Marine system technology
concepts and high performance
equipment for the engine room
from GEA Westfalia Separator
Mechanical Separation / GEA Westfalia Separator
Time for a
New Generation
Smart
The new Westfalia Separator eagleclass was developed
with the know-how of the technology leader in
centrifugal separation technology. The innovative
separator design and the new 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
3
up to 80 m / h for the first time ever. 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 Westfalia
Separator eagleclass particularly reliable and durable.
A further feature is Westfalia Separator capitalcare –
the proactive service of the original manufacturer.
This combination ensures maximum availability and
economy throughout the entire life cycle.
?
Westfalia Separator
eagleclass
Smart. Strong. Reliable.
GEA Westfalia Separator284423496424248822244864222476842724933
Contents
4 Overview engine room concepts 0 Flexible systems
High Performance Equipment for the 30 Custom-Made System Solutions for the
Engine Room Engine Room
31 Separator with Single Components
Centrifugal systems on board 3 CU Compact Unit – Flexible Modularisation
6 Process Overview 33 Westfalia Separator centripack –
Individual Modularisation
Manual cleaning separators
8 Westfalia Separator minimaXx 4 Sludge treatment
3 Process Overview
10 Self-cleaning separators 35 System Concepts for the Future
10 Westfalia Separator minimaXx 36 Economical Advantages – Ecological Merits
1 Self-cleaning separator
with Centripetal Twin Pump Bilgewater treatment
1 Westfalia Separator unitrolplus System – 38 Self-Cleaning Centrifugal System
Heavy Fuel Oil 0 Technologies to Protect the Sensitive
16 Westfalia Separator unitrolplus System – Marine Ecosystem
Lube Oil 1 Flexible Compact Unit Design
SafetyMaster
1 Diesel oil treatment
18 Process Overview 44 Hydraulic oil treatment plant
1 Manual Cleaning Solutions Westfalia Separator minimaXx –
0 Self-Cleaning Solutions Sophisticated Technology in Confined Spaces
22 Heavy fuel oil treatment 4 Fuel oil conditioning system
Process Overview 6 VBU – Visco Booster Unit
3 Plant Concepts with a System Complete System Between Service
Parallel Operation Tank and Engine
2 Lube oil treatment 4 Water desalination system
6 Process Overview 8 SWD – Sea Water Distiller
Plant Concepts for Efficient Operation
50 Westfalia Separator capitalcare –
2 Control units Maximum Process Efficiency, Installation
8 Automatic Process Control – Availability and Budget Security
More Safety, More Comfort
Westfalia Separator minimaXx –
Process Control for Every Requirement
GEA Westfalia Separator
High Performance Equipment
for the Engine Room
Overview engine room concepts
GEA Westfalia Separator offers leading technologies
and individual systems for marine use. Be it system
engineering from one source, high quality of work- Fuel oil conditioning system
manship or the unrivalled worldwide service – GEA
Westfalia Separator provides a system to rely on.
Fuel oil
day
Product range overview
tank
Fuel oil treatment
Fuel oil conditioning system
Lube oil treatment
Sludge treatment
Bilgewater treatment
Fuel oil
Fuel oil treatment
settling
Water desalination system
tank
Hydraulic oil treatment plants
GEA Westfalia Separator 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
Self-cleaning separators with Westfalia Separator
Fuel oil
unitrolplus automatically monitor the water level in
sludge
the oil and the separation of the solid material “round- tank
Sludge treatment
the-clock“. You get optimum separation efficiency
under any conditions with different fuel and lube oils.
The accumulated oil sludge can be processed directly
on board, thereby reducing the disposal costs
considerably. Servicing is necessary only after 8000
to 16,000 operating hours. Surveillance-free operation
reduces operating costs tremendously. All separation
Lube oil
systems are available as modules. Other ready-to-
sludge
tank
connect systems are also available as compact units
in combination with components such as Visco
Booster Units.
GEA Westfalia Separator
Water desalination system
Lube oil treatment M.E.
Bilgewater treatment
Lube oil treatment A.E.
Bilgewater
tank
GEA Westfalia Separator
Process Overview
Centrifugal systems on board
Fuel oil
conditioning
system
Service tank Lube oil tank
Utilities
Fuel oil
treatment plant
with centrifugal
separator
Sludge
Pump system
Settling tank Boiler plant Pump system
Pump system Clean oil
Sludge
treatment plant
with centrifugal
separator
Bunker tank Water
Bilgewater
system
Hydraulic oil tank Waste oil tank
Pump system
Separated oil
Hydraulic oil
treatment plant
with centrifugal
separator
GEA Westfalia Separator
Utilities
Lube oil
treatment plant
The centrepiece of a fuel or lube oil treatment plant
with centrifugal
separator
is the centrifugal separator.
