Westfalia Basic Training 1

Westfalia Separator
(S.E.A.) Pte Ltd Diagram of installation

Mechanical Separation
Stuffing box oil

Fuel
Settl.
tank Service
tank
Sludge Sludge tank
HFO - Sludge tank LO - Sludge tank
Lube oil Bilge water
26.04.2007 Novic Samillano, Service Dept.,

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Installation: "SINGLE MODE"

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Installation: "SINGLE MODE"
CU – Compact Unit

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Diagram of installation - HFO
settling Fuels like Heavy Fuel Oil or Diesel

tank service Oil will be kept in a settling tank
tank for a certain time. The water
accumulated on the bottom of the
tank will be drained by the
operator as a routine work.
The suction of the feed pump is

from the settling tank. The
discharge of the separator is to the
service tank.
* Installation may have an
overflow pipe from the service
tank to settling tank to eliminate
frequent shutdown of the
separator.
HFO – sludge tank

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Diagram of installation - LO
The treatment of Luboil is different: LO

is always treated in a bypass mode:
just a small amount of oil will be
treated by the separator. The total oil
content of the sump will be circulated
several times per day.
These so called circulation number

depends on the type of diesel engine
(four or two stroke) and the diesel
engine makers requirements.
The circulation number of 4-stroke

engines is higher than 2-stroke
engines.
LO - sludgetank
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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd The Separator
Separators are being used to clean liquids respectively liquid

mixtures. Our field of application is to treat mainly Heavy
Fuel Oil, Dieseloil and Luboil as well as Bilge water.
Beside solid particles the water must be removed from the

oil or the oil from the water.
Heavy Fuel Oil - HFO

Dieseloil - DO Bilge water
Luboil - LO

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd The Sedimentation
In a stationary settling tank liquids of different densities

along with the solids will form a deposit above each other
after a certain settling time. This is called as Sedimentation.
Because the density of the solids are higher compared to
water the solids will sink much faster to the tank bottom. The
liquid with the lowest density will float on top after a while:
the oil.
dirty oil in a settling tank a few hours later …

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd sedimentation surface area, path
The sedimentation becomes more effective

with a higher clarification surface area and
a smaller sedimentation path.
The design of the settling tank 1 is much
better compared to tank 2 with regard to
the clarification efficiency.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd The Sedimentation, g-force
In a separator the sedimentation will take place much faster

due to the high bowl speed. As the unit of measurement of
the field of gravity, "times g-force" is being used.
g-force g-force

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd g-force
The maximum g-force of a bowl depends on the diameter of

the bowl and the bowl speed and is limited mainly by the
bowl material (stainless steel) itself. The separator type OSD6
is the one with the highest bowl speed (n = 12.000 1/min).
The maximum g-force is about 20.000 times force of gravity.
The bowl of the OSD18 rotates with n = 11.500 1/min. The g-
force is with 22.000 even higher because of the bigger
diameter.
2
( 2 ⋅ π ⋅ n) ⋅ r
ξ=
9.81 ⋅ 3600
n = bowl speed [1/min]
r = bowl radius [m]
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WS Singapore
Westfalia Separator
Separators will be, beside the product which is being

treated, subdevided into the design of the drive and the
bowl:
1. flatbelt drive or gear drive

2. self-cleaning or non-self cleaning (solid wall bowl)
gear
flatbelt

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WS Singapore
Westfalia Separator
hood
bowl
frame
vertical shaft
horizontal shaft
electric motor worm wheel

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd The Separator, The bowl
In a centrifugal Separator different densities

are being utilized to discharge the liquids /
solids from each other by centrifugal force
CS PSL in a fast rotating bowl.

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WS Singapore
Westfalia Separator
1 separator frame
2 bowl – hydraulic
system
3 centripetal pumps
4 drive: clutch, flat belt
5 hood
6 electric motor
7 brake
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WS Singapore
Westfalia Separator

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Clarification, Purification
The removal of solids from the oil is called as clarification.

