Westfalia Separator

Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Mechanical Separation
Division

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

Westfalia Separator
Mineraloil Systems GmbH

model designation of separators

Mechanical Separation
Division

e.g. OSA7-02-066

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator
Mineraloil Systems GmbH

model designation of separators

Mechanical Separation
Division

OSA 7-02-066
application: 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 feedand discharge line or welded design with welded-on
or screwed-on feed and discharge connections
flange-type motor (horizontal), type B5, with clutch

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator
Mineraloil Systems GmbH

Diagram of installation

Mechanical Separation
Division

Stuffing box oil

Fuel

Settl.
tank

Service
tank

Sludge tank

Sludge

HFO - Sludge tank

LO - Sludge tank

Lube oil
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Bilge water
4

Westfalia Separator
Mineraloil Systems GmbH

Diagram of installation: SINGLE MODE

Mechanical Separation
Division

instrument air

feed valve

pre-heater
steam inlet

solenoid f+d water

motor starter
potable water
clean oil discharge

control unit

throttle valve

inspection cover

pressure switch
Separator
solenoid
operating water

pre-set valve
water discharges
feed pump
pre-strainer
dirty oil feed

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator
Mineraloil Systems GmbH

bowl: VARIZONE

Mechanical Separation
Division

dirty water discharges

clean oil discharge

dirty oil feed

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator
Mineraloil Systems GmbH

bowl: disk stack

Mechanical Separation
Division

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 sedimentation 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.

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator
Mineraloil Systems GmbH

bowl: disk stack

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator
Mineraloil Systems GmbH

Bowl: OSA7-02

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Westfalia Separator
Mineraloil Systems GmbH

bowl: OSA20 UNITROL

Mechanical Separation
Division

CS

30.06.2004

PSL

Ronald Eschmann, Service Dept., Hamburg

10

Westfalia Separator
Mineraloil Systems GmbH

bowl: OSB35-02

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

11

Westfalia Separator
Mineraloil Systems GmbH

Bowl: OSC4-02

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

12

Westfalia Separator
Mineraloil Systems GmbH

bowl: OSC4 UNITROL

Mechanical Separation
Division

CS

30.06.2004

PSL

Ronald Eschmann, Service Dept., Hamburg

13

Westfalia Separator
Mineraloil Systems GmbH

bowl: OSC30-91

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

14

Westfalia Separator
Mineraloil Systems GmbH

bowl: OSD6-91

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

15

Westfalia Separator
Mineraloil Systems GmbH

diagram of installation: SINGLE MODE

Mechanical Separation
Division

temperature switch high / low

pressure switch low (SMS)

conductivity sensor (WMS)

1: displacement water
2: operating water
3: 3/2 way feed valve
4: circulation valve
5: water discharge valve
6: dirty oil feed
7: feed return line
8: clean oil discharge

6
3
7

pressure switch

ejection monitoring

motor protection

vibration monitor

flow switch

HFO: single / parallel mode: recommended with increased water content

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

16

Westfalia Separator
Mineraloil Systems GmbH

diagram of installation: SINGLE MODE

Mechanical Separation
Division

HFO

return line of feed valve led back to settling tank

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

17

Westfalia Separator
Mineraloil Systems GmbH

diagram of installation: SINGLE MODE

Mechanical Separation
Division

LO

return line of feed valve led back to oil sump

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

18

Westfalia Separator
Mineraloil Systems GmbH

diagram of installation: SERIES MODE

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

19

Westfalia Separator
Mineraloil Systems GmbH

diagram of installation: SERIES MODE

Mechanical Separation
Division

HFO series mode: recommended with increased amount of solids in the feed
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

SERIES MODE of operation: HFO only

Mechanical Separation
Division

When running in series mode only the feed pump and pre-heater
of the first stage (purifier) are in operation. An attached feed
pump 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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

21

Westfalia Separator
Mineraloil Systems GmbH

diagram of installation: SERIES MODE

Mechanical Separation
Division

series mode of operation: process and installation diagram

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

22

Westfalia Separator
Mineraloil Systems GmbH

series mode with VESB-EC 1

Mechanical Separation
Division

holes open in
separating disc

holes closed in
separating disc

FIRST STAGE: PURIFIER

Function keys to be pre-selected
at timing unit type VESB-EC 1:

SECOND STAGE: CLARIFIER

Function keys to be pre-selected
at timing unit type VESB-EC 1:

F2, F3 and F13

F2, F3, F4, F10 and F13

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

23

Westfalia Separator
Mineraloil Systems GmbH

series mode with VESB-EC 1

Mechanical Separation
Division

Series Mode FAIL

Series Mode OFF

Series Mode ON

Feedback Signal

24 VDC from unit 1

Series Mode FAIL

Series Mode OFF

Series Mode ON

Feedback Signal

24 VDC from unit 2

VESB- Panel
INPUTS - UNIT 2
OUTPUTS -UNIT 2
No. 2
I 111
I 112
I 113
I 114 O 1013 O 1014 O 1015 O 1016
X1-Terminals 23 24 26 25 27 28 30 29 59 60 61 62 63 64 65 66