Sludge
The main duties of these separators are:
Pump system
Separation of solids
Separation of fresh water
Separation of salt water
Effective treatment ensures that only clean oil enters
the drive unit. The wear on the injection system and
Utilities
on components such as cylinders, cylinder liners and
the crankshaft of the diesel engine is minimized.
Concentrated Disposal e.g.
sludge incinerator
Two basic types of centrifugal separators are suitable
for these duties:
Manual cleaning separators with
solid-wall disc bowl
Clean water
Self-cleaning separators with disc bowl
overboard
and automatic bowl ejection facility
Bilgewater Utilities
treatment plant
with centrifugal
separator
Sludge
Pump system Waste oil tank
GEA Westfalia Separator
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
GEA Westfalia Separator
Filling water
Bowl cross-section of a manual
cleaning mineral oil separator
with pressure discharge of the
clean oil by centripetal pump
Dirty oil feed
Clean oil
discharge
Dirty water discharge
GEA Westfalia SeparatorWestfalia Separator minimaXx
Self-cleaning separators
Self-cleaning separators with disc bowl, single Bowl cross section of a
centripetal pump and automatic solids ejection are self-cleaning mineral oil separator
used where the percentage of solids in the oil is too with solid wall disc bowl
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).
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
10
GEA Westfalia SeparatorFilling and
displacement water
Dirty oil feed
Clean oil
discharge
Dirty water discharge
Solids discharge
Operating water discharge
11
GEA Westfalia Separator
Self-Cleaning Separator
with Centripetal Twin Pump
Self-cleaning separators with disc bowl and
Benefits
automatic solids ejection are used where the
Automatic operation
percentage of solids in the oil is too high for manual
Continuous operating mode
cleaning. These are used mainly for the clarification
Self-cleaning effect of the bowl
and purification of oils such as gas oil, diesel oil and
without CIP systems
lube oil. Self-cleaning separators discharge solid
Highly concentrated solids
matter automatically while the separator is running.
High separation efficiency
This avoids the need to shut down the separator for
Can be used as clarifier and purifier
frequent cleaning.
Closed discharge of the light phase
Self-cleaning separators operate continuously. Solids under pressure by centripetal pump
ejection occurs either by total or partial discharges, or
Low noise level
a combination of both. In the case of the total ejection
Belt drive gives you less wear and tear
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.
The clean oil and the separated water are conveyed to
the discharge under pressure by a centripetal twin
pump.
1
GEA Westfalia Separator
Filling and displacement water
Clean oil discharge
Dirty oil feed
Centripetal twin pump
Dirty water discharge
Solids discharge
Operating water discharge
Bowl cross-section of a
self-cleaning mineral oil
separator with disc bowl
1
GEA Westfalia Separator
Westfalia Separator unitrolplus –
Heavy Fuel Oil WMS / SMS in Single Stage
Self-cleaning separators
Modern fuel oil treatment plants from GEA Westfalia Just a few basic models are sufficient to cover all
Separator provide easy handling and optimum capacity ranges. This makes spare parts storage and
separating efficiency in difficult situations. The servicing very economical.
heart of these plants is a new generation of self-
cleaning mineral oil separators with the Westfalia
Separator unitrolplus. These separators operate
without regulating rings and can be applied for a
wide range of fuel oils with a specific density up
to 1.01 kg / l.
Clean oil
Filling and
Westfalia Separator
displacement discharge
unitrolplus
The essential features of these separators are both water
Dirty oil feed
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
Dirty water
manual adjustment are eliminated.
discharge
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 (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 the
disc stack is also cleaned. Work and cost intensive
measures for cleaning the disc stack by CIP systems
Solids
are not necessary; this ensures optimum separating
discharge
efficiency over a long period of operation. Maintenance
work is required only after 8000 to 16,000 operating
Operating water
hours. discharge
1
GEA Westfalia Separator
Dirty oil feed
Dirty water
discharge
Benefits
Westfalia Separator unitrolplus – High separation efficiency even in
a new sensor system for automatic critical situations
monitoring and control for water and Automatic bowl ejection
solids content monitoring Highly concentrated solids
Reliable treatment of particularly heavy Continuous processing
and severely contaminated fuels Self-cleaning effect of the bowl and
Self-thinking system – ideal also for the disc stack by total ejection
the unmanned engine room Versatility of application
Solids
Treatment of fuel oils up to 1 .01 kg / l Safe operation
discharge
Regulating rings are not required Belt drive gives you less wear and tear
Operating water
Automatic adjustment as clarifier or purifier Low noise level
discharge
1
GEA Westfalia Separator
Westfalia Separator unitrolplus –
Lube Oil WMS / SMS in Single Stage
Self-cleaning separators
Modern lube oil treatment plants from Just a few basic models are sufficient to cover all
GEA Westfalia Separator provide easy handling capacity ranges. This makes spare parts storage and
and optimum separating efficiency in difficult servicing very economical.
situations. The heart of these plants is a new
generation of self-cleaning mineral oil separators
with the Westfalia Separator unitrolplus. These
separators operate without regulating rings and
can be applied to a wide range of lube oils.
