connecting terminal + 0 V DC
C Grounding
D Status LED
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10.3.2 Sensor block


The sensor block serves to measure pressure, to detect oil or water and to control
the product flows. Depending on the separator version, it can consist of the parts
set out below that are wired to the terminal box.

Fig. 74

1 Pressure transmitter (product discharge line)


2 Pressure transmitter (unitrolplus system – SMS-function)
3 2/2-way solenoid valve (water discharge)
4 2/2-way solenoid valve (circuit)
5 Water detector (unitrolplus system – WMS function)
6 Test flange (product discharge pressure)
7 Test flange (circulation pressure unitrolplus system)
8 Terminal strip and cabling
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10.3.3 Terminal box


 All solenoid valves and supervisory equipment are installed ready-to-connect in
a local terminal box on the separator.
 The connection to the control cabinet must be created with the aid of a connect-
ing cable in accordance with the order-specific circuit diagram.

Separator without sensor block (example)

Fig. 75

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Separator with sensor block (example)

Fig. 76

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10.4 Double thermometer PT 100

The double thermometer (1) serves to


monitor and display the temperature of
the dirty oil after the pre-heater. It also
regulates the required separating tem-
perature.

IMPORTANT: The double thermometer


(1) is used only in conjunction with a
control system.

Fig. 77

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Connection plan

 The double thermometer (1) is inte-


grated in the 3/2-way piston control
valve.
 All sensors must be installed so that
they are continuously flushed with oil.

Fig. 78

Pos : 90 /BA/2000_Commod_Sep/Ins tallationsric htlini en/10_El ektroi nstallation/Elektromotoren_und_Sensor @ 36\mod_1467388174048_18.doc x @ 1357472 @ 2 @ 1

10.5 Electric motors and sensors


 Connection of electric motors and sensors with the aid of a cable loop enables
easy replacement and function testing of the components (see examples).

Example 1: Electric motor

Fig. 79

88 GEA Westfalia Separator Group


163/1507

2058-9600-020 / 22.08.16 Electrical installation

Example 2: Sensor

Fig. 80

Pos : 91 /BA/2000_Commod_Sep/Ins tallationsric htlini en/10_El ektroi nstallation/D urchführung_Elektroi nstallati on @ 36\mod_1467388257492_18.doc x @ 1357527 @ 2 @ 1

10.6 Execution of the lectrical installation


The following standards and guidelines must be taken into consideration in the
electrical installation unless the specifications and standards of classification socie-
ties have to be met:
 EN 60204-1 or VDE 0113-1
Safety of machines - Electrical equipment of machines - Part 1: General re-
quirements
 Low Voltage Directive 73/23/EC
 Electromagnetic Compatibility 89/336/EC
 …

Pos : 92 /BA/2000_Commod_Sep/Ins tallationsric htlini en/10_El ektroi nstallation/Potenti alausgleic h_Separators @ 36\mod_1467388261181_18.doc x @ 1357582 @ 3 @ 1

10.6.1 Voltage equalization of the separator

IMPORTANT: Protective grounding is a


measure which in the event of a fault,
routes a hazardous contact voltage to
earth.

 The separator must always be


grounded.
The grounding connection is marked
with this symbol (see separator frame).

GEA Westfalia Separator Group 89


164/1507

Electrical installation 2058-9600-020 / 22.08.16

 Including the insulated installed sepa-


rator in the voltage equalization of the
installation is done via the voltage
equalization connection on the motor
side.

 If there is no protective conductor in-


corporated in multi-core cables (e.g., in
the armoured marine cable), the drive
motor must also be integrated in the
equipotential bonding.
The same applies for pump motors and
electric pre-heaters.
Fig. 81

,  The cross-section of the equipotential


bonding cable, which is normally insu-
lated green-yellow, is connected to the
largest external equipotential bonding
cable in the customer network.

 In practice, table 1 from EN 60204-1 is


used for this.

 GEA Westfalia Separator chooses:


2 2
10 mm < S < 25 mm Cu

Fig. 82

Pos : 93 /BA/2000_Commod_Sep/Ins tallationsric htlini en/10_El ektroi nstallation/Potenti alausgleic h_Elektroerhi tzer @ 36\mod_1467388264923_18.doc x @ 1357637 @ 3 @ 1

10.6.2 Equipotential bonding of the electric heater

Fig. 83

Pos : 94 /BA/2000_Commod_Sep/Ins tallationsric htlini en/10_El ektroi nstallation/Potenti alausgleic h_Fundamentrahmen @ 36 \mod_1467388274802_18.doc x @ 1357692 @ 3 @ 1

90 GEA Westfalia Separator Group


165/1507

2058-9600-020 / 22.08.16 Electrical installation

10.6.3 Equipotential bonding of the foundation plate

 The customer must fit a marked con-


necting bolt to the foundation frame for
equipotential bonding.