X1-Terminals 59 60 61 62 63 64 65 66 23 24 26 25 27 28 30 29
VESB- Panel O 1013 O 1014 O 1015 O 1016 I 111
I 112
I 113
I 114
No. 1
OUTPUTS - UNIT 1
INPUTS - UNIT 1

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

24

Westfalia Separator
Mineraloil Systems GmbH

series mode with C7

Mechanical Separation
Division

holes open in
separating disc

holes closed in
separating disc

FIRST STAGE: PURIFIER

Function keys to be pre-selected
at timing unit type C7:
and
30.06.2004

SECOND STAGE: CLARIFIER

Function keys to be pre-selected
at timing unit type C7:
and

Ronald Eschmann, Service Dept., Hamburg

25

Westfalia Separator
Mineraloil Systems GmbH

series mode with C7

Mechanical Separation
Division

MPI-interface / MPI - code 1/2

MPI-interface / MPI - code 3/4

on
off
A

on
off

HFO 1
WMS-01-

Terminal strip
HFO 1
1

12

HFO 2
SMS -36-

Terminal strip
HFO 2
1 12

sc

sc

Cable type:
UNITRONIC-BUS-FD P L2/F.I.P
1x2x0,25 mm2 + screen
Attention:
Not laying MPI-data cables parallelly to power cables
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

26

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -02-

Mechanical Separation
Division

OSC4

VARIZONE -02-: no UNITROL valves

on the hood but a regulating ring;
suitable for products with max.
density of 0,991 kg/dm @ 15C
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

27

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -02-, regulating ring

Mechanical Separation
Division

OSC15

OSA20

Regulating ring (ringdam)

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -02-, regulating ring

Mechanical Separation
Division

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/dm @ 20C. Separation temp: 70C
The density of oil decreases linear with
increased temperature. Find the intersection
of the density line with the line of 70C.
Find the thick curves (here green). The
number in the field between two curves
shows the correct regulating ring: 70 mm.

OSC5-02-066

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -02-, regulating ring

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

30

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

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
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

31

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

1 Dirty oil feed

2 Clean oil discharge
3 Filling / Displacement water
4 Pressure switch (clean oil)
5 Regulating ring
6 Control unit
7 Centripetal pump (dirty water)
8 Centripetal pump (clean oil)
9 Separating disk
10 Sludge holding space
11 Dirty water discharge
12 Operating water discharge
13 Sludge discharge
14 Operating water feed
15 Solenoid valve block
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

32

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

clean oil discharge

dirty water
discharge to
frame drain

dirty oil feed

Two centripetal pumps

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

33

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

pressure switch in the dirty water

discharge: PAH breakover water discharge

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

OSC30

34

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

35

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

holes open !

All process parameters, timer adjustments, water flow rates, regulating

ring diagrams etc. of separator type -91- are identically with -02- design.
Please note, the screw pins needs to be removed from the lower centripetal pump chamber cover when running mode VARIZONE -91-.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

36

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

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
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

37

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

lower centripetal pump chamber cover

-UNITROLholes closed

30.06.2004

-VARIZONEholes open

Ronald Eschmann, Service Dept., Hamburg

38

Westfalia Separator
Mineraloil Systems GmbH

Separator type VARIZONE -91-

Mechanical Separation
Division

OSC30

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

39

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL-WMS -01-

Mechanical Separation
Division

OSC50

UNITROL-WMS: no ringdam;
with conductivity sensor, circulation- and water discharge
valve, suitable for products with
max. density of 1,01 kg/dm @
15C
30.06.2004

Water Monitoring System:

PURIFIER - FIRST STAGE

Ronald Eschmann, Service Dept., Hamburg

40

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL-WMS -01-

Mechanical Separation
Division

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

HFO

19
19: screw pins (holes open
in separating disc !)
p/n: 0019-9045-400
30.06.2004

17: operating water

discharge
18: operating water feed
Ronald Eschmann, Service Dept., Hamburg

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
41

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL-WMS -01-

Mechanical Separation
Division

HFO
5

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

42

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL-WMS -01-

Mechanical Separation
Division

holes open in
separating disc

PURIFICATION means the separation of liquid mixtures which

consists of two liquids, with simultaneous removal of the solids
contained in the [Link] is the removal of solids
from a liquid.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

43

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL-WMS -01-

Mechanical Separation
Division

CS

PSL

CS

Separation: Circulation valve

open, CS not activated
30.06.2004

PSL

Water discharge: CS activated,

water discharge valve open

Ronald Eschmann, Service Dept., Hamburg

44

Westfalia Separator
Mineraloil Systems GmbH

WMS - measuring relais : type DNAR

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

45

Westfalia Separator
Mineraloil Systems GmbH

WMS - measuring relais : type DNAR

Mechanical Separation
Division

old version until 1996

turn clockwise to max.

set to: 100 - 200

WS part number: 0005-3929-000 (220 VDC) 0005-3929-010 (110 VDC)