Clean oil Westfalia Separator
Filling and
The essential features of these separators are both the
displacement discharge unitrolplus
continuous monitoring of the oil for water and the water
Dirty oil feed
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 oil is checked
Dirty water
continuously for water by the Water Monitoring
discharge
System (WMS). The water in the oil is separated out
and discharged. The Sludge Space Monitoring System
(SMS) is to check the solids space for separated foreign
matter. 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 (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 are
fully taken into account. During total ejections
preferred by GEA Westfalia Separator 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
Solids
over a long period of operation. Maintenance work is
discharge
required only after 8000 to 16,000 operating hours.
Operating water
discharge
1
GEA Westfalia Separator42
Dirty oil feed
Dirty water
discharge
Benefits
Westfalia Separator unitrolplus – High separation efficiency even in
a new sensor system for automatic critical situations
monitoring and control for water and Automatic adjustment as clarifier or purifier
solids content monitoring Automatic bowl ejection
Reliable treatment of particularly heavy Highly concentrated solids
and severely contaminated fuels Continuous processing
Self-thinking system – ideal also for Self-cleaning effect of the bowl and
the unmanned engine room the disc stack by total ejection
Lube oil treatment of -stroke cross Versatility of application
Solids
head and -stroke trunk piston engine Safe operation
discharge
Regulating rings are not required Belt drive gives you less wear and tear
Operating water
Automatic adjustment as clarifier or purifier Low noise level
discharge
1
GEA Westfalia Separator
Process Overview
Diesel oil treatment
Centrifuges are essential for the efficient control and Efficient treatment protects the diesel engine from
removal of solids and water from fuel oils in fuel oil wear to important components such as cylinder liners,
safety treatment systems; they will continue to be so pistons, piston rings and the injection system.
in the future.
Service tank
Utilities
Fuel oil
treatment plant
with centrifugal
separator
Sludge
Pump system
Settling tank
Pump system
Bunker tank
1
GEA Westfalia SeparatorManual Cleaning Solutions
Feed pump
This Pipe Installation Diagram (PID) shows examples
of manual cleaning centrifugal systems for diesel oil
treatment.
Strainer
Dirty oil
feed
Piping and installation system
Clean oil
for marine diesel oil treatment
discharge
system with manual cleaning
Manual cleaning
separator without heater
separator
Piping and installation
Dirty water
Feed pump
discharge
system for marine diesel
oil treatment system with
manual cleaning separator
with electric heater
Strainer
Dirty oil
feed
Preheater
Dirty oil
return
Clean oil
discharge
Manual cleaning
separator
Dirty water
discharge
Self-Cleaning Solutions
Diesel oil treatment
This Pipe Installation Diagram (PID) shows examples
of self-cleaning centrifugal systems for diesel oil
treatment.
Feed pump
Compact unit CU D for
marine diesel oil treatment
Strainer
with self-cleaning separator
Dirty oil feed
OSD without heater.
Dirty oil return
Operating water
Clean oil
discharge
Self-cleaning
separator
Dirty water Operating Solids
discharge water discharge
discharge
Piping and installation system for marine diesel
oil treatment system with self-cleaning
separator without heater
0
GEA Westfalia SeparatorPiping and installation system
Feed pump
for marine diesel oil
treatment system with
self-cleaning separator with
electric heater
Regulating valve
Strainer
Dirty oil feed
Steam
Preheater
Condensate
Steam trap
Dirty oil return
Operating
water
Clean oil
discharge
Self-cleaning
separator
Dirty water Operating Solids
discharge water discharge
discharge
Process Overview
Heavy fuel oil treatment
Single-stage treatment plant
for fuel oil with separator with
Fuel oil
Westfalia Separator unitrolplus
conditioning
system
Service tank
Utilities
Fuel oil
treatment plant
Centrifuges are essential for the efficient control and
with centrifugal
removal of solids and water from fuel oils in fuel oil
separator
Sludge
safety treatment systems; they will continue to be so
in the future.
Pump system
Low-grade fuels from different refining processes
such as atmospheric or vacuum distillation as well as
from conversion plants such as catalytic cracker or
Settling tank
Visbreaker process must be purified efficiently too.
