diesel engine power plants en 12-10-0002
TRANSCRIPT
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engineering for a better world GEA Mechanical Equipment
Energy System Technology
High performance equipment for
diesel engine power plants
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The clever way to separate
Your Powerful Partner
More quality in power stations
4 Power Station System Solutions
Systems overview for diesel engine power plants
High Performance Equipment for Diesel Engine
Power Plants
Centrifugal systems in power stations
Process Overview
Self-cleaning separators
Double Centripetal Pump
GEA Westfalia Separator unitrol
System WMS / SMS in Single Stage
GEA Westfalia Separator minimaXx
Manual Cleaning Separators
Self-Cleaning Separators
Diesel oil treatment
Manual Cleaning Solutions
Self-Cleaning Solutions
Crude oil treatment
Plant Concepts with a System
Process Overview
Heavy fuel oil treatment
Plant Concepts with a System
Process Overview
Lube oil treatment
Plant Concepts for Efficient Operation
Process Overview
Sludge treatment
System Concepts for the Future
Economical Advantages
Ecological Merits
Content
Waste water treatment
Protect the Environment Self-Cleaning
Centrifugal System
GEA Westfalia Separator minimaXx
Manual Cleaning Centrifugal System
Fuel oil conditioning system
VBU GEA Westfalia Separator
ViscoBoosterUnit:
Complete System Between
Service Tank and Engine
Control units Automatic Process
Control More Safety, More Comfort
GEA Westfalia Separator minimaXx
Process Control for Every Requirement
Flexible systems
Energy Compact Units
Solutions for the Modern Power Plant
The Economical Solution
Various additional systems and equipment
Your Powerful Partner for Complete Systems
Process cooling systems
PHE Plate Heat Exchanger
Water desalination system
FWG Fresh Water Generator
Single Stage Evaporating System
Service that counts
serv&care
Proactive Service for Optimum Reliability
in Power Plants
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The power station industry often uses diesel
engines that burn heavy fuel oil, crude oil or diesel
oil. By supplying separation systems specifically
designed for continuous operation under roughest
conditions, GEA Westfalia Separator Group provides
for optimum power output and a long service life for
these engines while taking into consideration the high
environmental standards.
Self-cleaning separators with GEA Westfalia
Separatorunitrolsystems automatically monitor thewater level in the oil and the separation of the solid
material round the clock. As a result, optimum
separation efficiency for different fuel and lube oils
is ensured.
Like clockwork
Normally servicing is necessary only after 8000 to
16,000 operating hours. Surveillance-free operation
reduces personnel costs tremendously.
The accumulatedoil sludge can be processed directly
in the power station, thereby reducing the disposal
costs considerably. All separation systems are available
as modules. Other ready-to-connect systems are also
available as compact units in combination with
components such as GEA Westfalia SeparatorViscoBoosterUnits (VBU) or Plate Heat Exchangers
(PHE).
More quality in power stations
Power Station System Solutions
GEA Westfalia Separator minimaXxOTC 2 Energy Compact Unit for lube oil
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GEA Westfalia Separator eagleclass
Smart. Strong. Reliable.
Applications
Fuel oil separation
Lube oil separation
Separation of sludge
containing oil and water
Separation of waste water
System engineering
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High Performance Equipment for
Diesel Engine Power Plants
Systems overview for diesel engine power plants
GEA Westfalia Separator Group offers leading
technologies and individual systems for power station
use. System engineering from one source, high
quality of workmanship or unrivalled worldwide
service GEA Westfalia Separator Group provides
systems to rely on.
Product range overview
Fuel oil treatment
Fuel oil conditioning system
Lube oil treatment
Sludge treatment
Waste water treatment
Central cooling systemLube oil cooling system
Water desalination system
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1
Fuel oil service tank
2 Fuel oil storage tank
3 Fuel oil sludge tank
4 Lube oil sludge tank
5 Fuel oil conditioning system
6 Fuel oil treatment
7 Sludge treatment
8 Lube oil treatment
9
Waste water tank
10 Water desalination system
11 Auxiliaries
12 Charge air cooler M.E.
13 Waste water treatment
14 HT central coolers
15 LT central coolers
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The centrepiece of a fuel or lube oil treatment
system is the centrifugal separator.
Effective treatment ensures that only clean oil enters
the drive unit. The wear on the injection system andon components such as cylinders, cylinder liners and
the crankshaft of the diesel engine is minimized.
