Westfalia Separator® seaprotectsolutions - ShipServ

Liquids to ValueWestfalia Separator ® seaprotectsolutionsFor the offshore oil industryGEA Mechanical Equipment / GEA Westfalia Separator

Protection for the MarineEnvironment and Your InvestmentWestfalia Separator ® seaprotectsolutionsProtecting the ecosystem ofthe oceans and the investmentsof rig owners and operatorsWater is the source of all life on our planet. Ifthe balance of the extreme ly sensitive ecosystemof the oceans is exposed to any danger, all othereco systems are also in great danger. This asset, whichcannot be reproduced, accordingly requires the mosteffective protection that modern technology canoffer. For this purpose, the Inter national MaritimeOrganisation (IMO) and national legislativeauthorities have issued strict laws and directivesinvolving fines running into eight digits in the eventof failure to comply even in minor cases.These justified regulations mean that mobilerigs have to cope with consi de rable costs andrisks that cannot be managed cost-effectivelywith conventional separating systems.The new Westfalia Separator ® BilgeMaster ® ,Westfalia Separator ® SludgeMaster ® and WestfaliaSeparator ® CombiMaster ® systems from GEAWestfalia Separator secure the oceans’ sensitiveecosystems extremely effectively and also provideprotection for the value of the operators investment.combined with pronounced service friendliness and,of course, the significantly reduced disposal costsassociated with the method.The systems meet the prevailing sta tutory regulationsof the IMO with a residual oil content of much lessthan 15 ppm. The systems have been awarded typeapproval according to the IMO Resolution MEPC107(49). With an additional facility, the BilgeMastercan even achieve a residual oil content of lessthan 5 ppm.The main benefits of the systems are the high separatingefficiency, continuous unmanned operation2GEA Westfalia Separator

Contents4 Overview Westfalia Separator ® seaprotectsolutions4 High Performance Equipment for the Engine Room6 Westfalia Separator ® BilgeMaster ® Systems6 Self-Cleaning Centrifugal System7 So That Our Water Stays as Nature Made It – Clean8 Technologies to Protect the Sensitive Marine Ecosystem9 The Flexible Compact Unit Design is Suitable Both forboth Newbuildings or Retrofits10 Westfalia Separator ® minimaXx ® – Manual CleaningCentrifugal System12 Westfalia Separator ® minimaXx ® – Clean and Compact14 Westfalia Separator ® SludgeMaster ® System14 Process Overview15 System Concepts for the Future16 Economical Advantages – Ecological Merits18 Drain Water19 Drain Water with High Solids Content20 The Effective Combination21 Process Overview22 Westfalia Separator ® seaprotectsolutionsfor your payback22 Systems to Protect the Sensitive Marine Ecosystemand the Value of Your Investment3GEA Westfalia Separator

High Performance Equipmentfor the Engine RoomOverview Westfalia Separator ® seaprotectsolutionsGEA Westfalia Separator offers leading technologiesand individual systems for use within the oilindustry. Be it system engineering from onesource, high quality of workmanship or the unrivalledworldwide service – GEA Westfalia Separatorprovides a system to rely on.Fuel oilservicetankFuel oil conditioning systemProduct range overviewDiesel oil dewateringCrude oil dewateringLube oil treatmentSludge treatmentBilgewater treatmentCentral cooling systemLube oil cooling systemWater desalination systemHydraulic oil treatment plantsDrain water treatmentProduced water treatmentDrilling mud decanter centrifugesSlop oil treatmentFuel oilsettingtankFuel oil treatmentFuel oilsludgetankSludge treatmentLube oilA.E.Lube oilsludgetank4GEA Westfalia Separator

Water desalination systemLube oil treatmentM.E.Bilgewater treatmenttreatmentBilgewatertank5GEA Westfalia Separator

