Westfalia Separator Mineraloil Systems GmbH 分油机说明书.pdf

GEAMechanical Separation DivisionWestfalia Separator Mineraloil Systems GmbHInstruction Manual and Parts ListNo.:2059-9001-021Edition:0806Designation:Mineral oil centrifuge with self-cleaning bowlModel:OSD 18-0136-067/Westfalia SeparatorMineraloil Systems GmbH2Subject to modification!The authors are always grateful for comments and suggestions for improving the documentation.They can be sent toGEA Westfalia Separator Mineraloil Systems GmbHWerner-Habig-Str.1D-59302 Oelde GEA Westfalia Separator2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH3Westfalia SeparatorMineraloil Systems GmbHD-59302 Oelde(F.R.Germany)Model S/NBuilt in 0 in mmMax.admissible rated bowl speed in min-1Max.admissible density in kg/dm3 of productHeavy liquid Solidskg/dm3 kg/dm。min/max throughput m3/hmin/max temp,of product in min/max housing in barThis nameplate must be filled in by the operator.Please transfer the data from the centrifuge nameplate.2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH4ANote:For your safety Strictly adhere to instructions marked with this symbol.This avoids damage to the separator and other equipment.Take special care when carrying out operations marked with this symbol-otherwise danger to life.This symbol is not a safety precaution but rather a reference to information which help to better understand the separator or plant components and the processes.Observe the accident prevention regulations!The local safety and accident prevention regulations apply unconditionally to the operation of the separator.The plant operator must ensure compliance with these regulations.Follow the instructions in the manual.Follow only the instructions given in this manual.Repair and maintenance work that goes beyond the scope described in this manual may not be carried out.Operate the separator only in accordance with agreed process and operating parameters Maintain the separatoras specified in this manual.Carry out safety checks on the separator,as described in chapter Safety precautions in this manual Liability for the function of the machine passes to the owner.Liability for the function of the machine passes unconditionally to the owner or operator irrespective of existing warranty periods in so far as the machine is improperly maintained or serviced by persons other than Westfalia Separator service personnel or if the machine is not applied in accordance with the intended use.Westfalia Separator shall not be liable for damage which occurs as a result of non-observance of the above.Warranty and liability conditions in the Conditions of Sale and Delivery of Westfalia Separator are not extended by the above.2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH51 Safety precautions 91.1 Correct usage.101.2 Safety markings.101.2.1 Safety markings and their meaning.111.3 Basic operating principles.141.4 Bowl speed and product.141.5 Demands relating to service personnel and spare parts.151.6 Operations on the separator.161.6.1 Assembly.161.6.2 Electrical appliances.181.6.3 Before start-up.181.6.4 Starting.211.6.5 Shut-down and Emergency-Off.231.6.6 Maintenance and repair.241.7 Corrosion.271.8 Erosion.281.9 The health hazards involved when handling heavy oils and lube oils.301.9.1 Code of practice and personal protective measures.302 Machine description 312.1 Dimensioned drawing of the separator.322.2 Section through separator.342.3 General.352.4 OSD.-0136-.352.4.1 Separator with water content and sludge space monitoring system(WMS and SMS)for fuel oil treatment(design-0136-).372.4.2 Separator with water content monitoring system(WMS only!)for fuel oil treatment(design-0136-)(for operation in series).392.4.3 Separator with sludge space monitoring system(SMS only!)for fuel oil treatment(design-0136-)(for operation in series).402.5 Main components of the separator.412.5.1 Bowl.422.5.2 Bowl hydraulics.432.5.3 Centripetal pump.462.5.4 Sensing liquid pump.472.5.5 Drive.482.6 Technical data.493 Operation 533.1 Technical information.543.1.1 Separation.543.1.2 Notes for separation with the UNITROL system.543.1.3 General information on bowl ejection.543.2 Before start-up.563.2.1 Before the first start-up.563.2.2 Before every start-up.563.3 Starting the separator.573.4 Monitoring of operation.573.5 Setting the separation time.583.5.1 Mathematical calculation.582059-9001-021/0806Westfalia Separator6 Mineraloil Systems GmbH3.6 Ejecting the bowl.593.7 Shutting down the separator.603.8 Trouble shooting.623.8.1 Faults on the separator.623.8.2 Bowl faults.644 Installation-Maintenance-Repair 714.1 Installation of the separator.724.1.1 Transporting the separator.744.1.2 Installing the separator.754.1.3 Motor.764.1.4 Direction of rotation of the bowl.774.1.5 Speed and starting time of the bowl.784.2 Maintenance and lubrication.804.2.1 Maintenance schedule.804.2.2 Hoses and hose pipes.834.2.3 Lubrication.844.2.4 Lubrication Chart.864.2.5 Table of lubricating oils.884.2.6 Comments on