Technical Training

electric and instruments

Wärtsilä %DQJladHVK /WG

Project Kodda, Bangladesh

GEA Mechanical Equipment / GEA Westfalia Separator Group GmbH

1 Mechanical Equipment / Westfalia Separator

 GEA Westfalia Separator Group GmbH
technical training: electric and instruments
Ronald Eschmann, Service Centre Hamburg

1. electrical equipment - general layout plan

2. CS capacity sensor = water meter WMS
3. feed valve in dirty oil feed: V1+V4
4. water valves: V2+V3
5. UNITROL valves: V5+V6
6. temperature element: TE1+TE2 (Pt100)
7. SE: speed monitoring
8. motor current: IAL+TAH
9. ejection monitoring system
10. pressure transmitter: PT1 + PT2
11. pressure transmitter: PT4+V7
12. adjustments and setpoints
13. error messages and trouble shooting

2 Mechanical Equipment / Westfalia Separator

electrical equipment - general layout plan

V1 feed valve in dirty oil feed V06

V2 filling+displacement water valve V27
V3 operating water valve V27
V4 throttle valve in dirty oil feed V06
V5 UNITROL: circulation valve V62
V6 UNITROL: water discharge valve V61
V7 clean oil discharge: check valve V12
TE1 temperature element: steam valve T01
TE2 temperature element: temp. alarms T01
PT1 clean oil discharge pressure P12
PT2 UNITROL pressure (SMS) P61
PT4 dirty oil feed: feed pressure  feed rate Q01
SE speed element: speed monitoring
IAL motor current: ejection monitoring
CS capacity sensor = water meter WMS K61

3 Mechanical Equipment / Westfalia Separator

CS capacity sensor = water meter WMS

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CS capacity sensor = water meter WMS

water meter

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CS capacity sensor = water meter WMS

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CS capacity sensor = water meter WMS

The water meter (WM)

controls the water content of
the product (HFO or LO).

"false" = oil

"true" = water

The alarm "WMS system

fault – high water content"
will be released in case the
signal at input E0.5 is
„water“ for longer than the
monitoring time Timer T22
„high water content“.

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CS capacity sensor = water meter WMS

The water meter (WM)

controls the water content of
the product (HFO or LO).

"false" = oil

"true" = water

The alarm "WMS system

fault – high water content"
will be released in case the
signal at input E0.5 is
„water“ for longer than the
monitoring time Timer T22
„high water content“.

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feed valve in dirty oil feed: V1+V4

Each separator skid is equipped

with a slow acting feed valve.
The feed valve is spring loaded
in position „circulation“. The feed
valve is controlled straight by the
PLC and actuated with instru-
ment air: the air pressure will
override the spring tension and
V4
the valve will switch over to
"separation". In case of an alarm
the feed valve will switch over to
"circulation" again.

HFO: there is no need to throttle the feed rate by means of V4

because the supply pump is speed controlled. V4 needs to be
kept fully open.
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feed valve in dirty oil feed: V1+V4

including:
- pilot solenoid valve
- throttle valve (V4)
- double Pt100 (TE1+TE2)
- check valve
- flow indicator (PT4)

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 feed valve in dirty oil feed: V1+V4

* DN25: with 0.5 mm flow restriction in air supply

DN50: without flow restriction in air supply pilot solenoid valve* with
manual override

3/2 way feed

valve assy. (V1) throttle valve (V4)

double Pt100
to separator (TE1+TE2)

integrated from pump / heater

non-return valve
return to tank
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feed valve in dirty oil feed: V1+V4

position position
manual override
circulation separation

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feed valve in dirty oil feed: V1+V4

manual override

remove plastic cap and turn threaded piece clockwise approx. 10 mm

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feed valve in dirty oil feed: V1+V4

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feed valve in dirty oil feed: V1

PLC: digital outputs

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water valves: V2+V3

solenoid valve block with integrated water pressure reducer

There are two water solenoid valves at each self cleaning separator:
for filling + displacement water (V2) as well as for operating water
(V3). The valves must by fast acting (response time approx. 0.1 sec)
because of the "safety water impulse": water will be sprayed controlled
by Timer T06 into the closing water chamber of bowl in order to
compensate closing water losses over the course of time. In case the
amount of water sprayed is to too much the bowl will carry out an
ejection accidently. The alarm „bowl monitoring“ will come up.
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 water valves: V2+V3

