Westfalia Separator  

Mechanical Separation
Mineraloil Systems GmbH
Division

Safety Precautions and

User Instructions

for

Machine and Plant Components

No.: 2058-9601-100

Edition: 0707
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Subject to modification!

The authors are always grateful for comments and suggestions for improving
the documentation. They can be sent to
Westfalia Separator
Werner-Habig-Str. 1
D-59302 Oelde

© Westfalia Separator

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1 General 5

1.1 Qualification of the personnel ..................................................................5

1.2 Structure of documentation...................................................................... 5

2 Safety precautions 6

2.1 Correct usage ..........................................................................................6

2.2 Incorrect usage ........................................................................................ 6
2.3 Representation of warnings ..................................................................... 7
2.4 Remaining risks .......................................................................................8
2.5 Designation..............................................................................................8
2.6 Safety precautions for the operating staff................................................9
2.7 Safety precautions for adjustment / commissioning ................................ 9
2.8 Safety precautions for maintenance ........................................................9
2.9 Safety precautions for specific types of risks........................................... 9
2.9.1 Electricity..................................................................................................9
2.9.2 Oils, fats, and chemicals.......................................................................... 9

3 Product overview 10

3.1 Description and operating principle .......................................................10

3.2 Operating conditions..............................................................................10
3.3 Transport................................................................................................10
3.4 Storage ..................................................................................................10

4 Installation 11

4.1 Measures to be taken prior to installation..............................................11

4.2 Mounting ................................................................................................11
4.2.1 Fitting with threaded connection............................................................11
4.2.2 Fitting with flange connection ................................................................11
4.3 Electrical connection.............................................................................. 12
4.4 Pneumatic connection ...........................................................................12
4.5 Operation in an explosion-hazarded area ............................................. 12

5 Maintenance and servicing 13

5.1 Cleaning and servicing ..........................................................................13

5.2 Maintenance ..........................................................................................13
5.3 Repair ....................................................................................................13

6 Disposal 14

7 Spare parts 14

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1 General

These Safety Precautions and User Instructions provide important support for
– avoiding risks,
– reducing repair cost and down times, and
– extending the life cycle of components
The term „component“ will be used in singular although this document is appli-
cable to all components incorporated in the separators/plants.
To ensure perfect operating safety of the component, these safety precautions
and user instructions have to be thoroughly read and understood prior to :
– Installation
– transport, storage
– maintenance work (maintenance, servicing, repair) and
– disposal
For questions that cannot be solved with the aid of this documentation, please
check back with Westfalia Separator Mineraloil Systems GmbH.
Using this manual and direct handling of the component require specific qualifi-
cation of staff.

1.1 Qualification of the personnel

As mentioned under these instructions, certain operations may only be carried
out by qualified staff. For identifying the qualification level Westfalia Separator
Mineraloil Systems GmbH uses the following standard terms:
• Qualified staff have the necessary technical know-how and extensive ex-
perience enabling them to avoid the risks that can arise when handling elec-
trical or mechanical components. English language skills are prerequisite.
• Trained staff are instructed or supervised by qualified staff to enable them to
avoid the risks that can arise when handling electrical or mechanical compo-
nents.
When installing, operating and testing the equipment, the staff has to adhere to
the safety rules applicable in the respective industry.

1.2 Structure of documentation

By default the documentation for components comprises:

1. Instruction manuals for separators and/or start-up and shut-down instruc-

tions for plants
2. Safety precautions and user instructions (this document)
3. Reference to the component instructions and/or the technical data sheet of
the component according to DIN paper 146, in accordance with DIN EN
62079

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Danger through non-observance of the documentation

• All documents mentioned have to be adhered to!
– Instruction manuals for separators and/or start-up and shut-down instruc-
WARNING! tions for plants
– Safety precautions and user instructions
– Component manual
• All safety precautions and warning instructions given in the documents have
to be adhered to!
• Access to the documentation on site must be ensured at any time.

