westfalia service training
DESCRIPTION
Training manualTRANSCRIPT
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbHWestfalia Separator Mineraloil Systems GmbH
Service Training by Ronald Eschmann, Service Center Hamburg
- model designation- installation- bowl parts- single mode- series mode- running mode -02-- running mode -91-- running mode -01-- running mode -36-- running mode -96-- running mode -0196-- Displacement- potable water- syphons- centripetal pump
- Foundation- clutch, clutch shoes- gear oil- wear to gear- bottom bearing- misc.: OSA7, OSA20, OSB35- bowl unbalance- wear protection- refinery process / fuel problems- timing unit VESA, VESB, VESC- timing unit C7- alarm list- trouble shooting list
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 2
model designation of separators
e.g. OSA7-02-066
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 3
model designation of separators
OSA 7-02-066application: Mineral Oil
Separator with self-cleaning bowl
A-series of WS-Separators
size (efficiency) 7
bowl for clarification and separation with a disc stack
separator with single centripetal pump and discharge by gravity of the heavy component (water)
drive via centrifugal clutch, open frame, neck bearing standard or gas-tight; standard or EEx motor
hinged hood, either cast design with cast-on feed-and discharge line or welded design with welded-on
or screwed-on feed and discharge connections
flange-type motor (horizontal), type B5, with clutch
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 4
Diagram of installation
Fuel
Lube oil
Sludge
Bilge water
Stuffing box oil
HFO - Sludge tank LO - Sludge tank
Sludge tank
Settl.tank Service
tank
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 5
Diagram of installation: SINGLE MODE
Separator
throttle valve
pressure switch
feed valve
solenoid operating water
dirty oil feed
pre-strainer
feed pump
water discharges
inspection cover
control unit
motor starter
steam inlet
pre-heaterinstrument air
potable water
clean oil discharge
pre-set valve
solenoid f+d water
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 6
bowl: VARIZONE
clean oil discharge
dirty oil feed
dirty water discharges
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 7
bowl: disk stack
The disk stack consits a large number of conical disks situated on top of each other. Each disk is provided with spacers so that there are precisley defined narrow interspaces (very small radial sedimen-tation path). The solids will be collected on the upper wall of each inter-space. A smooth bottom disk surface is necessary to slide down the solids into bowl sludge holding space.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 8
bowl: disk stack
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 9
Bowl: OSA7-02
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 10
bowl: OSA20 UNITROL
CS PSL
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 11
bowl: OSB35-02
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 12
Bowl: OSC4-02
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 13
bowl: OSC4 UNITROL
CS PSL
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 14
bowl: OSC30-91
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 15
bowl: OSD6-91
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 16
diagram of installation: SINGLE MODE
1: displacement water 2: operating water3: 3/2 way feed valve4: circulation valve5: water discharge valve 6: dirty oil feed7: feed return line8: clean oil discharge
36
7
8
pressure switch low (SMS)
pressure switch
ejection monitoring motor protection vibration monitor flow switch
temperature switch high / low conductivity sensor (WMS)
HFO: single / parallel mode: recommended with increased water content
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 17
diagram of installation: SINGLE MODE
return line of feed valve led back to settling tank
HFO
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 18
diagram of installation: SINGLE MODE
LO
return line of feed valve led back to oil sump
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 19
diagram of installation: SERIES MODE
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 20
diagram of installation: SERIES MODE
HFO series mode: recommended with increased amount of solids in the feed
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 21
SERIES MODE of operation: HFO only
When running in series mode only the feed pump and pre-heater of the first stage (purifier) are in operation. An attached feedpump at the second stage (clarifier) must be disconnected from the horizontal shaft to avoid a run dry. If necessary the setpoint of TAL (temp. alarm low) needs to be lowered as well as the timer „alarm bridging time“ needs to be increased at the timing unit of second stage in order to avoid PAL (discharge pressure low) alarms.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 22
diagram of installation: SERIES MODE
series mode of operation: process and installation diagram
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 23
series mode with VESB-EC 1
FIRST STAGE: PURIFIERFunction keys to be pre-selected at timing unit type VESB-EC 1:
F2, F3 and F13
SECOND STAGE: CLARIFIERFunction keys to be pre-selected at timing unit type VESB-EC 1:
F2, F3, F4, F10 and F13
holes open in separating disc
holes closed in separating disc
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 24
series mode with VESB-EC 1
X1-Terminals 23 24 26 25 27 28 30 29 59 60 61 62 63 64 65 66
INPUTS - UNIT 2I 114I 113I 112I 111
VESB- Panel No. 2 O 1016
OUTPUTS -UNIT 2O 1015O 1014O 1013
X1-Terminals 59 60 61 62 63 64 65 66 23 24 26 25 27 28 30 29
OUTPUTS - UNIT 1O 1015O 1014O 1013 I 114I 113I 112I 111VESB- Panel
No. 1O 1016
INPUTS - UNIT 1
24 V
DC
fro
m u
nit
2
Feed
bac
k Si
gn
al
Seri
es M
od
e O
N
Seri
es M
od
e O
FF
Seri
es M
od
e FA
IL
24 V
DC
fro
m u
nit
1
Feed
bac
k Si
gn
al
Seri
es M
od
e O
N
Seri
es M
od
e O
FF
Seri
es M
od
e FA
IL
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 25
series mode with C7
FIRST STAGE: PURIFIERFunction keys to be pre-selected at timing unit type C7:
and
SECOND STAGE: CLARIFIERFunction keys to be pre-selected at timing unit type C7:
and
holes open in separating disc
holes closed in separating disc
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 26
series mode with C7
Attention:
Not laying MPI-data cables parallelly to power cables
1 1 2 sc 1
Terminal strip HFO 1
Cable type:UNITRONIC-BUS-FD P L2/F.I.P1x2x0,25 mm2 + screen
Terminal strip HFO 2
1 2 sc
A B
onoff
HFO 1WMS-01-
MPI-interface / MPI - code 1/2 MPI-interface / MPI - code 3/4
A B
onoff
HFO 2SMS -36-
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 27
Separator type VARIZONE -02-
VARIZONE -02-: no UNITROL valves on the hood but a regulating ring; suitable for products with max. density of 0,991 kg/dm³ @ 15°C
OSC4
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 28
Separator type VARIZONE -02-, regulating ring
OSA20
Regulating ring (ringdam)
OSC15
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 29
Separator type VARIZONE -02-, regulating ring
OSC5-02-066
To choose the correct size of regulating ring, the density of the oil as well as the separation temperature must be given.
