Technical Training

mode of operation and running modes

Wärtsilä Bangladesh Ltd

Project Kodda, Bangladesh

GEA Mechanical Equipment / GEA Westfalia Separator Group GmbH

1 Mechanical Equipment / Westfalia Separator

 GEA Westfalia Separator Group GmbH
technical training: mode of operation and running modes
Ronald Eschmann, Service Centre Hamburg

1. single mode
2. parallel mode
3. series mode
4. filling and displacement
5. running mode -01/36-
6. running mode -01/96-

Mechanical Equipment / Westfalia Separator

 diagram of installation: SINGLE MODE HFO

3 Mechanical Equipment / Westfalia Separator

 diagram of installation: SINGLE MODE LO

4 Mechanical Equipment / Westfalia Separator

 diagram of installation: PARALLEL MODE

HFO In the parallel mode of

operation the total flow
will be distributed in
equal shares to two
separators as it might be
necessary when running
bad low grade fuel (high
amount of water resp.
cat-fines etc.). Only one
feed pump and one
heater system is in
operation. Both
separators acting as
purifier.
purifier + purifier
purifier purifier

5 Mechanical Equipment / Westfalia Separator

 diagram of installation: SERIES MODE

HFO In the series mode of

operation the total flow
will be treated in two
stages:
purifier  clarifier.
The clarifier will trigger a
cleaning cycle by
accumulation (Sludge
Monitoring System) on
both stages and will
override the timer.
Because of that the
series mode is
recommended when
purifier clarifier
having problems with an
increased amount of
solids in the feed.
6 Mechanical Equipment / Westfalia Separator
 diagram of installation: SERIES MODE

PAL PAL
CS PSL CS PSL

First stage: Purifier second stage: Clarifier

Water Monitoring System Sludge Monitoring System
WMS-01- SMS-36-
7 Mechanical Equipment / Westfalia Separator
 diagram of installation: SERIES MODE

State-of-the-art separators
combines the key benefits of
the UNITROL Water Monito-
ring System WMS-01-and the
UNITROL Sludge Monitoring
System SMS-36- in a single
stage.
This has not been possible in
the past because of the limited
numbers of inputs and outputs
of the PLC. Because the
series mode does not affect
the separation efficiency the
series mode shall be deemed
to be obsolete.

8 Mechanical Equipment / Westfalia Separator

 filling and displacement

Before separating an oil-water mixture, the vessel must initially be

filled with water in order to prevent the oil to overflow at the dirty
water discharge. This water is known as "filling water", which
forms a water seal.

9 Mechanical Equipment / Westfalia Separator

 filling and displacement

Before separating an oil-water mixture, the vessel must initially be

filled with water in order to prevent the oil to overflow at the dirty
water discharge. This water is known as "filling water", which
forms a water seal.

PAL PAL PAL

after ejection during filling during separation

10 Mechanical Equipment / Westfalia Separator
 filling and displacement

Prior to each ejection the

feedvalve will switch over into PT1

mode circulation. In order to

PT2

displace the clean oil out of

the bowl water will be added
to the bowl timer controlled.
This is to minimize oil losses
due to ejections. The
separation line will start to
move inwards in case more
water will be added than
discharged.

11 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

- for HFO and MDO

- maximum density of oil: 1.010 kg/dm³ @ 15 °C
- two centripetal pumps
- no regulating ring
- with water meter (WM, formerly known as CS)
- no filling water required
- lower centripetal pump chamber cover: only one flow control
hole open)
- pressure transmitter in the clean oil discharge (PT1)
- pressure transmitter in the UNITROL system (PT2)
- time between ejections controlled by timer and by accumulation

12 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

After separator start-up the bowl is

HFO
closed and empty. The PT1 (clean
oil discharge) and PT2 (SMS
V5 PT1 UNITROL) showing 0 bar at the
WM PT2 PLC. The WM shows “oil” (contact
open) signal at the control unit.
V6

Water is sprayed intermittent

controlled by timer T06 closing
water impulse and timer T14
closing water interval into the
closing chamber to prevent bowl
opening due to small closing water
losses (water evaporated, small
leakages).