Fig. 84

Fig. 85

Pos : 95 /BA/2000_Commod_Sep/Ins tallationsric htlini en/10_El ektroi nstallation/Potenti alausgleic h_Sc hal tsc hrank @ 36\mod_1467388278506_18.doc x @ 1357747 @ 3 @ 1

GEA Westfalia Separator Group 91


166/1507

Electrical installation 2058-9600-020 / 22.08.16

10.6.4 Equipotential bonding of the control cabinet


 The connection is via the PE bar or terminal inside the control cabinet to the
frame connection.

PE connection

Fig. 86

PE connection

Fig. 87

PE connection

Fig. 88

Pos : 96 /BA/2000_Commod_Sep/Ins tallationsric htlini en/10_El ektroi nstallation/Kundens eitige_Beistellun_von_Elektromotoren @ 36 \mod_1467388480881_18.doc x @ 1357802 @ 2 @ 1

92 GEA Westfalia Separator Group


167/1507

2058-9600-020 / 22.08.16 Electrical installation

10.7 Electric motors procured by the customer


 When the motors are procured by the customer, they must have the following
specifications and comply with the following standards:

Design IM B5* according to IEC 34 – Part 7)


Rating Classification according to IEC 72 – Teil 2
Type of protection IM B5 according to IEC 34 – Part 5
Vibration severity Quality grade N * / S *(according to IEC 34 –
Part 14)
Full key balanced * / Half-key balanced *
Synchronous speed 50 Hz 60 Hz
3000 * / 1500 * 3600 * / 1800 *
Type of cooling 1C411 according to IEC 34 – Part 6
Flange sizes according to IEC 72
Shaft sizes according to IEC 72
Direction of rotation According to IEC 34 – Part 8
Insulation material class F according to IEC 34 – Part 1
Motor protection PTC thermistors as full motor protection
(PTC = Positive Temperature Coefficient)

 The PTC resistors must be fitted in the end


windings - one per strand.
 PTC resistors – temperature feelers which
are mounted on the winding package from
the outside are not acceptable.
Operating mode SI according to IEC 34 – Part 1

* depending on the separator type

IMPORTANT: Consequential damage to the separator caused by motors provided


by the customer cannot be asserted as warranty claims with GEA Westfalia Sepa-
rator.

Pos : 97 /---Notiz en (in 17 Spr achen)--- @ 13\mod_1401103296658_0.doc x @ 797090 @ @ 1

GEA Westfalia Separator Group 93


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Electrical installation 2058-9600-020 / 22.08.16

Note
注释
Noter
Notas
Notes
‫وتالحظ‬
Notater
Notatki
Notizen
Notities
Бележки
Pastabos
Märkmed
Σημειώσεις
Anotaciones
Для записей
Muistiinpanot

Pos : 98 /BA/Standard/00_Ü berschriften/Kapitel/14_Ersatzteile @ 0\mod_1328016648937_18.doc x @ 14543 @ 1 @ 1

94 GEA Westfalia Separator Group


169/1507

2058-9600-020 / 22.08.16 Spare parts

11 Spare parts

11.1 Use only genuine spare parts. ................................................................. 96

GEA Westfalia Separator Group 95


170/1507

Spare parts 2058-9600-020 / 22.08.16

Pos : 99 /BA/Standard/14_Ers atzteile/Original _Ersatzteile/Original _Ers atzteile_Sep_Dek @ 8\mod_1385995574267_18.doc x @ 477076 @ 2 @ 1

11.1 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. 89

WARNING Danger due to defective spare parts

Non-genuine or non-approved spare parts or operating materials reduce the avail-


ability of the centrifuge.
Non-genuine or non-approved spare parts or operating materials reduce the avail-
ability of the centrifuge.
 Use only genuine spare parts from GEA Westfalia Separator to assure the oper-
ating safety and optimum availability of the centrifuge.
Pos : 100 /---Neue Seite--- @ 0\mod_1317283043850_0.doc x @ 550 @ @ 1

96 GEA Westfalia Separator Group


171/1507

2058-9600-020 / 22.08.16 Spare parts

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

GEA Westfalia Separator Group 97


172/1507

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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
173/1507

Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list

Quotation-No.:

Global Comments: ---

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

Date: 11.07.2018 Dept.: 2162

Type: Power Plants Corr. Drawing: P1451886352-9937-PID002 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 = ---