For example: density is given with 0,873 kg/dm³ @ 20°C. Separation temp: 70°C
The density of oil decreases linear with increased temperature. Find the intersection of the density line with the line of 70°C.
Find the thick curves (here green). The number in the field between two curves shows the correct regulating ring: Ø 70 mm.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 30
Separator type VARIZONE -02-, regulating ring
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 31
Separator type VARIZONE -91-
OSC30
-91-: same working principle as VARIZONE -02-. Dirty water is not drained by gravity into the hood but discharged under pressure by means of a second centripetal pump
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 32
Separator type VARIZONE -91-
1 Dirty oil feed2 Clean oil discharge3 Filling / Displacement water4 Pressure switch (clean oil)5 Regulating ring6 Control unit7 Centripetal pump (dirty water)8 Centripetal pump (clean oil)9 Separating disk
10 Sludge holding space11 Dirty water discharge12 Operating water discharge13 Sludge discharge14 Operating water feed15 Solenoid valve block
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 33
Separator type VARIZONE -91-
dirty water discharge to frame drain
dirty oil feed
clean oil discharge
Two centripetal pumps
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 34
Separator type VARIZONE -91-
OSC30pressure switch in the dirty water discharge: PAH breakover water discharge
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 35
Separator type VARIZONE -91-
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 36
Separator type VARIZONE -91-
holes open !
All process parameters, timer adjustments, water flow rates, regulating ring diagram´s etc. of separator type -91- are identically with -02- design. Please note, the screw pins need´s to be removed from the lower centri-petal pump chamber cover when running mode VARIZONE -91-.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 37
Separator type VARIZONE -91-
regulating ring
Efficient dewatering of water-contained oils is only possible when the bowl is correctly adjusted to the difference in densities between oil and water.
The inner diameter of the regulating ring can be determined from the diagram or by experiment. The general rule of thumb is:
- narrow regulating ring for heavy oil
- wide regulating ring for light oil
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 38
Separator type VARIZONE -91-
lower centripetal pump chamber cover
-UNITROL-holes closed
-VARIZONE-holes open
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 39
Separator type VARIZONE -91-
OSC30
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 40
Separator type UNITROL-WMS -01-
OSC50
Water Monitoring System: PURIFIER - FIRST STAGE
UNITROL-WMS: no ringdam; with conductivity sensor, circu-lation- and water discharge valve, suitable for products with max. density of 1,01 kg/dm³ @ 15°C
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 41
Separator type UNITROL-WMS -01-
1: dirty oil feed2: clean oil discharge3: displacement
water feed
4: pressure indicator5: conductivity sensor6: pressure switch7: circulation valve8: water discharge
valve
9: sensing liquid flow10: sensing liquid pump11: control unit12: centripetal pump
(clean oil)13: separating disc14: dirty water discharge15: sludge holding space16: sludge discharge
17: operating water discharge
18: operating water feed
HFO
19
19: screw pin´s (holes open in separating disc !)p/n: 0019-9045-400
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 42
Separator type UNITROL-WMS -01-
85
7
HFO
19
After the feed valve is open the WMS function is activated. The conductivity sensor (5) in the bypass line monitors the liquid concentration and leads off registered water by opening the water discharge valve (8). When running WMS -01- there is no need for filling water. To avoid emulsification, conductivity measurement is intermittent, i.e. the circulation valve (7) is closed via TIMER 15 for 60 seconds followed by opening of the circulation valve for 15 seconds via TIMER 16. Only during this time can the conductivity sensor register and discharge water until oil is detected again. Subsequently the measuring cycle is re-started.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 43
Separator type UNITROL-WMS -01-
„PURIFICATION“ means the separation of liquid mixtures which consists of two liquids, with simultaneous removal of the solidscontained in the liquids.„CLARIFICATION“ is the removal of solids from a liquid.
holes open in separating disc
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 44
Separator type UNITROL-WMS -01-
CS PSL
Separation: Circulation valve open, CS not activated
CS PSL
Water discharge: CS activated, water discharge valve open
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 45
WMS - measuring relais : type DNAR
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 46
WMS - measuring relais : type DNAR
set to: „100 Ω - 200 Ω“
turn clockwise to max.