24 VDC

valve closed valve open

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water valves: V2+V3

V2: filling + displacement

manual override

water pressure
reducer
V3: operating water

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water valves: V2+V3

PLC: digital outputs

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water valves: V2+V3

pressure setpoint correction:

pressure setpoint too low:

- increase the pressure by turning
the screw clockwise

pressure setpoint too high:

- decrease the setpoint by turning
the screw counterclockwise

The operating water pressure is

indicated at gauge pos. 30 and
should be around 2.0 bar when the
operating water valve is open.

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UNITROL valves: V5+V6

The UNITROL separators are

equipped with two identical 2/2 way
valves on top of the hood: the
V5 PT1
WM PT2 circulation valve (V5) as well as the
water discharge valve (V6). Both
V6
are controlled straight by the PLC:
The circulation valve is open for 15
sec every minute (Timer T15 +
T16). The water discharge valve is
controlled by the signal of the water
meter.

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UNITROL valves: V5+V6

main components:

1 diaphragm
(0018-5545-830)
2 coupler socket
3 manual override

A closed
B open

The solenoid valve is a 2/2-way diaphragm straight-way valve

with internal piloting.
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UNITROL valves: V5+V6

V5: circulation valve

V6: water discharge valve

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UNITROL valves: V5+V6

PLC: digital outputs

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temperature element: TE1+TE2 (Pt100)

two temperature elements TE in one thermowell

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temperature element: TE1+TE2 (Pt100)

PLC E40: PEW758I = temperature

signal for the PID controller: Pt100 with
PLC: analogue inputs transmitter T2 p/n: 0005-3482-060
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temperature element: TE1+TE2 (Pt100)

120
95
105
85
5

2.00

95

At temperatures +/- 10 ° of setpoint

alarms "TAH / TAL oil feed" will be
released.
At temperatures +/- 5 ° of setpoint
warnings "TAH / TAL oil feed
PEW760 = for signal TAH + TAL warning" will be released.
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SE: speed monitoring

The spindle (1) generates speed pulses at the proximity switch.

The proximity switch (2) transmits the pulses to the control unit
(3). The control unit evaluates the speed pulses.

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SE: speed monitoring

After the separator motor has been started the PLC monitors the start-
up time of the bowl by timer T10 “Separator starting”. Within the first
30 sec after starting a speed signal must be indicated (> 30 rpm) as
otherwise the alarm “Belt monitoring - drive belt broken during
start up” will come up and the motor is being switched OFF. If a
speed signal is being indicated within this 30 sec the bowl will run up
to nominal speed. The signal “minimum speed” will override T10
"starting time". In case that start-up takes longer than T10 the alarm
“Separator-Start monitoring during Timer 10” will come up and the
motor is being switched OFF.

During separation, the minimum and maximum speed is monitored

(alarms "MIN / MAX speed monitoring"). There is an internal delay
time of 5 sec in order to avoid ghost alarms. Speed deviations of up to
5 % are permissible. In case the speed will reach the minimum resp.
maximum setpoint during operation the PLC will trigger an ejection.
The separator motor is being switched OFF.
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SE: speed monitoring

Align the proximity

switch as illustrated. The
speed sensor must be
aligned horizontally. The
sensor must be aligned
centrally to the central
axis of the spindle. The
distance X between the
spindle and the proximity
switch must be 3.5 mm.

The sensor head must

be centered (distance II
= II) to the contact
surface of the spindle.

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SE: speed monitoring

T2: p/n 0005-4509-000

sensor-power amplifier terminals
(pulse converter) type KCD 2-E2

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SE: speed monitoring

there are two pulses

per revolution

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motor current: IAL+TAH

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motor current: IAL+TAH

winding up time separation

separator motor characteristic: starting and separation

34 Mechanical Equipment / Westfalia Separator
motor current: IAL+TAH

Because of the high inertia and high speed of the bowl,

separators have a long acceleration time. The current during
acceleration exceeds the rated current for a few minutes. It is not
possible to protect the motor with an overload relay or equivalent
because it has to be by-passed during acceleration. The motors
used by GEA Westfalia Separator for separators with starting
clutch are equiped with PTC-thermistors for sole protection. In
this case the winding temperature of the motor is used as the
switch off criterion. When the thermistors are connected to a
tripping device, the motor is protected against unallowable high
winding temperature caused by overload during acceleration and
operation, single-phasing, excessive voltage fluctuation,
excessive coolant temperature or reduced cooling air flow.