2 Safety precautions

The machine or plant component is built according to state-of-the-art and to

prevailing safety rules and regulations. However, when using the component,
risks may arise for the use or thirds or the component or other valuables might
get impaired if it is
– operated by untrained or uninstructed staff,
– incorrectly used,
– inadequately maintained or serviced.

2.1 Correct usage

The component is incorporated in machines and plants.
Precise details on the function of the components are found in the component
manufacturer’s manual.
The characteristics of the medium specified in the data sheet and the pressure
and temperature limit values for the medium mentioned in the specification must
be adhered to at any time.
The specific values stated in the documents furnished with the component have
to be observed and adhered to.
Any use in an explosion-hazarded area is systematically not allowed. The only
exception: this is confirmed in the order or is mentioned in the Instruction Man-
ual or in the manufacturer’s data sheet.

2.2 Incorrect usage

Any use that deviates from or exceeds the intended use is considered to be
non-compliant. Solely the user of the machine/plant will be responsible for dam-
age resulting from incorrect usage. This also applies to modifications performed
on one’s one.
Non compliant is the use of
– materials with excessively high temperature
– materials under excessively high pressure
– material containing smouldering, burning, or sticking particles,
– highly explosive and pasty materials,
– materials chemically reacting with the material of the component

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Solely the user is responsible for the operation and/or layout of the component.

Incorrect usage of components

Danger to life and limb and/or risk of material damage when disregarding me-
chanical, chemical and electric danger.
DANGER! • The specific characteristics stated in the documents supplied with the com-
ponents have to be observed and adhered to.

2.3 Representation of warnings

Depending on likelihood and nature of a risk, warnings are set up with a signal
keyword (exclamation) and in a signal colour according to ANSI Z535:

Warning of a direct threat of danger, leading to serious injury or even death.

DANGER!

Warning of a possibly dangerous situation that might lead to serious injury or

even death.

WARNING!

Warning of a possibly dangerous situation that might lead to minor injury. This
text can also be used when warning of material damage.

CAUTION!

This symbol is to inform for better understanding the component and its func-
tions and tasks.

• A bullet point us used when describing work and/or operation steps. Be sure
to proceed in correct order: from top to bottom.
– The dash (horizontal bar) is used for listing.
Be sure to adhere to stickers, symbols and warning signs directly fastened on
the component. Do NOT remove them, and keep them clearly readable!

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2.4 Remaining risks

An element of risk will remain when using the components, even when strictly
adhering to all safety rules and regulations.
Any person working with the component has to be aware of these remaining
risks and must follow all the instructions avoiding accidents or damage.

Hazardous voltage - danger to life

Risk of death or serious injury through electric shock!
• Work on electric apparatus and/or on live component equipment must be
DANGER! performed by qualified staff only.
• Disconnect the power supply to electric equipment if required.
• Secure against unexpected restarting.
• Apply a warning sign forbidding to switch on.

Danger when not using personal protective equipment

Risk of lethal injury when not using personal protective equipment (PPE)!
• Operating/maintenance staff must be obliged to wear PPE.
DANGER!
• Wear safety boots, safety goggles, ear protection, etc., depending on tasks
and conditions.
• When working on components with surface temperatures above 50 °C or be-
low 0 °C, wear temperature-isolating safety gloves.

Danger through lack of attention when working in the area of the compo-
nent
Crushing, cutting and abrasion injuries.
WARNING! • Be sure to work and move carefully in the area around the component.

Risk of eye and/or skin injuries when medium discharges under high
pressure
Abrasive or corrosive substances destroy the component!
WARNING! • Wear protective goggles or face-mask with eye protection against spouting
medium.

2.5 Designation
The following signs and plates are fastened on the component or its accesso-
ries:

Warning of dangerous voltage!

The sign is fastened on the electric terminal box.

The terminal box may only be opened by qualified staff.

Nameplate The nameplate contains specific component data.