Main duties of centrifugal separators:
Separation of solids
Separation of water
Suitable types of centrifugal separators for
these duties:
Self-cleaning separators with disc bowl
and automatic bowl ejection facility
Manual cleaning separators with
solid-wall disc bowl
Centrifugal systems in power stations
Process Overview
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Fuel oil
conditioning
system
Fuel oil
treatment plant
with centrifugal
separator
Lube oil
treatment plant
with centrifugal
separator
Sludge
treatment plant
with centrifugal
separator
Waste water
treatment plant
with centrifugal
separator
Service tank Lube oil tank
Settling tank Boiler plant
Utilities Utilities
Sludge Sludge
Pump system
Clean Oil Utilities
WaterConcentrated
sludge
Disposal
e.g. incinerator
Waste oil tank
Utilities
Treated water
Pump system
Separated oil
Sludge
Waste oil tank
Storage tank
Pump system
Pump system
Pump system
Waste watersystem
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Double Centripetal Pump
Self-cleaning separators
Features
Automatic operation
Continuous operating mode
Self-cleaning effect of the bowl
without CIP system
Highly concentrated solids
High separation efficiency
Can be used as clarifier and purifier
Discharge of the light and heavy phase
under pressure by centripetal twin pump
Low noise level
Belt drive
Self-cleaning separators with disc bowl and
automatic solids ejection are used where the
percentage of solids in the oil is too high for manual
cleaning. They are used mainly for the clarification and
purification of fuel oils such as gas oil, diesel oil, crude
oil, heavy fuel oil and lube oil. The separated solids
slide down the underside of the disc into the solids
holding space. Self-cleaning separators eject solid
matter automatically while the separator is running.
This avoids shutting down the separator frequently
for cleaning. The clean oil and the separated waterare conveyed to the discharge under pressure by a
centripetal twin pump.
Self-cleaning separators operate continuously. Solids
ejection occurs either by total or partial ejections or
in a combination of both. In case of total ejection and
combination of total and partial ejections, there is
additional self-cleaning of the disc stack.
Labour-intensive and costly measures to clean the
discs using CIP (cleaning in place with chemicals)
systems are not necessary. Optimum separation
efficiency over long operating times is ensured. Major
maintenance work is required only after 8000 to
16,000 operating hours.
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Bowl cross section of a self-cleaning
mineral oil separator with disc bowl
Solids discharge
Untreated
oil feed
Treatedoil discharge
Separated
water discharge
Double centripetal pumpSealing and displacement water
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Self-cleaning separators
GEA Westfalia Separator unitrolSystem
WMS / SMS in Single Stage
Modern fuel oil and lube oil treatment plants
from GEA Westfalia Separator Group provide easy
handling and optimum separating efficiency in
difficult situations.
The heart of these systems is a new generation
of self-cleaning mineral oil separators with
unitrol system. These separators operate without
regulating rings and can be applied for a wide rangeof heavy fuel oils with a specific density up to
1.01 g / I as well as for a wide range of lube oils.
The essential features of these separators are both,
the continuous monitoring of the oil for water and
the continuous monitoring of the solids holding
space for optimum solids filling, in one stage.
Automatic monitoring means that regulating rings
are unnecessary and operating errors caused through
manual adjustment are eliminated.
The Water Monitoring System (WMS) ensures
reliable water separation. The water in the oil is
separated out and discharged. The Sludge Space
Monitoring System (SMS) checks the solids space
for separated foreign matter.
The oil is displaced prior to a bowl ejection. The
precisely defined displacement volume minimizes
oil losses.
A further innovative feature of these separators
is the bowls new hydraulic system (GEA Westfalia
Separator hydrostop). Extremely short ejection times
combined with maximized solid ejection ports pro-
vide highly concentrated solids. Further disposalmeasures are simplified, disposal costs reduced
and environmental considerations fully taken into
account.
During total ejections, preferred by GEA Westfalia
Separator Group, the disc stack is also cleaned. Work
and cost intensive measures for cleaning the disc
stack by CIP systems are not necessary; this ensures
optimum separating efficiency over a long period of
operation. Maintenance work is required only after
8000 to 16,000 operating hours.
Just a few basic models are sufficient to cover all
capacity ranges with the benefit of very economical
spare parts storing and servicing.
