Marine System Technology
Concepts and High Performance Equipment for the
Engine Room from GEA Westfalia Separator
engineering for a better world GEA Mechanical Equipment
Time for a
New Generation
Smart
The new GEA Westfalia Separator eagleclass was
developed with the know-how of the technology
leader in centrifugal separation technology. The
innovative separator design and the new GEA Westfalia
Separator unitrolplus sensor system are setting new
standards in the market segments energy, marine, oil
field, industry and environmental technology.
Strong
The strong g-force permits throughput capacities of
up to 80 m
3
/ h for the first time ever. GEA Westfalia
Separator unitrolplus assures highest separation
efficiency of the different media such as fuel and lube
oils, oily water, washing lye etc.
Reliable
The compact, robust construction makes the GEA Westfalia
Separator eagleclass particularly reliable and durable.
A further feature is GEA Westfalia Separator serv&care –
the proactive service of the original manu-facturer.
This combination ensures maximum availability and
economy throughout the entire life cycle.
4 Overview engine room concepts
4 High Performance Equipment for the
Engine Room
6 Manual cleaning separators
6 GEA Westfalia Separator minimaXx
?
8 Self-cleaning separators
8 Self-Cleaning Separator
with Centripetal Twin Pump
10 Self-cleaning separators
10 GEA Westfalia Separator unitrolplus –
Lube and Fuel Oil
12 Diesel oil treatment
12 Process Overview
12 Manual Cleaning Solutions
13 Self-Cleaning Solutions
14 Heavy fuel oil treatment
14 Process Overview
15 Plant Concepts with a System
16 Parallel Operation
18 Lube oil treatment
18 Process Overview
19 Plant Concepts for Efficient Operation
20 Control units
20 Automatic Process Control –
More Safety, More Comfort
21 GEA Westfalia Separator minimaXx
?
–
Process Control for Every Requirement
22 Flexible systems
22 Custom-Made System Solutions for the
Engine Room
23 Separator with Single Components
24 CU Compact Unit – Flexible Modularisation
25 GEA Westfalia Separator centripack –
Individual Modularisation
26 Sludge treatment
26 Process Overview
27 System Concepts for the Future
28 Economical Advantages – Ecological Merits
30 Bilgewater treatment
30 Self-Cleaning Centrifugal System
32 Technologies to Protect the Sensitive
Marine Ecosystem
33 Flexible Compact Unit Design
34 GEA Westfalia Separator
SafetyMaster
36 Fuel oil conditioning system
36 VBU – GEA Westfalia Separator ViscoBoosterUnits
37 Complete System Between Service
Tank and Engine
38 Water desalination system
38 SWD – GEA Westfalia Separator SafetyMaster
40 GEA Westfalia Separator BallastMaster ultraV
42 GEA Westfalia Separator serv&care –
Proactive Service for Optimum
Reliability on Board
Contents
32
High Performance Equipment
for the Engine Room
Overview engine room concepts
GEA Westfalia Separator Group offers leading
technologies and individual systems for marine use.
Be it system engineering from one source, high quality
of work manship or the unrivalled worldwide service –
GEA Westfalia Separator Group provides a system
to rely on.
Product range overview
? Fuel oil treatment
? Fuel oil conditioning system
? Lube oil treatment
? Sludge treatment
? Bilgewater treatment
? Water desalination system
? Hydraulic oil treatment plants
? Ballast water treatment
GEA Westfalia Separator Group supplies separation
systems specifically designed for continuous operation
under the roughest conditions. This gives you:
? Optimum power output
? Long service life for your engines
? High environmental standards
1 Fuel oil service tank
2 Fuel oil conditioning system
3 Fuel oil setting tank
4 Fuel oil treatment
5 Fuel oil sludge tank
6 Sludge treatment
1
2
3
4
5
6
7 Lube oil sludge tank
8 Lube oil treatment M.E.
9 Lube oil treatment A.E.
10 Water desalination system
11 Bilgewater treatment
12 Bilgewater tank
13 Ballast water treatment
14 Water tank
7
8
9
10
11
12
13
14
54
GEA Westfalia Separator minimaXx
?
Manual cleaning separators
Manual cleaning separators with solid wall bowl and
single centripetal pump are today used mostly for the
treatment of diesel oil and lube oil on smaller ships.
They are suitable for clarifying or purifying oils with
a low solids content of up to 0.1 percent by vol.
The clean oil is discharged from the bowl under
pressure by means of a centripetal pump. The
separated solids slide down the underside of the disc
into the solids holding space which must be emptied
by hand periodically.
Benefits
? Suitable for both clarifying and purifying
? Highly concentrated solids
? Simple construction
? Versatility of application
Bowl cross-section of a manual
cleaning mineral oil separator
with pressure discharge of the
clean oil by centripetal pump
Filling water
Dirty oil feed
Clean oil discharge
Dirty water discharge
Self-cleaning separators
Self-cleaning separators with disc bowl, single
centripetal pump and automatic solids ejection are
used where the percentage of solids in the oil is too
high for manual cleaning. These are used mainly
for the clarification and purification of oils such
as gas oil, diesel oil and lube oil. Self-cleaning
separators discharge solid matter automatically
while the separator is running. This avoids the need
to shut down the separator for frequent cleaning.