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 1 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
174/1507

Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXEUA11 Socket Gate Valve 0018-9912-600 159802 3/4’’ --- Part of N M L
AA601 PN16
DIN Ins. XXMJV21 BB010
Thr.
XXEUA11 Non return valve 0018-9914-600 RVA01-05 AVQ CuZn 3/4’’ Part of N M L
AA602 --- PN16
DIN Ins. XXMJV21 BB010
Thr.
XXEUA11 Diaphragm pump 8078-9200-120 DM20/75 ANV-X aluminium 3/4’’ / Pneumatic Part of N M L
AP020 NBR 1/4’’ motor XXMJV21 BB010
DIN Ins.
Thr./EN
10226-1
XXEUA11 Hose 0018-6585-710 141 x 10 x 400 NBR DN125 Part of Separator N M L
BR801 ---
Plug
male
XXEUA11 Hose 0018-6490-710 61 x 5 x 480 NBR DN50 Part of Separator N M L
BR802 ---
Plug
male
XXGHC11 2/2 way solenoid valve 0018-8133-600 0331 Latón --- Part of Separator N M L
AA010 FKM 0-10 bar

XXGHC11 2/2 way solenoid valve 0018-8133-600 0331 Latón --- Part of Separator N M L
AA015 FKM 0-10 bar

XXGHC11 Non-return valve 2058-8839-000 --- DN20 Part of Separator N M L


AA601 ---

XXGHC11 Solenoid valve block 0018-7614-000 --- 3/4’’ --- 24 V/DC, Part of N M L
AA602 Separator
DIN Ins.
Thr.

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 2 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
175/1507

Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXGHC11 Hose 0018-7944-000 13 x 780 NBR Part of Separator N M L
BR801

XXGHC11 Hose 0018-7941-000 6 x 1400 NBR Part of Separator N M L


BR802

XXGHC11 Hose 0018-8012-000 6 x 740 NBR Part of Separator N M L


BR803

XXGHC11 Pressure transmitter 0005-1529-300 NAE 1.4301 1/4’’ 0 to 16 bar, 24 V/DC, N M L


CP001 --- Part of Separator
DIN Outs.
Thr.
XXGHC11 Pressure gauge 0001-1572-600 --- 0 to 10 bar, N M L
CP501 ---
Part of
XXGHC11 AA602
XXGHC11 Water detector 0005-1464-080 CLS-50 --- --- Part of Separator N M L
CQ001 ---

XXMJV20 Electric motor DCM-3,0B 100 L LOOSE DELIVERY, N M L


AP010-M01 3 kW, 400V,
50 Hz with
anti condensate
heater 230 V, 50 Hz
XXMJV20 Pressure relief valve --- --- Set pressure: 4 bar, N M L
AA010-Y01 Part of gear pump unit

XXMJV20 Gear pump unit 9990-0320-180 KFF 80 RF 2 - D 15 - 1 1/2’’ LOOSE DELIVERY, N M L


AP010 PN25
SAE incl. Electric Motor
Flange XXMJV20 AP010-M01

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 3 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
176/1507

Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXMJV20 Strainer 0018-6129-210 22.050 EN-JS1049 DN65 LOOSE DELIVERY N M L
AT902 --- PN16
DIN
Flange
XXMJV20 Pressure gauge 0001-1820-400 RChG 100-3 Wetted Parts: 1.4404 / 1/2’’ LOOSE DELIVERY N M L
CP840 Case: 1.4301 ---
BSP -1 to 5 bar
Outs.
Thr.
XXMJV20 Pressure gauge 0001-1821-400 RChG 100-3 Wetted Parts: 1.4404 / 1/2’’ LOOSE DELIVERY N M L
CP860 Case: 1.4301 ---
BSP 0 to 10 bar
Outs.
Thr.
XXMJV21 Electric motor 5289-7835-139 W2X 160L-02 15 kW, 400 V, N M L
AT010-M01 50 Hz with anti
condensate heater
230 V, 50 Hz
XXMJV21 3/2-way piston valve 0018-7621-000 GGG-40 DN25 N M L
AA001 FKM (Viton) PN16
DIN2633
Flange
XXMJV21 3/2 way solenoid valve 0018-7621-600 GMV 3197 Latón 1/8’’ NC Integrated in N M L
AA001-Y01 FKM ---
ISO Ins. XXMJV21 AA001
Thr.
XXMJV21 Shut-off valve 0018-6050-240 22.046 RKWD 0.7043 DN40 N M L
AA110 --- PN16
EN 1092-
1 Flange
XXMJV21 2-way ball valve 0018-7960-400 ZE311062 1.4408 DN15 N M L
AA220 PTFE PN64
ISO1127
Welded

