Product Manual

Oil mist separator 2.0

Document ID DBAD633907b

Date of issue 11.01.2017

Status Approved

Classification Confidential
INSTRUCTIONS
 © Copyright by Wärtsilä Finland Oy
All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic,
mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior
written permission of the copyright owner.
THIS PUBLICATION IS DESIGNED TO PROVIDE AS ACCURATE AND AUTHORITATIVE INFORMATION
REGARDING THE SUBJECTS COVERED AS WAS AVAILABLE AT THE TIME OF WRITING. HOWEVER, THE
PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS AND THE DESIGN OF THE SUBJECT AND
PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY,
THE PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CANNOT TAKE ANY RESPONSIBILITY OR
LIABILITY FOR ANY EVENTUAL ERRORS OR OMISSIONS IN THIS PUBLICATION OR FOR DISCREPANCIES
ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT
FROM THOSE SHOWN IN THIS PUBLICATION. THE PUBLISHER AND COPYRIGHT OWNER SHALL NOT BE
LIABLE UNDER ANY CIRCUMSTANCES, FOR ANY CONSEQUENTIAL, SPECIAL, CONTINGENT, OR
INCIDENTAL DAMAGES OR INJURY, FINANCIAL OR OTHERWISE, SUFFERED BY ANY PARTY ARISING OUT
OF, CONNECTED WITH, OR RESULTING FROM THE USE OF THIS PUBLICATION OR THE INFORMATION
CONTAINED THEREIN.
 Product Manual

Table of Contents

1. About this manual........................................................................................................................................ 1-1

1.1. Product identification............................................................................................................................... 1-1
1.2. Objective.................................................................................................................................................. 1-1
1.3. Use of symbols........................................................................................................................................ 1-2
1.4. Preconditions........................................................................................................................................... 1-2

2. Safety notes.................................................................................................................................................. 2-1

2.1. General safety notes................................................................................................................................ 2-1
2.2. Elementary plant safety........................................................................................................................... 2-1
2.3. Safety instructions for installation work................................................................................................... 2-2
2.3.1. Welding precautions......................................................................................................................... 2-3
2.4. Safety notes for maintenance work......................................................................................................... 2-4

3. Unit description............................................................................................................................................ 3-1

3.1. Design...................................................................................................................................................... 3-1
3.2. Functional description............................................................................................................................. 3-3
3.3. Control..................................................................................................................................................... 3-4

4. Installation..................................................................................................................................................... 4-1
4.1. Product handling..................................................................................................................................... 4-1
4.1.1. Unpacking and inspection................................................................................................................ 4-1
4.1.1.1. Inspecting the delivery................................................................................................................ 4-1
4.1.1.2. Inspecting the pipes................................................................................................................... 4-2
4.1.2. Storing the unit after the inspection.................................................................................................. 4-2
4.1.3. Lifting a load...................................................................................................................................... 4-2
4.1.3.1. Lifting with a crane..................................................................................................................... 4-3
4.2. Planning the installation work.................................................................................................................. 4-3
4.2.1. Installation environment.................................................................................................................... 4-4
4.3. Installing the oil mist separator unit......................................................................................................... 4-4
4.4. Installation of pipes.................................................................................................................................. 4-5
4.4.1. Installing the external pipes.............................................................................................................. 4-5
4.4.2. Pipe connections on the oil mist separator unit................................................................................ 4-6
4.5. Electrical installation................................................................................................................................ 4-7
4.5.1. Earthing the unit................................................................................................................................ 4-7
4.5.2. Connecting the power supply and control cables............................................................................ 4-7
4.6. Finalizing the installation.......................................................................................................................... 4-7
4.6.1. Touch-up and repair painting............................................................................................................ 4-7

5. Commissioning............................................................................................................................................. 5-1
5.1. Inspecting the installation........................................................................................................................ 5-1
5.2. Adjusting the throttle valve...................................................................................................................... 5-1

6. Operation...................................................................................................................................................... 6-1
6.1. Start and stop.......................................................................................................................................... 6-1
6.1.1. Starting the oil mist separator unit.................................................................................................... 6-1
6.1.1.1. Starting after a prolonged stop.................................................................................................. 6-1
6.1.1.2. Starting after maintenance work................................................................................................ 6-2
6.2. Performing the regular inspections.......................................................................................................... 6-2
6.3. Abnormal operation................................................................................................................................. 6-2
6.3.1. Leakage............................................................................................................................................. 6-2
6.4. Alarms and faults..................................................................................................................................... 6-3
6.4.1. Oil mist separator not running alarm................................................................................................. 6-3
6.4.2. Variable frequency drive faults.......................................................................................................... 6-3