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

46

Westfalia Separator
Mineraloil Systems GmbH

WMS - measuring relais : type RM-3 LA1

Mechanical Separation
Division

function: the time from that the

conductivity sensor is detecting water
until water is being discharged
R-sector: the full scale adjustment: 50 k
R-value : to be adjusted to approx. 20
means the actual setpoint has been adjusted to 20 k. 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

WS part number: 0005-3929-020 (since summer 1996)

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

47

Westfalia Separator
Mineraloil Systems GmbH

WMS - measuring relais : type RM-3 LA1

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

48

Westfalia Separator
Mineraloil Systems GmbH

WMS - measuring relais : type RM-4 LA3 2MW

Mechanical Separation
Division

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.

empty / fill selection: set to empty

sensivitiy range / delay function selection:
set to 50
sensivity range: 0 - 50 k
function: ON-delay (the time from
detecting water to water discharge)

WS part number: 0005-3929-030; since summer 2003

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

49

Westfalia Separator
Mineraloil Systems GmbH

replacement DNAR by RM3 / RM4

Mechanical Separation
Division

terminal

30.06.2004

DNAR

RM3 / RM4

11

15

12

16

14

18

B2

B1

A1

A1

A2

A2

Ronald Eschmann, Service Dept., Hamburg

50

Westfalia Separator
Mineraloil Systems GmbH

WMS: conductivity sensor 0005-1347-000

Mechanical Separation
Division

1
2
3
4
5
6
7
8
9
10
11
12

30.06.2004

housing
isolating piece
cover
hex head screw
sensor
threaded piece
gasket (2 pcs)
gasket (2 pcs)
cable head
cable
plug
plug

Ronald Eschmann, Service Dept., Hamburg

0005-1347-010
0005-1347-020
0005-1347-030
0019-6842-400
0005-1347-100
0019-0576-600
0007-2507-750
0007-1866-830
0005-0637-000
0005-0400-008
0019-0644-600
0019-1492-000

51

Westfalia Separator
Mineraloil Systems GmbH

WMS: conductivity sensor 0005-1347-000

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

52

Westfalia Separator
Mineraloil Systems GmbH

WMS: conductivity sensor 0005-1347-000

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

53

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -36-

Mechanical Separation
Division

OSC50

UNITROL-SMS -36-: no ringdam; pressure switch and circulation valve in use, running in
second stage when running in
series mode only, HFO clarifier
30.06.2004

Sludge Monitoring System:

CLARIFIER - SECOND STAGE

Ronald Eschmann, Service Dept., Hamburg

54

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -36-

Mechanical Separation
Division

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

HFO

19
19: screw pins (holes closed
in separating disc !)
p/n: 0019-9045-400
30.06.2004

17: operating water

discharge
18: operating water feed
Ronald Eschmann, Service Dept., Hamburg

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
55

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -36-

Mechanical Separation
Division

HFO
6

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

56

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -36-

Mechanical Separation
Division

holes closed in
separating disc

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

57

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -36-

Mechanical Separation
Division

CS PSL

Separation:
circulation valve
open, sensing liquid
pressure above the
setpoint of pressure
switch
30.06.2004

CS

PSL

Separation: circulation
valve open, sludge
holding space filled up
with solids, sensing liquid
pressure dropped below
setpoint
Ronald Eschmann, Service Dept., Hamburg

CS PSL

Ejection: on both
stages triggered by the
self thinker, feed
valve closed .

58

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -96-

Mechanical Separation
Division

OSC50

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.
30.06.2004

Sludge Monitoring System

for Lube oil

Ronald Eschmann, Service Dept., Hamburg

59

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -96-

Mechanical Separation
Division

CS PSL

Filling: no pressure at
the PSL, CS not in use,
holes in separating
disc open, bowl
partially pre-filled
30.06.2004

CS PSL

Separation: sensing
liquid pressure above
the setpoint

Ronald Eschmann, Service Dept., Hamburg

CS PSL

Separation: sludge
holding space filled up
with water and solids,
sensing liquid pressure
dropped below setpoint,
ejection triggered
60

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -96-

Mechanical Separation
Division

1: dirty oil feed

2: clean oil discharge
3: displacement
water feed
4: pressure indicator
5: conductivity sensor
6: pressure switch
7: circulation valve

LO

8: water discharge
valve
9: sensing liquid flow
10: sensing liquid pump
11: control unit
12: centripetal pump
(clean oil)
19

19: screw pins (holes open in

separating disc !)
p/n: 0019-9045-400

30.06.2004

13: separating disc

17: operating water
discharge

14: dirty water discharge

18: operating water feed

16: sludge discharge

Ronald Eschmann, Service Dept., Hamburg

15: sludge holding space

61

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -96-

Mechanical Separation
Division

LO
6

19

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).
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

62

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -SMS -96-

Mechanical Separation
Division

holes open in
separating disc

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 needs to be installed in the
filling- and displacement water assy.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

63

Westfalia Separator
Mineraloil Systems GmbH

LO: Separator type UNITROL-WMS+SMS -0196-

Mechanical Separation
Division

UNITROL-WMS+SMS: no ringdam; conductivity sensor, circulation- and water discharge

valve as well as pressure switch
in use. For LO only.
30.06.2004

Water Monitoring System +

Sludge Monitoring System

Ronald Eschmann, Service Dept., Hamburg

64

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL WMS+SMS -0196-

Mechanical Separation
Division

CS

PSL

CS

After the ejection the bowl is

empty. Sliding piston as well as
annular piston are in sealing
position.
30.06.2004

PSL

FILLING: the bowl will be filled

with water timer controlled.
The signal of the pressure
switch will override the timer.