WS part number: 0005-3929-000 (220 VDC) 0005-3929-010 (110 VDC)
old version until 1996
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 47
WMS - measuring relais : type RM-3 LA1
WS part number: 0005-3929-020 (since summer 1996)
function: the time from that the conductivity sensor is detecting water until water is being discharged
R-sector: the full scale adjustment: 50 kΩ
R-value Ω: to be adjusted to approx. 20 means the actual setpoint has been adjus-ted to 20 kΩ. When do the „fine tuning“ at site (adding water manually) please check the switch back from „water discharge“ to „purification“. The setpoint needs to be decreased in case the program does not switch back to „purification“
Time value s: value of delay time: 1 sec
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 48
WMS - measuring relais : type RM-3 LA1
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 49
WMS - measuring relais : type RM-4 LA3 2MW
WS part number: 0005-3929-030; since summer 2003
time delay adjustment: set to 1 sec
sensitivity adjustment: set to 40 % of full scale, to be balanced at site. The setpoint is to be reduced in case the WMS does not switch back from “water discharge“ to “circulation“.
sensivitiy range / delay function selection:set to 50 sensivity range: 0 - 50 kΩfunction: ON-delay (the time from detecting water to water discharge)
empty / fill selection: set to empty
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 50
replacement DNAR by RM3 / RM4
terminal DNAR RM3 / RM4
11 15
12 16
14 18
O B2
M B1
A1 A1
A2 A2
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 51
WMS: conductivity sensor 0005-1347-000
1 housing 0005-1347-0102 isolating piece 0005-1347-0203 cover 0005-1347-0304 hex head screw 0019-6842-4005 sensor 0005-1347-1006 threaded piece 0019-0576-6007 gasket (2 pcs) 0007-2507-7508 gasket (2 pcs) 0007-1866-8309 cable head 0005-0637-000
10 cable 0005-0400-00811 plug 0019-0644-60012 plug 0019-1492-000
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 52
WMS: conductivity sensor 0005-1347-000
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 53
WMS: conductivity sensor 0005-1347-000
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 54
Separator type UNITROL -SMS -36-
OSC50
Sludge Monitoring System: CLARIFIER - SECOND STAGE
UNITROL-SMS -36-: no ring-dam; pressure switch and circu-lation valve in use, running in second stage when running in series mode only, HFO clarifier
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 55
Separator type UNITROL -SMS -36-
14: dirty water discharge
1: dirty oil feed2: clean oil discharge3: displacement
water feed
4: pressure indicator5: conductivity sensor6: pressure switch7: circulation valve8: water discharge
valve
9: sensing liquid flow10: sensing liquid pump11: control unit12: centripetal pump
(clean oil)13: separating disc
15: sludge holding space16: sludge discharge
17: operating water discharge
18: operating water feed
HFO
19
19: screw pin´s (holes closed in separating disc !)p/n: 0019-9045-400
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 56
Separator type UNITROL -SMS -36-
6
7
HFO
19
A small amount of sensing liquid is diverted via the separating disc (13). It is conveyed by the sensing liquid pump (10), the circulation valve (7) to the pressure switch (6) and recycled back into the feed. If the sensing liquid intake becomes blocked due to water or solid accumulation in the sludge holding space (15) the pressure switch sends a pulse to the control unit. The automatic solids ejection program for both first stages is triggered (so called „self thinker“). The pressure switch is working as PSL. The circulation valve is open over the whole period of time of separation.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 57
Separator type UNITROL -SMS -36-
A clarifier is not able to discharge water continiously just by de-sludgings only. The system of WMS -01- and SMS -36- are identically. To rebuild the separator from WMS into SMS just close the holes in the separating disc by means of two screw pins and re-adjust the timing unit.
holes closed in separating disc
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 58
Separator type UNITROL -SMS -36-
Separation:circulation valve open, sensing liquid pressure above the setpoint of pressure switch
CS PSL CS PSL
Separation: circulation valve open, sludge holding space filled up with solids, sensing liquid pressure dropped below setpoint
CS PSL
Ejection: on both stages triggered by the „self thinker“, feed valve closed .
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 59
Separator type UNITROL -SMS -96-
OSC50
Sludge Monitoring Systemfor Lube oil
UNITROL-SMS-96-: no ringdam; pressure switch and circulation valve in use, designed for LO only; same working principles as SMS-36-, holes open in sep. disc.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 60
Separator type UNITROL -SMS -96-
CS PSL
Separation: sensing liquid pressure above the setpoint
CS PSL
Separation: sludge holding space filled up with water and solids, sensing liquid pressure dropped below setpoint, ejection triggered
PSLCS
Filling: no pressure at the PSL, CS not in use, holes in separating disc open, bowl partially pre-filled
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 61
Separator type UNITROL -SMS -96-
1: dirty oil feed
2: clean oil discharge
3: displacement water feed
4: pressure indicator
5: conductivity sensor
6: pressure switch
7: circulation valve
8: water discharge valve
9: sensing liquid flow
10: sensing liquid pump
11: control unit
12: centripetal pump (clean oil)
13: separating disc
14: dirty water discharge
15: sludge holding space
16: sludge discharge
17: operating water discharge
18: operating water feed
19
LO
19: screw pin´s (holes open in separating disc !)p/n: 0019-9045-400
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 62
Separator type UNITROL -SMS -96-
6
719
LO
A small amount of sensing liquid is diverted via the holes in the separating disc (13). It is conveyed by the sensing liquid pump (10), the circulation valve (7) to the pressure switch (6) and recycled back into the feed. If the sensing liquid intake becomes blocked due to water or solid accumulation in the sludge holding space (15) the pressure switch sends a pulse to the control unit. The automatic solids ejection program is triggered (so called „self thinker“). The pressure switch is working as PSL. Before feed valve is open the bowl is partially filled with water. This is not to create a water seal but will improve the clarification (discharge of solids from the oil).
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 63
Separator type UNITROL -SMS -96-
When running with UNITROL SMS -96- the flowrate of filling- and displacement water must not exceed 0,1 l/s. To achieve this reduced flowrate a orifice plate of bore 3,0 mm need´s to be installed in the filling- and displacement water assy.
holes open in separating disc
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 64
LO: Separator type UNITROL-WMS+SMS -0196-
UNITROL-WMS+SMS: no ring-dam; conductivity sensor, circu-lation- and water discharge valve as well as pressure switch in use. For LO only.
Water Monitoring System + Sludge Monitoring System
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 65
Separator type UNITROL WMS+SMS -0196-
CS PSL
After the ejection the bowl is empty. Sliding piston as well as annular piston are in sealing position.