Self-cleaning separators operate continuously. Total
ejections are used with a self-cleaning effect of the disc
stack. Labour-intensive and costly measures to clean the
discs using CIP systems are not necessary. Optimum
separation efficiency over long operating times is
ensured. Maintenance work is not required until up
to 8000 operating hours (i.e. approx. only once a year).
Filling and
displacement water
Dirty oil feed
Clean oil discharge
Dirty water discharge
Solids discharge
Operating water discharge
The clean oil is conveyed to the discharge under
pressure by means of a centripetal pump. The
separated water flows under gravity via a regulating
ring to the discharge.
Benefits
? Automatic operation
? Continuous operating mode
? Self-cleaning effect of the bowl
without CIP systems
? Highly concentrated solids
? High separation efficiency
? Can be used as clarifier and purifier
? Closed discharge of the light phase
under pressure by centripetal pump
? Low noise level
? Belt drive gives you less wear and tear
Bowl cross section of a
self-cleaning mineral oil separator
with solid wall disc bowl
76
Self-cleaning separators with disc bowl and
automatic solids ejection are used where the
percentage of solids in the oil is too high for manual
cleaning. These are used mainly for the clarification
and purification of oils such as gas oil, diesel oil
and lube oil. Self-cleaning separators discharge
solid matter automatically while the separator
is running. This avoids the need to shut down the
separator for frequent cleaning.
Self-cleaning separators operate continuously. Solids
ejection occurs either by total or partial discharges,
or a combination of both. In the case of the total
ejection and the combination of total and partial
ejections, there is additional self-cleaning of the
disc stack. Labour-intensive and costly measures to
clean the discs using CIP systems are not necessary.
Optimum separation efficiency over long operating
times is ensured. Maintenance work is required only
after 8000 to 16,000 operating hours.
Bowl cross-section of a
self-cleaning mineral oil
separator with disc bowl
Filling and displacement water
Clean oil discharge
Dirty water discharge
Solids discharge
Centripetal twin pump
Operating water discharge
Self-Cleaning Separator
with Centripetal Twin Pump
Dirty oil feed
The clean oil and the separated water are conveyed
to the discharge under pressure by a centripetal twin
pump.
Benefits
? Automatic operation
? Continuous operating mode
? Self-cleaning effect of the bowl
without CIP systems
? Highly concentrated solids
? High separation efficiency
? Can be used as clarifier and purifier
? Closed discharge of the light phase
under pressure by centripetal pump
? Low noise level
? Belt drive gives you less wear and tear
98
GEA Westfalia Separator unitrolplus –
Lube and Fuel Oil WMS / SMS in Single Stage
Self-cleaning separators
Modern lube and fuel oil treatment plants from
GEA Westfalia Separator Group provide easy
handling and optimum separating efficiency in
difficult situations. The heart of these plants is a new
generation of self-cleaning mineral oil separators
with the unitrolplus. These separators operate
without regulating rings and can be applied for
a wide range of lube and fuel oils with a specific
densityup to 1.01 kg / l.
The essential features of these separators are both
the continuous monitoring of the oil for water and
the continuous monitoring of the solids holding
space for optimum solids filling in one stage.
Automatic monitoring means that regulating rings
are unnecessary and operating errors caused through
manual adjustment are eliminated.
The water content of the oil is checked continuously
using the Water Monitoring System (WMS). The
water in the oil is separated out and discharged. The
Sludge Space Monitoring System (SMS) checks the
solids space for separated foreign matter such as cat
fines, sand, abrasives and rust.
The oil is displaced prior to a bowl ejection. The
precisely defined displacement volume minimises
oil losses. A further innovative feature of these
separators is the bowl’s new hydraulic system
(GEA Westfalia Separator hydrostop). Extremely
short ejection times with the maximum outlet
diameter provide for highly concentrated solids.
Further disposal measures are simplified, disposal
costs reduced and environmental considerations fully
taken into account. During total ejections preferred by
GEA Westfalia Separator Group the disc stack is also
cleaned. Work and cost intensive measures for cleaning
the disc stack by CIP systems are not necessary; this
ensures optimum separating efficiency over a long
period of operation. Maintenance work is required
only after 8000 to 16,000 operating hours.
Just a few basic models are sufficient to cover all
capacity ranges. This makes spare parts storage and
servicing very economical.