The removal of water and solids is called as purification.
Purifier Clarifier
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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Bowl

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd bowl: the disk stack
The disk stack is acting like a very high number

of flat shallow settling tanks above each other.
There are spacers on top of each disk acting as
distance pieces. Because of the short
sedimentation path a disk stack separators are
very efficient. The dirty oil will enter the disk
stack from the outer diameter. The clean oil is
being discharged in the center.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd bowl: the disk stack
The solids will be collected on the upper wall of each inter-

space and slide down to the sludge holding space of the
bowl. Because of that the bottom surface must not be
scratched nor suffering on scaling as this will result in
reduced efficiency. The bottom side of disks are super finish
polished by factory.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd bowl: centripetal pump
Centripetal pumps are

non-rotating Impeller
tightly connected with
the separator hood.
Centripetal pumps turns
rotation of the liquid
into delivery height
(pressure). Because of
that the clean oil can be
discharged to the service
tank without additional
transfer pump.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd bowl: centripetal pump
Centripetal pumps are acting as transfer pumps. Because of

that the separator motor current during separation is much
higher compared to no-load operation.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd The self-cleaning Separator
Today, almost only self-cleaning

separators are installed. The entire
process will be monitored and
CS PSL
observed by a control cabinet and a
timing unit.
The solids (sludge) collected in the
sludge holding space of bowl will be
discharged in regular intervalls.
When doing so the separation
process will be interrupted for the
cleaning cycle. The sludge discharge
ports in the bowl bottom will be
opened at full bowl speed.
OSA, OSB, OSC, OSD

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Separator Typ VARIZONE
dirty water
clean oil discharge
dirty oil

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WS Singapore
Westfalia Separator
Prior to each ejection the

feedvalve will switch over
to circulation mode: from
tank to tank.
In order to displace the

clean oil out of the bowl
fresh water will be added
to the bowl timer
controlled.
Before the ejection the

bowl is filled with water.
OSA, OSB
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WS Singapore
Westfalia Separator
There is a closing chamber

above and a opening
chamber below the
sliding piston.
During ejection both

chambers are filled with
water timer controlled.
The pressure in both
chambers is the same
but the surface area
of the opening
chamber is bigger.
Because of that the
opening force is higher
than the closing force. OSA, OSB
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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Ejection
After total ejection bowl is empty. The product in the bowl creates a
The sliding piston as well as the certain pressure to force the sliding
annular piston are in the sealing piston down. The pressure from the
position. The water impulse is to re- closing chamber is higher (density,
fill the closing water chamber surface) and keeps the bowl closed.

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WS Singapore
Westfalia Separator

After the operating water solenoid is As soon as the opening water chamber
activated for ejection the closing is filled the annular piston will be lifted.
water chamber will be filled at first The closing water will flow into the
to overflow. After that water will fill „hydro-stop“ chamber and the sliding
the opening chamber . piston will move down .

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WS Singapore
Westfalia Separator
The backpressure from the hydro-stop The hydro-stop chamber runs empty
chamber into the closing water and the annular piston comes down
chamber will close the bowl. The slowly to sealing position. To obtain
annular piston is still lifted. The proper filled closing water chamber
opening water chamber runs empty. the water impulse is necessary.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Bowl: the separation line
The position of the interface

in between oil and water in
the bowl is called as
separation line.
Ideally the separation line
should be adjusted to the
outer diameter of the disk
stack: the entire clarification
surface area will clean the oil.
This will result in best separa-
tion efficiency and minimum
oil losses.
The separation line will move
in or out in case the density
of the oil changes.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd The separation efficiency
Besides on the general condition of the separator skid, the

separation efficiency of a separator depends upon on the:
- density and micron size of the solid particles
- viscosity and density of the oil
- clarification surface area of bowl disk stack
- g-force of the bowl
- flowrate

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd The separation efficiency
Water which is emulsified or in suspension cannot be

discharged from the oil. Solid particles which are in solution
with the oil and/or of the same density as the oil and/or of
very small micron size cannot be discharged by means of a
centrifugal separator.
In case the amount of water cannot not be reduced the

position of the separation line needs to be checked.
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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Efficiency, separation temperature
The main factor with regard to the efficiency is the separation

temperature because the temperature is effecting the density
as well as the viscosity of the oil.
If no order-specific operating data sheet is available, the
separators must be operated as mentioned below:
The efficency will drop down in case the oil is too cold.
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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd VARIZONE: maximum densities
Based on the fact that Heavy Fuel Oil – HFO may have
densities clearly above 0.991 kg/dm³ @ 15 °C a regulating
ring does not work but the UNITROL System only. UNITROL
is todays state of the art technology for HFO treatment. Oil
with a density above 1.01 kg/dm³ @ 15 °C cannot be treated
with an centrifugal separator in purifier mode.
CS PSL
VARIZONE -91- UNITROL -0136-