This treatment protects the diesel engine from wear
Pump system
to important components such as cylinder liners,
pistons, piston rings and the injection system. The
whole plant concept for fuel oil treatment is rounded
Bunker tank
off with Visco Booster Units.
GEA Westfalia Separator
Plant Concepts with a System
Under normal circumstances, GEA Westfalia
Separator recommends single-stage treatment for
heavy fuel oils.
The high efficiency of separation with the 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.
Regulating
valve
Strainer
Operating
water
Dirty oil return
Steam Clean oil
discharge
Self-cleaning
separator
Feed pump
Preheater
Filter
Solids
Dirty water
Dirty oil
discharge discharge
feed
Steam trap
Condensate
GEA Westfalia Separator
Parallel Operation
Condensate Steam
(High Water Content)
Heavy fuel oil treatment
A stand-by centrifuge operating in parallel is Fuel oil treatment plant with
recommended in emergencies when the water Westfalia Separator unitrolplus
content in the fuel is greater than 10 percent by and activated stand-by separator
volume. for parallel operation.
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.
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
GEA Westfalia SeparatorClean oil
Dirty oil Operating
Dirty oil
Regulating valve
Condensate Steam
discharge
feed return water
Strainer
Feed pump
Preheater
Filter
Self-
cleaning
separator
Steam trap
Dirty water
Solids
discharge
discharge
Regulating valve
Strainer
Feed pump
Preheater
Filter
Self-cleaning
separator
Steam trap
Dirty water Solids
discharge
discharge
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.
Schematic illustration of a
lube oil treatment plant with manual
cleaning separator.
Feed pump
Lube oil tank
Utilities Lube oil
treatment plant
with centrifugal
Strainer
separator
Dirty oil
Sludge
feed
Pump system
GEA Westfalia SeparatorPlant Concepts for
Efficient Operation
Self-cleaning mineral oil centrifuges are chiefly All GEA Westfalia Separator marine separators for
used for the purification and dewatering of lube the treatment of fuel and lube oil have identical
oils, especially when there is a requirement for design features allowing the use of common
24-hour, unattended operation. components. This simplifies store management and
maintenance immensely.
The whole range of centrifuges is available for
efficient and reliable treatment of lube oil.
Schematic illustration of a lube oil
treatment plant with self-cleaning separator.
Feed pump
Feed pump
Regulating valve
Strainer
Dirty oil
feed
Steam
Preheater
Condensate
Steam trap
Preheater
Clean oil
Operating
discharge
water
Clean oil
discharge
Manual cleaning
separator
Dirty water
discharge
Self-cleaning
separator
Dirty water Solids
discharge dischargeAutomatic Process Control –
More Safety, More Comfort
Control units
For Westfalia Separator unitrolplus and
centripetal twin pump system
Display with
backlighting and 4 lines
Easy handling by
Micro Memory Card
Keys F1 – F4
which stores setting
Soft keypad, screen
and history data for
dependent
D10 and E40.
Status LEDs
Keys 1 – 0,
Function keypad with
fixed allocation
D10 with
text display
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.
E40 with graphic
The standard control unit is designed for unattended display and
operation of a separator. Profibus DP
28
GEA Westfalia SeparatorWestfalia Separator
minimaXx – Process Control
for Every Requirement
1
Motorstarter box
1
Motorstarter separator
Motorstarter feed pump
OMB 220
2
Overflow monitoring box
Water seal broken alarm
Control unit MC-1
3
Motorstarter separator
2
Motorstarter feed pump
Flow monitoring FAH
Control unit CC-1
4
Motorstarter separator
Motorstarter feed pump
Flow monitoring FAH
Temperature monitoring TAL / TAH
Preheater interlocking
3
Control unit CD-1
5
Control and monitoring
system for self-cleaning
Westfalia Separator
minimaXx separator.
Motorstarter separator
Motorstarter feed pump
Flow monitoring FAH
4
Flow monitoring FAL
Clean oil outlet
Temperature monitoring TAL / TAH
Preheater interlocking
Sludge pump control
D10
5
29
GEA Westfalia SeparatorCustom-Made System Solutions
for the Engine Room
Flexible systems
Design engineers have to be flexible with the Separators with single components, modular compact
planning of an engine room. GEA Westfalia units or individually installed Westfalia Separator
Separator has, therefore, thought of everything. centripack systems give customers flexible systems
designed precisely for their needs.