13 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-, sensor check

To check the function of the PT2 as

HFO
well as to calculate the Timer T01
Displacement water and T02 Filling
V5 PT1 water water will be added into the
WM PT2 bowl in mode “make and break” until
PT2 indicates a pressure > 0,5 bar.
V6
The SMS sensor check is monitored
by timer T44 SMS Sensor Check.
The water is added in a first step by
timer T60 Start-Impulse following
intermittent by timer T61 Sensor-
Interval and T62 Sensor-Impulse. In
case T44 is elapsed before pressure
signal at PT2 is detected the alarm
“SMS Sensor fault” will be triggered
by PLC.

14 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-; self calibration

Example: calculation of Displace-

HFO
ment timer T01 for OSE80:
Known or stored values in the control
V5 PT1 unit:
WM PT2
displacement volume: 13.0 liter
V6 volume until SMS signal: 23.0 liter
Time until volume SMS: 230 s
(measured during sensor check)
230 s
Formula: T 01  13l 
23l
Calculated time for T01 = 130s
Every 10th cleaning cycle (controlled
by counter 4 sensor check) and after
every start of the process the system
will run through the sensor check.

15 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

The feedvalve will switch over from

HFO
ciruclation to separation after
performing a double discharge.
V5 PT1
WM PT2
The water discharge valve is
V6
controlled by the signal of the WM.
Whenever the signal is water
(contact closed) the dirty water will
be drained in batches. The dirty oil
will displace the water from the
UNITROL system. V6 will close in
case the signal of the WM will turn
the “oil” (contact open) again.

16 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

The circulation valve V5 is open

HFO
controlled by timer T16 Circulation
valve open and closed controlled by
V5 PT1 timer T15 Circulation valve closed.
WM PT2

V6

17 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

The circulation valve V5 is open

HFO
controlled by timer T16 Circulation
valve open and closed controlled by
V5 PT1 timer T15 Circulation valve closed.
WM PT2

In case the signal at the WM is "oil"

V6
the sensing liquid will be re-
circulated into the dirty oil feed.

18 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

Over the course of time dirty water

HFO
will be accumulated in the bowl and
finally reach the WM during T16
V5 PT1 Circulation valve open. The
WM PT2 maximum period of a single water
discharge is monitored by timer T22
V6
High water content. In case the
maximum water discharge time is
exceeded the alarm “WMS SYSTEM
FAULT - too much water“ will come
up.

19 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

The water content in the HFO is

HFO
being checked and monitored by
timer T22 as well as by the time
V5 PT1 record TR1 WMS time. TR1 will
WM PT2 count the accumulated total water
discharge time within 24 hours. In
V6
case a maximum time is exceeded
the warning “WMS activated too
often“ will come up. A warning will
not stop the process but will trigger
an audible signal only. Somebody
needs to acknowledge the message.

20 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

The SMS is controlled by the signal

HFO
of the pressure transmitter PT2. In
case the sludge holding space is
V5 PT1 filled with solids the internal
WM PT2 circulation stops causing pressure at
PT2 to drop. The PLC will trigger an
V6
ejection by accumulation with prior
displacement delayed by timer T27
SMS PSL delay. The SMS signal
will override the timer T20
Separation (time between two
forced ejections).

21 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

In case the SMS pressure at PT2

HFO
drops too early within a monitoring
time T21 Min. Separation time after
V5 PT1 the last cleaning cycle the alarm
WM PT2 „MIN. SEPARATING TIME < 10 min“
will come up.
V6

During every cleaning cycle the

pressure at PT1 must drop because
there is no flow at all. In case the
pressure does not drop the alam
"PT1 monitoring" will be released.

22 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

During idle running (bowl is spinning

HFO
at nominal speed but the feedvalve
is in position "circulation") there must
V5 PT1 be no SMS pressure at the PT2.
WM PT2 Otherwise this indicates a leakage at
the filling water valve or feed valve or
V6
clean oil discharge non-return valve.
The alarm "SMS Sensor active in
idle run" will be released.
In order to avoid overheating of the
bowl Timer T39 Separator off after
idle run will stop the separator when
running idle automatically. The alarm
"Sep. motor off" will be released.

23 Mechanical Equipment / Westfalia Separator

 UNITROL HFO -01/36-

In UNITROL mode -01/36- WMS and SMS running in parallel.