Features
unitrol system in one stage WMS and SMS
Treatment of fuel oils up to 1.01 kg / I
Regulating rings are not required
High separation efficiency even in
critical situations
Automatic adjustment as
clarifier or purifier
Automatic bowl ejection
Highly concentrated solids
Continuous processing
Self-cleaning effect of bowl
and disc stack by total ejection
Versatility of application
Safe operation
Belt drive
Low noise level
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Sealing and displacement water
Untreated
oil feed
Treated oil discharge
Separated
water discharge
Solids discharge
GEA Westfalia Separatorunitrolsystem
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Manual cleaning separators with solid-wall bowl and
single centripetal pump are today mostly used for the
treatment of diesel oil and lube oil in smaller power
stations.
They are suitable for clarifying or purifying oils with
a low solids content of up to 0.01 % by vol.
The clean oil is discharged from the bowl under
pressure by means of a centripetal pump. Theseparated solids slide down the underside of the disc
into the solids holding space which must be emptied
by hand periodically.
Bowl cross section of a manualcleaning mineral oil separator with
pressure discharge of the clean oil
by centripetal pump
GEA Westfalia Separator minimaXx
Sealing water
Untreated
oil feed
Treated
oil discharge
Separated
water discharge
Manual Cleaning Separators
Features
Suitable for both clarifying and purifying
Highly concentrated solids
Solid design
Versatility of application
Low noise level
Belt drive
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Self-cleaning separators with disc bowl, single
centripetal pump and automatic solids ejection are
used where the percentage of solids in the oil is too
high for manual cleaning. These are used mainly for
the clarification and purification of fuel oils such as
gas oil, diesel oil and lube oil. Self-cleaning separators
discharge solid matter automatically while the separator
is running. This avoids shutting down the separator
frequently for cleaning.
Self-cleaning separators operate continuously. Solidsejection occurs by total discharge with a self-cleaning
effect of the disc stack. Labour-intensive and costly
measures to clean the discs using CIP systems are not
necessary. Optimum separation efficiency over long
operating times is ensured.
The clean oil is conveyed to the discharge under
pressureby means of a centripetal pump. The separated
water flows under gravity via a regulating ring to the
discharge.
Bowl cross section of aself-cleaning mineral oil
separator with solid wall
disc bowl
Sealing and
displacement water
Solids discharge
Operating water discharge
Untreated
oil feed
Treated oil
discharge
Separated
water discharge
GEA Westfalia Separator minimaXx
Self-Cleaning Separators
Features
Automatic operation
Continuous operating mode
Self-cleaning effect of the bowl
without CIP system
Highly concentrated solids
High separation efficiency
Can be used as clarifier and purifier
Closed discharge of the light phase
under pressure by centripetal pumpLow noise level
Belt drive
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Its payback time
During the transportation from the refinery to the
power plant diesel oils are often contaminated with
sea water and other impurities. Centrifuges are essential
for the efficient control and removal of solids and
water from fuel oils in safety fue l oil treatment
systems; they will continue to be so in the future.
Efficient treatment protects the diesel engine from
wear of important components such as cylinder liners,
pistons, piston rings and the injection system. Bigcost savings because of less filter cleaning and less
replacements of filter inserts; no problems with bacteria
growth. The entire plant concept is completed with
the feeder unit.
Compact unit CU D2 for diesel
oil treatment with self-cleaning
separator OSD 2 without heater.
Schematic illustration of a
diesel oil treatment system
with manual cleaning
separator without heater
Manual Cleaning Solutions
Diesel oil treatment
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1 Untreated oil feed
2 Strainer
3 Manual cleaning separator
4 Separated water discharge
5 Feed pump
6 Treated oil discharge
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Self-Cleaning Solutions
Schematic illustration
for oil treatment systemwith self-cleaning
separator without heater
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5
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Feed pump
2 Untreated oil feed
3 Untreated oil return
4 Strainer
5 Operating water
6 Separated water discharge
7 Operating water discharge
8 Solids discharge
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Self-cleaning separator
10 Treated oil discharge
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Safety first
Increasingly crude oil is used in diesel engine power
plants, especially for crude oil pipeline projects.
The crude oil is delivered to the power plant in a
pre-cleaned and degassed condition. However, after
the pre-cleaning the fuel quality is still too poor to be
burnt in a diesel engine.
The viscosity ranges from diesel oil to heavy fuel oil.
As crude oil contains wax which is getting liquid only
at a temperature of min. 50C, the separating temperatureis between 60 C and 98 C. Due to the low flash point,
the system must be equipped with explosion protection.