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motor current: IAL+TAH

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ejection monitoring system

winding up time separation cleaning cycle

The bowl speed will drop during ejection causing a spike in the motor
current because of the additional torque to the separator motor. This
spike is being utilized by the ejection monitoring system.
37 Mechanical Equipment / Westfalia Separator
ejection monitoring system: speed signal

The ejection monitoring system

will check the speed dip or the
spike in the motor current
controlled by monitoring timer

bowl speed
motor current
T28 ejection monitor.

The bowl speed must drop by

more than 100 rpm within T28
as otherwise the alarm
"ejection monitoring" will
come up.

The alarm "bowl monitoring"

will come up in case there is
speed dip > 100 rpm during cleaning cycle
T06 "safety water impulse".
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ejection monitoring system: speed signal

7000
6300

6800 100

20 A
100

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ejection monitoring system: current signal

In case „speed monitoring“ is

not available the motor current
will take over: the spike during
ejection must exceed e.g. 1,5 A

bowl speed
motor current
(setpoint is separator specific!).
The software will check the
motor current before and after
the ejection.

The caluclated difference must

exceed the setpoint within T28
as otherwise the alarm "IAL -
ejection monitoring" will
come up.
cleaning cycle

40 Mechanical Equipment / Westfalia Separator

ejection monitoring system: current signal

The motor current will be transformed first into a 0 ... 1 A signal

and finally into a 4 … 20 mA signal.

PEW 752

1 motor starter with current transformer 1T1

2 current transmitter 1U3
3 analogue input AI of PLC
41 Mechanical Equipment / Westfalia Separator
ejection monitoring system: current signal

The motor current will be transformed first into a 0 ... 1 A signal

and finally into a 4 … 20 mA signal.
1U3: current transducer p/n 0005-3482-070

42 Mechanical Equipment / Westfalia Separator

ejection monitoring system: current signal

The motor current will be transformed first into a 0 ... 1 A signal

and finally into a 4 … 20 mA signal.
1U3: current transducer p/n 0005-3482-070

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pressure transmitter: PT1 + PT2

V5 PT1
WM PT2

V6

Each Separator is equipped with two pressure transmitter: PT1

monitors the clean oil discharge pressure. PT2 monitors the
UNITROL pressure (Sludge Monitoring System).

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pressure transmitter: PT1 + PT2

PT1: discharge pressure transmitter

PT2: SMS pressure transmitter

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pressure transmitter: PT1 + PT2

1.5 m cable
16 bar = 20 mA

p/n:
0005-1529-300

PLC: analogue inputs

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pressure transmitter: PT1 + PT2

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pressure transmitter: PT1 + PT2

48 Mechanical Equipment / Westfalia Separator

pressure transmitter: PT1 + PT2

20.0

2.0
1.0
3.0

4.5
1.0

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pressure transmitter: PT4+V7

10 m cable
16 bar = 20 mA

p/n:
0005-1533-300

V7

A set of orifice plates (Pos. 1) will be delivered along with the

separator. The commissioning engineer needs to fit the correct
orifice plate as per the contract flow rate in accordance to a
individual table in the manual. The PT4 (Pos. 2) monitors the feed
pressure. The software calculates a feed rate based on the feed
pressure. V7 is a check valve (NRV) in the clean oil discharge.
50 Mechanical Equipment / Westfalia Separator
pressure transmitter: PT4

The required orifice plate inner diameter for the various throughput
capacities (feed rates) can be taken from the following table:

The table above has been taken from the manual of OSE80.
Please check the individual manual.
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pressure transmitter: PT4

PLC type E40: the feed rate will be displayed in the screen and in
the analog input list utilising the PT4 and appropriate software.

