westfalia separator visco booster unit en 9997 0787 030

Westfalia Separator® ViscoBoosterUnitsIf you like to keep it well treated

GEA Mechanical Equipment / GEA Westfalia Separator

Liquids to Value

Cool Calculations. Hot Facts.Efficient solutions at the best conditions

Efficient operation of ship and power station

diesel engines necessitates optimum fuel supply.

This key condition is accomplished by the

Westfalia Separator® ViscoBoosterUnits develo-

ped for fuel treatment.

This unit consists of a treatment system that meets

the fuel requirements, in terms of the required

injection viscosity and temperature, between the

clean oil tank and injection system for the main and

auxiliary engines. The purpose-built booster pumps

provide for the necessary system pressure. The

modules are designed to the different engine

con sumption levels depending on their power

ratings, as well as the injection viscosity (approx.

10 – 24 cSt) and corres ponding injection tempera-

tures (approx. 120 – 150 °C).

Westfalia Separator® ViscoBoosterUnit

2

GEA Westfalia Separator

Fulfills all requirements Depending on the engine manufacturer, different

variants are required for the inte gration of

Westfalia Separator® ViscoBoosterUnits.

GEA Westfalia Separator has res pon ded by offering

a variety of system solutions. Whether with or

without stand-by function for feeder pumps,

booster pumps and heavy fuel oil preheaters, or

for one or more engines – you will always find a

solution that meets your needs and expectations.

Naturally, all systems are compact, lightweight,

reliable, easy to install and simple to maintain

with all main components operating at optimum

performance.

Approved by all major classification societies

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Full Speed Ahead!Marine units

Efficient and reliable compact modules are required

for supplying HFO to the main and auxiliary

engines onboard ships. GEA Westfalia Separator

marine units satisfy these requirements in full.

They comprise all important main components

(pumps, preheaters) as stand-by units as well as

further elementary functions like automatic product

filtration by compressed air-assisted cleaning, fuel

consumption and viscosity measurement. An

optimum arrangement on a base frame enables

a compact construction while at the same time

ensuring good operability. Split add-on modules

(feeder / booster component) for adaptation to the

respective installation conditions are available

if required.

Advantages Adjustment to all available motor sizes

Standard modules available

Shell and tube preheater as standard

Central monitoring system

Pressure control valve

Standardized units

Type VBU VBU VBU VBU VBU VBU VBU

3.5 / 25 5.0 / 32 7.0 / 40 9.5 / 50 12.5 / 50 16.5 / 65 21.0 / 65

Engine

output 3500 kW 5000 kW 7000 kW 9500 kW 12,500 kW 16,500 kW 21,000 kW

Length 2500 mm 2500 mm 2600 mm 2800 mm 3000 mm 3250 mm 3350 mm

Width 1300 mm 1300 mm 1300 mm 1500 mm 1500 mm 1650 mm 1650 mm

Height 2000 mm 2000 mm 2000 mm 2000 mm 2000 mm 2000 mm 2000 mm

Weight 1800 kg 1800 kg 1900 kg 2200 kg 2400 kg 2700 kg 3100 kgDim

ensio

ns &

Wei

ght

4


HFO

MDO

Changeover valve

Feeder pump module

Changeover valve

Strainer

Stand-by

Feeder pump

Changeover valve

Stand-by

Optimally harmonized modules guarantee reliable functionality

Stand-by

Stand-by

Steam trap

Booster pump

Regulating valve

Steam or thermal oil

Preheater

Condensate or thermal oil

Viscosity sensor

Mixing / Degassing tank

Flow meter

Fuel to engine

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Fuel to day tank

Fuel from engine

Automaticbackflushing filter

Degassing valve

Feeder pump

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Westfalia Separator® pumpstation was developed

in cooperation with a leading pump manufacturer.

The completely new design of these stations allows

GEA Westfalia Separator to offer the most compact

booster modules and improve our position as

market leader in quality.

More functions – less space requirement. The modular

stations incorporate multiple useful functions for all

applications with two pumps. Compared to single

components you save up to 50 percent space.

Double stations are used, if a second standby pump

is required for safety. Westfalia Separator® pumpstation

has been designed to be highly modular and with

many useful options.