table of lubricating oils for separators from Westfalia Separator.894.3 Bowl.904.3.1 Dismantling the bowl.924.3.2 Cleaning the bowl.1044.3.3 Cleaning the frame.1054.3.4 Cleaning the strainer and the operating water feeding system.1054.3.5 Important instructions.1064.3.6 Assembling the bowl.1084.3.7 Replacing the polyamide gasket in the annular piston.1204.3.8 Replacing the polyamide gasket(bowl top).1224.3.9 Reworking the sliding piston.1244.4 Closing the hood.1264.5 Motor and centrifugal clutch.1294.6 Drive.1304.6.1 Important instructions.1324.6.2 Removing the drive belt and spindle assembly.1344.6.3 Dismantling the spindle assembly.1384.6.4 Removing the centrifugal clutch.1414.6.5 Fitting the spindle assembly.1454.6.6 Fitting the centrifugal clutch.1474.6.7 Fitting the motor.1524.7 Height adjustment.1554.7.1 Bowl height.1554.7.2 Centripetal pump clearance.1564.8 Final checks after assembling the separator.1584.9 Before a long-term shut-down of the separator.1584.10 Before restarting.1594.11 Standard tools.160Accessories 1635.1 Solenoid valve block.1645.2 Solenoid valves.1662059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH75.3 Pressure switch.1676 Parts list 171Guide to ordering spare parts.173Set of plates.175Frame,compl.177Brake bolt,complete.178Solenoid valve block,complete.179Solenoid valve block,compl.180Drive,complete.183Clutch shoes.183Set of drive parts-50 Hz(bowl speed:9 600 min-1).185Set of drive parts-50 Hz(bowl speed:11,500 min-1).185Set of drive parts-60 Hz(bowl speed:10,000 min-1).185Set of drive parts-60 Hz(bowl speed:11,500 min-1).185Spindle,complete-50 Hz(motor speed:2 915 min-1-bowl speed:9 600 min-1).187Spindle,complete-60 Hz(motor speed:3,495 min-1-bowl speed:10,000 min-1).187Spindle,complete-50 Hz(motor speed:2,915 min-1-bowl speed:11,500 min-1).189Spindle,complete-60 Hz(motor speed:3,495 min-1-bowl speed:11,500 min-1).189Centrifugal clutch,compl.191Bowl,complete.193Accessories for separating disk.194Disk stack,complete.195Centripetal pump,compl.196Hood,complete.199Retaining bracket,compl.200Water feed line,compl.201Valve,complete.202Corrugated hose,compl.203Solenoid valve,compl.204Set of tools and accessories.207Lubricants(hazardous materials!).207Set of spare parts bowl/hood(operation:1 year or 8,000 hours).209Set of spare parts drive-50 Hz(motor speed:2915 min-1-bowl speed:9600 min-1)(operation:1 year or 8000 operating hours).211Set of spare parts drive-60 Hz(motor speed:3495 min-1-bowl speed:10,000 min-1)(operation:1 year or 8000 hours).211Set of spare parts drive-50 Hz(motor speed:2915 min-1-bowl speed:11,500 min-1)(operation:1 year or 8000 operating hours).213Set of spare parts drive-60 Hz(motor speed:3495 min-1-bowl speed:11,500 min-1)(operation:1 year or 8000 hours).213Set of spare parts drive-50 Hz(motor speed:2,915 min-1-bowl speed:9,600 min-1)(operation:2 years or 16,000 hours).215Set of spare parts drive-60 Hz(motor speed:3495 min-1-bowl speed:10,000 min-1)(operation:2 years or 16,000 hours).2152059-9001-021/0806Westfalia Separator8 Mineraloil Systems GmbHSet of spare parts drive-50 Hz(motor speed:2915 min-1-bowl speed:11,500 min-1)(operation:2 years or 16,000 operating hours).217Set of spare parts drive-60 Hz(motor speed:3495 min-1-bowl speed:11,500 min-1)(operation:2 years or 16,000 operating hours).2172059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH91 Safety precautions1.1 Correct usage.101.2 Safety markings.101.2.1 Safety markings and their meaning.111.3 Basic operating principles.141.4 Bowl speed and product.141.5 Demands relating to service personnel and spare parts.151.6 Operations on the separator.161.6.1 Assembly.161.6.2 Electrical appliances.181.6.3 Before start-up.181.6.4 Starting.211.6.5 Shut-down and Emergency-Off.231.6.6 Maintenance and repair.241.7 Corrosion.271.8 Erosion.281.9 The health hazards involved when handling heavy oils and lube oils.301.9.1 Code of practice and personal protective measures.302059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH101.1 Correct usageThe separator is designed in accordance with the chemical and physical properties of the product specified by the customer and in accordance with the method of application of the separator agreed with Westfalia Separator.In particular,products not conforming to the specifications on the nameplate may not be used.Any mode of operation deviating herefrom is not proper and correct.Prior to any intended deviation from the agreed operating mode,it is therefore imperative to obtain the consent of Westfalia Separator.1.2 Safety markingsThe safety markings(adhesive and metal plates)are attached to all separators on the hood and frame of the respective separator in such a way that they are clearly visible.All safety markings on the separator,control system and plant components must always be in perfect condition.Clean dirty safety markings.Replace damaged safety markings.Fig.1 Example of markings on a separator12 3 4 5Safety stickerOil qualityPlates Nameplate Makers nameplateThe