Plant Concepts with a System
Crude oil treatment
Crude oil treatment unit with control panel for hazardous area installation
Centrifuges are essential for the efficient control and
removal of solids and water from fuel oils in fuel oil
safety treatment systems; they will continue to be so
in the future.
Crude oil fuels from different sources must be purified
efficiently. This treatment protects the diesel engine
from wear of important components such as cylinder
liners, pistons, piston rings and the injection system.
The whole plant concept for crude oil treatment isrounded off with ViscoBoosterUnits.
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Process Overview
Under normal circumstances, GEA Westfalia Separa-
tor Group recommends single-stage treatment for
crude oils.
The high efficiency of separation in a single stage
process ensures low wear of the engine. The high
reliability and long service intervals ensure low operating
costs and continuous, unattended automatic operation
for months. The stand-by centrifuge can be saved for
occasional use in abnormal conditions during
increased solids loading for example.
All equipment with electrical components are useable
for Ex zone 2 (Category 3) Explosion Group II A or B,
Temperature Class T3 in accordance to ATEX EG-RL94/9.
Purging / flushingfor the separator is integrated.
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Regulating valve
2 Strainer
3 Steam
4 Pre-heater
5 Condensate6 Steam trap
7 Untreated oil return
8 Feed pump
9
Strainer
10 Operating water
11
Self-cleaning separator
12 Separated water discharge
13 Untreated oil feed14 Purging / flushing
15 Solids discharge
16 Treated oil discharge
Single stage treatment
plant for fuel oil with
separator
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Heavy fuel oil treatment
Protect your engine
Owing to its low price, residual oil is widely available
on the international market. During combustion
however, impurities cause corrosion and deposits.
Depending on the application, treatment systems are
available both for high-grade and low-grade fuels.
When rating the throughput capacity of the plant,
the following fuel oil data are of central importance:
Viscosity (cSt)
Density (kg/l) Solids and liquid impurities (%)
The results of a research programme confirm optimum
treatment even of fuel oils with viscosities up to
1650 cSt/50C and densities up to 1.01 kg/l (15C).
Centrifuges are essential for the efficient control and
removal of solids and water from fuel oils in fuel oil
safety treatment systems; they will continue to be so
in the future.
Low-grade fuels from different refining processes such
as atmospheric or vacuum distillation as well as
from conversion plants such as catalytic cracker or
visbreaker process must also be purified efficiently.
This treatment protects the diesel engine from wear of
important components such as cylinder liners, pistons,piston rings and the injection system. The whole plant
concept for heavy fuel oil treatment is rounded off
with ViscoBoosterUnits.
Plant Concepts with a System
Energy Compact Unit 2 with two
separators type OSD 35 for HFO treatment
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Process Overview
Under normal circumstances, GEA Westfalia Separator
Group recommends single-stage treatment for heavy
fuel oils.
The high efficiency of separation in a single-stage
process ensures low wear of the engine. The high
reliability and long service intervals ensure low
operating costs and continuous, unattended automatic
operation for months. The stand-by centrifuge can be
saved for occasional use in abnormal conditions during
increased solids loading for example.
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Regulating valve
2 Strainer3 Steam
4 Pre-heater
5 Condensate
6 Steam trap
7 Untreated oil return8 Feed pump
9
Strainer
10 Operating water
11
Self-cleaning separator
12 Separated water discharge13 Untreated oil feed
14 Solids discharge
15 Treated oil discharge
Single-stage treatment plant for
fuel oil with separator incl.
unitrol system
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GEA Westfalia Separator lifecyclebenefit
During application lube oils are exposed to
continuous contamination. Foreign matter such as
abrasives, dust, condensate and decomposition products
deposit in the lube oil sump. Furthermore, acids
contained in the oil and foreign matter from catalysts
can lead to premature aging.
In case of diesel engines, particularly trunk piston
engines, combustion residue and unused fuel find
their way into the crankcase compartment, especiallywith partia l load operation. Sulphurous res idues
and cleavage products of the fuel condensate form
acid water with the water vapour produced during
combustion in the cylinder. All this culminates in
damage of bearings, pistons and cylinders.
Centrifugal separation is the most common method
of lube oil treatment. The separator is located in a
by-pass loop within the lube oil treatment system.
Plant Concepts for Efficient Operation
Lube oil treatment
Schematic illustration of a lube oil treatment
plant with manual cleaning separator
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2
3
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5
1
Feed pump
2 Untreated oil feed
3 Strainer
4 Pre-heater
5 Separated water discharge6 Manual cleaning separator
7 Treated oil discharge
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Process Overview
Self-cleaning mineral oil centrifuges are mainly used
for the purification and dewatering of lube oils,
especially if there is a requirement for 24-hour
unattended operation. Lube oil cleaning reduces
wear and prolongs the life of the lube oil.