Self-CleaningCentrifugal SystemWestfalia Separator ® BilgeMaster ® systemsWaste oil tankClean wateroverboardSeparated oilDirty bilgewaterreturnBilgewatertreatmentplantwith centrifugalseparatorUtilitiesSludgeBilgewatersystemPump systemWaste oil tankThe treatment of bilgewater on board offshorefacilities is strictly controlled by national andinternational laws.Bilgewater may only be discharged into the sea afterprior de-oiling with specially approved treatmentsystems. The maximum oil content must not exceed15 ppm. The limit has even been reduced to 5 ppmin special areas.15 ppm is too muchOily water from rig operations may only be dischargedinto the sea if the residual oil content in the effluentis below 15 ppm. 15 parts of oil to one million partsof water seems small but GEA Westfalia Separatorbelieves this is still too high. Moreover, practicehas shown that this value is not attained in manyconventional installations. The further we can reducethis value, the greater the benefit for our oceans.SteamCondensateBilgewater is a mixture of the followingconstituentsSea and cooling water leakagesOil leaks, crude, diesel and lubeDrainages from settling and sludge tanksEffluent from various cleaning processesSoot and dirt particlesMudOperatingwater6GEA Westfalia Separator

So that Our Water Stays asNature Made it – CleanThe product (i.e. oily water) is sucked up from theoily water tank drain system and fed by the feedpump through the filter and preheater via thefeed valve to the separator. During the start-up orejection program it is led back into the oily watertank. The product flows from above into the centreof the separator bowl. The heavy water phase isseparated from the finest oil particles and thenconveyed under pressure by a centripetal pump tothe discharge.The separated impurities accumulated in thesludge space are discharged into the sludge tankperiodically.The clean water discharge is supervised by an oilmonitor and discharged into the environment. Ifthe oil content exceeds 15 or 5 ppm the water isrecirculated into the oily water tank. An intelligentprocess control adapts the capacity of the system tothe changes of the product.DirtybilgewaterfeedSeparated oildischargeDirty bilgewaterreturnClean water dischargeoverboardAutomaticfilterAdsorptionfilterHeaterOilmonitorDirty bilgewaterreturnSelf-cleaningseparatorSolids discharge Dirty water discharge7GEA Westfalia Separator

Technologies to Protectthe Sensitive Marine EcosystemWestfalia Separator ® BilgeMaster ® systemsThe bilgewater treatment system is designed for useon rigs and ships.The system is supplied as a complete, self-containedWestfalia Separator ® centripack incorporating allauxiliaries necessary for trouble-free operation.Bilgewater feedThe main components of the system are:Self-cleaning centrifugal separatorFeed pumpFilterPreheaterControl panelOil monitor for 5 / 15 ppm bilge alarmsBase frame with small sludge tankor sludge transfer unitDemulsifier plant (optional)Adsorption filterClean oildischargeCleanbilgewaterBenefits of the centrifugeHigh separation efficiency due to largeclarification areaControlled de-sludging withhigh solid content due to theWestfalia Separator ® hydrostop systemGentle treatment due to theWestfalia Separator ® softstream systemContinuous separation of oil and water phaseSelf-cleaning effect of discstack due to total ejectionNo impact of the rig movementon the separation efficiencyOption: System suitable forzone 1/2 – class 1 DIV 1 or 28GEA Westfalia Separator