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 4 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
177/1507

Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXMJV21 2-way ball valve 0018-7966-400 ZE311021 1.4408 1/4’’ N M L
AA250 PTFE PN64
DIN2999
Ins. Thr.
XXMJV21 2-way ball valve 0018-7966-400 ZE311021 1.4408 1/4’’ N M L
AA260 PTFE PN64
DIN2999
Ins. Thr.
XXMJV21 Non-return valve 0018-1346-300 MR330027 1.4301 1 1/2’’ N M L
AA601 FKM PN16
ISO 228
Ins. Thr.
XXMJV21 Flanged globe valve 0018-6050-210 22.046 0.6025 DN40 N M L
AA602 --- PN16
EN 1092-
1 Flange
XXMJV21 Spring safety valve 0018-7553-400 SAFE-TCP 67.961 1.4581 1/2’’ NC 67.961 / 10 bar N M L
AA705 --- PN100
ISO 228
Outs.
Thr./ISO
228 Ins.
Thr.
XXMJV21 Plate heat exchanger 9085-1105-000 OC4-60 1.4404 1“ N M L
AC010

XXMJV21 Separator OSE 40-0196-067 --- --- incl. Electric Motor N M L


AT010 XXMJV21 AT010-M01
Flange/
Welded
XXMJV21 Sludge Transfer Unit Complete 2026-1165-120 --- N M L
BB010

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 5 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
178/1507

Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXMJV21 Orifice plate 2062-8829-000 --- --- DN40 Set of Orifice Plates, N M L
BP601 --- PN16
Part of Separator,
Diameters
10/12/15/18/21/24
XXMJV21 Orifice plate 2062-8829-000 --- --- DN40 Set of Orifice Plates, N M L
BP602 --- PN16
Part of Separator,
Diameters
10/12/15/18/21/24
XXMJV21 Corrugated Hose 0018-7028-100 40 x 1150 1.4541 / 1.4301 DN40 Part of Separator N M L
BR801
BSP
Outs.
Thr.
XXMJV21 Corrugated Hose 0018-7028-100 40 x 1150 1.4541 / 1.4301 DN40 Part of Separator N M L
BR802
BSP
Outs.
Thr.
XXMJV21 Hose 0018-6585-710 141x10x400 NBR DN125 Part of N M L
BR803 --- ---
XXMJV21 BB010
XXMJV21 Desludging Control 0005-0924-070 --- --- --- Part of Separator, N M L
CE501 --- integrated in Control
Cabinet / by Motor
Current Measurement
XXMJV21 Level switch 0005-1884-000 LBFS 03121.C/8016 1.4404 1/2’’ Part of N M L
CL101 --- ---
DIN Outs. XXMJV21 BB010
Thr.

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 6 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
179/1507

Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXMJV21 Level switch 0005-1884-000 LBFS 03121.C/8016 1.4404 1/2’’ Part of N M L
CL102 --- ---
DIN Outs. XXMJV21 BB010
Thr.
XXMJV21 Pressure transmitter 0005-1533-300 NAE 1.4301 1/4’’ 0 to 16 bar, 24 V/DC, N M L
CP001 --- ---
DIN Outs.
Thr.
XXMJV21 Pressure transmitter 0005-1529-300 NAE 1.4301 1/4’’ 0 to 16 bar, 24 V/DC, N M L
CP010 --- Part of Separator
DIN Outs.
Thr.
XXMJV21 Pressure gauge 0001-1821-400 RChG 100-3 Wetted Parts: 1.4404 / 1/2’’ 0 to 10 bar N M L
CP520 Case: 1.4301 ---
BSP
Outs.
Thr.
XXMJV21 Pressure gauge 0001-1572-600 RgG 63-1 rm Brass / Stainless Steel R1/4’’ 0 to 10 bar, Part of N M L
CP530 --- --- Separator
DIN Outs.
Thr.
XXMJV21 Speed Sensor 0005-0868-000 NJ5-11-NG --- Part of Separator N M L
CS001 --- ---

XXMJV21 PTC-Feeler --- --- --- Part of Separator, N M L


CT001 ---
integrated in
Separator motor
XXMJV21 Resistance thermometer PT 100 0005-1534-400 MBT 5250 1.4571 G1/2A N M L
CT010 Silicone ---
ISO Outs.
Thr.