1
Separator with single components
1
No modularisation
CU – Compact Unit
2
Flexible modularisation
CP – Westfalia Separator centripack
3
Individual modularisation
2
3
30
GEA Westfalia SeparatorSeparator 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 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
Preheater
Operating and displacement water valve Steam trap
3 / 2 way valve Safety valve
Feed pump Prestrainer Strainer Regulating
valve
31
GEA Westfalia SeparatorCU Compact Unit –
Flexible Modularisation
Flexible systems
In addition to the detail engineering of single The modular CU compact units offer the opportunity
components there is the need for simple block to use flexible, low cost modules. All units are mounted
engineering. CU compact units provide a modular on bases that can be connected easily, even in a
design to meet this need. confined area.
32
GEA Westfalia SeparatorWestfalia Separator centripack –
Individual Modularisation
The Westfalia Separator centripack is a compact, completely assembled and function tested by GEA
self-contained treatment plant package system, Westfalia Separator; faulty installation of single
ready for connection. All elements necessary for operating components on site is thus eliminated. The
safe and efficient oil treatment are mounted ready unified design also saves money and makes
for connection in a space-saving arrangement on a maintenance easier.
sturdy foundation frame. These include separators,
motors, pumps, prestrainer, alarm system and a The Westfalia Separator centripack is available either
control and monitoring system. with self-cleaning separators and control unit
including control and monitoring equipment for
The discharge pipes for solids and water as well as unmanned operation, or with manual cleaning
the frame drain pipe are led through the foundation separators.
frame.
The Westfalia Separator centripack modules are
The design makes possible space-saving installation available with one to five separators depending on
direct in corners or against walls. It is also possible to requirements.
install several modules side-by-side to form a complete
plant. The Westfalia Separator centripack is
Westfalia Separator
centripack – complete
ready-to-connect module for
the treatment of fuel oil
33
GEA Westfalia SeparatorProcess 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.
Settling tank / Boiler plant
Recovered oil
Electrical energy
Heating energy Water
Sludge treatment plant with
centrifugal separator
Concentrated
Operating water
sludge
Disposal e.g. Bilgewater
incinerator system
Fuel oil sludge tank Lube oil sludge tank
Lube oil
Settling tank
separator
Fuel oil Lube oil
separator filter
Fuel oil filter
Diesel oil
separator
34
GEA Westfalia SeparatorSystem Concepts for the Future
The sludge is pumped from the sludge tank by an tank where final concentration takes place. Excess
eccentric screw pump and is fed via a heater to the water and oil is allowed to overflow back to the sludge
centrifugal separator. tank.
The sludge components of water, oil and solids are The concentrated sludge is pumped from the unit
separated in the separator by centrifugal force. The automatically by a solids discharge pump controlled
recovered oil and water is discharged under pressure by a level switch.
by centripetal pumps.
A microprocessor-based control cabinet supervises
The concentrated sludge is discharged intermittently and controls the complete concentration process.
via the sludge transfer unit into a heated sedimentation
Regulating
Operating
valve
water
Clean oil
discharge
Steam
Centrifugal
Dirty oil return
separator
Vibration
Preheater monitoring
Steam trap
Condensate
Feed pump
Dirty water
Sludge
discharge
transfer unit
Sludge
concentration
Oily water
unit
Filter
Concentrated sludge
Oil sludge feedEconomical Advantages –
Ecological Merits
Sludge treatment
Oil, water and solids can represent 2.5 percent of
marine fuels. Indeed many port authorities use this
figure when carrying out ship inspections.
With increasing environmental awareness as well as
Filling and displacement water
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
Oily sludge feed owners today.
Dirty water discharge
Clean oil discharge
36
GEA Westfalia SeparatorThe GEA Westfalia Separator sludge treatment
Separation results sludge treatment MV Fantasy
plant incorporating a specially designed centrifugal
Portion
separator is capable of reducing the volume of sludge
120
for disposal by up to 90 percent. In addition, fuel oil
100
is recovered for re-use and recovered lube oil can be
80
used as boiler fuel.
60
Benefits
40
Saves up to 90 percent disposal costs
120
20
Recovers valuable fuel oil
100
0
Unburdens the bilgewater system
80 Feed Oil Outlet Water Outlet
from oil residues
60
Sample taken from
Solids
Protects our sensitive marine ecosystem
Oil
40
Water
20
0
% (by vol.) % (by vol.) % (by vol.)
Treatment system for oily and watery Oil 10 .0 99.6 0.5
sludge with self-cleaning centrifugal Water 89.6 0.4 99.5
separator to reduce the disposal costs Solids 0.4 0.0 0.01
37
GEA Westfalia SeparatorSelf-Cleaning
Centrifugal System
Bilgewater treatment
Clean water
Waste oil tank
overboard
Separated oil Bilgewater Utilities
treatment plant
with centrifugal
separator
Dirty bilgewater
Sludge
return
Bilgewater
Pump system Waste oil tank
system
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
Steam
Oily water from ship operation may only be Bilgewater is a mixture of the following
discharged into the sea if the residual oil content in constituents:
the effluent is below 15 ppm. 15 parts of oil to one Sea and cooling water leakages
Condensate
million parts of water seems small but GEA Westfalia Fuel and lube oil leakages
Separator believes this is still too high. Moreover, Drainages from settling and sludge tanks
practice has shown that this value is not attained in Effluent from various cleaning processes
many conventional plants under practical operation Soot and dirt particles
conditions anyway. The further we can reduce this
value, the greater the benefit for our oceans.