Filling and
displacement
water
Clean oil
discharge
Dirty water
discharge
Solids
discharge
GEA Westfalia Separator
unitrolplus
Benefits
? GEA Westfalia Separator unitrolplus –
a new sensor system for automatic
monitoring and control for water and
solids content monitoring
? Reliable treatment of particularly heavy
and severely contaminated fuels
? Self-thinking system – ideal also for
the unmanned engine room
? Treatment of fuel oils up to 1.01 kg / l
? Lube oil treatment of 2-stroke cross
head and 4-stroke trunk piston engine
? Regulating rings are not required
? Automatic adjustment as clarifier or purifier
? High separation efficiency even in
critical situations
? Automatic bowl ejection
? Highly concentrated solids
? Continuous processing
? Self-cleaning effect of the bowl and
the disc stack by total ejection
? Versatility of application
? Safe operation
? Belt drive gives you less wear and tear
? Low noise level
Operating water
discharge
Dirty oil feed
1110
Process Overview
Diesel oil treatment
Centrifuges are essential for the efficient control and
removal of solids and water from fuel oils in fuel oil
safety treatment systems; they will continue to be so
in the future.
Efficient treatment protects the diesel engine from
wear to important components such as cylinder liners,
pistons, piston rings and the injection system.
This Pipe Installation Diagram (PID) shows examples
of manual cleaning centrifugal systems for diesel oil
treatment.
Manual Cleaning
Solutions
Piping and installation system
for marine diesel oil treatment
system with manual cleaning
separator without heater
Settling tank
Pump system
Pump system
Bunker tank
Utilities
Sludge
Service tank
Fuel oil
treatment plant
with centrifugal
separator
Self-Cleaning Solutions
Diesel oil treatment
1 Dirty oil feed
2 Strainer
3 Feed pump
1 Dirty oil feed
2 Strainer
3 Feed pump
4 Preheater
5 Regulating valve
6 Steam
7 Steam trap
8 Condensate
9 Dirty oil return
10 Operating water
11 Self-cleaning separator
12 Clean oil discharge
13 Dirty water discharge
14 Operating water discharge
15 Solids discharge
Piping and installation system
for marine diesel oil
treatment system with
self-cleaning separator with
electric heater
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
13 14 15
4 Manual cleaning separator
5 Clean oil discharge
6 Dirty water discharge
This Pipe Installation Diagram (PID) shows examples
of self-cleaning centrifugal systems for diesel oil treat-
ment.
1312
Process Overview
Heavy fuel oil treatment
Centrifuges are essential for the efficient control and
removal of solids and water from fuel oils in fuel oil
safety treatment systems; they will continue to be so
in the future.
Low-grade fuels from different refining processes
such as atmospheric or vacuum distillation as well as
from conversion plants such as catalytic cracker or
Visbreaker process must be purified efficiently too.
This treatment protects the diesel engine from wear
to important components such as cylinder liners,
pistons, piston rings and the injection system. The
whole plant concept for fuel oil treatment is rounded
off with GEA Westfalia Separator ViscoBoosterUnits.
Plant Concepts with a System
Under normal circumstances, GEA Westfalia
Separator Group recommends single-stage
treatment for heavy fuel oils.
The high efficiency of separation with the GEA Westfalia
Separator unitrolplus WMS/SMS in a single-stage
process ensures low wear on the engine. The high
reliability and long service intervals ensure low
operating costs and continuous, unattended automatic
operation for months. The stand-by centrifuge can
be saved for occasional use in abnormal conditions –
for example, during increased solids loading in heavy
seas. It can also be used for occasional topping-up of
the diesel oil day tank. An additional separator for
diesel oil treatment is not necessary.
Single-stage treatment plant
for fuel oil with separator with
GEA Westfalia Separator unitrolplus
Settling tank
Pump system
Fuel oil
treatment plant
with centrifugal
separator
Pump system
Bunker tank
Utilities
Sludge
Service tank
Fuel oil
conditioning
system
1 Steam
2 Strainer
3 Regulating valve
4 Preheater
5 Dirty oil return
6 Clean oil discharge
7 Self-cleaning separator
8 Operating water
9 Dirty water discharge
10 Solids discharge
11 Feed pump
12 Filter
13 Dirty oil feed
14 Steam trap
15 Condensate
1
2
3
4
5
6
7
8
9 10
11
12
13
14
15
1514
Parallel Operation
(High Water Content)
Heavy fuel oil treatment
A stand-by centrifuge operating in parallel is
recommended in emergencies when the water
content in the fuel is greater than 10 percent by
volume.
The effective throughput of each machine should be
reduced to 50 percent. Splitting the feed across two
machines and effectively doubling the dwell time of
the fuel in the centrifuges allows the machines to
remove the excess water effectively and quickly.
Fuel oil treatment plant with
GEA Westfalia Separator
unitrolplus
and activated stand-by separator
for parallel operation.
This gives the following benefits
? Automatic total ejection of both centrifuges
with optimally filled solids holding space
? Longer intervals between solids ejections
? Low water consumption
? Reduced sludge tank loading
? Lower disposal costs
1 Condensate
2 Steam
3 Strainer
4 Regulating valve
5 Preheater
6 Dirty oil feed
7 Dirty oil return
8 Operating water
9 Self-cleaning separator
10 Clean oil discharge
11 Dirty water discharge
12 Solids discharge
13 Feed pump
14 Filter
15 Steam trap
1 2
3
3
4
4
5
5
6 7 8
9
9
11
11
12
12
13
13
14
14
15
15
10
1716
Process Overview
Lube oil treatment
Centrifugal separators are the most widespread
method of lube oil treatment. The separator is located
in a by-pass loop within the lube oil treatment system.