Your advantages More functions

More safety with two pumps

50 percent less space requirement

Simple installation

Available with magnetic coupling

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Less Space Required, More Functions and Lower in Costs

The new Westfalia Separator® pumpstation

All functions and pipework

are implemented in one compact

station block

Reliability through a stand-by

pump which is always available

Significantly lower in cost

Conventional structure Complex module structure

Individual components

More space requirement

8


Technical Features of Westfalia Separator® pumpstation

11

1

1

2

9

14

13

12

4

5

315

7

10

6

8

9


Technical Features of Westfalia Separator® pumpstation

Technical data DKC.At 0 bar, 75 mm²/s

240 – 2400(KFT 5 – KFT 20)

1600 – 5000(KFT 32 – KFT 42)

3000 – 9000(KFT 55 – KFT 85)

5500 – 13000(KFT 105 – KFT 118)

Qth (1450 min-1, 50 Hz) 5 – 20 l / min 32 – 42 l / min 58 – 83 l / min 100 – 118 l / min




Max. press. pressure flange 16 bar 16 bar 16 bar 16 bar

Temperature

With standard mechanical seal 150 °C 150 °C 150 °C 150 °C

With hard material mechanical seal ata 180 °C 180 °C 180 °C 180 °C

With magnetic coupling 250 °C 250 °C 250 °C 250 °C

Viscosity

Min. 2 mm²/s 2 mm²/s 2 mm²/s 2 mm²/s

Dimensions and weights

DNs / DNd SAE 1 1/2“ 3.000 PSI SAE 1 1/2“ 3.000 PSI SAE 2“ 3.000 PSI SAE 2“ 3.000 PSI

kg 170 kg 215 kg 475 kg 475 kg

Capacities are valid for the operation of one pump.

1 Extremely easy connection Via the suction connection and pressure flange, which are easily accessible, the pipelines are connected to the front.

2 Different liquidsThe 3 / 2-way valve is used to switch between two liquids.

3 Reversing valveThis valve is used to disconnect one pump from the operating system.

4 Safety valvesTo prevent unacceptably high internal pressure being caused by thermal expansion when the pump is heated, there are two small safety valves in the cylinder of the changeover valve.

5 Suction strainerTo prevent damages at the screw spindle pumps a basket strainer for each pump is fitted.

6 Pump variantsThe pump stations are fitted with spindle pumps up to 16 bar or up to 40 bar.

7 Sealing variantsFor the shaft seal, many seal options are available. The hermetically sealed magnetic coupling provides particularly high reliability.

8 Non-return valveWhen the pump has been switched off, no liquid flows back out of the station.

9 Temperature indicatorFor monitoring the temperature of the pumped medium, two thermometers are optionally supplied.

10 Pressure indicatorFor monitoring the suction pressure two vacuum meters for each pump are fitted in the station.

11 Pressure indicatorFor monitoring the feed pressure, a manometer is fitted centrally in the station.

12 Pressure control valveThe pressure control valve ensures constant feed pressure even if the demand for liquid varies.

13 Cooling finsFor cooling the return flow.

14 Pressure switchA pressure switch is used for automatic switch over to stand-by pump.

15 Heating systemElectrical or fluid heating system for preheating highly viscous liquids.

Flow measurementA flow meter can be optionally fitted. A volumeter make measurement of the flow rate possible.

Differential pressure monitoringFor monitoring the strainer polution, an optical differential pressure indicator can be used. A differential pressure indicator with electrical output signal is also available.

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 “Marine Unit”

into a “Feeder Unit” and, depending on the number

of engines, into several “Booster Units”.

Advantages: Easy adjustment

to the engines in operation

Higher availability

of the complete insta lla tion

Simple switch-over to

HFO / DO for each engine

Easy adjustment if the system

is later upgraded

GEA Westfalia Separator has de ve loped the right

systems for this task.

The flow chart shown in figure 1 represents one

possible solution.

The available sizes are set out in the adjacent

tables.

Power to the PeoplePower station units

HFO

DO

Return to day tank

Pressure control valve

Strainer

Strainer

Stand-by

Feeder pump

DO pump

Automaticbackflushing filter

Fuel from engine


Steam trap

Booster pump

Booster pump

Fuel to engine

Viscosity sensor

Flowmeter

Fuel to day tank

Fuel from

engine

HFO

DO

HFO

DO

Stand-by / Option

Stand-by / Option

Stand-by / Option

Stand-by / Option

Steam trap

Regulatingvalve


Preheater

Preheater

Degassing valve


Flowmeter

The split into feeder and booster unit guarantees high

capacities in power stationsFeeder Unit:

Sizes Flow rate

10,000 kW 3.5 m3 / h

20,000 kW 7.0 m3 / h

40,000 kW 14.0 m3 / h

60,000 kW 21.0 m3 / h

80,000 kW 28.0 m3 / h

100,000 kW 35.0 m3 / h

Booster Unit(s):

Sizes Flow rate

3500 – 5000 kW 2.2 to 3.2 m3 / h

5000 – 7000 kW 3.2 to 4.7 m3 / h

7000 – 9500 kW 4.7 to 5.6 m3 / h

9500 – 12,500 kW 5.6 to 7.9 m3 / h

12,500 – 16,500 kW 7.9 to 10.4 m3 / h

16,500 – 21,000 kW 10.4 to 13.3 m3 / h

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Fuel to day tank

Fuel from engine

Degassing valve


Regulatingvalve


Fuel to engine

Viscosity sensor

Everything under ControlSystem control

The control system as a compact, space-optimized

control cabinet in 3-piece design for a redundant

feeder system. Reliable hardware-based switch-over

in case of loss of a feeder with constant operating

reliability. The complete operation and visualizaton

is via a user-friendly touch panel. All parameters

and functions can be controlled from this panel and

can be adapted to suit the application and needs

of the operator. Switch-over from viscosity regu-

lation to temperature regulation is possible at any

time. All necessary information can be read off at a

glance on the operator side. Operation of the plant

in the event of failure of the PLC is assured by a

manual level.