38
GEA Westfalia SeparatorSo That Our Water Stays
As Nature Made It – Clean
The product (i.e. oily water) is sucked up from the pump to the discharge. The separated impurities
oily water tank or engine room bilge and fed by the accumulated in the sludge space are discharged
feed pump through the automatic filter and preheater into the sludge tank periodically. The clean water is
via the feed valve to the separator. The automatic discharged via an adsorption filter and supervised
filter prevents coarse particles from reaching the by an oil monitor before being discharged into the
bowl and blocking the rising channel within the disc environment. The residual oil content is adjustable to
stack. During the start-up or ejection program it is led >5 ppm and >15 ppm. If the oil content exceeds the
back into the oily water tank. The product flows from adjusted limit the water is recirculated into the oily
above into the centre of the separator bowl. The heavy water tank. An intelligent process control adapts the
water phase is separated from the finest oil particles capacity of the system to the changes of the product.
and then conveyed under pressure by a centripetal A chemical dosing system is not necessary anymore.
Dirty
Separated oil Dirty bilgewater Clean water
bilgewater
discharge return discharge overboard
feed
Automatic
filter
Adsorption
filter
Heater
Oil
monitor
Operating
water
Self-cleaning
separator
Dirty bilgewater
return
Solids discharge Dirty water dischargeTechnologies to Protect the Sensitive
Marine Ecosystem
Bilgewater treatment
The bilgewater treatment system is designed for ships
Bilgewater feed
which use high-density residual fuel oils. The system
is supplied as a complete, self-contained Westfalia
Separator centripack incorporating all auxiliaries
necessary for operation.
The main components of the system are:
Self-cleaning centrifugal separator Clean oil
discharge
Feed pump
Clean
Filter
bilgewater
Preheater
Control panel
Oil content meter for 5 / 15 ppm bilge alarms
Base frame with small sludge tank
Demulsifier plant
Adsorption filter
Benefits of the centrifuge
High separation efficiency
due to large clarification area
Controlled de-sludging with high solid content
due to the Westfalia Separator hydrostop system
Gentle treatment due to the
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
The systems are approved by
the latest IMO regulations and
U.S. Coast Guard.
40
GEA Westfalia SeparatorBilgewater treatment system WSD 18
The Flexible Compact Unit Design is Suitable
Both for Newbuildings or Retrofit
Separation results oily water treatment Benefits
With normal feed conditions, i.e.
Water outlet less than 5 / 15 ppm
solids content: < 0.1 percent
Reliable
chloride content: < 30,000 ppm
Easy handling
pH: 6 – 9
Low maintenance cost
and no excessive oil emulsions in the water phase,
Small dimensions
the residual oil content in the clean water discharge is
Low weight
10 – 12 ppm. By varying the pump output, it is possible
Quick return on investment
to even further reduce the oil content. In the case of
high oil and solids contents, it is prudent to separate
the bilgewater in several stages.
When high emulsion fractions are present or when
conveying residual oil contents below 5 ppm, it is
recommended to add emulsion-breaking chemicals in
the feed or to install an adsorption filter in the clean
water discharge.
41
GEA Westfalia SeparatorClean water
Dirty
Separated oil Dirty bilgewater
discharge
bilgewater
discharge return
overboard
feed
Automatic
filter
Oil monitor
Steam
Heater
Condensate
Operating
water
Self-cleaning
separator
Dirty bilgewater
return
Solids discharge Dirty water discharge
42
GEA Westfalia SeparatorClean water
discharge
overboard
SafetyMaster
Additional security beyond the regulations of MARPOL
As an integrated part of the BilgeMaster D series the
Adsorption
SafetyMaster provides additional security beyond
filter
the regulations of MARPOL against unintended
overboard discharge of oil polluted bilgewater. 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 Inputs to the SafetyMaster are the 24 V power supply,
part of the BilgeMaster-D series or as stand-alone the status signal separator running, compressed air,
unit. cleaning water and cooling water. The cooling water
for the sample liquid can be connected either to the
Description of the system LT (low temperature) cooling system or to the cleaning
The SafetyMaster is mounted on the filter unit and water connection. Outputs from the SafetyMaster to
incorporates the oil monitor, the sample taking and the separator control are the analogue output 4 – 20
sample return connection, the constant pressure mA of the oil monitor, the status of the alarm circuit
valve, the sample water cooler, the flow switch in the and the status of the position switch of the overboard
sample water line and the overboard valve. The valve. A flow meter is installed in the clean water
overboard valve is directly controlled by the oil outlet of the separator outside the SafetyMaster. The
monitor. In line of the alarm circuit are the flow flow is used to measure the volume discharged
switch and the end position switch of the door. The overboard and to monitor the condition of the feed
overboard valve is supervised by a micro switch pump, the bowl and the oil content in the product
giving an alarm and interrupting the separation feed to the separator. All data of the status of the
process if the oil content is > 15 ppm while the valve system including the position of the ship are recorded
is de-energized but not completely closed. in a data log.