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2.6 Safety precautions for the operating staff

The component must be operated only in perfect condition, for the intended use,
taking into account security rules and being aware of risks, duly adhering to the
documentation.
Any fault – especially those potentially impairing safety - must be remedied im-
mediately!
Clearly define and adhere to responsibilities for operation and maintenance.
Only this is how errors can be avoided – especially in dangerous situations.
Do not use the component until all protection and safety devices are installed
and serviceable! Do NOT remove them during operation.
In case of malfunction or safety-relevant change in operational behaviour, shut
down and secure the separator or the plant. Have faults remedied by qualified
staff immediately.
Leaking dangerous material must be discharged so as to avoid danger to the
operator and to the environment.
Do NOT touch damaged, cracked and, especially, live components.

2.7 Safety precautions for adjustment / commissioning

The medium throughput might change or be interrupted while the component is
being commissioned. Prior to commissioning, make sure that there will be no
risk for people or the environment while performing adjustments.
Each adjustment must be followed by a functional check.
Take appropriate measures to prevent crushing injuries by moving adjustment
devices.

2.8 Safety precautions for maintenance

When carrying out maintenance work, strictly adhere to all rules and regulations
applicable for handling the component or the medium (e.g. protective clothing,
no smoking).
Adhere to the check-up or inspection intervals specified in applicable laws
and/or in the documentation.
Check wires and hoses for damage and replace if necessary, especially on
moving components.

2.9 Safety precautions for specific types of risks

2.9.1 Electricity
Never carry out work on live parts!
Do nor change safety-affecting design parameters! Especially, do NOT restrict
leakage paths, air gaps, and clearances with insulating coatings.
Check wires for damage at regular intervals and replace if necessary.

2.9.2 Oils, fats, and chemicals

When handling oils, fats, and chemicals, adhere to applicable rules and regula-
tions and manufacturers’ data sheets for these materials concerning storage,
handling, usage, and disposal!
After eye or skin contact, rinse the affected area immediately with water.

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3 Product overview

3.1 Description and operating principle

The detailed description and functional principle of the relevant component are
given in the respective component manual.

3.2 Operating conditions

Housing and gasket materials are selected in accordance with operating condi-
tions. Operating conditions essentially determine the service live of the compo-
nent.
Technical characteristics and the essential permissible limit values, especially
for pressure and temperature of the medium, are given in the manufacturer’s
manual.
Care must be taken that the component will only be used where the layout crite-
ria comply with the values stated on the nameplate. Correct transport and ap-
propriate storage are prerequisite.
Faults arising from moving elements must be prevented by taking appropriate
measures.

3.3 Transport
Be sure to comply with the following :

Danger through contact with substances hazardous to health

During operation the component might have come into contact with substances
that are hazardous to health.
WARNING! • De-contaminate the component prior to packing and/or transport.

• Use lifting devices to transport heavy components that cannot be moved by

hand.
• Screw eye bolts or lugs into the component and suspend them properly to the
lifting device, and then transport.
• When using lifting straps, place them around the component, provide sharp-
edge protection if required, and watch for proper weight distribution.
• During transport, protect the component against external force (impacts, vi-
bration, etc.).
• Protect the sealing surfaces of connections against damage.
• Do not damage the corrosion-preventive coating.

3.4 Storage
Be sure to comply with the following :
• Protect the component against external impacts and contamination.
– Keep the storage room as dry and dust-free as possible.
– Avoid water condensation.
– Protect open connection ports from dirt.

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4 Installation

Component-specific information is given in the component manual!

Prior to installation, read and adhere to the safety precautions given in chapter 2
of this manual. Observe the accident prevention regulations!

4.1 Measures to be taken prior to installation

Packaging damaged during transport and/or storage

Component might not comply with safety rules.
• Check for possible damage prior to installation.
CAUTION!
• Do not install any defective component.

Take the following measures prior to installation:

• Check that the line system and the component are perfectly clean.
• Remove protection caps from the connectors directly before installation only.
• Do NOT damage sealing surfaces and threads respectively.