The whole range of centrifuges is available for efficient
and reliable treatment of lube oil.
All fuel and lube oil treatment centrifuges from
GEA Westfalia Separator Group have identical design
features allowing the use of common components.This simplifies store management and maintenance
immensely.
Schematic illustration
of a lube oil treatment
plant with self-cleaning
separator
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Feed pump
2 Untreated oil feed
3 Strainer
4 Pre-heater
5 Operating water
6 Separated water discharge
7 Regulating valve
8 Steam
9 Condensate
10 Steam trap11 Treated oil discharge
12 Self-cleaning separator
13 Solids discharge
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Sludge treatment
Save natural resources
The trend towards burning higher viscosity and
higher density fuel oils, together with an increasingly
common usage of residuals, means that the amount
of sludge being created from both, fuel and lube oil
systems, is increasing.
The sludge is pumped from the sludge tank by an
eccentric screw pump and is fed via a heater to the
centrifugal separator. The sludge components of
water, oil and solids are separated by centrifugal force.The recovered oil and water is discharged under pressure
by centripetal pumps.
The concentrated sludge is discharged intermittently
via the sludge transfer unit into a heated sedimentation
tank where final concentration takes place. Excess
water and oil is allowed to overflow back to the
sludge tank. The concentrated sludge is pumped from
the unit automatically by a solids discharge pump
controlled by a level switch.
A microprocessor-based control cabinet supervises
and controls the complete concentration process.
System Concepts for the Future
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1 Regulating valve
2 Steam
3 Pre-heater4 Condensate
5 Steam trap
6 Feed of oil sludge mixture
7 Feed pump
8 Filter
9 Operating water10 Untreated oil return
11 Vibration monitoring
12 Separated water discharge
13 Sludge concentration unit
14 Oily water
15 Concentrated sludge16 Sludge transfer unit
17 Centrifugal separator
18 Treated oil discharge
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Approximately 2.5 % of a powe r plan ts f uel
consumption remains as an unwanted by-product in
the form of an oily water sludge mixture.
With increasing environmental awareness as well as
strict regulations and controls, most operators dispose
of this sludge by incineration or by shoreside
disposal using contract companies. In either case
sludge disposal is becoming an expensive problem for
the operators today.
The GEA Westfalia Separator Group sludge treatment
plant incorporating a specially designed centrifugal
separator is capable of reducing the volume of sludge
for disposal by up to 90%. In addition, fuel oil is
recovered for re-use and recovered lubricating oil can
be used as boiler fuel.
Economical Advantages
Ecological Merits
0
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40
60
80
100
120
Feed Oil outlet Water outlet
Solids
Water
Oil
Sludge treatment system ESD 18 with
self-cleaning centrifugal separator to
reduce the disposal costs
Separation results sludge treatment
Sample taken from
Portion
Benefits
Saves up to 90% disposal costs
Recovers valuable fuel oil
Unburdens the waste water
system from oil residues
Protects our sensitive power ecosystem
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Protect the Environment
Self-Cleaning Centrifugal System
Waste water treatment
system WSD 18
Waste water treatment
in many conventional plants under practical opera-
tion conditions anyway. The further we can reduce
this value, the greater the benefit for our environ-
ment. Waste water is a mixture of the following
constituents:
Cooling water leakages
Fuel and lube oil leaks
Drainages from settling and sludge tanks Effluent from various cleaning processes
The product (i.e. oily water without excessive emul-
sion) is sucked up from the oily water tank and fed by
the feed pump through the filter and pre-heater via
the feed valve to the separator. During the start-up or
ejection program it is led back into the oily water tank.
The product flows from above into the centre of the
separator bowl. The heavy water phase is separated
from the finest oil particles and then conveyed under
pressure by a centripetal pump to the discharge.
Water is the source of life
The treatment of waste water is strictly controlled by
national and international laws.
Waste water may only be discharged after prior
de-oiling with specially approved treatment systems.
The maximum oil content must not exceed 15 ppm. The
limit has even been reduced to 10 ppm in some areas.
Our water must stay clean
Water is the source of all life on earth. The environment
is the habitat of all life and therefore needs our special
protection. Indeed we have a responsibility to future
generations who have the same right on a rich nature
as we do.