WMS-01- SMS-36-

V5 PT1 V5 PT1
WM PT2 WM PT2

V6 V6

WMS: discharging the water when- SMS: ejection whenever the

ever the bowl is filled with water bowl is filled with sludge
24 Mechanical Equipment / Westfalia Separator
 UNITROL LO -01/96-

LO
V5 PT1
WM PT2

V6

Water Monitoring System +

Sludge Monitoring System
25 Mechanical Equipment / Westfalia Separator
 UNITROL LO -01/96-

- for LO
- maximum density of oil: 0.991 kg/dm³ @ 15 °C
- two centripetal pumps
- with water meter (WM, formerly known as CS)
- filling water required (water seal)
- lower centripetal pump chamber cover: four or eight holes open
- pressure transmitter in the clean oil discharge (PT1)
- pressure transmitter in the dirty water discharge (PT2)
- time between ejections controlled by timer and by accumulation
- WMS and SMS are activated one after the other

26 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: sensor check

After separator start-up the bowl is

LO
closed and empty. The PT1 (clean
oil discharge) and PT2 (dirty water
V5 PT1 discharge and SMS) showing 0 bar
WM PT2 at the PLC. The WM shows “oil”
(contact open) signal at the control
V6
unit.

Water is sprayed intermittent

controlled by timer T06 closing
water impulse and timer T14
closing water interval into the
closing chamber to prevent bowl
opening due to small closing water
losses (water evaporated, small
leakages).

27 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: sensor check

To check the function of the PT2 and

LO
the WM as well as to calculate the
Timer T01 Displacement water and
V5 PT1 T02 Filling water water will be added
WM PT2 into the bowl in mode “make and
break” until PT2 indicates a pressure
V6
> 0,5 bar.
The SMS sensor check is monitored
by timer T44 SMS Sensor Check.
The water is added in a first step by
timer T60 Start-Impulse following
intermittent by timer T61 Sensor-
Interval and T62 Sensor-Impulse. In
case T44 is elapsed before pressure
signal at PT2 is detected the alarm
“SMS Sensor fault” will be triggered
by PLC.

28 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: self calibration (T01, T02)

Example: calculation of Displace-

LO
ment timer T01 for OSE20:
Known or stored values in the control
V5 PT1 unit:
WM PT2
displacement volume: 2.0 liter
V6 volume until SMS signal: 3.6 liter
Time until volume SMS: 36.0 s
(measured during sensor check)
36s
Formula: T 01  2.0l 
3.6l
Calculated time for T01 = 20 s
Every 10th cleaning cycle (controlled
by counter 4 sensor check) and after
every start of the process the system
will run through the sensor check.

29 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

After the sensor check the process

LO
will start to run. In a first step there
will be a double ejection in order to
V5 PT1 clean the bowl.
WM PT2

In the next step the filling water

V6
valve is open controlled by timer
T02 filling water to fill the bowl
partially with fresh water. This water
will form the water seal.

The separator in mode -01/96- will

always start to run in mode WMS
controlled by timer T32 WMS mode.
After T32 went down to zero the
PLC will switch over to SMS mode.

30 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

The feed valve will switch over from

LO
circulation to separation after a
delay time T09 waiting after filling.
V5 PT1
WM PT2 The water discharge valve V6 will
close delayed by T38 WMS sensor
V6
flushing in order to drain excessive
filling water from the bowl.

31 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

Because there is a flow at the clean

LO
oil discharge there is a pressure
signal at the PT1.
V5 PT1
WM PT2 Because there is not too much water
in the feed there is no flow at the
V6
dirty water discharge (no PT2
signal).

32 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

Over the course of time dirty water

LO
will be accumulated in the dirty
water chamber. This will cause a
V5 PT1 pressure signal at the PT2.
WM PT2

V6

33 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

After the PLC registers a PT2 signal

LO
the water discharge valve will open
for three seconds. Because there is
V5 PT1 no flow at the dirty water discharge
WM PT2 the pressure at PT2 will drop. This
will be registred by the PLC. The
V6
monitoring timer T47 minimum
SMS time will start to count down.

34 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

The monitoring timer T47 minimum

LO
SMS time will check how long does
it takes to the next PT2 signal. In
V5 PT1 case this time is too short that
WM PT2 indicates that there is an increased
amount of water in the feed.
V6

35 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

There is a reset of timer T47 after

LO
the PT2 signal drops. The numbers
of PT2 pressure signals within T47
V5 PT1 will be monitored by counter C5
WM PT2 SMS time interval - water content.
The factory setting of C5 is 5.
V6

In case counter C5 went down to

zero (five PT2 signals each within
monitoring time T47) the warning
“warning water content” will come
up which needs to get
acknowledged by the operator.