The Flexible Compact Unit Design isSuitable Both for Newbuildings or RetrofitSeparation results oily water treatmentWith normal feed conditions, i.e.solids content: < 0.1 %chloride content: < 10,000 ppmpH: 6 – 9and no excessive oil emulsions in the water phase, theresidual oil content in the clean water discharge is10 – 12 ppm. By varying the pump output, it is possibleto even further reduce the oil content. In the case ofhigh oil and solids contents, it is prudent to separatethe bilge water in tank cleaning mode beforedischarging overboard.GEA Westfalia Separator expands theWestfalia Separator ® BilgeMaster ® systemfrom three to nine sizes. The bilgewatertreatment system is hence now even moreprecisely tailored to actual needs.The figure shows Westfalia Separator ®BilgeMaster ® -D 3000.Technical data Westfalia Separator ® BilgeMaster ® -D 1000 1500 2000 2500 3000 4000 5000 6000 7000Separator Type WSD 8 WSD 18 WSD 35*Adsorption Type AF 220 AF 300 AF 410 AF 300 AF 410 AF 500 AF 410 AF 500 AF 610filterCapacity Effective throughput for l / h 500 – 500 – 750 – 1000 – 1000 – 1500 – 2000 – 2000 – 2500 –oily water treatment 1000 1500 2000 2500 3000 4000 5000 6000 7000Weight Module complete kg 1385 1400 1425 1475 1500 1525 2375 2400 2500Dimensions Length mm 2630 2630 2630 2780 2780 2780 3380 3380 3380Width mm 1100 1100 1100 1100 1100 1100 1500 1500 1500Height mm 1550 1550 1550 1550 1550 1550 1564 1564 1564* Also avaible as Westfalia Separator ® CombiMaster ® with a sludge capacity9GEA Westfalia Separator

Westfalia Separator ® minimaXx ® –Manual Cleaning Centrifugal SystemWestfalia Separator ® BilgeMaster ® systemsWaste oil tankClean wateroverboardSafety waterfeedSeparated oilDirty bilgewaterreturnBilgewatertreatment plantwith centrifugalseparatorBilgewater systemBilgewatersystemPump systemPlant conceptThe bilgewater treatment system will be suppliedas a ’Compact Unit’ (CU). The CU consists of fourmain components:Westfalia Separator ® minimaXx ® separatorPump / pre-filterPreheaterAdsorption filterControl unitAll the components are small and lightweightto make them easy to transport and to fit intoany space. The components are installed on acommon base frame. The modular concept can beincorporated in an existing system.10GEA Westfalia Separator

The clever solutionDirty bilgewaterfeedDirty bilgewaterreturnClean water dischargeoverboardThe new bilgewater treatment system withthe Westfalia Separator ® minimaXx ® separator typeWTC was specially designed for the rough conditionsoffshore.The product is fed by the feed pump via thepreheater into the centre of the separator bowl.Within the rotating bowl, the product is separatedinto a heavy and light phase.Feed pumpOil monitorThe heavy water phase is separated from thefinest oil droplets and dirt particles and thenconveyed under pressure by the centripetal pump to thedischarge. If the oil concentration on the clean wateroutlet of the centrifuge exceeds 15 ppm the water isled through an adsorption filter. The lighter oil phasePre-filterflows to the centre of the bowl and is dischargedby gravity.Warm waterWarm waterpreheaterThe separated sludge is collected in the solids holdingspace and must be removed by hand.An intelligent control and monitoring system assuresproblem-free, round-the-clock unmanned operation. Italso ensures that only water with an oil content lowerthan 15 ppm is re leased into the environment.AdsorptionfilterManual cleaningseparatorWaste oilcollection tank

Westfalia Separator ® minimaXx ® –Clean and CompactWestfalia Separator ® BilgeMaster ® systemsBilgewaterfeedCleanbilgewaterClean oildischarge12GEA Westfalia Separator

Separation results oily water treatmentWith normal feed conditions, i.e.solids content: < 0.1 %chloride content: < 30,000 ppmpH: 6 – 9and no excessive oil emulsions in the water phase,the residual oil content in the clean water dischargeis 10 – 12 ppm. By using the adsorption filter in theclean water discharge the residual oil content can bedropped down below 5 ppm.BenefitsWater outlet less than 5 / 15 ppmReliableEasy handlingLow maintenance costSmall dimensionsLow weightQuick return on investmentTechnical data Westfalia Separator ® BilgeMaster ® 200Separator Type WTC 2Three-phase Power kW 1.1AC motor Speed at 50 Hz min-1 3000Speed at 60 Hz min-1 3600Centripetal Light liquid phase bar –pump Heavy liquid phase bar 0.5Capacity Effective throughput foroily water treatment l / h 200Weight Module complete kg 265Dimensions Length mm 900Width mm 725Height mm 120013GEA Westfalia Separator