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7. Maintenance................................................................................................................................................. 7-1

ii Confidential DBAD633907b
 Product Manual 1. About this manual

1. About this manual

1.1 Product identification GUID-F80694F8-C2FC-41C6-8B47-BA8284B20FC8

This manual deals with the oil mist separator 2.0, which is suitable for use with all Wärtsilä
engines. The manual covers the following models:

Oil mist separator 2.0 Single Unit with one oil mist separator
Oil mist separator 2.0 Double Unit with two oil mist separators

Table 1-1 Reference documents

Flow diagram Dimensional drawing Device list

Oil mist separator
DBAD468891a DBAD509971c DBAD468888b
2.0 Single
Oil mist separator
DBAD468889a DBAD509963c DBAD468890b
2.0 Double

1.2 Objective GUID-1E179645-9320-4D9C-82E6-B3BBD6107A24

This manual includes information for the installation and operation of the oil mist separator.
There are separate chapters describing the installation work and the operation of the unit.

Installation
The main objective is to give guidance information for installing the equipment in a safe and
correct way.
Detailed instructions on performing different installation tasks are available in the
documents in the plant installation manual. During the installation, also refer to the drawings
and lists provided.
The information given in this document is for guidance only, and the local conditions must
be considered when applying the information. Also, any local regulations must always be
followed.

Operation
The purpose is to ensure that the operators have all the information necessary to safely run
the oil mist separator in normal operating conditions.
The operating procedures for the oil mist separator are part of the overall procedures for the
plant. The instructions given in this manual only cover procedures related to the oil mist
separator. For instructions on operating the engine and the entire plant, refer to the engine
instruction manual and the plant operation manual.
Detailed information about process equipment and components is given in the
documentation issued by the original equipment manufacturers.

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1. About this manual Product Manual

1.3 Use of symbols GUID-7CCEB85B-87B1-4B4A-B618-FD8B38F102A6

This manual includes different kinds of notes emphasized with a symbol. They are meant to
draw the reader's attention to possible dangers involved or other things to take into
consideration when performing an operation.
The following notes and warnings are used:

NOTE
Note is used in the text for highlighting important information or requirements.

WARNING
Warning is used in the text whenever there is a risk of personal injury.

WARNING - ELECTRICITY
The electricity warning is used in the text when there is a risk of personal injury
due to electrical shocks.

CAUTION
Caution is used in the text whenever there is a risk of damaging equipment.

1.4 Preconditions GUID-67C2D2FC-AC9D-4F37-889F-2D19209B6D81

Properly trained and experienced personnel must be available to perform the actions
required in the instructions. All tools and equipment used must be in good condition.
The equipment described in this manual must not be used for any other purpose than it was
designed for, and it must not be modified in any way without the supplier’s written
permission. The information in this manual is no longer valid if modifications are made to
the equipment.
Wärtsilä accepts no responsibility for situations arising from unintended use or unauthorized
modifications to the equipment, or from work performed by untrained personnel.

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 Product Manual 2. Safety notes

2. Safety notes
For detailed information about plant safety, first aid and actions in emergency situations,
refer to the separate plant safety instruction documents. All personnel working in the plant
must read the safety instructions and be familiar with the safety routines.

2.1 General safety notes GUID-B2F39505-B588-4D24-9B53-5874E70B9D0C

Only persons with adequate training are allowed to operate the equipment in the plant.
Before starting to operate the plant, read the manuals provided by the component
manufacturers. Read and obey the safety instructions provided by the equipment
manufacturers and the material safety data sheets for the chemicals handled in the plant.
Observe the warning signs on the equipment. The signs must not be removed.
To prevent injury, be aware of moving parts. Never run the engine or any auxiliary
equipment without having the covers and protective shields properly mounted. Before
starting any maintenance work, adjustments or inspection, take the necessary precautions
to prevent accidental starting of the equipment.

WARNING
Electromagnetic fields. Electrical or mechanical equipment in this power plant
may interfere with the operation of a pacemaker or other implanted devices that
are sensitive to electromagnetic fields. Check with your doctor or other
physician/specialist before entering this facility to reduce the risk of serious
health consequences.