15 ppm is too much
Oily water may only be discharged if the oil content
in the effluent is below 15 ppm. 15 parts of oil to one
million parts of water seems small but GEA Westfalia
Separator Group believes this is still too high. More-
over, practice has shown that this value is not attained
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The separated impurities accumulated in the sludge
space are discharged into the sludge tank periodically.
The treated water discharge is monitored by an oil
content meter and discharged into the environment.
If the oil content exceeds 15 or 10 ppm the water is
recirculated into the oily water tank. If an oil content
of 10 ppm is required, our treatment systems are
generally fitted with an absorption filter that can be
connected to ensure that the required result is
achieved.
1 Steam
2 Condensate
3 Automatic filter
4 Heater
5 Untreated waste
water return
6 Pre-de-oiled wastewater feed
7 Operating water
8 Separated water discharge
9 Emulsion breaker
10 Solids discharge
11 Recovered waste oil
12 Self-cleaning separator
13 Absorption filter
14 Treated waste water return15 Treated water discharge
16 Oil monitor
Centrifugal waste water treatment
with self-cleaning separator in
combination with absorption filter
and emulsion breaker
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Waste water treatment
GEA Westfalia Separator minimaXx
Manual Cleaning Centrifugal System
Protect the environment
The waste water treatment system will be supplied as
a Compact Unit (CU). The CU consists of four main
components:
minimaXxseparator
Pump / Prefilter
Absorption filter
Control unit
All the components are small and lightweight to make
them easy for transporting and fitting into the engine
room. The components are installed on a common base
frame. The modular concept can be incorporated into
an existing system.
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1 Pre-de-oiled waste water feed
2 Pre-filter
3 Waste oil collection tank
4 Treated waste water return
5 Feed pump
6 Manual cleaning separator7 Treated water discharge
8 Oil monitor
9 Absorption filter
The clever solution
The waste water treatment system with the
minimaXx separator type WTC was specially
designed for small capacities.
The product (i.e. oily water without excessive emulsion)
is fed by the feed pump into the centre of the separator
bowl. Within the rotating bowl, the product is
separated into heavy and light phase.
The heavy water phase is separated from the finest
oil droplets and dirt particles and then conveyed
under pressure by the centripetal pump to the
discharge. If the oil concentration on the clean
water outlet of the centrifuge exceeds 15 ppm the
water is led through an absorption filter. The lighter
oil phase flows to the centre of the bowl and is
discharged by gravity.
The separated sludge is collected in the solids holding
space and must be removed by hand.
An intelligent control and monitoring system assures
problem-free, round-the-clock unmanned operation.
It also ensures that only water with an oil content
lower than 15 ppm is released into the environment.
A pre-heater is recommended if the waste water con-
tains oils of a higher viscosity.
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Safety first
With the ViscoBoosterUnits, GEA Westfalia
Separator Group offers a complete, compatible system
for a safe and economic fuel oil treatment from the
service tank to the engine.
ViscoBoosterUnits are supplied as package systems.They are designed for 24-hour unattended operation.
Efficient operation of power station diesel engines
requires optimum fuel supply. This key condition is
accomplished by the ViscoBoosterUnitsdeveloped by
GEA Westfalia Separator Group for fuel conditioning.
This unit consists of a treatment system that meets the
fuel requirements between the clean oil tank and injection
system for the diesel engine in terms of the required
injection viscosity and temperature. Supply and booster
pumps are provided for a stable system pressure.
The modules are designed for the different engines as
well as to the required injection viscosity (approx.
10 24 cSt) and corresponding temperature (approx.
135 150C).
To be able to ensure a high plant availability and
to achieve the high plant capacities, several diesel
generators are frequently installed in power stations.
We recommend splitting the classical Energy Unit
into a Feeder Unit and, depending on the number
of engines, into several Booster Units.
GEA Westfalia Separator Group has developed the right
systems for this task.