Plant Concepts for
Efficient Operation
Schematic illustration of a
lube oil treatment plant with manual
cleaning separator.
Schematic illustration of a
lube oil treatment plant with
self-cleaning separator.
Self-cleaning mineral oil centrifuges are chiefly
used for the purification and dewatering of lube
oils, especially when there is a requirement for
24-hour, unattended operation.
The whole range of centrifuges is available for
efficient and reliable treatment of lube oil.
All GEA Westfalia Separator Group marine separators
for the treatment of fuel and lube oil have identical
design features allowing the use of common components.
This simplifies store management and maintenance
immensely.
Lube oil
treatment plant
with centrifugal
separator
Pump system
Utilities
Sludge
Lube oil tank
1 Dirty oil feed
2 Strainer
3 Feed pump
4 Preheater
5 Regulating valve
6 Steam
7 Steam trap
8 Condensate
9 Operating water
10 Clean oil discharge
11 Self-cleaning separator
12 Dirty water discharge
13 Solids discharge
1 2
3
4
5
6
7
8
9
10
11
12 13
1918
Automatic Process Control –
More Safety, More Comfort
For GEA Westfalia Separator unitrolplus and
centripetal twin pump system.
Control units
Modern control and monitoring systems, using the
latest PLC modules, ensure a high degree of operating
safety and user comfort.
They perform the automatic control of the ejection cycles
and the monitoring of the self-cleaning separators.
The ejection programs are preselectable. Partial or
total ejections are initiated in adjustable, periodic
intervals with prior displacement of the oil from
the bowl.
The standard control unit is designed for unattended
operation of a separator.
GEA Westfalia Separator minimaXx
?
–
Process Control for Every Requirement
Keys F1 – F4
Soft keypad, screen
dependent
Keys 1 – 0,
Function keypad with
fixed allocation
Status LEDs
Display with
backlighting and 4 lines
D10 with
text display
E40 with graphic
display and
Profibus DP
Motorstarter box
Motorstarter separator
Motorstarter feed pump
OMB 220
Overflow monitoring box
Water seal broken alarm
Control unit MC-1
Motorstarter separator
Motorstarter feed pump
Flow monitoring FAH
Control unit CC-1
Motorstarter separator
Motorstarter feed pump
Flow monitoring FAH
Temperature monitoring TAL / TAH
Preheater interlocking
Control unit CD-1
Control and monitoring
system for self-cleaning
GEA Westfalia Separator
minimaXx
?
separator.
Motorstarter separator
Motorstarter feed pump
Flow monitoring FAH
Flow monitoring FAL
Clean oil outlet
Temperature monitoring TAL / TAH
Preheater interlocking
Sludge pump control
D10
Easy handling by
Micro Memory Card
which stores setting
and history data for
D10 and E40.
1
1
2
3
4
5
2
3
4
5
2120
Custom-Made System Solutions
for the Engine Room
Flexible systems
Design engineers have to be flexible with the planning
of an engine room. GEA Westfalia Separator Group
has, therefore, thought of everything.
Separators with single components, modular
compact units or individually installed GEA Westfalia
Separator centripack systems give customers flexible
systems designed precisely for their needs.
Separator with single components
No modularisation
CU – Compact Unit
Flexible modularisation
CP – GEA Westfalia Separator centripack
Individual modularisation
Separator with
Single Components
When planning the detail engineering of an engine
room, design engineers need to construct plants
precisely to meet customers’ needs.
GEA Westfalia Separator Group helps its customers
develop individual systems by making all its
constructive components available separately. This
way systems can be adapted and built to the special
needs that may apply.
Examples of elements that can be ordered separately
Feed pump Regulating
valve
Operating and displacement water valve
StrainerPrestrainer
Preheater
Safety valve
Steam trap
3 / 2 way valve
1
2
3
1
2
3
2322
CU Compact Unit –
Flexible Modularisation
Flexible systems
In addition to the detail engineering of single
components there is the need for simple block
engineering. CU compact units provide a modular
design to meet this need.
The modular CU compact units offer the opportunity
to use flexible, low cost modules. All units are mounted
on bases that can be connected easily, even in a
confined area.
GEA Westfalia Separator centripack –
Individual Modularisation
The centripack is a compact, self-contained treatment
plant package system, ready for connection. All
elements necessary for safe and efficient oil
treatment are mounted ready for connection in a
space-saving arrangement on a sturdy foundation
frame. These include separators, motors, pumps,
prestrainer, alarm system and a control and
monitoring system.
The discharge pipes for solids and water as well as
the frame drain pipe are led through the foundation
frame.