52 Mechanical Equipment / Westfalia Separator

pressure transmitter: PT4

The PT4 needs to be fitted at the feed valve.

53 Mechanical Equipment / Westfalia Separator

pressure transmitter: PT4

To activate the indication of the feed rate the option “flow metering”
needs to be set to “ON” in the configuration list 3. A new directory
will appear.

54 Mechanical Equipment / Westfalia Separator

adjustments and setpoints - HFO

Temperature Controller TC 98°C (Sep. temp.)

Temperature alarm low - warning TAL 93°C
Temperature alarm low TAL 88°C
Temperature alarm high - warning TAH 103°C
Temperature alarm high TAH 108°C
Water pressure reducer PC 2 bar g @ open valve
Compressed air pressure PC 3.0 bar g
PT1 clean oil discharge PAL 1.0 bar g
PT1 clean oil discharge PAH 3.0 bar g
PT2 Sludge Monitoring System PSH 1.0 bar g

55 Mechanical Equipment / Westfalia Separator

adjustments and setpoints - LO

Temperature Controller TC 95°C (Sep. temp.)

Temperature alarm low - warning TAL 90°C
Temperature alarm low TAL 85°C
Temperature alarm high - warning TAH 100°C
Temperature alarm high TAH 105°C
Water pressure reducer PC 2 bar g @ open valve
Compressed air pressure PC 3.0 bar g
PT1 clean oil discharge PAL 1.0 bar g
PT1 clean oil discharge PAH 3.0 bar g
PT2 Sludge Monitoring System PSH 0.5 bar g

56 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: MOTOR-PROTECTION

Temp. > max. °C

Motor shut off

Help informations:
Please check:
> fuses / circuit breaker in motor starter
> thermistor relay (1F01)
> clutch (slipping friction pads?)
> correct numbers of friction pads
> brake relased?
> bowl hydraulic system (bowl closed?)
> motor current (check at am-meter)
57 Mechanical Equipment / Westfalia Separator
error messages – trouble shooting

alarm: PAL-CLEANOIL-OUTLET

pressure < 1.0 bar

Separation stop

Help informations:
Please check:
> clean oil back pressure (PT1)
> dirty oil feed rate
> feedpump operation / clutch of feedpump
> leaking of closing water (bowl closed?)
> function of pressure switch PAL cleanoil
> setting Timer T06 "closing water impulse"
> amount of operating water / water pressure
58 Mechanical Equipment / Westfalia Separator
error messages – trouble shooting

alarm: PAH-CLEANOIL-OUTLET

pressure > 3.0 bar

Separation stop

Help informations:
Please check:
> clean oil back pressure / dirty oil feed rate
> feed pump speed (variable speed drive)
> separation temperature
> function of pressure switch PAH clean oil

59 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: FAH-WATER-OUTLET

Flow too high

Separation stop

Help informations:
Please check:
> clean oil back pressure / dirty oil feed rate
> amount of filling water (water seal)
> leakages at the polyamid gasket (water seal)
> amount of operating water / water pressure
> setting of Timer T06 "closing water impulse"
> sense of bowl rotation / bowl height
> condition of operating water solenoid valve
60 Mechanical Equipment / Westfalia Separator
error messages – trouble shooting

alarm: TAL-PRODUCT-FEED

Temp. min: < Setpoint

Separation stop

Help informations:
Please check:
> setpoint TAL in analogue input list
> temp. indicator in dirt yoil feed
> function of pre-heating system
> function of temperature element
> feed rate

61 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: TAH-PRODUCT-FEED

Temp. max: > Setpoint

Separation stop

Help informations:
Please check:
> setpoint TAH in analogue input list
> temp. indicator in dirty oil feed
> function of temperature controller
> function of temperature element
> feed rate
> function of feedpump

62 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: EJECTION MONITOR

current < Setpoint

Separation stop

Help informations:
Please check:
> ejections ("bang" and current spike)
> setpoint of ejection monitor system (AI)
> increase T28 monitoring timer to 5.0 sec
> amount of operating water / water pressure
> condition of clutch shoes and belt
> lower lower section of frame (oil mist?)
> function of bowl (condition of bowl gaskets)
63 Mechanical Equipment / Westfalia Separator
error messages – trouble shooting

alarm: LSHH - SLUDGETANK

level-high-high
Separation stop

Help informations:
Please check:
> function of sludge pump
> function of level switch
> sense of bowl rotation / bowl height
> sludge tank venting
> leakages at sludge discharge
> cleanoil back pressure (PT1)