The warning is supressed after the

last cleaning cylce controlled by
timer T17 water content bridging.

36 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

The a.m. warning will come up in

LO
case the water content in the feed
will exceed approx. 0.5 % by
V5 PT1 volume. Even this amount of water
WM PT2 is not sufficient to cause a constant
flow of water at the dirty water
V6
discharge.

The separation process will not stop

after the warning but the water
discharge valve V6 kept open to the
next cleaning cycle or to the next
SMS test.

37 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

There is a flow at the dirty water

LO
discharge in case the PT2 pressure
does not drop even after keeping
V5 PT1 the discharge valve V6 open for
WM PT2 three seconds. At this stage the WM
will be activated by software but not
V6
earlier. In case there is a PT2 signal
and a the WM shows “water”
(contact closed signal) the alarm
“WMS system fault – too much
water” will come up delayed by
timer T22 high water content.

38 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

There is a flow at the dirty water

LO
discharge in case the PT2 pressure
does not drop even after keeping
V5 PT1 the discharge valve V6 open for
WM PT2 three seconds. In case there is a
PT2 signal and the WM shows “oil”
V6
(contact open signal) the discharge
valve V6 will close delayed by timer
T34 circulation valve delay.
Simultaneously the circulation valve
V5 will open.

39 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

Finally the alarm “no water seal

LO
during T35” will come up delayed
by timer T35 water seal broken
V5 PT1 delay.
WM PT2

This is formerly known as alarm

V6
“breakover water discharge“. In case
the water seal got lost somehow the
oil will overflow to the dirty water
discharge accidently causing a
pressure at PT2.

40 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: WMS mode

The overflow will cause the clean oil

LO
discharge pressure at PT1 to drop
as well. The alarm “PAL – clean oil
V5 PT1 discharge” will come up delayed by
WM PT2 timer T07 alarm delay. The same
alarm will come up e.g. in case the
V6
feed pump fails or the bowl drops
open accidently during separation
(lack of closing water or too much
water sprayed somehow during T06
closing water impulse.

41 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: SMS mode

After timer T32 WMS mode went

LO
down the discharge valve V6 will
close and the system will switch
V5 PT1 over to the SMS mode delayed by
WM PT2 timer T33 SMS mode.
V6
The purpose of the SMS mode is to
check whether the sludge holding
space of the bowl is clean or
blocked already with solids (sludge)
or not.

42 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: SMS mode

For the SMS test fresh water will be

LO
added in mode “make and break”
controlled by timer 36 SMS
V5 PT1 pressure check as well as T37
WM PT2 SMS waiting. In case the bowl is
clean the added water will cause a
V6
pressure signal at PT2. If this the
case the SMS test is finished. The
system will switch back to WMS
mode and timer T32 WMS mode
again starts to count down.

43 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: SMS mode

The numbers of water injections is

LO
controlled by counter C3 SMS
filling.
V5 PT1
WM PT2 In case there is no pressure signal
at PT2 even after several water
V6
injections (counter C3 went down)
the PLC will trigger an ejection by
accumulation with prior displace-
ment.

44 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: SMS mode

The numbers of water injections is

LO
controlled by counter C3 SMS
filling.
V5 PT1
WM PT2 In case there is no pressure signal
at PT2 even after several water
V6
injections (counter C3 went down)
the PLC will trigger an ejection by
accumulation with prior displace-
ment.

During every cleaning cycle the

pressure at PT1 must drop because
there is no flow at all. In case the
pressure does not drop the alam
"PT1 monitoring" will be released.

45 Mechanical Equipment / Westfalia Separator

 UNITROL LO -01/96-: SMS mode

During idle running (bowl is spinning

LO
at nominal speed but the feedvalve
is in position "circulation") there
V5 PT1 must be no SMS pressure at the
WM PT2 PT2. Otherwise this indicates a
leakage at the filling water valve or
V6
feed valve or clean oil discharge
non-return valve. The alarm "SMS
Sensor active in idle run" will be
released.
In order to avoid overheating of the
bowl Timer T39 Separator off after
idle run will stop the separator
when running idle automatically. The
alarm "Sep. motor off" will be
released.

46 Mechanical Equipment / Westfalia Separator

Many Thanks for Your Attention!

Mechanical Equipment / Westfalia Separator