Process OverviewWestfalia Separator ® SludgeMaster ® systemThe trend towards burning higher viscosity andhigher density fuel oils together with an increasinglycommon usage of residuals as the fuel for mediumspeed diesel engines means that the amount ofsludge being created from both fuel and lube oilsystems is increasing.Settling tank / boiler plantRecovered oilElectrical energyRegulatingvalveHeating energySludge treatment plantwith centrifugal separatorWaterOperating waterConcentratedsludgeSteamDisposal e.g.incineratorBilgewatersystemCondensateSteamtrapFuel oil sludge tankLube oil sludge tankFeed pumpSettling tankLube oil separatorFuel oil separatorLube oil filterFuel oil filterDiesel oil separatorFilter14GEA Westfalia SeparatorOil sludge feed

Payback time of sludge treatment plantAssumptionOperating time: 300 days / yearAverage load: 85 %Sludge amount: 2.5 % fuel consumptionActual figures depending on current rates of fuel,oil process and sludge disposal costs.Payback (Years)3.02.52.0With increasing environmental awareness as wellas strict regulations and controls, most rig operatorsdispose of this sludge by incineration or by shoresidedisposal using contract companies. In either casesludge disposal is becoming an expensive problem foroff shore operatorsThe GEA Westfalia Separator sludge treatmentplant incorporating a specially designed centrifugalseparator is capable of reducing the volume of sludgefor disposal by up to 90 %. In addition, fuel oil isrecovered for re-use and recovered lubricating oil canbe used as boiler fuel.1.51.00.507500 10,000 20,000 30,000Diesel engine output (kW)Technical data Westfalia Separator ® SludgeMaster ® 300Separator Type ESD 18Three-phase Power kW 5.5AC motor Speed at 50 Hz min-1 3000Speed at 60 Hz min-1 3600Centripetal Light liquid phase bar 2.0pump Heavy liquid phase bar 2.5Capacity Effective throughput foroily water treatment l / h 300Weight Module complete kg 900Bowl kg 72Dimensions Length mm 2450Width mm 1000Height mm 1950BenefitsSaves up to 90 % disposal costsRecovers valuable fuel oilUnburdens the bilgewatersystem from oil residuesProtects our sensitive marine ecosystem17GEA Westfalia Separator

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Separation ofsolids andtwo liquid phasesof drain waterRecovery of oilphase in drain waterReduction ofdisposal costsThe oil can be mixedwith fuel oil andprocessedin the gen sets orpropulsion enginesProfit instead ofdisposal costsDrain Waters with High Solids ContentCleaning highly contaminated drainage waters with thecombination of a decanter and a disk stack centrifugeOn platforms, drilling ships, and rigs all kinds ofdrain fluids are produced. They come from drainages,residues, cleaning processes, drilling cuttings, rainand seawater. Most of these drain liquids contain ahigh percentage of oil and solids. If this drain wateris treated, not only disposal costs can be reduced,but profit can also be generated with the oil phaserecovered from the drain water.As the oil as well as water content can vary from10 to 90 % and the solid content can vary from 1 to10 %, either disk stack centrifuges or decanters can beused for treatment of the drain water. Decanters arenormally used in feed with a solid content of morethan approx. 5 % (by vol.) A disk stack self-cleaningcentrifuge can be used downstream of the decanterto polish either oil or water phase or both. For thefinal water phase treatment GEA Westfalia Separatorapplies the IMO certified system as described onpage 7. This way the whole process can be consideredas certified in accordance to IMO ResolutionMEPC 107(49).19GEA Westfalia Separator