CS PSL
FILLING: the bowl will be filled with water timer controlled. The signal of the pressure switch will override the timer.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 66
Separator type UNITROL WMS+SMS -0196-
CS PSL
SEPARATION: the upper centripetal pump is acting as a gravity disk. Dirty water will be discharged continiously.
CS PSL
HIGH WATER: Alarm will be given once that a certain amount of water is being discharged (Timer controlled)
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 67
Separator type UNITROL WMS+SMS -0196-
CS PSL CS PSL
SMS mode: after the WMS mode is over by timer the SMS mode is activated. Water will be added timer controlled.
SMS mode: Both valves are closed. No signal of the pressure switch means: sludge holding space is filled up.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 68
Separator type UNITROL WMS+SMS -0196-
CS PSL
SMS mode: Ejections will be triggered timer controlled. The signal of the pressure switch will override the timer (T20)
CS PSL
BREAKOVER: Alarm will be given when the water seal has been lost however: Signal from the PSL but no signal from the CS.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 69
non-self-cleaning type: solid wall bowl
Type OTBType OTA Type OTC
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 70
Separator type UNITROL -DISPLACEMENT-
CS PSL
Separation: sludge hol-ding space filled up with solids, sensing liquid pressure dropped below setpoint
Displacement: Filling + Displacement and circulation valve open, clean oil displaced to the clean oil discharge
CS PSL CS PSL
Ejection: on both stages triggered by the „self thinker“, oil losses minimized
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 71
Potable water
condensate as well as desillate is not permissible
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 72
Potable water
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 73
Potable water
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 74
Potable water
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 75
water discharges: syphons
If no syphon is installed, the frame drain as well as the dirty water discharge must always be submerged below the minimum tank level so as to produce a liquid seal.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 76
water discharges: syphons
If a syphon is installed, submerging of the water discharges is not required because a liquid seal is already present. The dimension „h min“ for defining the syphon lenght is specified in the table.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 77
centripetal pump
lower centripetal pumpupper centripetal pump
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 78
centripetal pump
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 79
OSA, OSB, OSC: Foundation
Vibrations from the vessel / ship structure into the separator skid must be reduced as good as possible (rubber cushion, cap springs, flexible hoses, stiff foundation etc.)
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 80
OSA, OSB, OSC: Foundation
wrong !
wrong ! Tighten the lower nut lightly by hand. Use an open-end wrench to tighten the nut by a further turn. Then check the tightened nut with the upper nut by counterholding.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 81
Foundation
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 82
foundation / max. vibration limit
max. vibration limit at installation surface with stopped separator
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 83
OSD: Foundation
0021-3308-7500021-3309-750
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 84
OSD: Foundation
OSD 6 / OSD 18
pos. 340: 2058-1467-000
pos. 350: 0021-3308-750
OSD 35 / OSD 60
pos. 390: 2057-1467-000
pos. 400: 0021-3309-750
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 85
clutch, clutch shoes
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 86
fitting of clutch shoes
for OSC15 (belt drive only)
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 87
clutch driver, clutch shoes OSA, OSB, OSC
For all gear driven separators
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 88
OSD: clutch, cluch shoes
One friction pad for all OSD type of separators
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 89
clutch drive: permissable wear holding slit
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 90
gear oil - oil level in gear box
Check oil level daily. Check whether the oil bath contains water (milky colouring) or product (HFO - dark colouring). If so change immediatly.
OTC2OTC3
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 91
gear oil CLP100
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 92
gear oil CLP220
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 93
gear oil ISO-VG 220
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 94
gear oil ISO-VG 68
For belt driven separators only.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 95
synthetic gear oil, running in procedure
list of approved oils:MOBIL SHC 630SHELL Delima HT 220CASTROL Alphasyn T 220CASTROL Alphasyn HG 220BP Enersyn HTX 220ESSO Teresso SHP 220ELF (Lub Marine) EPONA SA 220FINA Gearan 220
The gear must be run in with mineral lube oil for approx. 1500 - 1750 running hours. The running-in marks must be clearly visible on each tooth of worm wheel.b = min. 1,5 - 2,5 mm for OSC4, OSC5, ESC4, OTA7, OTB9, OTA14 etc.b = min. 2,0 - 3,0 mm for OSA20, OSB/C30, OSA/B35, OTA18/30, OSC50 etc.All approved oils are in accordance with ISO-VG 220 and on poly-alpha-olefin basis (WS p/n: 0015-0018-200). In case of very high ambient temperature gear oil of ISO-VG 320 is recommended for OSA20, OSB/C30, OSA/B35, OTA18/30 and OSC50. The remaining viscosity @ 100 °C is approx. 30 cSt [mm²/s].
For OSC15 (flat belt drive !) synthetic gear oil of ISO-VG 68 is recommended.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 96
synthetic gear oil, running in procedure
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 97
wear to gear
The gear parts (both worm wheel as well as vertical spindle need´s to be replaced incase the tip of tooth worn out to 1/2 to dimension “h”.
The gear parts (both worm wheel as well as vertical spindle need´s to be replaced incase the base of the tooth shows sign of wear.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 98
bottom bearing
OSC50
- both bearings may only be replaced together (same maker) !- the bottom bearings may only be loaded axially in one direction !- fit both bearings so that the outside narrow rim faces upwards to the bowl !- incorrect fitting will decrease service life dramatically (crash) !- heat bearings and protection ring to approx. 80 °C before fitting
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 99
bottom bearing : sherical plain bearing
This joint is not a crack but necessary to fit the inner ring in the factory. There is no special instruction how to install the bearing.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 100
OSB35 - modified hydraulic system
1 x 0007-1892-750 385/405x10
2 x 0007-1674-750 393,1/407,1x7
new previous
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 101
OSB 35: hard metal ring of sliding piston
Y
OSB35
The sealing surface of the sliding piston can be remachined several times when worn (up to 1,5 mm in total) before replacement of sliding piston becomes nescessary. When re-machining, make sure that the shoulder on diameter „X“ is at least 1.0 mm. When in doubt check dimension „Y“ of which must be at least 21.0 mm
Remachine the sealing surface as soon as possible as there are sligh-test traces of erosion (of 0.2 - 0.3 mm depth). After the re-machining the polaymid gasket in the bowl top needs to be replaced. Rebalancing of bowl is not necessary.