Ronald Eschmann, Service Dept., Hamburg

65

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL WMS+SMS -0196-

Mechanical Separation
Division

CS

PSL

CS

SEPARATION: the upper

centripetal pump is acting as a
gravity disk. Dirty water will be
discharged continiously.
30.06.2004

PSL

HIGH WATER: Alarm will be

given once that a certain
amount of water is being
discharged (Timer controlled)

Ronald Eschmann, Service Dept., Hamburg

66

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL WMS+SMS -0196-

Mechanical Separation
Division

CS

PSL

CS

SMS mode: after the WMS

mode is over by timer the SMS
mode is activated. Water will
be added timer controlled.
30.06.2004

PSL

SMS mode: Both valves are

closed. No signal of the pressure
switch means: sludge holding
space is filled up.

Ronald Eschmann, Service Dept., Hamburg

67

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL WMS+SMS -0196-

Mechanical Separation
Division

CS

PSL

CS

SMS mode: Ejections will be

triggered timer controlled. The
signal of the pressure switch
will override the timer (T20)
30.06.2004

PSL

BREAKOVER: Alarm will be given

when the water seal has been lost
however: Signal from the PSL but
no signal from the CS.

Ronald Eschmann, Service Dept., Hamburg

68

Westfalia Separator
Mineraloil Systems GmbH

non-self-cleaning type: solid wall bowl

Mechanical Separation
Division

Type OTA

30.06.2004

Type OTB

Ronald Eschmann, Service Dept., Hamburg

Type OTC

69

Westfalia Separator
Mineraloil Systems GmbH

Separator type UNITROL -DISPLACEMENT-

Mechanical Separation
Division

CS

PSL

Separation: sludge holding space filled up with

solids, sensing liquid
pressure dropped below
setpoint

30.06.2004

CS PSL

Displacement: Filling
+ Displacement and
circulation valve open,
clean oil displaced to
the clean oil discharge

Ronald Eschmann, Service Dept., Hamburg

CS PSL

Ejection: on both stages

triggered by the self
thinker, oil losses
minimized

70

Westfalia Separator
Mineraloil Systems GmbH

Potable water

Mechanical Separation
Division

condensate as well as desillate is not permissible

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

71

Westfalia Separator
Mineraloil Systems GmbH

Potable water

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

72

Westfalia Separator
Mineraloil Systems GmbH

Potable water

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

73

Westfalia Separator
Mineraloil Systems GmbH

Potable water

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

74

Westfalia Separator
Mineraloil Systems GmbH

water discharges: syphons

Mechanical Separation
Division

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

75

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Mineraloil Systems GmbH

water discharges: syphons

Mechanical Separation
Division

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

76

Westfalia Separator
Mineraloil Systems GmbH

centripetal pump

Mechanical Separation
Division

upper centripetal pump

30.06.2004

lower centripetal pump

Ronald Eschmann, Service Dept., Hamburg

77

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Mineraloil Systems GmbH

centripetal pump

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

78

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Mineraloil Systems GmbH

OSA, OSB, OSC: Foundation

Mechanical Separation
Division

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.)
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

79

Westfalia Separator
Mineraloil Systems GmbH

OSA, OSB, OSC: Foundation

Mechanical Separation
Division

wrong !

wrong !

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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.

80

Westfalia Separator
Mineraloil Systems GmbH

Foundation

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

81

Westfalia Separator
Mineraloil Systems GmbH

foundation / max. vibration limit

Mechanical Separation
Division

max. vibration limit at installation surface with stopped separator

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

82

Westfalia Separator
Mineraloil Systems GmbH

OSD: Foundation

Mechanical Separation
Division

0021-3308-750
0021-3309-750

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

83

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Mineraloil Systems GmbH

OSD: Foundation

Mechanical Separation
Division

OSD 6 / OSD 18

OSD 35 / OSD 60

pos. 340:

2058-1467-000

pos. 390:

2057-1467-000

pos. 350:

0021-3308-750

pos. 400:

0021-3309-750

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

84

Westfalia Separator
Mineraloil Systems GmbH

clutch, clutch shoes

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

85

Westfalia Separator
Mineraloil Systems GmbH

fitting of clutch shoes

Mechanical Separation
Division

for OSC15 (belt drive only)