43
GEA Westfalia SeparatorWestfalia Separator minimaXx –
Sophisticated Technology in
Confined Spaces
Hydraulic oil treatment plant
Hydraulic oil tank
Pump system
Hydraulic oil
treatment plant
with centrifugal
separator
The part played by separators in the shipping The new compact units of the Westfalia Separator
industry has changed drastically in recent years. Not minimaXx class are made in a space-saving design.
just stand-alone machines, but complete systems, Each one is based on a separator of the Westfalia
even for small product streams, are required to face Separator minimaXx family. This is mounted together
the increasing demands for high performance and with all necessary monitoring equipment in a mobile
low costs. The new generation of compact units system.
with Westfalia Separator minimaXx separators
was developed to fulfill these requirements and Special fields of application:
features: Hydraulic oil treatment
High standard of separating efficiency
High separation temperature up to 95 °C
High standard of economy
Low space requirement
Low weight
Modular design
Plug & play
No filter aids required
Service intervals up to 1 6,000 h
Low maintenance
44
GEA Westfalia SeparatorMobile treatment system
Feed pump
for hydraulic oil.
Dirty oil feed
Preheater
Clean oil
discharge
Manual cleaning
separator
Dirty water discharge
45
GEA Westfalia SeparatorVBU – Visco Booster Unit
Fuel oil conditioning system
Fuel oil
conditioning
system
Service tank
Efficient operation of ship and power station diesel VBU for marine
engines requires optimum fuel supply. This key application
condition is accomplished by the Visco Booster
Units developed by GEA Westfalia Separator for
fuel conditioning.
Stand-by
Fuel to
This unit consists of a treatment system that meets
day tank
the fuel requirements between the clean oil tank and
Fuel from
injection system for the main and auxiliary engines
engine
in terms of the required injection viscosity and
temperature. Supply and booster pumps are provided
Automatic
Feeder pump
backflushing
for a stable system pressure.
filter
The modules are designed for the different engines
as well as to the required injection viscosity (approx.
Strainer
10 – 24 cSt) and corresponding temperature (approx.
HFO
135 – 150° C).
MDO
Pressure control valve
46
GEA Westfalia SeparatorComplete System Between
Service Tank and Engine
With the Visco Booster Units, GEA Westfalia
Separator offers a complete, compatible system
from the service tank to the engine for safe and
economic fuel oil treatment.
Visco Booster Units are supplied as package systems.
The Visco Booster Units 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.
Degassing valve
Viscosity
sensor
Stand-by
Fuel to
day tank
Fuel from
engine
Automatic
Fuel to
backflushing
engine
filter
Booster pump
Preheater Stand-by
Flow meter
Regulating Condensate or
valve thermal oil
Mixing / Steam trap
Degassing tank
Steam or
thermal oil
47
GEA Westfalia SeparatorSWD – Sea Water Distiller
Water desalination system
Shore independent generation of fresh water on
Sea Water
Jacket water
board by single stage evaporation technology.
Fresh water
generator
Sea water is fed through the condenser, where it
Fresh Water
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
HT central
coolers
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).
distillate, it is either led to the distillate tank or, if the
The vapour produced passes through the demister maximum allowable residual salt content is exceeded,
located in the upper casing to remove entrained back to the evaporator.
droplets of water and is led to the condenser. The
distillate is drawn from the condenser by the distillate All parts in contact with sea water are constructed of
pump and discharged through the salinity measuring corrosion-resistant materials (PP, stainless steel). The
unit. Depending on the residual salt content of the plates are made of titanium.
48
GEA Westfalia SeparatorSingle Stage
Evaporating System
Benefits
Compact
Easy to operate
Reliable
Low weight
Low maintenance costs
Integrated anti-scaling system
Corrosion-resistant materials
High performance
Thermal oil / hot water heated
Heat
exchanger
Jacket water heated
Sea water
Seawater pump
Jacket water
Distillate
Feed
Demister
water
Heating water
Circulation pump
Steam heated
Steam
Brine
Steam jet liquid pump
Condensate
Overboard
49
GEA Westfalia SeparatorWestfalia Separator capitalcare –
Maximum Process Efficiency, Installation
Availability and Budget Security
Westfalia Separator capitalcare combines decades of service experience for mechanical
separation technology.