4.2 Mounting
• Remove all packaging material immediately before installation only.
• No dirt particles must seep into the component!
• Bear in mind the flow direction indicated on the component if required.

After installation
• Check for possible leakage and for proper function.
• Arrange for specified operating status.

4.2.1 Fitting with threaded connection

• Use appropriate sealing aid.
• Arrange the piping layout so that flux across the component will be avoided.

4.2.2 Fitting with flange connection

• Use the specified screws. Use all the flange bores provided.
• Insert appropriate seals and center them properly between the flanges.
• Tighten the screws evenly and crosswise to prevent warping. Under no cir-
cumstances should the pipeline be pulled against the component.
• Watch for proper location of seals.
• Tighten screws to the specified torques.

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4.3 Electrical connection

For a component with electric equipment:

Hazardous voltage - danger to life

Risk of death or serious injury through electric shock!
• Work on electric apparatus and/or on live component equipment must be per-
DANGER! formed by qualified staff only.
• Disconnect the power supply to electric equipment.
• Prevent unexpected restarting.
• Apply a warning sign forbidding to switch on.
• Earth the component according to local rules.
• Take adequate preventive measures according to the provisions of the local
electric power company.

4.4 Pneumatic connection

Use conditioned compressed air only. Install a upstream compressed-air control
assembly if required.

4.5 Operation in an explosion-hazarded area

Any use in an explosion-hazarded area is systematically not allowed. The only
exception: this is confirmed in the order or is mentioned in the Manual or in the
manufacturer’s data sheet.

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5 Maintenance and servicing

This chapter comprises: cleaning and servicing, maintenance and repair.

Prior to repair work, read and observe chapter 2 of this manual.

5.1 Cleaning and servicing

Damage to the component, caused by a layer of dirt

Plugging-up of functional openings. Impaired of heat dissipation!
• Arrange for efficient covering of the component when carrying out dirt-emitting
CAUTION! work near the separator or the plant (e.g. laying concrete, brickwork, painting,
sand-blasting).
• Clean at regular intervals.

Malfunction due to damage to the component

Risk of material damage through inappropriate cleaning!
• When cleaning with aqueous detergents, mind the type of enclosure of electric
CAUTION! components. Do not apply them when in doubt!
• Do not use aggressive cleaning agents. Otherwise metal or plastic surfaces as
well as hose connections might be attacked.
• Never clean sensitive components with hard brushes with strong mechanical
pressure.
• Use lint-free cleaning rags only.

5.2 Maintenance
The maintenance intervals have to be re-determined (shortened) by the opera-
tor according to prevailing operating conditions.
The component has to be checked and maintained for operating-safety reasons.
When doing so, observe the following minimum requirements:
– Check visible condition of the component and its accessories at regular in-
tervals.
– Actuate the component parts on a regular basis to ensure that proper func-
tioning of all moving parts will not be impaired by long-term standstill.

5.3 Repair

Material damage due to mechanical overload on component parts

Impacts by kicks, mechanical stress originating from connected pipelines, ex-
cessive ambient temperatures will destroy the component!
WARNING! • Install parts without force. Avoid tension and strain.
• Avoid excessive load, e.g. impacts by kicks (wrongfully climbing on the com-
ponent).
• Avoid welding and thermal treatment.
• Avoid working on the component with tools (e.g. drilling).

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6 Disposal

Be sure to comply with applicable legislation for adequate and environmentally-

friendly disposal.

Danger through contact with substances hazardous to health.

During operation the component might have come into contact with substances
that are hazardous to health.
WARNING! • Be sure to decontaminate prior to disposal.

7 Spare parts

Use only genuine spare parts from Westfalia Separator.

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Mineraloil Systems GmbH
Take the Best – Separate the Rest

A company of GEA Group

Westfalia Separator Mineraloil Systems GmbH ● Werner-Habig-Straße 1 ● D-59302 Oelde (Germany)

Phone.: +49 (0) 25 22/77-23 94 ●

http://www.westfalia-separator.com/ ● mailto:[email protected]