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

86

Westfalia Separator
Mineraloil Systems GmbH

clutch driver, clutch shoes OSA, OSB, OSC

Mechanical Separation
Division

For all gear driven separators

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

87

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Mineraloil Systems GmbH

OSD: clutch, cluch shoes

Mechanical Separation
Division

One friction pad for all OSD type of separators

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

88

Westfalia Separator
Mineraloil Systems GmbH

clutch drive: permissable wear holding slit

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

89

Westfalia Separator
Mineraloil Systems GmbH

gear oil - oil level in gear box

Mechanical Separation
Division

OTC2
OTC3

Check oil level daily. Check whether the oil bath contains water (milky
colouring) or product (HFO - dark colouring). If so change immediatly.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

90

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Mineraloil Systems GmbH

gear oil CLP100

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

91

Westfalia Separator
Mineraloil Systems GmbH

gear oil CLP220

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

92

Westfalia Separator
Mineraloil Systems GmbH

gear oil ISO-VG 220

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

93

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Mineraloil Systems GmbH

gear oil ISO-VG 68

Mechanical Separation
Division

For belt driven separators only.

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

94

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Mineraloil Systems GmbH

synthetic gear oil, running in procedure

Mechanical Separation
Division

list of approved oils:

MOBIL SHC 630
SHELL Delima HT 220
CASTROL Alphasyn T 220
CASTROL Alphasyn HG 220
BP Enersyn HTX 220
ESSO Teresso SHP 220
ELF (Lub Marine) EPONA SA 220
FINA 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 [mm/s].
For OSC15 (flat belt drive !) synthetic gear oil of ISO-VG 68 is recommended.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

95

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Mineraloil Systems GmbH

synthetic gear oil, running in procedure

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

96

Westfalia Separator
Mineraloil Systems GmbH

wear to gear

Mechanical Separation
Division

The gear parts

(both worm wheel
as well as vertical
spindle needs to
be replaced incase
the tip of tooth
worn out to 1/2 to
dimension h.

30.06.2004

The gear parts

(both worm wheel
as well as vertical
spindle needs to
be replaced incase
the base of the
tooth shows sign
of wear.

Ronald Eschmann, Service Dept., Hamburg

97

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Mineraloil Systems GmbH

bottom bearing

Mechanical Separation
Division

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
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

98

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Mineraloil Systems GmbH

bottom bearing : sherical plain bearing

Mechanical Separation
Division

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

99

Westfalia Separator
Mineraloil Systems GmbH

OSB35 - modified hydraulic system

Mechanical Separation
Division

new

previous

2 x 0007-1674-750
393,1/407,1x7
30.06.2004

1 x 0007-1892-750
385/405x10
Ronald Eschmann, Service Dept., Hamburg

100

Westfalia Separator
Mineraloil Systems GmbH

OSB 35: hard metal ring of sliding piston

Mechanical Separation
Division

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

OSB35
Guide values for re-machining:
Tool: carbide-tipped tool of M30 or K20
Speed: 10 - 12 rpm
Depth of cut: max. 0.15 mm
Rate of feed: max. 0.1 mm/rev
30.06.2004

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.

Ronald Eschmann, Service Dept., Hamburg

101

Westfalia Separator
Mineraloil Systems GmbH

OSB 35: correction of bowl height

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

102

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Mineraloil Systems GmbH

OSA20 - modified hydraulic system

Mechanical Separation
Division

new

previous

2040-9958-000

2178-9959-000

2 x 0007-1851-750
304,2/318,2x7
30.06.2004

1 x 0007-1851-750
304,2/318,2x7
Ronald Eschmann, Service Dept., Hamburg

103

Westfalia Separator
Mineraloil Systems GmbH

OSA20 - threaded ring 2178-6627-010

Mechanical Separation
Division

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

104

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Mineraloil Systems GmbH

OSA 20 - hard metal ring of sliding piston

Mechanical Separation
Division

Guide values for re-machining:

OSA20

Tool: carbide-tipped tool of M30 or K20

Speed: 10 - 12 rpm
Depth of cut: max. 0.15 mm
Rate 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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

105

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Mineraloil Systems GmbH

OSA 20 - frame venting

Mechanical Separation
Division

In order to improve the frame venting a pipe should be

installed in the frame drain as shown above.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

106

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Mineraloil Systems GmbH

hard metal ring of sliding piston OSA7

Mechanical Separation
Division

OSA7

Guide values for re-machining:

Tool: carbide-tipped tool of M30 or K20
Speed: 10 - 12 rpm
Depth of cut: max. 0.15 mm
Rate of feed: max. 0.1 mm/rev
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.