The design makes possible space-saving installation
direct in corners or against walls. It is also possible
to install several modules side-by-side to forma
complete plant. The centripack is completely
assembledand function tested by GEA Westfalia
Separator Group; faulty installation of single operating
components on site is thus eliminated. The unified
design also saves money and makes maintenance
easier.
The centripack is available either with self-cleaning
separators and control unit including control and
monitoring equipment for unmanned operation, or
with manual cleaning separators.
The centripack modules are available with one to five
separators depending on requirements.
GEA Westfalia Separator centripack –
complete ready-to-connect module for
the treatment of fuel oil
2524
Process Overview
Sludge treatment
The trend towards burning higher viscosity and
higher density fuel oils together with an increasingly
common usage of residuals as the fuel for medium
speed diesels engines means that the amount of
sludge being created from both fuel and lube oil
systems is increasing.
System Concepts for the Future
The sludge is pumped from the sludge tank by an
eccentric screw pump and is fed via a heater to the
centrifugal separator.
The sludge components of water, oil and solids are
separated in the separator by centrifugal force. The
recovered oil and water is discharged under pressure
by centripetal pumps.
The concentrated sludge is discharged intermittently
via the sludge transfer unit into a heated sedimentation
tank where final concentration takes place. Excess
water and oil is allowed to overflow back to the sludge
tank.
The concentrated sludge is pumped from the unit
automatically by a solids discharge pump controlled
by a level switch.
A microprocessor-based control cabinet supervises
and controls the complete concentration process.
Settling tank Lube oil separator
Water
Electrical energy
Heating energy
Operating water
Fuel oil separator Lube oil filter
Concentrated
sludge
Fuel oil filter
Disposal e.g.
incinerator
Diesel oil separator
Bilgewater
system
Recovered oil
Fuel oil sludge tank Lube oil sludge tank
Settling tank / Boiler plant
Sludge treatment plant with
centrifugal separator
1 Steam
2 Regulating valve
3 Preheater
4 Steam trap
5 Condensate
6 Feed pump
7 Filter
8 Oil sludge feed
9 Dirty oil return
10 Operating water
11 Centrifugal separator
12 Clean oil discharge
13 Vibration monitoring
14 Dirty water discharge
15 Sludge transfer unit
16 Sludge concentration unit
17 Oily water
18 Concentrated sludge
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
2726
Economical Advantages –
Ecological Merits
Sludge treatment
Oily sludge mainly consisting of oil, water and
solids can amount to 2.5 percent of the marine fuels
consumed. Indeed many port authorities use this
figure when carrying out ship inspections.
With increasing environmental awareness as well
as strict regulations and controls, most operators
dispose of this sludge by incineration or by shoreside
disposal using contract companies. In either case
sludge disposal is becoming an expensive problem
for ship owners today.
The GEA Westfalia Separator Group sludge treatment
plant incorporating a specially designed centrifugal
separator is capable of reducing the volume of sludge
for disposal by up to 90 percent. In addition, fuel oil
is recovered for re-use and recovered lube oil can be
used as boiler fuel.
Benefits
? Saves up to 90 percent disposal costs
? Recovers valuable fuel oil
? Unburdens the bilgewater system
from oil residues
? Protects our sensitive marine ecosystem
Treatment system for oily and watery
sludge with self-cleaning centrifugal
separator to reduce the disposal costs
Filling and displacement water
Oily sludge feed
Clean oil discharge
Dirty water
discharge
Separation results sludge treatment
MV Fantasy
Solids
Oil
Water
Feed Oil Outlet Water Outlet
Portion
0
20
40
60
80
100
120
0
20
40
60
80
100
120
Sample taken from
% (by vol.) % (by vol.) % (by vol.)
Oil 10.0 99.6 0.5
Water 89.6 0.4 99.49
Solids 0.4 0.0 0.01
2928
Self-Cleaning
Centrifugal System
Bilgewater treatment
The treatment of bilgewater on board ships is strictly
controlled by national and international laws.
Bilgewater may only be discharged into the sea after
prior de-oiling with specially approved treatment
systems. The maximum oil content must not exceed
15 ppm. The limit has even been reduced to 5 ppm
in special areas.
15 ppm is too much
Oily water from ship operation may only be
discharged into the sea if the residual oil content in
the effluent is below 15 ppm. 15 parts of oil to one
million parts of water seems small but GEA Westfalia
Separator Group believes this is still too high.
Moreover, practice has shown that this value is not
attained in many conventional plants under practical
operation conditions anyway. The further we can
reduce this value, the greater the benefit for our
oceans.
Bilgewater is a mixture of the following constituents:
? Sea and cooling water leakages
? Fuel and lube oil leakages
? Drainages from settling and sludge tanks
? Effluent from various cleaning processes
? Soot and dirt particles
So That Our Water Stays
As Nature Made It – Clean
The product (i.e. oily water) is sucked up from the
oily water tank or engine room bilge and fed by the
feed pump through the automatic filter and preheater
via the feed valve to the separator. The automatic
filter prevents coarse particles from reaching the bowl
and blocking the rising channel within the disc stack.