Guide values for re-machining:Tool: carbide-tipped tool of M30 or K20Speed: 10 - 12 rpmDepth of cut: max. 0.15 mmRate of feed: max. 0.1 mm/rev
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 102
OSB 35: correction of bowl height
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 103
OSA20 - modified hydraulic system
2 x 0007-1851-750 304,2/318,2x7
1 x 0007-1851-750 304,2/318,2x7
new previous
2040-9958-000 2178-9959-000
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 104
OSA20 - threaded ring 2178-6627-010
In some cases the threaded ring pos. 308 cannot be loosened. To take off the ring by means of a lathe please use carbide-tipped tool and about 40 to 70 m/min. Control the thread of the bowl bottom and the leading surface regarding marks. Smooth the surface. CAUTION: the threaded ring can be loosen during cut off.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 105
OSA 20 - hard metal ring of sliding piston
OSA20
Guide values for re-machining:
Tool: carbide-tipped tool of M30 or K20Speed: 10 - 12 rpmDepth of cut: max. 0.15 mmRate of feed: max. 0.1 mm/rev
The sealing surface of the sliding piston can be re-machined several times when worn (up to 1,0 mm in total) before replacement of sliding piston becomes nescessary. When remachining, make sure that the shoulder on diameter „X“ is at least 1.5 mm. Remachine the sealing surface as soon as possible as there are slightest traces of erosion (of 0.2 - 0.3 mm depth). After the remachining the polaymid gasket in the bowl top needs to be replaced. Rebalancing of bowl is not necessary.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 106
OSA 20 - frame venting
In order to improve the frame venting a pipe should beinstalled in the frame drain as shown above.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 107
hard metal ring of sliding piston OSA7
The sealing surface of sliding piston can be re-machined several times when worn (up to 1,0 mm in total) before replacement of sliding piston becomes nescessary. When re-machining, make sure that the shoulder on diameter „X“ is at least 1.5 mm.
Re-machine the sealing surface as soon as possible as there are sligh-test traces of erosion (of 0.2 - 0.3 mm depth). After the re-machining the polaymid gasket in the bowl top needs to be replaced.
Re-balancing of bowl is not necessary
Guide values for re-machining:Tool: carbide-tipped tool of M30 or K20Speed: 10 - 12 rpmDepth of cut: max. 0.15 mmRate of feed: max. 0.1 mm/rev
OSA7
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 108
bowl: Table of bowl height´s
type X [mm] Y [mm] 50 Hz [rpm] 60 Hz [rpm]OSC4 54-56 * 9980 10030OSC5 54-56 * 9980 10030OSA7 80-82 1,50 8520 8510OSC15 37-39 * 9960 / 10240 11490 / 11470OSA20 120-122 2,00 7500 7500OSC30 16-18 2,00 7500 7500OSB35 38-40 2,00 6440 6540OSC50 -old- 43-45 2,00 6500 6500OSC50 -new- 34-36 2,00 6500 6500 *: height not adjustable
Yadjustment of bowl height:- unscrew bottom bearing cap (3)- remove gasket (1)- Adjust the bowl height by turning bottom bearing
threaded piece (2). A full turn will raise or lower the bowl by the dimension Y.
bowl is too high: turn anti-clockwisebowl is too low: turn clockwise
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 109
separator bowl - unbalance
when having trouble with unbalance of bowl please check if:
- all “0“ marks are in-line and all locking devices are in perfect condition
- the disc stack pressure has been lost (blind disk or disk to be added)
- any damages / erosion / corrosion / cavitation are to be noticed
- the bowl has been re-assembled completely (missing parts ?)
- all bowl parts are arranged in fixed positions to one onother
- bowl part´s from different bowl has been mixed
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 110
separator bowl - unbalance
The bowl need´s to be exchanged when the bowl top or bowl bottom has been damaged. These bowl parts cannot be replaced without re-balancing of complete bowl because of the positions of balancing area.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 111
bowl: taper seat of bowl bottom / spindle
The conical seat of bowl bottom and worm spindle must be absolutely dry when assembling the bowl.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 112
separator bowl: chrome layer peeling
The sliding surfaces of bowl are protected with a crome layer to prevent bowl parts from seizing during the run-ning-in phase. This crome layer is necessary during the first few hundret running hours only and may peel off. The scope and location of this peeling can differ from bowl to bowl. The product, the operating mode and the number of ejections etc. can influence the overall picture. There is no effect on the separation efficiency, maintenance schedule and service life of bowl.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 113
separator bowl OSA, OSB - wear protection
Bowls type OSA and OSB are equipped with wear protection against erosion when running with HFO: wear liner, wear inserts and hard metal ring. Please never run bowl without wear protection with HFO or any other abrasive product (sludge, palmoil etc.)