30.06.2004

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

Ronald Eschmann, Service Dept., Hamburg

107

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Mineraloil Systems GmbH

bowl: Table of bowl heights

Mechanical Separation
Division

type

X [mm] Y [mm] 50 Hz [rpm]

60 Hz [rpm]

OSC4

54-56

9980

10030

OSC5

54-56

9980

10030

OSA7

80-82

1,50

8520

8510

OSC15

37-39

OSA20

120-122

2,00

7500

7500

OSC30

16-18

2,00

7500

7500

OSB35

38-40

2,00

6440

6540

OSC50 -old-

43-45

2,00

6500

6500

OSC50 -new-

34-36

2,00

6500

6500

9960 / 10240 11490 / 11470

*: height not adjustable

adjustment 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-clockwise
bowl is too low: turn clockwise

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

108

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Mineraloil Systems GmbH

separator bowl - unbalance

Mechanical Separation
Division

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 parts from different bowl has been mixed

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

109

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Mineraloil Systems GmbH

separator bowl - unbalance

Mechanical Separation
Division

The bowl needs 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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

110

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Mineraloil Systems GmbH

bowl: taper seat of bowl bottom / spindle

Mechanical Separation
Division

The conical seat of bowl bottom and worm spindle

must be absolutely dry when assembling the bowl.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

111

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Mineraloil Systems GmbH

separator bowl: chrome layer peeling

Mechanical Separation
Division

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

112

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Mineraloil Systems GmbH

separator bowl OSA, OSB - wear protection

Mechanical Separation
Division

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.)
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

113

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Mineraloil Systems GmbH

Refinery process

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

114

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Mineraloil Systems GmbH

cat fines

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

115

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Mineraloil Systems GmbH

Residual Marine fuel standards

Mechanical Separation
Division

ISO, BSI, CIMAC

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

116

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Mineraloil Systems GmbH

Incompatibility of Fuels

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

117

Westfalia Separator
Mineraloil Systems GmbH

Incompatibility of Fuels

Mechanical Separation
Division

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 is
a paraffin-base destillate.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

118

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Mineraloil Systems GmbH

Incompatibility of Fuels

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

119

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Mineraloil Systems GmbH

Stability of Fuels

Mechanical Separation
Division

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

120

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Mineraloil Systems GmbH

Precipitation of Paraffin (wax) / Spot test

Mechanical Separation
Division

It must be remembered that fuel oils may contain components of a

paraffine 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 paraffin
begins 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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

121

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Mineraloil Systems GmbH

fuel problem: contamination with chemicals

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

122

Westfalia Separator
Mineraloil Systems GmbH

fuel problem: contamination with chemicals

Mechanical Separation
Division

pittings / cavitations at the sensing liquid pump (HFO)

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

123

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Mineraloil Systems GmbH

fuel problem: contamination with chemicals

Mechanical Separation
Division

CS

30.06.2004

5 bar

CS

Ronald Eschmann, Service Dept., Hamburg

35 bar

124

Westfalia Separator
Mineraloil Systems GmbH

fuel problem: contamination with chemicals

Mechanical Separation
Division

pittings / cavitations at the sensing liquid pump (HFO)

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

125

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Mineraloil Systems GmbH

electrical equipment -general layout plan

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

126

Westfalia Separator
Mineraloil Systems GmbH

Diagram of installation: SINGLE MODE

Mechanical Separation
Division

feed valve

pre-heater

solenoid filling/
displacement
water

Motor
starter

control unit
pressure
switch

Separator

solenoid
operating
water

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

127

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Mineraloil Systems GmbH

Timing unit type VESA

Mechanical Separation
Division

Voll
Elektronische
Steuerung
A- Typ
30.06.2004

timing unit type VESA

installed 1980 - 1990
Ronald Eschmann, Service Dept., Hamburg

128

Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESA

Mechanical Separation
Division

Voll
Elektronische
Steuerung
A- Typ
30.06.2004

timing unit type VESA

installed 1980 - 1990
Ronald Eschmann, Service Dept., Hamburg

129

Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESA

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

130

Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESA

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

131

Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESA

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

132

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Mineraloil Systems GmbH

Timing unit type VESA

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

133

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Mineraloil Systems GmbH

Timing unit type VESA

Mechanical Separation
Division

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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Mineraloil Systems GmbH

Timing unit type VESB

Mechanical Separation
Division

Voll
Elektronische
Steuerung
B- Typ

timing unit type VESB

installed 1990 - 1999
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Mineraloil Systems GmbH

Timing unit type VESB

Mechanical Separation
Division

timing unit type VESB

installed 1990 - 1999

Voll
Elektronische
Steuerung
B- Typ
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Mineraloil Systems GmbH

Timing unit type VESB

Mechanical Separation
Division

timing unit type VESB

installed 1990 - 1999
PLC100/1WS-part number : 0005-4050-260
PLC100/2WS-part number : 0005-4050-270
PLC100/3WS-part number : 0005-4050-280
PLC100/4WS-part number : 0005-4050-290
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

Voll
Elektronische
Steuerung
B- Typ
137

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Mineraloil Systems GmbH

Timing unit type VESB: PLC100

Mechanical Separation
Division

1: control unit PLC 100

2: LED off / input status
3: LED on / output status
4: Cursor up
5: Cursor down
6: Output range
7: Input range
8: Counter range
9: Timer range
10: Copy program
11: Status text
12: display
13: Operation LED (control unit READY)
14: numeric keys
15: Enter key
16: Specific call-up in preselected mode
17: Function keys: F0 - TEST
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Mineraloil Systems GmbH
Mechanical Separation
Division