During the start-up or ejection program it is led back
into the oily water tank. The product flows from above
into the centre of the separator bowl. The heavy water
phase is separated from the finest oil particles and
then conveyed under pressure by a centripetal pump to
the discharge. The separated impurities accumulated
in the sludge space are discharged into the sludge
tank periodically. The clean water is supervised by
an oil monitor before being discharged into the
environment. The residual oil content is adjustable
to >5 ppm and >15 ppm. If the oil content exceeds
the adjusted limit the water is recirculated into the
oily water tank. An intelligent process control adapts
the capacity of the system to the changes of the
product. A chemical dosing system is not necessary
anymore.
Waste oil tank
Separated oil
Pump system
Dirty bilgewater
return
Bilgewater
system
Waste oil tank
Utilities
Sludge
Clean water
overboard
Bilgewater
treatment plant
with centrifugal
separator
1 Dirty bilgewater feed
2 Steam
3 Condensate
4 Heater
5 Operating water
6 Dirty bilgewater
return
7 Solids discharge
8 Operating water
discharge
9 Self-cleaning separator
10 Separated oil discharge
11 Dirty bilgewater return
12 Clean water
discharge overboard
13 Oil monitor
1
2
3
4
5
6
7 8
9
10 11
12
13
3130
The main components of the system are:
? Self-cleaning centrifugal separator
? Frequency controlled feed pump
? Automatic self-cleaning filter
? Preheater
? Control panel
? Oil monitor for 5 / 15 ppm bilge alarms
? Pump/preheater unit
? Compact unit with sludge transfer unit
? Control and monitoring unit
Benefits of the centrifuge
? High separation efficiency
due to large clarification area
? Controlled de-sludging with high solid content
due to the GEA Westfalia Separator hydrostop
system
? Gentle treatment due to the
GEA Westfalia Separator softstream system
? Continuous separation of oil and water phase
? Self-cleaning effect of
disc stack due to total ejection
? No impact of the ship''s movement
on the separation efficiency
Technologies to Protect the Sensitive
Marine Ecosystem
Bilgewater treatment
The systems are
approved by the
atest IMO regulations
and U.S. Coast Guard.
Bilgewater feed
Clean oil
discharge
Clean
bilgewater
The bilgewater treatment system is designed for ships
which use high-density residual fuel oils. The system
is supplied as a complete, self-contained Compact Unit
incorporating all auxiliaries necessary for operation.
The Flexible Compact Unit Design is Suitable
Both for Newbuildings or Retrofit
Separation results oily water treatment
With normal feed conditions, i.e.
solids content: < 0.1 percent
chloride content: < 30,000 ppm
pH: 6 – 9
and no excessive oil emulsions in the water phase,
the residual oil content in the clean water discharge
is 10 – 12 ppm. By varying the pump speed and
separation temperature, it is possible to reduce the oil
content even below 5 ppm.
Benefits
? Water outlet less than 5 / 15 ppm
? Reliable
? Easy handling
? Low maintenance cost
? Small dimensions
? Low weight
? Quick return on investment
? No adsorption filter and chemicals
3332
As an integrated part of the GEA Westfalia
Separator BilgeMaster
?
-D series the GEA Westfalia
Separator SafetyMaster provides additional security
beyond the regulations of MARPOL against un-intended
overboard discharge of oil polluted bilge-water. All
components for sample taking, sample monitoring
and overboard discharge control are combined and
enclosed in a lockable stainless steel box. Further safety
is provided by monitoring the flow to the oil monitor
and supervising the function of the overboard valve.
A data recorder integrated in the separator control
provides complete information of the status of the
bilgewater treatment system over the last 18 months
including the position of the vessel and the volume
of water discharged.
The SafetyMaster is available optionally as integrated
part of the BilgeMaster
?
-D series or as stand-alone
unit.
Description of the system
The SafetyMaster is mounted on the control and
monitoring unit and incorporates the oil monitor,
the sample taking and sample return connection, the
constant pressure valve, the sample water cooler, the
flow switch in the sample water line and the overboard
valve. The overboard valve is directly controlled by
the oil monitor. In line of the alarm circuit are the
flow switch and the end position switch of the door.
The overboard valve is supervised by a micro switch
giving an alarm and interrupting the separation
process if the oil content is > 15 ppm while the valve
is de-energized but not completely closed.
Inputs to the SafetyMaster are the 24 V power supply,
the status signal separator running, compressed air,
cleaning water and cooling water. The cooling water
for the sample liquid can be connected either to the LT
(low temperature) cooling system or to the cleaning
water connection. Outputs from the SafetyMaster to
the separator control are the analogue output 4 – 20 mA
of the oil monitor, the status of the alarm circuit
and the status of the position switch of the over-
board valve. A flow meter is installed in the
clean water outlet of the separator outside the
GEA Westfalia Separator SafetyMaster. The flow is
used to measure the volume discharged overboard
and to monitor the condition of the feed pump, the
bowl and the oil content in the product feed to the
separator. All data of the status of the system including
the position of the ship are recorded in a data log.