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 7 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
180/1507

Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXMJV21 Resistance thermometer 0001-1579-400 2xPT100 1.4571 1/2’’ Integrated in N M L
CT020 ---
DIN Outs. XXMJV21 AA001
Thr.
XXMJV21 Dial Thermometer 0001-1822-400 S73.100 1.4571 1/2’’ 0 to 200°C N M L
CT501 ---
DIN Outs.
Thr.
XXMJV21 Dial Thermometer 0001-1822-400 S73.100 1.4571 1/2’’ 0 to 200°C N M L
CT502 ---
DIN Outs.
Thr.
XXMJV21 Dial Thermometer 0001-1822-400 S73.100 1.4571 1/2’’ 0 to 200°C N M L
CT510 ---
DIN Outs.
Thr.
XXMJV21 Vibration pick up 0005-1747-000 PCH 1220 1.4305 --- Part of Separator, N M L
CY001 --- integrated in Control
Cabinet / by Motor
Current Measurement
XXQFB11 3/2 way solenoid valve 0018-9930-610 GMV 3197 straight screw Brass 1/4’’ NC Part of N M L
AA030 connection NBR PN16
ISO Ins. XXMJV21 BB010
Thr.
XXQFB11 Throttle valve 0018-1677-280 491 Aluminium G1/4 N M L
AA102 --- PN16
DIN Ins.
Thr.
XXQFB11 Throttle valve 0018-1677-280 491 Aluminium G1/4 N M L
AA103 --- PN16
DIN Ins.
Thr.

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 8 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
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Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXQFB11 Air compressor regulator 0018-9922-560 AW20-F02BG-A plastic material 1/4’’ Part of N M L
AA120 NBR-Ms PN16
DIN Ins. XXMJV21 BB010
Thr.
XXQFB11 Air compressor regulator 0018-9922-560 AW20-F02BG-A plastic material 1/4’’ N M L
AA121 NBR-Ms PN16
DIN Ins.
Thr.
XXQFB11 Manometer --- --- 1/8’’ 0 to 16 bar, N M L
CP501 ---
DIN Outs. Integrated in
Thr. XXQFB11 AA121
XXQFB11 Manometer --- --- 1/8’’ 0 to 16 bar, N M L
CP502 ---
DIN Outs. Integrated in
Thr. XXQFB11 AA120
XXQLB11 Control valve 0018-9513-220 23.405 EN-GJS-400-18LT DN40 with limit switch N M L
AA001 (GGG-40.3) PN16 Open/Closed
DIN open & close
---
Flange
XXQLB11 3/2 way solenoid valve 0018-3734-620 0330 Brass 1/4’’ NC N M L
AA001-Y01 NBR ---
ISO Ins.
Thr.
XXQLB11 Control valve 0018-8156-220 STEVI 23.440 1.4021 DN25 NC PREMIO el. Kvs 6,3 N M L
AA031 PN25 WS-actuator
EN 1092- 1,6 kN
1 Flange
XXQLB11 Strainer 0018-7042-210 22.050 EN-JS1049 DN40 N M L
AT602 --- PN16
DIN
Flange

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 9 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
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Customer: MAN Diesel & Turbo SE, Proj. Project-/Order-No.: 886352 / 1451886352
Chittagong
Location: --- Project-title: EN_1_886352_2_LO
LO Separator Unit ECU OSE 40 with GEA Westfalia Separator
Steam Pre-Heater
LO SEPARATOR UNIT ECU
Device list
Position Description Part-No. Type Object Material DN Rest Position Drive Remarks A B C
Gasket Material PN Feedback
Typ
XXQLC11 Steam trap 0018-7589-200 FT14-10 EN-GJS-400-15 (GGG- 1’’ N M L
AA601 40) PN16
DIN 2999
Ins. Thr.
XXQLC11 Globe valve 0018-6048-210 22.046 EN-JS1049 DN25 N M L
AA605 metallic sealing PN16
DIN
Flange

Created Date: 20.02.2018 Checked Date: 20.02.2018 Approved Date: Document No.: Revision: Page:
By: Vering.Ga By: Lorenz.An By: P1451886352-9937-DVL002 10 / 10
Copyright. © All rights reserved Issued for: ,
Filename: SV42080OEL9306\BL Marine/Energy - MA/EN\Kundenauftraege\DM\MAN\MAN Diesel & Turbo SE, Proj. Chittagong\EN_1_886352_2_LO.prj@SV42080OEL9306\WS Projekt/Dokumentablage\Basic and Process Engineering\Equipmentlisten\P1451886352-9937-DVL002
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Process Data Sheet