64 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: FEEDPUMP

Motor-protection
pump out of order

Help informations:
Please check:
> fuses / circuit breaker in motorstarter
> function of pump and motor
> motor temperature / motor current
> isolation valves in inlet / outlet
> function of pressure relief valve
> sense of rotation

65 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: SLUDGEPUMP

Motor-protection
pump out of order

Help informations:
Please check:
> fuses / circuit breaker in motorstarter
> function of pump and motor
> motor temperature / motor current

66 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: VIBRATION STAGE 1

Vibration > 4.5 mm/s

start ejection program

Help informations:
Please check:
> ejections ("bang" and current spike)
> amount of operating water / water pressure
> reduce T20 "separation"
> reduce counter C00 "flushing"
> adjustment / function of vibration monitor
> correct bowl assembly
> one-sided sludge accumulation?
67 Mechanical Equipment / Westfalia Separator
error messages – trouble shooting

alarm: VIBRATION STAGE 2

Vibration > 7.0 mm/s

Motor OFF

Help informations:
Please check:
> ejections ("bang" and current spike)
> amount of operating water / water pressure
> adjustment / function of vibration monitor
> correct bowl assembly
> check for noises (bearing damage)

68 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: SERIES MODE FAILURE

connection / pre-set failure

Help informations:
Please check:
> key „SERIES 1<=>2“ on both timing units
> MPI-cables / plugs on both timing units
> both separators in „Ready for operation“

69 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: MIN. SEPARATION TIME < 10 min

high water content

Help informations:
Please check:
> water content in dirty oil feed
> leakages at filling water valve?
> spindle misalignment
> adjustment / function of PT2 (SMS)
> setting of timer T21 "min. sep. time": 600 sec
> flow control hole in centripetal pump cover

70 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: WMS - alarm high water content

WMS-SYSTEM NOT OK
high water during Timer 22

Help informations:
Please check:
> WMS-signal (DI 0.5)
> adjustment / function of measuring relay
> function of CS (water meter)
> leakages at filling water valve?
> function of water discharge valve
> setting of timer T22 "high water" HFO: 180 s
> setting of timer T22 "high water" LO: 10 s
71 Mechanical Equipment / Westfalia Separator
error messages – trouble shooting

alarm: Water seal broken during Timer 35

SMS- FUNCTION NOT OK

Help informations:
Please check:
> clean oil back pressure / dirty oil feed rate
> amount of filling water (water seal)
> leaking of closing water (bowl closed?)
> leakages at the polyamid gasket (water seal)
> amount of operating water / water pressure
> setting of Timer T06 "closing water impulse"
> sense of bowl rotation / bowl height
72 Mechanical Equipment / Westfalia Separator
error messages – trouble shooting

alarm: PT1 monitoring

Cleanoil outlet pressure

no dip during discharge

Help informations:
Please check:
> function of cleanoil check valve
> function of feedvalve
> function of PT1 (clean oil discharge)

73 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: Bowl monitoring

Closing water impulse T06

Help informations:
Please check:
> amount of operating water / water pressure
> setting of Timer T06 "closing water impulse"
> setpoint of bowl monitoring system (AI)
> condition of operating water solenoid valve

74 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: Separator off

Separator off function active T39

(no ACK after alarm raised)

Help informations:
Please check:
> setting of T39 "Separator off after idle run"
> factory setting: T39 = 1800 sec

75 Mechanical Equipment / Westfalia Separator

error messages – trouble shooting

alarm: SMS sensor active

SMS sensor active

in idle operation

Help informations:
Please check:
> function of pressure transmitter PT2
> leakages at filling water valve?
> feed valve in position "circulation" ?
> function of check valve in cleanoil discharge

76 Mechanical Equipment / Westfalia Separator

Many Thanks for Your Attention!

Mechanical Equipment / Westfalia Separator