Timing unit type VESB: PLC100,

function keys

F0

program STOP with ejection

F1

program START with ejection

F2

displacement

F3

flushing

F4

clarifier operation: step FILLING suppressed

F5

diagnostics: help function

F6

alarm acknowledgement

F10

self-thinker control ON

F11

free

F12

free (displacement with product)

F13

series operation ON

F14

free

F15

diesel oil operation: alarm TAL suppressed

F16

free

SHIFT
30.06.2004

gives access to key F10 to F16

Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESB: PLC100

Mechanical Separation
Division

PLC100 without EPROM

PLC100: 16 inputs, 8 + 8 outputs, maker: SCHLEICHER

30.06.2004

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Mineraloil Systems GmbH

Timing unit type VESB: replacing PLC100

Mechanical Separation
Division

1. Please make a note of the original settings of all timer and counter
2. Please switch off the main switch and plug off all plug connectors as
well as the EPROM (please never plug off EPROM while contol
cabinet 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 be
24 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-key
6. Press the COPY-key, then ENTER and STATUS again.
7. Now you can change the present timer and counter setting`s to the
original ones. To do this please press the "TIMER" key. By means
of the cursor keys you can scroll trough the timer list and change
the settings . To call up the timer please press the "ENTER" key.
PLC100/1 can be replaced by PLC100/1 or PLC100/3.
PLC100/2 can be replaced by PLC100/2 or PLC100/4.
30.06.2004

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Mineraloil Systems GmbH

Timing unit type VESB: Password PLC100

Mechanical Separation
Division

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Mineraloil Systems GmbH

VESB function keys - HFO series mode -01-36-

Mechanical Separation
Division

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.
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Mineraloil Systems GmbH

Timing unit type VESC

Mechanical Separation
Division

Voll
Elektronische
Steuerung
C- Typ
30.06.2004

timing unit type VESC

installed 1995 - 1999
Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESC

Mechanical Separation
Division

Voll
Elektronische
Steuerung
C- Typ
30.06.2004

timing unit type VESC

installed 1995 - 1999
Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESC

Mechanical Separation
Division

Voll
Elektronische
Steuerung
C- Typ

timing unit type VESC

installed 1995 - 1999
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

146

Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESC, check of PSU card

Mechanical Separation
Division

timing unit type VESC

installed 1995 - 1999
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

147

Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESC , check of PSU card

Mechanical Separation
Division

R13

four pin socket

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

148

Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESC , check of PSU card

Mechanical Separation
Division

R13 burned

rear side of PSU card

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESC , check of PSU card

Mechanical Separation
Division

R13 new

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESC

Mechanical Separation
Division

power supply unit, part

number: 0005-4097-100

Voll
Elektronische
Steuerung
C- Typ

VESC-1-W
(8155-0202-050)
to be installed
on the wall
VESC-1-S
(8155-0202-060)
to be installed
inside control
cabinet.

timing unit type VESC

installed 1995 - 1999
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Mineraloil Systems GmbH

Timing unit type VESC

Mechanical Separation
Division

EPROM; software:
0005-2045-100

Voll
Elektronische
Steuerung
C- Typ
30.06.2004

timing unit type VESC

installed 1995 - 1999
Ronald Eschmann, Service Dept., Hamburg

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Westfalia Separator
Mineraloil Systems GmbH

Timing unit type VESC

Mechanical Separation
Division

Voll
Elektronische
Steuerung
C- Typ
EPROM; software:
0005-2045-100

30.06.2004

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153

Westfalia Separator
Mineraloil Systems GmbH

Timing unit type C7

Mechanical Separation
Division

0005-4050-300
0005-4050-310
0005-4050-320
0005-4050-340
0005-4050-350
0005-4050-360

C7-623 (A)
C7-626 (A)
C7-626 (A) DP
C7-623 (P)
C7-626 (P)
C7-626 (P) DP

UD700: 0005-4040-190 (software update)

C7-623

C7-626

timing unit type SIEMENS

C7 installed from 2000
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

154

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7-626

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

155

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7-626

Mechanical Separation
Division

30.06.2004

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156

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7-623

Mechanical Separation
Division

30.06.2004

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157

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7-623

Mechanical Separation
Division

30.06.2004

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158

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7-626

Mechanical Separation
Division

30.06.2004

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159

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7-626

Mechanical Separation
Division

Display

Softkeys

Status /fault
indicator

Function key

30.06.2004

Softkeys

Ronald Eschmann, Service Dept., Hamburg

System keys

160

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7- softkeys

Mechanical Separation
Division

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.

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Ronald Eschmann, Service Dept., Hamburg

161

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7- softkeys

Mechanical Separation
Division

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)

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

162

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Mineraloil Systems GmbH

Timing Unit type C7- softkeys

Mechanical Separation
Division

WMS 01: WATER MONITORING SYSTEM UNITROLHFO: single or parallel mode of operation, first stage
in series mode
SMS 36: SLUDGE MONITORING SYSTEM UNITROLHFO: second stage in series mode

SMS 96: SLUDGE MONITORING SYSTEM UNITROL-LO

SERIES MODE for UNITROL-HFO only.