No.: P1451876293-9937-PDS002 Date 13.02.2018 Sheets:4 Sheet: 1

Module: Power Plants

Accompanying drawings: P1451876293-9937-PID002/LAY002

Belongs to:

Drawn (Date/ Name): 13.02.2018 – A. Pohl Abt./ Dep.: E-PED-4.2.3

Checked (Date/ Name): 13.02.2018 – A. Lorenz Abt./ Dep.: E-PMS-8.7.4

Standard checked (Date/ Name): Abt./ Dep.:

Customer: MAN Diesel & Turbo SE

Project: Bogra-1, Bangladesh


Customers Order No.:

Order No.: 1.451.876.293

more project-order dates: XXMJV 21

Lube Oil Treatment

A 14.02.2018 Feed Pump installation A. Pohl A. Lorenz


0 13.02.2018 First Issue A. Pohl A. Lorenz
Date / Approval.
Rev. Fecha Status Date / Details / Detalles Prepared / Approved / Released /
Fecha estado de Prebarado Aprobado Autorizado
aprobación
GEA Westfalia Separator Group GmbH
GEA Westfalia Separator Group GmbH
Werner-Habig-Straße 1, 59302 Oelde, Deutschland
Tel. +49 2522 77-0, Fax +49 2522 77-2488, www.gea.com
Sitz der Gesellschaft: Oelde, Registergericht: Amtsgericht Münster, HR B 7223, UST-ID-Nr. DE 812 459 899
Geschäftsführung: Norbert Breuer, Tobias Dieckmann, Guido Faltis, Ansgar Hoffmann
Aufsichtsratsvorsitzender: Dr. Matthias Decker
Deutsche Bank AG, Bielefeld (BLZ 480 700 20) 066922600, SWIFT: DEUT DE 3 B, IBAN DE72 4807 0020 0066 9226 00
Commerzbank AG, Bielefeld (BLZ 480 800 20) 0213384200, SWIFT: DRES DE FF 480, IBAN DE13 4808 0020 0213 3842 00
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Process Data Sheet


No.: P1451876293-9937-PDS002 Date 13.02.2018 Sheets: 4 Sheet: 2

Process Conditions

Oil to be processed

Kind: LO
Viscosity: SAE40
Density: 0,9 kg/dm³ at 15°C
Feed temperature: 50°C
Separating temperature: 95°C
Separating capacity: 5750 dm³/h

Separator

Type: OSE 40-0196-067/25


Quantity: 1 per unit / 6 units
Operation mode: single stage, purifier / clarifier
Kind of ejection: total
Clean oil discharge press. : max. 2,0 bar g

Feed Pump

Kind: gear pump aggregate


Type: KFF 80 RF 2 − D 15
Quantity: 1 per unit, installed outside the module
Pump capacity: 6780 l/h ( 113 l/min )
Suction height: - 0,4 bar g
Delivery height: 3 bar g
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Process Data Sheet


No.: P1451876293-9937-PDS002 Date 13.02.2018 Sheets: 4 Sheet: 3

Steam Heater

Type: OC4-60
Quantity: 1 per unit, installed on the module
Steam Pressure (System) /: 8 bar (g) (9 bar abs)
Steam Temperature (System) /: ≈ 160 °C
Steam Pressure (Heater) /: 3 bar (g) (4 bar abs)
Steam Temperature (Heater) /: 142,9 °C
Steam Consumption /: ≈ 229 kg/h per heater /

Environmental Conditions

Ambient temperature: +5°C up to +50°C


Humidity: up to 92% rel.
Altitude: up to 100 m above sea level
Installation of equipment: indoor

Electrical Supply

Infeed: 3 x 400 V ± 5% / ± 10% short time*


50 Hz ± 2% / ± 5% short time*
Control voltage: 230 V, generated in control cabinet
Valve operating voltage: 24 VDC, generated in control cabinet
* As per IEC 60034-1

Operating water (condensate is not permitted)

Hardness: max. 107 mg/dm³ CaCO3


Chloride ions: max. 100 mg/dm³
ph-value: 6,5 – 8,5
Suspended matter: max. 10 mg/dm³
Particle size: max. 50 µm
Feed temperature: +10°C up to 85°C
Feed pressure: 3 - 10 bar g
Required capacity of the water feed system: 1,2 dm³/s (4320 dm³/h)
continuously available but only used during
bowl ejection cycle
Average water consumption per bowl ejection: ≈ 13 l per separator (approx. every 2 hours, sludge
dependent)

Compressed Air

Feed pressure: 3,0 – 8,0 bar g


Average air consumption: ≈ 115 Ndm³/h per separator (if one bowl ejection
happens every 2 hours)
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Process Data Sheet