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd VARIZONE and UNITROL
HFO of a density in between 0.991 und 1.01 kg/dm³ is a so

called "high density oil". To treat HFO is much more difficult
compared to light oils: the process, the timing unit, the soft-
ware, the supervisory and monitoring equipment is more
sophisticated.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd UNITROL-System
WSM separators running with UNITROL are designated with

-0136- resp. -0196-. Both systems are a combination of the
Water Monitoring System –WMS- with the Sludge Monitoring
System -SMS- but in different ways.
-0136-: UNITROL for HFO

-0196-: UNITROL for LO

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd UNITROL HFO -0136-
HFO-UNITROL -0136-: always two centripetal pumps ! One is

discharging the clean oil. The second one circulates a certain
amount of sensing liquid from the bowl to the conductivity
sensor (CS) at the hood. The conductivity of oil and water is
different. Oil will be discharged back into the dirty oil feed.
Water is discharged to the dirty water discharge. These
process is called Water Monitoring System –WMS 01-

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WS Singapore
Westfalia Separator
HFO When running UNITROL -0136- there

is no need for filling water at all. The
bowl is empty before being filled
CS PSL with dirty oil.
The circulation valve is open every
minute for 15 sec timer controlled.
During that time the sensing liquid
will be circulated by WMS.
It will take some time until the WMS
will discharge water after de-sludging
because the bowl needs to be filled
with dirty water.
A pressure switch monitors the
sensing liquid pressure.

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WS Singapore
Westfalia Separator
HFO After a certain time the dirty

water accumulated in the bowl
will reach the CS. Controlled by
CS PSL the signal of the CS the dirty
water will be discharged by a
water discharge valve.
Once that the CS detects oil
again the discharge will stop
without delay.
The maxium period of the water
discharge is controlled by timer.

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WS Singapore
Westfalia Separator
In case the sludge holding space is

HFO
filled with solids up to the
position of the two control holes
CS PSL in the separation disk the sensing
liquid pressure will drop down.
The timing unit will trigger an
ejection by Sludge Monitoring
System –SMS-36-.

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WS Singapore
Westfalia Separator
In UNITROL HFO -0136-

mode the WMS and SMS
are running in parallel.
timing
In case the sensing unit
liquid pressure
drops down (SMS)
within a moni-
toring time after
the last cleaning
cycle an correspon-
ding alarm will be
given by timing unit.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd UNITROL LO -0196-
LO When running UNITROL

-0196- for LO the WMS
and the SMS are
CS PS activated by timer one
after the other.
After the ejection the
bowl is empty and the
bowl is spinning at
nominal speed. There is
no signal from the
Conductivity Sensor (CS)
as well as no signal from
the Pressure Switch (PS)
in the dirty water
discharge.

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WS Singapore
Westfalia Separator
LO FILLING: the bowl will be

filled with water timer
controlled. The signal of
CS PS
the pressure switch will
override the timer. The
water is acting as a
water seal.

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WS Singapore
Westfalia Separator
LO WMS mode: the separation

line is being adjusted by
means of a regulating ring.
CS PS
During normal operation
there is no signal from the CS
neither the PS.
The dirty water will be
discharged continiously and
the water discharge valve is
open.
The separator is running in
mode WMS controlled by
Timer 32.

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WS Singapore
Westfalia Separator
LO SMS mode: after the WMS

mode is over by timer the SMS
mode will be activa-ted. Timer
CS PS 33 starts to run. Both the
water discharge valve as well
as circulation valve are closed.
After a waiting time water
will be added controlled by
timer and counter. This is to
check whether the sludge
holding space is filled up with
solids or not. If not the signal
of the PS will turn from "0" to
"1".