30.06.2004

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163

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Mineraloil Systems GmbH

Timing Unit type C7- function keys

Mechanical Separation
Division

The LED in the keys shows the actual status:

permanent lighting: OPERATION
slow flashing: FAULT from motor protection
rapid flashing: winding up time or delay to stop time
No other function.

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

164

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7- function keys

Mechanical Separation
Division

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.

30.06.2004

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Mineraloil Systems GmbH

C7 display: contrast, background illumination

Mechanical Separation
Division

626

623

30.06.2004

The contrast at C7 623 is adjusted by

pressing the SHIFT and +/- key.

Ronald Eschmann, Service Dept., Hamburg

166

Westfalia Separator
Mineraloil Systems GmbH

Timing Unit type C7- system keyboard

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

167

Westfalia Separator
Mineraloil Systems GmbH

C7 control cabinet, inside view

Mechanical Separation
Division

Use only approved shielded cables for wiring the analog in

- and outputs as well as the IM, V.24 and MPI interfaces
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

168

Westfalia Separator
Mineraloil Systems GmbH

C7 control cabinet, inside view

Mechanical Separation
Division

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Mineraloil Systems GmbH

C7: view from rear, interfaces

Mechanical Separation
Division

1: IM port
2: Analog inputs
3: Analog outputs
4: AUX digital inputs
5: Serial interface V.24
6: Digital inputs (top)
7: Digital outputs (bottom)
8: DI/DO 24 VDC power supply

30.06.2004

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Mineraloil Systems GmbH

C7 series mode: first and second stage

Mechanical Separation
Division

MPI-plug: 0005-1408-000

30.06.2004

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171

Westfalia Separator
Mineraloil Systems GmbH

C7 series mode: first, second, third stage

Mechanical Separation
Division

30.06.2004

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Westfalia Separator
Mineraloil Systems GmbH

C7: alarm list

Mechanical Separation
Division

no.
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
30.06.2004

description
motor protection separator-motor
clean oil discharge pressure low
clean oil discharge pressure high
breakover water discharge
temperatur low
temperatur high
ejection monitoring system
sludgetank level high high
free
motor protection feed pump
motor protection sludge pump
vibro stage 1
vibro stage 2
series mode failure
minimum sep. time not o.k.
free
WMS alarm- high water content
Ronald Eschmann, Service Dept., Hamburg

PTC
PAL
PAH
FSH
TSL
TSH
ISL
LSHH
PTC
PTC
NAH
NAHH

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Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 001: MOTOR-PROTECTION

Temp. > max. C
Motor shut off
Help informations:
Please check:
> fuses in starter
> Thermistor relais
> clutch
> correct numbers of clutch shoes
> brake
> motor current
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

174

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 002: PAL-CLEANOIL-OUTLET

pressure < setpoint
Separation 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
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 003: PAH-CLEANOIL-OUTLET

pressure > 3,0 bar
Separation stop
Help informations:
Please check:
> valve / position in cleanoil outlet pipes
> adjusting of back pressure
> flow rate
> oil temperature-setting
> setpoint of frequency converter

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

176

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 004: FAH-WATER-OUTLET

Flow too high
Separation stop
Help informations:
Please check:
> adjustment of back pressure
> flow rate feedpump
> adjusting of setpoint
> leaking of hydraulic liquid

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

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Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 005: TAL-PRODUCT-FEED

Temp. min: < Setpoint
Separation stop
Help informations:
Please check:
> Temp. setting of Analog / Input
> Temp. indicator in feedline
> function of heating system

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

178

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Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 006: TAH-PRODUCT-FEED

Temp. max: > Setpoint
Separation stop
Help informations:
Please check:
> Temp. setting of Analog / Input
> Temp. indicator in feedline
> function of heating system

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

179

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Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 007: EJECTION MONITOR

current < Setpoint
Separation stop
Help informations:
Please check:
> Ejection current
> Setpoint of ejection monitor
> Amount of operating water
> clutch shoes
> function of bowl

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

180

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Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 008: LSHH- SLUDGETANK

level-high
Separation stop
Help informations:
Please check:
> Function of sludge pump
> Function of level switch / wiring
> Handvalve position
> clutch shoes
> system / leakages

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

181

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

182

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Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

183

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

184

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

185

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

186

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

187

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

alarm 017: WMS - alarm high water content

WMS-SYSTEM NOT OK
high water during Timer 22
Help informations:
Please check:
> WMS-signal
> settings of measuring relais
> function of WMS
> function of water discharge valve

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

188

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

189

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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
30.06.2004

Ronald Eschmann, Service Dept., Hamburg

190

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

191

Westfalia Separator
Mineraloil Systems GmbH

C7: error messages

Mechanical Separation
Division

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

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

192

Westfalia Separator
Mineraloil Systems GmbH
Mechanical Separation
Division

Service Training

Thank
you.

30.06.2004

Ronald Eschmann, Service Dept., Hamburg

193