Additional security beyond the regulations of MARPOL
GEA Westfalia Separator SafetyMaster
Optional in combination with GEA Westfalia Separator
SafetyMaster: system-integrated or “stand-alone”
1 Dirty bilgewater feed
2 Steam
3 Condensate
4 Heater
5 Operating water
6 Dirty bilgewater return
7 Solids discharge
8 Operating water discharge
9 Self-cleaning separator
10 Separated oil discharge
11 Dirty bilgewater return
12 Clean water discharge overboard
13 Oil monitor
1
2
3
4
5
6
7 8
9
10 11 12
13
3534
VBU – GEA Westfalia Separator
ViscoBoosterUnits
Fuel oil conditioning system
Efficient operation of ship and power station
diesel engines requires optimum fuel supply.
This key condition is accomplished by the
ViscoBoosterUnits developed by GEA Westfalia
Separator Group for fuel conditioning.
This unit consists of a treatment system that meets
the fuel requirements between the clean oil tank and
injection system for the main and auxiliary engines
in terms of the required injection viscosity and
temperature. Supply and booster pumps are provided
for a stable system pressure.
The modules are designed for the different engines
as well as to the required injection viscosity (approx.
10 – 24 cSt) and corresponding temperature (approx.
135 – 150° C).
Complete System Between
Service Tank and Engine
With the ViscoBoosterUnits, GEA Westfalia
Separator Group offers a complete, compatible
system from the service tank to the engine for safe
and economic fuel oil treatment.
ViscoBoosterUnits are supplied as package systems.
The ViscoBoosterUnits can be delivered as separate
systems or as a complete module for the main
engine and auxiliary engines for heavy fuel oil and
diesel oil. They are designed for 24-hour unattended
operation and meet the requirements of the
classification societies.
VBU for marine
application
Pump system
Fuel oil
treatment plant
with centrifugal
separator
1 HFO
2 MDO
3 Pressure control valve
4 Strainer
5 Feeder pump
6 Stand-by
7 Fuel to day tank
8 Fuel from engine
9 Automatic backflushing filter
10 Flow meter
11 Mixing / Degassing tank
12 Booster pump
13 Preheater
14 Regulating valve
15 Steam or thermal oil
16 Steam trap
17 Condensate or thermal oil
18 Fuel to engine
1
2
3
4
5
6 6
6
7
8
9
10
11
12
13
14
15
16
17
18
3736
SWD – GEA Westfalia Separator
SeaWaterDistiller
Water desalination system
Shore independent generation of fresh water on
board by single stage evaporation technology.
Sea water is fed through the condenser, where it
absorbs the latent heat of the condensing vapour.
Some sea water is used as feed water for the evaporator
whilst the remaining brine and non-condensable
gases are discharged using a combined ejector. In the
evaporator the sea water is heated up to the saturation
temperature corresponding to the vacuum maintained
by the ejector and a proportion is evaporated.
The evaporator generally utilizes the waste heat
from the main diesel engine jacket water; however,
other heating media may also be used (e.g. steam,
thermal oil).
The vapour produced passes through the demister
located in the upper casing to remove entrained
droplets of water and is led to the condenser. The
distillate is drawn from the condenser by the distillate
Single Stage
Evaporating System
pump and discharged through the salinity measuring
unit. Depending on the residual salt content of the
distillate, it is either led to the distillate tank or, if the
maximum allowable residual salt content is exceeded,
back to the evaporator.
All parts in contact with sea water are constructed of
corrosion-resistant materials (PP, stainless steel). The
plates are made of titanium.
Benefits
? Compact
? Easy to operate
? Reliable
? Low weight
? Low maintenance costs
? Integrated anti-scaling system
? Corrosion-resistant materials
? High performance
Sea water
Fresh water
Jacket water
HT central coolers
Fresh water
generator
1 Thermal oil /
hot water heated
2 Heat exchanger
3 Jacket water
4 Circulatio pump
5 Steam heated
6 Steam
7 Steam jet liquid pump
8 Condensate
9 Jacket water heated
10 Sea water
11 Seawater pump
12 Distillate
13 Heating water
14 Feed water
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
15 Overboard
16 Brine
3938
8
1
7
2
1
Ballasting
2
De-ballasting
3
Ballast pump
4
By-pass
5
Filter 20 μm
6
Transfer pump
7
UV1
8
UV2
9
UV3
10
Back-flushing water overboard
11
Ballast water tank
Ballasting
De-ballasting
1
1
3
5
6
10
7
9
11
2
2
2
2
4
4
3
5
6
10
8
9
11
1
2
GEA Westfalia Separator BallastMaster ultraV
Mechanical ballast water treatment without the use and generation of chemicals
GEA Westfalia Separator BallastMaster ultraV
provides you with an all-round, worry-free system
which meets current and future IMO standards for
ballast water treatment.