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WS Singapore
Westfalia Separator
LO
SMS mode: In case there is
no "1" signal at the PS
neither CS after the water
CS PS
injection an ejection will be
triggered by SMS: the sludge
holding space is filled up
with solids.
The SMS signal of the
pressure switch will override
the timer T20 (time between
two cleaning cycles). !!!This
is to be considered when
doing visual inspection of
the separator in operation.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Ejection monitoring
LO The ejection monitoring

system is utilizing the
separator motor current
CS PS to check whether the
ejection were properly or
not. During the ejection
itself the bowl speed will
drop down. In case the
spike in the current is too
low or will be detected
too late an corresponding
alarm will be given by
timing unit.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd motor current characteristic
1. separator motor start

2. feedvalve open
3. feedvalve closed
4. operating water v/v open
5. feedvalve open
winding up time separation
1 2 3 4 5
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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd motor current characteristic, clutch
The ejection monitoring system is just monitoring the spike

of the motor current. In case the ejection took place but
there is no spike at all the clutch needs to be checked along
with clutch shoes and flat belt. Impurities will cause a
slipping belt.
1: separator-motor
2: clutch
3: flatbelt
4: spindle with bowl

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd clutch
It will take some time to reach to nominal speed because of

the high inertia and weight of the bowl. As bigger the
diameter and the weight of the bowl as longer the winding
up time. As higher the torque to be transmitted as higher
the number of clutch shoes.
OSD6: electric motor

3 kW 4 kW
50 Hz 60 Hz 50 Hz 60 Hz
number of clutch shoes
3 2 4 3

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Clutch

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd clutch, clutch shoes
The numbers of clutch shoes can be adjusted by the operator.

Too much clutch shoes will result in increased wear rate of
the worm wheel because of the too short winding up time.
Please make sure that the clutch shoes are evenly spaced as
otherwise this will cause unbalance. Please never replace
indiviual clutch shoes but always in a set.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd motor protection - PTC
During the winding up time the motor current may reach

alomst 2 times of the nominal current. Because of that an
overload relay is not suitable to protect the electric motor.
WSM separators have got PTC-feeler in each of the three
windings as sole protection: in case the temperatures
becomes too high the thermistor will stop the motor
without delay.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Belt
The design of a flatbelt drive is not too sophisticated.

Because there is no horizontal shaft a belt driven separator
requires always an external feedpump unit.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Belt
For each separator a set of gear parts for 50 Hz and 60 Hz is

available. In addition to that a gear with reduced speed is
available as an option sometimes. This is to be considered
when ordering spare parts. For example the separator type
OSD18 is available with two different bowl speeds for 50 Hz
as well as 60 Hz.
Attention ! The bowl rotates with overspeed in case a 50 Hz

drive will be operated on 60 Hz. Danger !

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd maintenance schedule
In the relavent Instruction Manual of the separator the

recommended maintance intervalls are mentioned. WSM
recommends that the operator should maintain (cleaning,
inspection …) his machine in regular intervals as specified.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd Lubrication oil

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Westfalia Separator

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Westfalia Separator

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Westfalia Separator

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd The bowl
The bowls are balanced in the factory at

the balancing rim on the bowl top as
well as bowl bottom.
It may become necessary to send the
bowl for re-balancing after replacing
certain bowl parts.
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WS Singapore
Westfalia Separator
Left hand thread !
Beside the separator motor and clutch the bowl might by a

possible reason for vibrations as a result of unbalance. The
position of the bowl parts are fixed by means of arresting
pins and "0" marks. Attention: A wrong assembled bowl will
cause unbalance. Danger !
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WS Singapore
Westfalia Separator
To avoid unbalance of bowl as a result of the interchange of

bowl parts the bowl serial number is punched an all critical
bowl parts. Those parts are not available as spare parts. The
exchange on site must be carried our by WSM certified Field
Service Engineer.
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WS Singapore
Westfalia Separator
In case the bowl rotates for a longer

period of time without product this
will result in bowl overheating due
to friction on air in the frame.
Overheating is a very serious
problem because the bowl as well
as bowl gasket material, bowl
speed, tolerances of bowl parts etc.
it all depends on the operating
temperature.
Overheating quite often means the

total loss of the bowl. WSM keeps a
certain number of loan / exchange
bowl in stock. A repair is possible in
max. 30 min one of our certified workshops.
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WS Singapore
Westfalia Separator
Clean and wipe dry the spindle cone as well as the bowl hub
with a cloth. Do not grease the cone parts as this will result
in bowl damages.