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 114
Refinery process
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 115
cat fines
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 116
Residual Marine fuel standards
ISO, BSI, CIMAC
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 117
Incompatibility of Fuels
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 118
Incompatibility of Fuels
Sludge of an asphalt nature may be produced if fuels from different refineries are mixed and this sludge may cause serious trouble. If this happens the fuels are said to be incompatibile. Such disruptions first become evident in the centrifuge in the form of excessive amounts of sludge separating out. Asphalt sludge may also clog the pipes, pre-heater and filter and collect in the tanks. Changing the temperature of the oil has virtually no effect on the formation of sediment. The reason is that the more intensive refining process and particularly the use of the visbreaker, produces a higher content of aspahltenes. Many of these large molecules are at the limit of their solubility in the parent oil (are in a labile state). It is ensured that the above disorders do not occur in refineries by appropriate management of the process and by admixing selected components (e.g. cracked gas oil to act as a low-viscosity component). If however a heavy oil of this kind is mixed with a fuel with a lower capacity for dissolved asphaltenes, then the asphaltenes precipitate. Instability of this nature exists even when for example admixed component isa paraffin-base destillate.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 119
Incompatibility of Fuels
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 120
Stability of Fuels
Occationally layers of low and high-viscosity oil occure which have nothing to do with stability but are due to inadequate blending of the components. This may cause an oil overflow to the dirty water discharge.
The chemical stability of a residual oil decreases the more deficient the carbon molecules is in the hydrogen atoms which would be needed to occupy all its free valences. Therefore it is easy for external influences to bring about a change in the chemical make-up of the molecules. This danger is thus accentuated with the fairly hydrogen-deficinet residues from cracking plants (catalytic crackers and visbreakers).
The residues in question oxidise by absorbing oxygen from the atmosphere and as a result of polymerisation (linking) of molecules they form fairly large structures which precipitate as sludge. The tendency to oxidise increases with the content of unsaturated hydrocarbons, of which there is a particularly high concentration in residues from cracking. The tendency also increases sharply as temperature rises. For this reason feed tanks should not be heated very much above the pump temperature.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 121
Precipitation of Paraffin (wax) / Spot test
It must be remembered that fuel oils may contain components of aparaffine nature. Paraffins in the narrower sense are usually understood to be those members of a homologues series of saturated straight-chain hydrocarbons which exits as a solid phase at room temperature. So long as the fuel oil is kept at an appropriate temperature, the paraffines remain in solution but as their solubility decreases as temperature drops, paraffin components may separate out in solid form if the fuel oil cools down. The temperature at which the precipitation of the paraffinbegins depends on the mean molecular weight of the fuel oil and also on the amount of paraffins present and their melting points. As the majority of fractions of this kind are cracked off in cracking plants, the precipitation of paraffins is more frequently encountered with residues from pure destillation.
A small amount of the phase flowing out on the water side is heated to approximately 100 °C and a spot placed on a filter paper. If a nucleus collects, then what is involved is the precipitation of asphaltenes or the separating out of products of oxidation and if not then it is the precipitation of paraffins.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 122
fuel problem: contamination with chemical´s
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 123
fuel problem: contamination with chemical´s
pittings / cavitations at the sensing liquid pump (HFO)
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 124
fuel problem: contamination with chemical´s
5 barCS 5 barCS 3 bar
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 125
fuel problem: contamination with chemical´s
pittings / cavitations at the sensing liquid pump (HFO)
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 126
electrical equipment -general layout plan
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 127
Diagram of installation: SINGLE MODE
Separator
control unit
feed valve pre-heater
solenoid filling/ displacement water
Motor starter
pressure switch
solenoid operating water
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 128
Timing unit type VESA
timing unit type VESA installed 1980 - 1990
Voll Elektronische Steuerung A- Typ
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 129
Timing unit type VESA
timing unit type VESA installed 1980 - 1990
Voll Elektronische Steuerung A- Typ
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 130
Timing unit type VESA
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 131
Timing unit type VESA
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 132
Timing unit type VESA
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 133
Timing unit type VESA
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 134
Timing unit type VESA
d1: Waiting
d2: Displacement
d3: Ejection
d4: Speed recovery time
d5: Filling
d6: Bridging time after ejection
d7: Alarm delay time
d8: Ejection monitoring time
digital adjuster at the rear side of VESA
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 135
Timing unit type VESB
timing unit type VESB installed 1990 - 1999
Voll Elektronische Steuerung B- Typ
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 136
Timing unit type VESB
timing unit type VESB installed 1990 - 1999
Voll Elektronische Steuerung B- Typ
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 137
Timing unit type VESB
timing unit type VESB installed 1990 - 1999
PLC100/1WS-part number : 0005-4050-260PLC100/2 WS-part number : 0005-4050-270PLC100/3 WS-part number : 0005-4050-280PLC100/4 WS-part number : 0005-4050-290
Voll Elektronische Steuerung B- Typ
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 138
Timing unit type VESB: PLC100
1: control unit PLC 1002: LED off / input status3: LED on / output status4: Cursor up5: Cursor down6: Output range7: Input range8: Counter range9: Timer range
10: Copy program11: Status text12: display13: Operation LED (control unit READY)14: numeric key´s15: Enter key16: Specific call-up in preselected mode17: Function key´s: F0 - TEST
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 139
Timing unit type VESB: PLC100, function keys
gives access to key F10 to F16SHIFT
freeF16
diesel oil operation: alarm TAL suppressedF15
freeF14
series operation – ONF13
free (displacement with product)F12
freeF11
self-thinker control – ONF10
alarm acknowledgementF6
diagnostics: help functionF5
clarifier operation: step FILLING suppressedF4
flushingF3
displacementF2
program START with ejectionF1
program STOP with ejectionF0
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 140
Timing unit type VESB: PLC100
PLC100 without EPROM
PLC100: 16 inputs, 8 + 8 outputs, maker: SCHLEICHER
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 141
Timing unit type VESB: replacing PLC100
PLC100/1 can be replaced by PLC100/1 or PLC100/3.PLC100/2 can be replaced by PLC100/2 or PLC100/4.