The Effective CombinationFor drain water GEA Westfalia Separator recommendsthe combination of decanters and disk stack centrifugesTwo-phase decanter to separatesolids from liquid phasesDisk stack self-cleaning separator toseparate the two liquid phasesNormally, the water phase is treatedfurther downstream to avoid disposalcosts for oily waterOptionally the oil phase can be polished toburn it in gen sets or propulsion enginesOily water treatment systems fromGEA Westfalia Separator can reduce thefree oil content in water down to 5 ppmAs an alternative, three-phase decantersare availableProductProduct mixing tankDemulsifierHeaterPumpFeed pumpStrainerHeaterCA 458 in container on the drillship West NavigatorSludgeLiquid phase20GEA Westfalia Separator

Product mixing tankDirty bilgewaterfeedAutomaticfilterSeparated oildischargeDirtybilgewaterreturnClean water dischargeoverboardHeaterDemulsifierSteamOil monitorAdsorptionfilterCondensateHeaterOperatingwaterSelf-cleaningseparatorDirty bilgewaterreturnSolidsdischargeOperating waterdischarge21GEA Westfalia Separator

Systems to Protect the SensitiveMarine Ecosystem and the Valueof Your InvestmentWestfalia Separator ® seaprotectsolutions for your paybackGEA Westfalia Separator provides reliableand future-proofed separating technologywith the Westfalia Separator ® BilgeMaster ® ,Westfalia Separator ® SludgeMaster ® and WestfaliaSeparator ® CombiMaster ® systems.The powerful processing systems protect notonly endangered ecosystems in the oceans,they also assure the sustainability of yourinvestments.The benefits are as follows:Reduced operating costsOil recycled from the separating process can beused as fuel oil. Recovered lubricating oil canbe recycled as fuel for generating heat.Reduced quantity of sludge means lowerdisposal costs thanks to separating technology.The sludge processingsystem quickly pays for itself.Legal certainty as the machines operatewith values lower than defined limits.Space-saving design.High separating efficiencyLarge equivalent clarification area(up to 25,000 m²) due to centrifugal forcesof up to 8000 g (times of gravity).Compared with static separating systems,separators in bilgewater systems have atheoretical separating limit for oil droplets thathas been reduced by a factor of 10 (1 – 2 µm).Continuous separation of oil and water phase.Self-cleaning effect of disk stack due to totalejection.Adaptation of the flow rate tothe changing product conditions.Improvement of the separation efficiencyby combination with other equipmentlike dosing unit for emulsion breakerReduction of oil residues inthe bilgewater system.High separating efficiencyLarge equivalent clarification areadue to centrifugal forces.Compared with static separating systems,separators in bilgewater systems have atheoretical separating limit for oil dropletsthat has been reduced by a factor of10 (1 – 2 µm).Continuous separation of oiland water phase.Self-cleaning effect of disk stackdue to total ejection.22GEA Westfalia Separator

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Beverage TechnologyDairy TechnologyRenewable ResourcesChemical / Pharmaceutical TechnologyMarineEnergyOil & GasEnvironmental TechnologyEngineeringSecond Hand MachineryOriginal Manufacturer ServiceThe information contained in this brochure merelyserves as a non-binding description of our productsand is without guarantee.Binding information, in particular relating to capacitydata and suitability for specific applications, can only beprovided within the framework of concrete inquiries.Westfalia ® , Westfalia Separator ® , BilgeMaster ® ,BilgeMaster ® -D, SludgeMaster ® and minimaXx ®are registered trademarks of GEA Westfalia Separator GmbH.Printed on chlorine-free bleached paper9997-1182-030/0810 ENPrinted in GermanySubject to modificationGEA Mechanical EquipmentGEA Westfalia SeparatorWerner-Habig-Straße 1 · 59302 Oelde (Germany)Phone +49 2522 77-0 · Fax +49 2522 77-1778www.westfalia-separator.com