Wherever separating technology tasks have to be Training provided on site or in the modern training Westfalia Separator capitalcare accordingly makes Maximum availability
carried out, Westfalia Separator capitalcare assures centre of GEA Westfalia Separator ensures that the for maximum process efficiency and installation
comprehensive services right from the very beginning. customer‘s employees receive training in the proper availability as well as budget security. And these Absolute budget reliability
In close cooperation with the customer, solutions are handling of the high-tech installations. This provides benefits are provided throughout the entire life cycle
identified to meet their needs. additional safety. of the entire installation. Permanent efficiency
The partners benefit not only from traditional Authorized workshops worldwide Service from the original manufacturer:
services such as inspection, maintenance, original And if problems occasionally occur or if a spare part Service engineers quickly on site
spare parts and repair work provided by the original is required at short notice, the specialists are able to Extensive service network In addition to traditional
services such as maintenance
manufacturer; they also benefit from pro-active attend to the customer quickly. This is ensured by a Risk avoided by service provided
or repair, Westfalia Separator
solutions which avoid risk, e.g. online and offline global network with more than 50 sales and service by the original manufacturer
capitalcare also provides
monitoring with Westfalia Separator wewatch. companies as well as 60 further sales partners. Pro-active solutions which avoid risk
solutions which avoid risk and
with which the installation
Authorized workshops are able to service every Upgrading to boost performance
availability can be pro-actively
Accompanying modernisation or upgrading to state- location in the world at short notice. Staff training
assured.
of-the-art technology also offer the option of boosting
performance as required.
50
GEA Westfalia SeparatorWestfalia Separator capitalcare –
Maximum Process Efficiency, Installation
Availability and Budget Security
Westfalia Separator capitalcare combines decades of service experience for mechanical
separation technology.
Wherever separating technology tasks have to be Training provided on site or in the modern training Westfalia Separator capitalcare accordingly makes Maximum availability
carried out, Westfalia Separator capitalcare assures centre of GEA Westfalia Separator ensures that the for maximum process efficiency and installation
comprehensive services right from the very beginning. customer‘s employees receive training in the proper availability as well as budget security. And these Absolute budget reliability
In close cooperation with the customer, solutions are handling of the high-tech installations. This provides benefits are provided throughout the entire life cycle
identified to meet their needs. additional safety. of the entire installation. Permanent efficiency
The partners benefit not only from traditional Authorized workshops worldwide Service from the original manufacturer:
services such as inspection, maintenance, original And if problems occasionally occur or if a spare part Service engineers quickly on site
spare parts and repair work provided by the original is required at short notice, the specialists are able to Extensive service network In addition to traditional
services such as maintenance
manufacturer; they also benefit from pro-active attend to the customer quickly. This is ensured by a Risk avoided by service provided
or repair, Westfalia Separator
solutions which avoid risk, e.g. online and offline global network with more than 50 sales and service by the original manufacturer
capitalcare also provides
monitoring with Westfalia Separator wewatch. companies as well as 60 further sales partners. Pro-active solutions which avoid risk
solutions which avoid risk and
with which the installation
Authorized workshops are able to service every Upgrading to boost performance
availability can be pro-actively
Accompanying modernisation or upgrading to state- location in the world at short notice. Staff training
assured.
of-the-art technology also offer the option of boosting
performance as required.
51
GEA Westfalia Separator
Beverage Technology
Dairy Technology
Oils and Fats Processing
Chemicals, Pharmaceuticals
and Biotechnology
Oils and Fats Recovery
Starch Technology and
Industrial Biotechnology
Marine
Energy
Oilfield
Industry
Environmental Technology
Engineering
Second Hand Machinery
Cross-Flow Filtration
with Ceramic Elements
Service
The information contained in this brochure merely
serves as a non-binding description of our products
and is without guarantee.
Binding information, in particular relating to capacity
data and suitability for specific applications, can only be
provided within the framework of concrete inquiries.
Printed on chlorine-free bleached paper
www.kabutz.de
9997-1098-030/0708 EN
Printed in Germany
Subject to modification
Mechanical Separation
GEA Westfalia Separator Systems GmbH
Werner-Habig-Stra?e 1 · 59302 Oelde (Germany)
Phone +49 2522 77-0 · Fax +49 2522 77-2488
ws.mineraloilsystems@geagroup.com · www.westfalia-separator.com |
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