The OSE 120 mineral oil separator

The OSE 120 mineral oil separator is the biggest unit in the new Eagleclass series by GEA Westfalia. It has a capacity of 80 m3/hr, a speed of 5900 r/min and consumes up to 75 kW.

GEA Westfalia Separator launched the Eagleclass, a new generation of mineral oil separators joining the company’s existing D-type separator series, which has been on the market since 2002 and is still available. The Eagleclass, or E-type separators, is completely new and features two more models in comparison with its predecessor D class.  

They are the smaller OSE 5 and the bigger OSE 120 model, making a total of six model types. Dr. Kurt Poprawa, head of the business unit Marine at GEA Westfalia Separator, explained that a larger choice of models means an even more personalized customer configuration, which allows more flexibility in the application. “To give a practical example, for the HFO treatment on a 12 000 TEU container vessel with a fuel oil consumption of approximately 20 m3/hr and a treatment capacity need of 20 800 L/hr, we currently used two model OSD 60/40 units,” said Poprawa. “However, with the E-type separators, the customer will only need to use one model OSE 80/80 unit.” Poprawa said the new Eagleclass separators have a higher g-force for the treatment of fuel and lube oils, which allows them to bring the capacity up to 80 m3/hr in the model OSE 120 used for containersships of 30 000 TEU and above together with a high separation efficiency.

Space and weight are two of the biggest concerns in larger commercial vessels. “The E-type separators have been developed with a compact design, resulting in low weight and space requirements,” said Poprawa. “For example, the new design offers an opening bowl where no hood disconnection is necessary for maintenance. In practice, there is simply no need to find a place to put the hood while the necessary maintenance operations are performed.”

“The next biggest concerns for customers are fuel consumption and exhaust emissions,” said Poprawa. 

“However, these separators ensure low energy consumption with reduced CO2 emissions, which contributes to minimizing operating costs.” Among the innovations introduced with the Eagleclass is a new bearing technology that allows the bearings to reach higher centrifugal forces. This fact is particularly significant in the OSE 120 model.

The OSE 120, the largest model in the Eagleclass, is capable of reaching a speed of 5900 r/min, with a power  consumption up to 75 kW. The whole unit weighs 2500 kg; the bowl alone weighs 700 kg. It has been developed with several new features including a hood, drive, bowl and frame.

 “Our company has a plant in Saudi Arabia in a 1240 m3/hr light Arabian crude oil field that utilizes 32 of our D-type OSD 60 model units. In the future, that same customer will need to use only 16 of our OSE 120 units,”explained Poprawa. “The main benefits for the customer in this case are less space requirements and less pipework

for the installation.” In fact, the mineral oil separator model OSE 120 is not only suitable for marine applications, but also for larger power stations as applications trend toward larger gas turbine and diesel engine sizes. “In recent years the interest in power stations seemed to be concentrated in the range of 50 to 80 MW, but the trend is now going to poweroutputs between 100 and 300 MW.Thus, more powerful separators areneeded to cope with such high-performanceapplications,” said Poprawa.

 In power generation applications, the quality of fuel is an important concern, as the quality of high-viscous heavy fuel oils is not always guaranteed. The technology in the new Eagleclass enables it to cope with increasingly complex fuels. The OSE 120, in particular, is ideal for coping with the higher throughput capacities as well as with poorer fuel qualities. Since the OSE 5 is the smaller model of the E-type class, it is better suited for treating heavy fuel oil and marine applications in small vessels.

Poprawa cites comparisons with the precedent D-type model OSD 6. “Both units have the same speed, 12 000 r/min, but the power consumption is 3.5 kW for the OSD 6 and is 2.8 kW for the OSE 5. The pressure of the centripetal pump is the same, but the OSE 5 weighs 50 kg less than the OSD 6. Also, the width of the new units is 35% less than in the OSD 6, as well as the length and height being significantly smaller.” The new Unitrolplus control units are available for the whole Eagleclass. According to Poprawa, “The new Unitrolplus is a follow-up generation of our Unitrol system. It integrates sensors in the hood of the machine for the water and sludge monitoring systems,protecting the devices from the environment.  With the new system, the treatment is automatically monitored, controlled and is capable of the highest separation efficiency, even with heavily contaminated fuels,” said Poprawa.

 The new OSE series offers the advantage of a flexible modularization of compact units. The base module is represented by the separator Compact Unit (CU), paired with its Control and Monitoring Unit (COMU). Other components such as the Sludge Transfer Unit (STU), Heather Unit (HU) and Feed Pump Unit (FPU) are added in the same module. Together with the new class of mineral oil separators, GEA Westfalia Separator launched its Capitalcare concept. Capitalcare is the umbrella joining all services from the manufacturer to the customer, including technical service, applied service consulting and customer’s training.

GEA Westfalia Separator also announced 10 additional centers of competence to open throughout 2009 in strategically important ports to ensure it places the utmost importance in the marine sector to achieve global access to service personnel and spare-parts availability. The technical service area has been improved with the capability of a condition monitoring-based system that focuses on vibration analysis to identify problems at an early stage.

GEA Westfalia Separator offers an interesting exchange proram for bowls, allowing the customer to receive an exchange bowl to replace one that is being repaired. The program was extended to cover preventive bowl maintenance as well. Finally, the safety check has been added to the company’s offering. At regular intervals, the company carries out and certifies a check as prescribed by certification societies for the operation and reliability of the installations.

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