texts and part numbers of the safety markings change depending on the languages required by the customer.2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH111.2.1 Safety markings and their meaningThe following safety markings must be attached to the separator as adhesive labels.Fig.2Fig.3Refer to the machine documentation!Every person who is assigned the task of installing,operating,maintaining and repairing the machine must have read and understood the documentation.The documentation must be complete kept near to the machine and be readily accessible to the operators.It must be available to the op-_ erators at all times!2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH12Before carrying out work,disconnect power to the all components of the monitoring system!Risk of injury due to electrical voltage and unintended start-up of the separator!Before carrying out work on the separator and electrical plant components:Make sure the separator is at a standstill.Switch off all electrical appliances via the main switch,Lock the installation to prevent it from being accidentally switched on.Danger o life and limb through rotating machine parts!Do not loosen any part and do not carry out maintenance or repair work on the separator before the separator is at a standstill.Methods of how to check standstill are described in the machine documentation.Fig.5S2Fig.6Warning of unusual noises or vibrations!When unusual noises or vibrations occur on the separator:Immediately shut down the separator with filled bowl via“emergency-off.”Never trigger a bowl ejection!Evacuate the room.Do not re-enter the room until the centrifuge has come to a standstill.2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH13Frequency converter operation!When setting the frequency converter,do not exceed the admissible bowl speed(see nameplate)Note:This adhesive plate is only used for frequency converter operation.Fig.7AFig.8Warning of extreme surface temperatures!The surfaces of the separator and plant components can be hot!Note:This adhesive plate is only used for hot operation.2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH141.3 Basic operating principlesSeparators are used for the separation of liquid mixtures or for the separation of solids out of liquids or liquid mixtures.Fig.9High centrifugal forces are produced in the rotating bowl.Under the influence of the centrifugal forces,separation of the liquid mixture and/or ejection of the solids particles takes place most rapidly.The specifically heavier components are displaced to the bowl periphery,whereas the specifically lighter components are displaced towards the centre of the bowl.The high centrifugal force is produced by very high bowl speeds.On the one hand,high bowl speeds signify high efficiency,while on the other hand,they signify high material stressing of the separator.1.4 Bowl speed and productThe max.permissible bowl speed is an important parameter when rating the separator.It depends on the chemical and physical properties of the product such as temperature,if higher than 100 (212 F)or lower than 0 (32 F),density of the fluid and solid components,aggressiveness of the product as regards corrosion and erosion(has influence on the selection of the bowl material).The bowl speed is determined on the basis of these parameters allowing for an adequate safety margin.Before using a product with properties different from those stated when placing the order,it is imperative to obtain the manufacturers approval.2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH151.5 Demands relating to service personnel and spare partsSenuinepaORIGINALFEILB出 Westfalia Se吧Fig.10 Use only genuine spare parts from Westfalia Separator.The use of non-genuine parts leads to:-Safety risks-Lower durability and availability-Increased maintenance requirementIf a safety risk arises,this may have legal consequences for the responsible persons.In this case,Westfalia Separator shall assume no liability or warranty.Deploy only well trained personnel for maintenance work,e.g.service personnel from Westfalia Separator or personnel trained by Westfalia Separator.An incorrectly maintained/assembled machine poses a safety risk for the operators.2059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH161.6Operations on the separatorFig.11The separator works reliably,provided that it is operated and maintained in accordance with our operating instructions.Special attention must be given to:assembly starting shutting-down maintenance and servicing1.6.1 AssemblyFig.12 If the plant has several centrifuges,be careful not to interchange parts of different bowls since each bowl has been balanced individually.The bowl parts are marked with the serial-number of the machine or with the last three digits of the serialnumber.Damaged parts must be replaced immediately by new parts.Fig.132059-9001-021/0806Westfalia SeparatorMineraloil Systems GmbH17 After installing certain critical spare bowl parts,the bowl must be