VBU GEA Westfalia Separator
ViscoBoosterUnit: Complete System Between
Service Tank and Engine
Fuel oil conditioning system
Benefits
Easy adjustment to the engines in
operation
Higher availability of the complete
installation
Simple switch-over to
HFO / MDO for each engine
Easy adjustment if the system is
upgraded later
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VBU (divided module)
VBU for power plant
application
Features
Compact, robust design
Good operability
Automatic viscosity control
Automated control system via control
cabinet with redundant power supply
Automatic, compressed-air controlledfilter system for particle separation
Low weight
Easy installation
Low maintenance costs
1 HFO
2 MDO
3 Feeder pump
4 Strainer
5 Stand-by
6 Pressure control valve
7 Fuel to day tank
8 Fuel from engine
9 Automatic backflushing filter
10 Flow-meter
11 Mixing / Degassing tank
12 Degassing valve
13 Booster pump
14 Stand-by
15 Regulating valve
16 Steam trap
17 Steam or thermal oil
18 Pre-heater
19 Stand-by
20 Condensate or thermal oil
21 Viscosity sensor22 Fuel to engine
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Automatic Process Control
More Safety, More Comfort
The E40 control unit is specifically designed for
the eagleclass. Even the most complex separator and
system applications are controlled with precision.
The E40 control unit performs process and control
functions over and above those of the D10. To
facilitate understanding, operating states, current
process values, faults and changes in system status
are shown by a change in color in the color display.
Machine or system-specific display screens with
assigned touch keys reduce the possibility of
operating faults even further. MMC cards function as
program memory; the lifetime data of the systems
can be read out by technical staff for interval or
preventive maintenance purposes.
As an option, the control unit can be patched into the
wor ldwide web using the Sm@rt Cli ent server
function of the panel and the integrated Ethernet
port. Sm@rt Client allows remote servicing to be
effected quickly and simply. The machine can be
operated and observed from any workstation within
the customers network.
Program control
The control unit controls the program automatically
as well as monitoring the separator completely. In
addition to all the electrical components on the sepa-
rator itself, it is also possible to incorporate in the
control and monitoring system the peripherals
required for a customers specific application.
Keys F1 F4
Soft keypad, screen
dependent
Keys 1 0
Function keypad with
fixed allocation
Status LEDs
Touch display with
backlighting and
4 linesEasy handling by
Micro Memory Card
which stores setting
and history data for
D10 and E40.
D10 with
text display
Control units
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1 Motorstarter box
Motorstarter separator
Motorstarter feed pump
2 OMB 220
Overflow monitoring box
Water seal broken alarm
3 Control unit MC-1 Motorstarter separator
Motorstarter feed pump
Flow monitoring FAH
4 Control unit CC-1
Motorstarter separator
Motorstarter feed pump
Flow monitoring FAH
Temperature monitoring TAL / TAH
Preheater interlocking
5 Control unit CD-1
Control and monitoring system for
self-cleaning minimaXxseparator.
Motorstarter separator
Motorstarter feed pump
Flow monitoring FAH
Flow monitoring FAL
Clean oil outlet
Temperature monitoring TAL / TAH
Preheater interlocking
Sludge pump control
D10
GEA Westfalia Separator minimaXx
Process Control for Every Requirement
1 2
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Flexible systems
Energy Compact Units Solutions for
the Modern Power Plant
GEA Westfalia Separator Groups design engineers
have integrated flexibility into all their products.
Single-, Double- and Triple-Energy Compact Units
(ECU) with optimum layout to meet power plant
requirements are available as standard modules.
ECU 1
ECU 2
ECU 3
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The Economical
Solution
Customer benefits
All systems:
Are installed, piped and electrically wired,
ready for operation on rigid,
stable foundation frames
Are completely checked and tested
Require small installation costs
Are of very compact design, small volume and
weight (less transportation costs)
Can be started up immediately
Are very easy to operate
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Various additional systems and equipment
Your Powerful Partner for Complete Systems
GEA Westfalia Separator Group provides various
systems tailor-made to customers needs.
Modern module design ready for installation.
System intergration into the power plant concept.
Engineering and total system design. All available
from GEA Westfalia Separator Group.
Desalting module for fuel oil washing
Container enclosure for complete modules
Fuel oil unloading module
Heat recovery module
Module supply
Fuel oil unloading module
Fuel oil transfer module
Heat recovery module
Desalting module for fuel oil
Additive dosing module
Water booster module
Air compressor module
Container enclosure for complete modules
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Additive dosing module Air compressor module
Fuel oil transfer module
Water booster module
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Process cooling systems
PHE Plate Heat Exchanger
PHEs are used for cooling purposes, e.g. mainly for
central, lube oil, jacket water circuits, as well as for
auxiliaries, charge air, etc.
A wide range of flexible plate configurations are
offered to cover all heat exchange applications. Suitable
materials like titanium, different grades of stainless
steel, etc. are available.