Just add water
With the GEA Westfalia Separator BallastMaster
ultraV, it is very simple to ensure that there is
only water in your ballast tanks – with no harmful
organisms such as plankton, bacteria or viruses.
Everything beneath the waves is under control, so
you don’t have to worry about it. Water goes in – easy.
Exceeding the standards
The IMO convention requires that new and currently
operated ships must have ballast water management
systems, with the law coming into full effect in 2016.
These new guidelines may lead some ship owners and
operators into uncharted territory. It’s important to
have a ballast water management system that is easy
to use, complies with the terms of the convention and
can be used for many years to come. The GEA Westfalia
Separator BallastMaster ultraV is a highly efficient
mechanical and physical system for treating ballast
water, including water with a high concentration of
organisms and sedimentary particles.
Two-step treatment for highest efficiency and safety
BallastMaster ultraV combines pre-filtration and UV-C.
It doesn’t need any chemical substances or generate any
hazardous by-products. It uses a low pressure UV section,
which is energy-efficient and requires no cooling.
Initial cleaning by mechanical filtration
In the first stage, a mechanical filtration process
removes all organisms and sedimentary particles
larger than 20 microns. This prevents sedimentary
deposits from accumulating in the ballast water tanks,
as the terms of the IMO convention stipulate. It also
guarantees optimum results in the second stage,
the ballast water disinfecting. The filter module
is cleaned automatically by vacuum extraction
(self-cleaning process).
Disinfection by means of UV-C
In the second stage, the pre-filtered ballast water is then
disinfected by UV-C radiation. The monochromatic
UV-C radiation (254 nm) eliminates organisms such
as bacteria or phytoplankton. The micro cavitation
delivered by ultrasonic guarantees that the biofilms
and non-organic deposits in the UV-C tubes are
cleaned off efficiently and remain permanently clean.
Future-proof compliance according to IMO D2 and
USCG phase II
UV-C disinfection and ultrasonic cleaning provide
consistent, high quality disinfecting in accordance with
IMO guidelines. This ensures that harbour checks of any
kind are passed without problems. The type approval
for the GEA Westfalia Separator BallastMaster ultraV
was issued by BSH on 19 December, 2011.
UV Transmission
Flow-Regulation
Status "on"
UV Transmission
Flow-Regulation
Status "off"
PLC
PLC
4140
In addition to traditional services
such as maintenance or repair,
serv&care also provides solutions
which avoid risk and with which
the installation availability can be
proactively assured.
serv&care accordingly makes for maximum operating
reliability, machine availability, process efficiency
and budget security. And these benefits are
provided throughout the entire life cycle of the
entire installation.
Service from the original manufacturer:
? Service engineers quickly on site
? Extensive service network
? Risk avoidance through service provided
by the original manufacturer
? Proactive solutions
? Upgrading to boost performance
? Crew training
Safety first: this is precisely what the service concept
serv&care stands for.
Ship owners not only benefit from traditional
services such as inspection, maintenance, original
spare parts and repair work provided by the original
manufacturer; they also benefit from proactive
solutions which avoid risk, e. g. online and offline
monitoring with GEA Westfalia Separator wewatch
?
.
These preventive services are the best pre-condition
for a smooth operation.
Enhanced process efficiency also follows from
maximum operating reliability and machine
availability. Accompanying modernization or
upgrading to state-of-the-art technology also offer
the option of boosting performance as required.
serv&care – Proactive Service for Optimum
Reliability on Board
The proactive, risk-free services of serv&care optimize operating
reliability and permanent availability of the drive systems.
Training provided on site or in the modern training
centre of GEA Westfalia Separator Group ensures that
the plant operator’s employees receive training in the
proper handling of the high-tech installations. This
provides additional safety.
Authorized workshops worldwide
And if problems occasionally occur or if a spare part
is required at short notice, the specialists are able
to attend to the ships quickly. This is ensured by a
global network with more than 50 sales and service
companies. Authorized workshops are able to service
every location in the world at short notice.
serv care
4342
GEA Mechanical Equipment
GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1, 59302 Oelde, Germany
Phone +49 2522 77-0, Fax +49 2522 77-1778
www.gea.com The information contained in this br
ochur
e mer
ely serves as a non-binding description of our pr
oducts and is without guarantee. Binding information, in particular r
elating to capacity data and suitability for specific applications, can only be pr
ovided within the framework of concr
ete
inquiries. Printed on chlorine-fr
ee bleached paper · Printed in Germany · Subject to modification · W
estfalia
?
, W
estfalia Separator
?
, mini
maXx
?
,
Bilge
Master
?
and we
watch
?
ar
e r
egister
ed trademarks of GEA Mechanical Equipment GmbH.
B_MA-12-08-0007 EN
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX
?
Europe 600 Index.
We live our values.
Excellence
?
Passion
?
Integrity
?
Responsibility
?
GEA-versity
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