No.: P1451876293-9937-PDS002 Date 13.02.2018 Sheets: 4 Sheet: 4

Adjustments and set points

XXMJV21 CT010 Temperature Element TE 67°C

XXMJV21 CT020 Temperature Controller TC 95°C

XXMJV21 CT020 Temperature alarm low TAL 85°C

XXMJV21 CT020 Temperature alarm high TAH 105°C

XXGHC11 AA602 Water pressure reducer PC 2 bar g, if operating


water valve is opened

XXQFB11AA120 Compressed air control assembly PC 3,0 bar g

XXMJV21 CP010 Pressure transmitter clean oil discharge PAL 1,0 bar g

XXMJV21 CP010 Pressure transmitter clean oil discharge PAH 3,0 bar g

XXGHC11 CP001 Pressure transmitter sludge monitoring PSH 1,0 bar g


System

XXMJV21 BP601 Orifice plate - separator feed ∅i 15 mm


(refer to Separator manual chapter 2.7.1)

XXMJV21 BP602 Orifice plate - separator discharge ∅i 12 mm


(refer to Separator manual chapter 2.7.3)
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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
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–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.
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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


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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
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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:
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• 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.
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Instruction manual
Designation: Operating panel
Model: GEA IO 4

No. 8555-9001-050
Edition 27.11.2017
202/1507

About this document 8555-9001-050 / 05.01.18

ORIGINAL INSTRUCTION MANUAL


Contents subject to modification!

The authors are always grateful for remarks and suggestions


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

2 GEA Westfalia Separator Group


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8555-9001-050 / 05.01.18 About this document

1 About this document 7

1.1 Sphere of application ................................................................................. 8


1.2 Note on figures and descriptions ............................................................... 8
1.3 Other applicable documents ...................................................................... 8
1.4 Structure of safety notices ....................................................................... 10
1.5 Target groups .......................................................................................... 11
1.5.1 Operator ................................................................................................... 11
1.5.2 Skilled worker .......................................................................................... 12
1.5.3 Trained specialist ..................................................................................... 12
1.6 Service offers ........................................................................................... 12
1.6.1 Service ..................................................................................................... 12
1.6.2 Training .................................................................................................... 12
1.7 Additional documentation ........................................................................ 13

2 Safety precautions 15

2.1 Intended use ............................................................................................ 16


2.2 Reasonably foreseeable misuse ............................................................. 16
2.3 Qualification of personnel ........................................................................ 16
2.1 Responsibility of the plant operator ......................................................... 17
2.2 Modifications or manipulation of the unit ................................................. 17
2.3 Avoiding hazards due to the HMI device ................................................. 17
2.3.1 Open equipment ...................................................................................... 18
2.3.2 Electrical power ....................................................................................... 18
2.3.3 Operating the HMI device safely ............................................................. 18
2.3.4 Areas at risk of explosion ........................................................................ 18
2.3.5 High-frequency radiation ......................................................................... 18
2.3.6 Instructions for using the device .............................................................. 18
2.4 Requirements for spare parts and operating materials ........................... 19
2.5 Liability ..................................................................................................... 19

3 Description 21

3.1 Personal safety gear ................................................................................ 23


3.2 Function of control unit and GEA IO operator panel ............................... 23
3.3 HMI device ............................................................................................... 23
3.3.1 4“ HMI device........................................................................................... 24
3.3.2 Interfaces ................................................................................................. 26
3.4 Features ................................................................................................... 27
3.5 Getting to know the operator panel of your GEA IO ................................ 27
3.5.1 Treating the GEA IO user interface properly ........................................... 27
3.5.2 Arrangement of the control panel ............................................................ 29
3.5.3 Meaning of the icons in the main navigation area ................................... 29
3.5.4 Meaning of the status displays ................................................................ 31
3.5.5 Alarms, warnings and message screens ................................................. 32
3.5.6 Displaying active and inactive elements .................................................. 33
3.5.7 Displaying icons for switching on and off ................................................ 35
3.5.8 Displaying media in pipelines .................................................................. 35
3.5.9 Displaying output fields ............................................................................ 36
3.5.10 Displaying input fields .............................................................................. 37
3.6 Editing data in input fields ........................................................................ 38
3.6.1 Opening input fields ................................................................................. 38
3.6.2 Changing values in input fields ................................................................ 38
3.7 Password protection ................................................................................ 40

GEA Westfalia Separator Group 3


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About this document 8555-9001-050 / 05.01.18