1 Operator panel (graphic / colour)

2 Flow indicator

3 Pilot lamp “Voltage supply to control cabinet”

4 Pilot lamp “Fault trace heating”

5 Pilot lamp “Trace heating in operation”

6 Selector switch “Stand-by feed pump 1/2”

7 Selector switch “Stand-by booster pumps 1/2”

8 Selector switch “Trace heating ON/OFF”

9 Button “Emergency - Off”

10 Pilot lamp “Feed pump 1 fault”

11 Pilot lamp “Feed pump 1 in operation”

12 Pilot lamp “Voltage supply 1”

13 Pilot lamp “Booster pump 1 fault”

14 Pilot lamp “Booster pump 1 in operation”

15 Selector switch “Feed pump ON-MANUAL-AUTOMATIC-OFF”

16 Selector switch

“Booster pump ON-MANUAL-AUTOMATIC-OFF”

17 Button “Emergency off pump control 1”

18 Main switch “Pump control 1”







26 Selector switch




Control Panel

with PLC

1

10 11

2

6

12


12 13 20 21 22 23 2414

15 16 25 26

7

8

3 4 5 3

9

1718 27 28

1 Operator panel (graphic / colour)

2 Flow indicator

3 Pilot lamp “Voltage supply to control cabinet”

4 Pilot lamp “Fault trace heating”

5 Pilot lamp “Trace heating in operation”

6 Selector switch “Stand-by feed pump 1/2”

7 Selector switch “Stand-by booster pumps 1/2”

8 Selector switch “Trace heating ON/OFF”

9 Button “Emergency - Off”

10 Pilot lamp “Feed pump 1 fault”






16 Selector switch










26 Selector switch




A focus on the essentials Compact, robust design

Good operability

Automatic viscosity control

Automated control system via common

control cabinet with redundant power supply

Automatic, compressed-air controlled

filter system for particle separation

Low weight

Easy installation

Low maintenance costs

VBU

13


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Wherever separating technology tasks have to be

carried out, Westfalia Separator® capitalcare assures

comprehensive services right from the very beginning.

In close cooperation with the customer, solutions

are identified to meet their needs.

The partners benefit not only from traditional

services such as inspection, maintenance, original

spare parts and repair work provided by the original

manufacturer; they also benefit from pro-active solu-

tions which avoid risk, e.g. online and offline monito-

ring with Westfalia Separator® wewatch®.

Accompanying modernisation or upgrading to state-

of-the-art technology also offer the option of boosting

performance as required.

Training provided on site or in the modern training

centre of GEA Westfalia Separator ensures that the

customer‘s employees receive training in the proper

handling of the high-tech installations. This provides

additional safety.

Authorized workshops worldwideAnd if problems occasionally occur or if a spare part

is required at short notice, the specialists are able to

attend to the customer quickly. This is ensured by a

global network with more than 50 sales and service

companies as well as 60 further sales partners.

Authorized workshops are able to service every

location in the world at short notice.

Westfalia Separator® capitalcare combines decades of service experience for mechanical separation technology.

Westfalia Separator® capitalcare – Maximum Process Efficiency, Installation Availability and Budget Security

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Maximum availability

Permanent efficiency

Absolute budget reliability

In addition to traditional services such as maintenance or repair, Westfalia Separator® capitalcare also provides solutions which avoid risk and with which the installation availability can be pro-actively assured.

Westfalia Separator® capitalcare accordingly makes

for maximum process efficiency and installation

availability as well as 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 avoided by service provided

by the original manufacturer

Pro-active solutions which avoid risk

Upgrading to boost performance

Staff training

The information contained in this brochure merely serves as a non-binding description of our productsand is without guarantee.

Binding information, in particular relating to capacity data and suitability for specific applications, can only beprovided within the framework of concrete inquiries. Westfalia®, Westfalia Separator ® and wewatch®

are registered trademarks of GEA Westfalia Separator GmbH. Printed on chlorine-free bleached paperwww.kabutz.de 9997-0787-030/0809 EN Printed in Germany Subject to modification

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Original Manufacturer Service

Werner-Habig-Str. 1 · 59302 Oelde (Germany) Phone +49 2522 77-0 · Fax +49 2522 77-1778 [email protected] · www.westfalia-separator.com

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