Features
High heat transmission coefficient
Optimised heat transfer surfaces
Compact design
Low life cycle costs
Simple inspection and maintenance
Low liquid content
Glued and glueless gaskets
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1 From main engine2 To main engine
3 Circulation pump
4 From main engine
5 To main engine6 Circulation pump
7 Auxiliaries
8 Charge air cooler
9 Lube oil cooler10 Cooling water pump
11 Cooling water
12 LT central cooler
13 HT central cooler14 Cooling water
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Water desalination system
FWG Fresh Water Generator
Independent generation of fresh water by single
stage evaporation technology.
Sea water is fed through the condenser, where it
absorbs the latent heat of the condensing vapour.
Some sea water is used as feed water for the evaporator
whilst the remaining brine and non-condensible
gases are discharged using a combined ejector. In
the evaporator the sea water is heated up to the
saturation temperature corresponding to the
vacuum maintained by the ejector, and part of itis evaporated.
The evaporator generally utilizes the waste heat from
the main diesel engine jacket water, however, other
heating media may also be used (e.g. steam, thermal oil).
The vapour produced passes through the demister
located in the upper casing to remove trapped droplets
of water and is led to the condenser. The distillate
is drawn from the condenser by the distillate pump
and discharged through the salinity measuring unit .
Depending on the residual salt content of the distillate,
it is either led to the distillate tank or, if the maximum
allowable residual salt content is exceeded, back to
the evaporator.
All parts in contact with sea water are made of
corrosion-resistant materials (CuNi, stainless steel).
The plates are made of titanium.
On request GEA Westfalia Separator Group can also
supplyMulti Flash Water Generators in a range from
100 3000 t/d.
Process overview
Sea water Jacket water
Fresh water
Fresh water
Fresh water
generator
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Thermal oil / hot water heated
Single Stage Evaporating System
Benefits
Compact
Easy operating, fully automatically controlled
Reliable
Low weight
Low maintenance costs
Integrated anti-scaling system
Corrosion resistant materials
High performance
1 Heat exchanger
2 Jacket water
3 Circulation pump
4 Steam heated
5 Steam6 Steam jet liquid pump
7 Condensate
8 Sea water
9 Distillate
10 Heating water
11 Jacket water heated12 Circulation pump
13 Feed water
14 Brine
15 Brine
16 Demister
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Safety first: this is precisely what the service concept
serv&carestands for.
Shipowners not only benefit from traditional
services such as inspection, maintenance, original
spare parts and repair work provided by the original
manufacturer; they also benefit from proactive
solutions which avoid risk, e. g. online and offline
monitoring with GEA Westfalia Separator wewatch.
These preventive services are the best pre-condition
for a smooth operation.
Enhanced process efficiency also follows from
maximum operating reliability and machine
availability. Accompanying modernization or
upgrading to state-of-the-art technology also offer
the option of boosting performance as required.
serv&care Proactive Service for Optimum
Reliability on Board
The proactive, risk-free services of serv&care optimize operating
reliability and permanent availability of the drive systems.
Training provided on site or in the modern training
centre of GEA Westfalia Separator Group ensures that
the plant operators employees receive training in the
proper handling of the high-tech installations. This
provides additional safety.
Authorized workshops worldwide
And if problems occasionally occur or if a spare part
is required at short notice, the specialists are able
to attend to the ships quickly. This is ensured by a
global network with more than 50 sales and service
companies. Authorized workshops are able to service
every location in the world at short notice.
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In addition to traditional services
such as maintenance or repair,
serv&carealso provides solutions
which avoid risk and with which
the installation availability can be
proactively assured.
serv&careaccordingly makes for maximum operating
reliability, machine availability, process efficiency
and budget security. And these benefits are
provided throughout the entire life cycle of the
entire installation.
Service from the original manufacturer:
Service engineers quickly on site
Extensive service network
Risk avoidance through service provided
by the original manufacturer
Proactive solutions
Upgrading to boost performance
Crew training
serv care
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thisbrochuremerelyservesasanon-bindingdescription
ofourproductsandiswithoutguarantee.
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inparticularrelatingtocapacitydataandsuitabilityforspe
cificapplications,canonlybeprovidedwithintheframework
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freebleachedpaperPrintedinGermanySubjecttomodificationWestfalia,
WestfaliaSeparator,
lifecyclebenefit
,minimaXxa
ndwewatcha
reregisteredtrademarksofGEAMechanicalEquipmentGmbH.
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EN-12-10-0002EN
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX Europe 600 Index.
We live our values.
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