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd List of alarms
Alarm 01 – Motor protection

Alarm 02 – PAL clean oil discharge
Alarm 03 – PAH clean oil discharge
Alarm 05 – TAL oil feed
Alarm 06 – TAH oil feed
Alarm 07 – Ejection monitoring (current offset)
Alarm 08 – LAHH sludge tank
Alarm 09 – Feed pump fault (motor protection)
Alarm 10 – Sludge pump fault
Alarm 14 – Minimum separation time
Alarm 15 – WMS system fault
Alarm 16 – No water seal
Alarm 17 – PSL 1 monitoring
Alarm 18 – Bowl monitoring (current)
Alarm 19 – Separator motor off
Alarm 20 – SMS sensor fault

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WS Singapore
Westfalia Separator
Alarm 21 – WMS sensor fault

Alarm 22 – Excessive running time of sludge pump
Alarm 23 – WMS activated too often
Alarm 24 – SMS activated in idle run
Alarm 25 – Maintenance required
Alarm 28 – Water content >0.5%
Alarm 31 – TAL oil feed warning
Alarm 32 – TAH oil feed warning
Alarm 33 – Ejection monitoring
Alarm 34 – Bowl monitoring (speed drop)
Alarm 35 – Separator start
Alarm 36 – Belt Monitoring
Alarm 37 – Maximum speed monitoring
Alarm 38 – Minimum speed monitoring
Alarm 39 – Pressure transmitter monitoring
Alarm 40 – No water seal

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WS Singapore
Westfalia Separator
Alarm 41 – Minimum separation time (PT)

Alarm 42 – SMS sensor fault (PT)
Alarm 43 – SMS activated in idle run (PT)
Alarm 44 – PAL clean oil discharge (PT)
Alarm 45 – PAH clean oil discharge (PT)
Alarm 46 – Emergency stop

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WS Singapore
Westfalia Separator
(S.E.A.) Pte Ltd spare parts

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Westfalia Separator

(S.E.A.) Pte Ltd Diagram of installation

Stuffing box oil

Sludge Sludge tank

HFO - Sludge tank LO - Sludge tank

Lube oil Bilge water

26.04.2007 Novic Samillano, Service Dept.,

26.04.2007 Novic Samillano, Service Dept.,

26.04.2007 Novic Samillano, Service Dept.,

settling Fuels like Heavy Fuel Oil or Diesel

The suction of the feed pump is

HFO – sludge tank

26.04.2007 Novic Samillano, Service Dept.,

The treatment of Luboil is different: LO

These so called circulation number

The circulation number of 4-stroke

Separators are being used to clean liquids respectively liquid

Beside solid particles the water must be removed from the

Heavy Fuel Oil - HFO

26.04.2007 Novic Samillano, Service Dept.,

In a stationary settling tank liquids of different densities

dirty oil in a settling tank a few hours later …

26.04.2007 Novic Samillano, Service Dept.,

The sedimentation becomes more effective

26.04.2007 Novic Samillano, Service Dept.,

In a separator the sedimentation will take place much faster

26.04.2007 Novic Samillano, Service Dept.,

The maximum g-force of a bowl depends on the diameter of

Separators will be, beside the product which is being

1. flatbelt drive or gear drive

26.04.2007 Novic Samillano, Service Dept.,

electric motor worm wheel

26.04.2007 Novic Samillano, Service Dept.,

In a centrifugal Separator different densities

26.04.2007 Novic Samillano, Service Dept.,

26.04.2007 Novic Samillano, Service Dept.,

The removal of solids from the oil is called as clarification.

26.04.2007 Novic Samillano, Service Dept.,

The disk stack is acting like a very high number

26.04.2007 Novic Samillano, Service Dept.,

The solids will be collected on the upper wall of each inter-

26.04.2007 Novic Samillano, Service Dept.,

Centripetal pumps are

26.04.2007 Novic Samillano, Service Dept.,

Centripetal pumps are acting as transfer pumps. Because of

26.04.2007 Novic Samillano, Service Dept.,

Today, almost only self-cleaning

OSA, OSB, OSC, OSD

clean oil discharge

26.04.2007 Novic Samillano, Service Dept.,

Prior to each ejection the

In order to displace the

Before the ejection the

There is a closing chamber

During ejection both

26.04.2007 Novic Samillano, Service Dept.,

26.04.2007 Novic Samillano, Service Dept.,

26.04.2007 Novic Samillano, Service Dept.,

The position of the interface

26.04.2007 Novic Samillano, Service Dept.,

Besides on the general condition of the separator skid, the

26.04.2007 Novic Samillano, Service Dept.,

Water which is emulsified or in suspension cannot be

In case the amount of water cannot not be reduced the