1. Please make a note of the original settings of all timer and counter2. Please switch off the main switch and plug off all plug connectors as
well as the EPROM (please never plug off EPROM while contolcabinet is energized)
3. Replace the PLC100 and plug in the connectors and (new) EPROM(check both fuses and the output of the 24 V power supply: must be24 VDC steady otherwise the power supply is damaged)
4. Switch on the main switch and press following keys:“STATUS” then “#” then “TEST”
5. Enter the password: “02522” and finally press the “ENTER”-key6. Press the “COPY”-key, then “ENTER” and “STATUS” again.7. Now you can change the present timer and counter setting`s to the
original one´s. To do this please press the "TIMER" key. By meansof the cursor key´s you can scroll trough the timer list and changethe settings . To call up the timer please press the "ENTER" key.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 142
Timing unit type VESB: Password PLC100
To download the soft-ware from the EPROM into the CPU by means of the COPY function as well as to change the timer settings in the timer list, the password protection needs to be lifted. Please follow the procedure.
Please note: the EPROM must not returned to WS in case the PLC 100 is gone.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 143
VESB function key´s - HFO series mode -01-36-
First stage: WMS -01-: VESB-EC-1, with DISPLACEMENT and FLUSHING. Please pre-select function key F2 for DISPLACEMENT, F3 for FLUSHING and F13 to activate the series mode.
Second stage: SMS -36-: VESB-EC-1, with DISPLACEMENT and FLUSHING. Please pre-select function key F2 for DISPLACEMENT, F3 for FLUSHING, F4 for CLARIFIER OPERATION, F10 to activate the SMS and F13 to activate the series mode.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 144
Timing unit type VESC
Voll Elektronische Steuerung C- Typ
timing unit type VESC installed 1995 - 1999
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 145
Timing unit type VESC
Voll Elektronische Steuerung C- Typ
timing unit type VESC installed 1995 - 1999
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 146
Timing unit type VESC
Voll Elektronische Steuerung C- Typ
timing unit type VESC installed 1995 - 1999
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 147
Timing unit type VESC, check of PSU card
timing unit type VESC installed 1995 - 1999
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 148
Timing unit type VESC , check of PSU card
R13
four pin socket
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 149
Timing unit type VESC , check of PSU card
R13 burned
rear side of PSU card
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 150
Timing unit type VESC , check of PSU card
R13 new
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 151
Timing unit type VESC
Voll Elektronische Steuerung C- Typ
timing unit type VESC installed 1995 - 1999
power supply unit, part number: 0005-4097-100
VESC-1-W (8155-0202-050)to be installed on the wall
VESC-1-S (8155-0202-060)to be installed inside control cabinet.
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 152
Timing unit type VESC
EPROM; software: 0005-2045-100
Voll Elektronische Steuerung C- Typ
timing unit type VESC installed 1995 - 1999
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30.06.2004 Ronald Eschmann, Service Dept., Hamburg 153
Timing unit type VESC
Voll Elektronische Steuerung C- Typ
EPROM; software: 0005-2045-100
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 154
Timing unit type C7
0005-4050-300 C7-623 (A) 0005-4050-310 C7-626 (A) 0005-4050-320 C7-626 (A) DP 0005-4050-340 C7-623 (P) 0005-4050-350 C7-626 (P) 0005-4050-360 C7-626 (P) DP
UD700: 0005-4040-190 (software update)
C7-623 C7-626
timing unit type SIEMENS C7 installed from 2000
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Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 155
Timing Unit type C7-626
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 156
Timing Unit type C7-626
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 157
Timing Unit type C7-623
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 158
Timing Unit type C7-623
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 159
Timing Unit type C7-626
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 160
Timing Unit type C7-626
Display
Status /fault indicator
Function key System key´s
Softkey´s
Softkey´s
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 161
Timing Unit type C7- softkeys
ALARMS: Picture-dependent function key as per display. On the PROCESS page you can use this key to call up and view alarm message buffer.
OPERATION: Pressing this key takes you from any display page to the main menue (PROCESS page - this is the graphic process picture)
UP and DOWN: Keys are normally used in the display to access the next / previous level. Other functions are picture-dependent and are shown in the display.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 162
Timing Unit type C7- softkeys
SEPARATOR PROGRAM OFF
This key stops the separating program, closes the feed valve in separation mode and empties the bowl. On the OSC separators two total ejections are triggered automatically.
SEPARATOR PROGRAM ON
This key starts the separating program. When the ejection program has run the feed valve is openend. The ejection monitoring system is suppressed after pressing this key because there is no de-sludging when the bowl is empty (on C-type of separators only)
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 163
Timing Unit type C7- softkeys
WMS 01: WATER MONITORING SYSTEM UNITROL-HFO: single or parallel mode of operation, first stage in series mode
SMS 36: SLUDGE MONITORING SYSTEM UNITROL-HFO: second stage in series mode
SMS 96: SLUDGE MONITORING SYSTEM UNITROL-LO
SERIES MODE for UNITROL-HFO only.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 164
Timing Unit type C7- function keys
The LED in the key´s shows the actual status:permanent lighting: OPERATIONslow flashing: FAULT from motor protectionrapid flashing: winding up time or delay to stop time
No other function.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 165
Timing Unit type C7- function keys
PARTIAL EJECTION: OSC type of separators allow partial ejections. To do this, pre-select the number of partial ejections on Counter C01 to be triggered before the total ejection and the press the key PARTIAL.
HEATER RELAESE: Press this key only if an EXTERNAL FEEDPUMP is fitted. An optional heating system will be relaesed which is then process-dependently controlled.
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 166
C7 display: contrast, background illumination
626
The contrast at C7 623 is adjusted by pressing the SHIFT and +/- key.