3.8 Commissioning ........................................................................................ 40


3.9 Commissioning (Easyline) ....................................................................... 41
3.10 Factory settings ....................................................................................... 42
3.11 I/O check .................................................................................................. 45
3.11.1 Test digital inputs ..................................................................................... 47
3.11.2 Test digital outputs .................................................................................. 49
3.11.3 Test analogue inputs ............................................................................... 50
3.11.4 Test analogue outputs ............................................................................. 51
3.12 Data backup............................................................................................. 52
3.12.1 Backup data ............................................................................................. 52
3.13 User management ................................................................................... 53
3.14 Operation ................................................................................................. 55
3.14.1 Display and set feed data ........................................................................ 56
3.14.2 Displaying and setting machine data ....................................................... 64
3.14.3 Displaying and setting discharge data ..................................................... 67
3.14.4 Displaying alarms and warnings .............................................................. 69
3.14.5 Opening the “Motor" screen..................................................................... 70
3.14.6 Opening the “Analogue input” screen ...................................................... 72
3.14.7 Opening the “Digital signal” screen ......................................................... 76
3.14.8 Opening the “Valve" screen ..................................................................... 76
3.14.9 Open the “Controller” screen ................................................................... 78
3.14.10 Open the “Step motor valve" screen ....................................................... 81
3.15 Help ......................................................................................................... 85
3.15.1 Documentation......................................................................................... 86
3.15.2 Colour concept......................................................................................... 86
3.15.3 Messaging function .................................................................................. 87
3.15.4 Remote operation .................................................................................... 88
3.15.5 Screen settings ........................................................................................ 89
3.15.6 Machine information ................................................................................ 94
3.15.7 Measurements ......................................................................................... 95
3.16 Service ..................................................................................................... 97
3.16.1 Contact/hotline ......................................................................................... 97
3.16.2 4.2 Preventative maintenance ................................................................. 98
3.17 Training .................................................................................................. 100
3.18 GEA Westfalia Separator ...................................................................... 101

4 Technical data 103

4.1 Technical specifications ......................................................................... 104


4.1.1 Certificates and approvals ..................................................................... 104
4.1.2 Directives and declarations ................................................................... 104
4.1.3 Dimensional drawings of 4" Operator panel .......................................... 104
4.1.4 Technical data of the Operator panel .................................................... 104

5 Transport and storage 109

5.1 Safe transport of the HMI device ........................................................... 110


5.1.1 Safety during transport .......................................................................... 110
5.1.2 Hazards from ambient temperatures ..................................................... 110
5.1.3 Check for transport damage .................................................................. 110
5.2 Conditions of transport and storage conditions ..................................... 110
5.2.1 Mechanical and climatic conditions of transport and storage ................ 110

6 Assembly and installation 111

6.1 Safety information .................................................................................. 112


6.1.1 Avoid hazards during installation and connection ................................. 112
6.2 Operating conditions .............................................................................. 112

4 GEA Westfalia Separator Group


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8555-9001-050 / 05.01.18 About this document

6.2.1 Mechanical and climatic conditions of use ............................................ 112


6.2.2 Use with additional measures................................................................ 112
6.2.3 Mechanical ambient conditions ............................................................. 112
6.3 Specify mounting position ...................................................................... 113
6.4 Preparing the mounting cut-out ............................................................. 114
6.5 Installing the HMI device ....................................................................... 115
6.5.1 Positioning the clamps ........................................................................... 115
6.5.2 Inserting the mounting gasket ............................................................... 116
6.5.3 Inserting the HMI device ........................................................................ 116
6.6 Connecting the HMI device ................................................................... 117
6.6.1 Connection instructions ......................................................................... 117
6.6.2 Equipotential bonding ............................................................................ 117
6.6.3 Requirements for equipotential bonding ................................................ 118
6.6.4 Connecting the power supply ................................................................ 119
6.6.5 Connecting the configuration PC ........................................................... 120
6.6.6 Connecting the control unit .................................................................... 121
6.6.7 Connecting a USB device ...................................................................... 121
6.6.8 Connecting a printer .............................................................................. 122
6.6.9 Connecting an audio device .................................................................. 122
6.6.10 Switching on and testing the HMI device .............................................. 123

7 Settings 125

7.1 Parameterizing the HMI device ............................................................. 126


7.1.1 Displaying functions of the control panel ............................................... 126
7.2 Visualisation file in the HMI device ........................................................ 128
7.2.1 Restoring a new visualisation (“Restore”) ............................................. 128
7.2.2 Backing up the current visualisation ...................................................... 132
7.3 Set IP address ....................................................................................... 136

8 Commissioning 141

8.1