623
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 167
Timing Unit type C7- system keyboard
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 168
C7 control cabinet, inside view
Use only approved shielded cables for wiring the analog in - and outputs as well as the IM, V.24 and MPI interfaces
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 169
C7 control cabinet, inside view
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 170
C7: view from rear, interfaces
1: IM port2: Analog inputs3: Analog outputs4: AUX digital inputs5: Serial interface V.246: Digital inputs (top)7: Digital outputs (bottom)8: DI/DO 24 VDC power supply
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 171
C7 series mode: first and second stage
MPI-plug: 0005-1408-000
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 172
C7 series mode: first, second, third stage
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 173
C7: alarm list
no. description001 motor protection separator-motor PTC002 clean oil discharge pressure low PAL003 clean oil discharge pressure high PAH004 breakover water discharge FSH005 temperatur low TSL006 temperatur high TSH007 ejection monitoring system ISL008 sludgetank level high high LSHH009 free010 motor protection feed pump PTC011 motor protection sludge pump PTC012 vibro stage 1 NAH013 vibro stage 2 NAHH014 series mode failure015 minimum sep. time not o.k.016 free017 WMS alarm- high water content
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 174
C7: error messages
alarm 001: MOTOR-PROTECTION
Temp. > max. °CMotor shut off
Help informations:Please check:> fuses in starter> Thermistor relais> clutch> correct numbers of clutch shoes> brake> motor current
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 175
C7: error messages
alarm 002: PAL-CLEANOIL-OUTLET
pressure < setpointSeparation stop
Help informations:Please check:> adjusting of back pressure> flow-rate feedpump> hydraulic function> leaking of hydraulic liquid> clutch of feedpump> condition of pre-strainers
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 176
C7: error messages
alarm 003: PAH-CLEANOIL-OUTLET
pressure > 3,0 barSeparation stop
Help informations:Please check:> valve / position in cleanoil outlet pipes> adjusting of back pressure> flow rate> oil temperature-setting> setpoint of frequency converter
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 177
C7: error messages
alarm 004: FAH-WATER-OUTLET
Flow too highSeparation stop
Help informations:Please check:> adjustment of back pressure> flow rate feedpump> adjusting of setpoint> leaking of hydraulic liquid
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 178
C7: error messages
alarm 005: TAL-PRODUCT-FEED
Temp. min: < SetpointSeparation stop
Help informations:Please check:> Temp. setting of Analog / Input> Temp. indicator in feedline> function of heating system
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 179
C7: error messages
alarm 006: TAH-PRODUCT-FEED
Temp. max: > SetpointSeparation stop
Help informations:Please check:> Temp. setting of Analog / Input> Temp. indicator in feedline> function of heating system
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 180
C7: error messages
alarm 007: EJECTION MONITOR
current < SetpointSeparation stop
Help informations:Please check:> Ejection current> Setpoint of ejection monitor> Amount of operating water> clutch shoes> function of bowl
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 181
C7: error messages
alarm 008: LSHH- SLUDGETANK
level-highSeparation stop
Help informations:Please check:> Function of sludge pump> Function of level switch / wiring> Handvalve position> clutch shoes> system / leakages
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 182
C7: error messages
alarm 010: FEED-PUMP
Motor-protection pump out of order
Help informations:Please check:> Fuses / breaker in motorstarter> Function of pump> Function of motor> Motor temperature> Nominal current
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 183
C7: error messages
alarm 011: SLUDGE-PUMP
Motor-protection pump out of order
Help informations:Please check:> Fuses / breaker in motorstarter> Function of pump> Function of motor> Motor temperature> Nominal current
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 184
C7: error messages
alarm 012: VIBRATION STAGE 1
Vibration > 4,5 mm/s start ejection program
Help informations:Please check:> operation water system> bowl hydraulic> sludge outlet> vibration monitor> correct bowl assembly> setpoint stage 1
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 185
C7: error messages
alarm 013: VIBRATION STAGE 2
Vibration > 7,0 mm/s Motor switch off
Help informations:Please check:> operation water system> bowl hydraulic> sludge outlet> vibration monitor> correct bowl assembly> setpoint stage 2
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 186
C7: error messages
alarm 014: SERIES MODE FAILURE
connection / pre-set failure
Help informations:Please check:> key „SERIES 1<=>2“ on both timing units> MPI-cables / plugs on both timing units> Both separators in „Ready for operation“
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 187
C7: error messages
alarm 015: MIN. SEPARATION TIME < 10 min
high water content
Help informations:Please check:> water content in dirty oil feed> Leakage of water valve> control holes in separation disk HFO / LO
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 188
C7: error messages
alarm 017: WMS - alarm high water content
WMS-SYSTEM NOT OKhigh water during Timer 22
Help informations:Please check:> WMS-signal> settings of measuring relais> function of WMS> function of water discharge valve
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 189
C7: error messages
alarm 018: Water seal broken during Timer 35
SMS- FUNCTION NOT OK
Help informations:Please check:> function of SMS pressure switch> amount of filling water> product feed
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 190
C7: error messages
alarm 019: PSL pressure switch monitoring
Clean oil outlet pressure
Help informations:Please check:> adjusting of back pressure> flowrate feedpump> bowl closing> hydraulic function> leaking of hydraulic liquid> clutch of feed pump
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 191
C7: error messages
alarm 020: Bowl monitoring
Closing water impulse T06
Help informations:Please check:> adjustment of closing water impulse> operating water pressure> clutch shoes> function of bowl
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 192
C7: error messages
alarm 021: Separator off
Separator off function active T39(no ACK after alarm raised)
Help informations:Please check:> Separator off function active > Separator shut down after T39 elapsed
Mechanical SeparationDivision
Westfalia SeparatorMineraloil Systems GmbH
30.06.2004 Ronald Eschmann, Service Dept., Hamburg 193
Service Training
Thank you.