2.2 Elementary plant safety GUID-9BB1105A-D014-4FF7-B6CB-C42ED81DC65E

General safety notes

Only adequately trained persons that are familiar with the function of the equipment may
operate it.
● No unauthorized persons must be allowed to enter the area. Keep the doors locked
when the operator is not present.
● Ensure the access to service platforms and exit areas.
● Before starting to operate the equipment, read the instructions provided by the
component manufacturers. Pay special attention to the safety information.
● All equipment and safety devices must be in good condition when the system is running.
Do not operate any equipment that appears damaged.
● Do not disable or bypass any important component or safety device when the system is
in operation.
● Observe the warning signs on the equipment. The signs must not be removed.
● Beware of moving parts. Never run any equipment without having the covers and
protective shields properly mounted.
● Before starting any maintenance, adjustment or inspection work, take the necessary
precautions to prevent accidental starting of the equipment.

Handling of chemicals
Before using a chemical, study the safety data sheets provided by the supplier of the
chemical.

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2. Safety notes Product Manual

● Any chemical should be considered potentially hazardous unless it is known to be

harmless.
● When handling chemicals, contact with skin and eyes must be avoided. Protective
clothing has to be used, including safety glasses and impermeable gloves. Respiratory
protective equipment may also be required.
● The chemicals must be stored in appropriate containers and kept in a well ventilated
place.
● Do not eat or drink while handling chemicals.
● Spills must be properly collected and the chemicals disposed of in accordance with the
local regulations.

Electrical safety
The electrical equipment poses a risk of serious injury if inappropriately handled.

WARNING - ELECTRICITY
Only authorized electricians may perform work on electrical equipment.

● To prevent electrical shocks, do not open any electrical cabinet during operation.
● Do not touch any electrical wiring or components until the main switch has been turned
off and secured.

Protective clothing
To prevent personal injury, adequate protective clothing must always be used.
● Use overalls made according to safety regulations, protective gloves, safety glasses,
safety footwear, ear protection and hard hat. The protective gloves have to be strong
and heat resistant.
● Respiratory protective equipment must be used whenever there is a risk of hazardous
fumes.

Clean working space

The working space shall always be kept tidy.
● Wipe up spills and dispose of all debris that might cause accidents.
● Do not store any irrelevant material in the area.

2.3 Safety instructions for installation work GUID-35A6A0F8-5D6B-44D9-B9CA-8804680FCB1D

To prevent personal injury or equipment damage, it is important that the safety instructions
are always observed during the installation. All installation tasks must be performed by
adequately trained workers, and no unauthorized people must be allowed in the area. All
installation equipment must be in excellent condition and thoroughly inspected.
The following general safety precautions are to be followed during the installation work:
● Always use adequate personal protective equipment.
● Do not go under a unit that is being lifted.

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 Product Manual 2. Safety notes

● Electrical installations must always be done by certified electricians. Improperly

connected electrical wires may cause severe personal injury or equipment damage.
○ Before connecting power cables or starting any other electrical installation work,
check that the system is not energized. Also make sure that the power cannot be
connected during the installation work.
○ Be careful not to damage any cables or other electrical equipment during the
installation.
● All welding operations must be performed by qualified personnel.
○ Before starting the welding, check that there is no flammable material nearby. Also
make sure that there are no explosive gases and that the ventilation is sufficient.
○ Beware of hot surfaces during and after the welding.
● The material safety data sheets (MSDS) provided with the chemicals must be thoroughly
studied before the chemicals are used.
○ When handling chemicals, contact with skin and eyes must be avoided. Therefore,
always use protective clothing, including safety glasses and impermeable gloves. A
respirator may also be required. Never eat or drink while handling chemicals.
○ The chemicals must be kept in a well ventilated place. Spills must be properly
collected and the chemicals disposed of in accordance with the regulations and the
material safety data sheet.
● Make sure that all units are properly supported during the installation work, so that they
cannot fall or tip over.
● Notify the other installation workers before starting an installation task that requires
special attention from co-workers.

2.3.1 Welding precautions GUID-44821E79-E7A8-4B82-922B-E581ED88ED66

To prevent personal injury when welding, adequate protective clothing and equipment must
always be used. To improve the insulation, use dry rubber boots and leather gloves. If
necessary, perform the welding work on an insulating protective mat. Always use adequate
eye protection and fireproof clothing.
To prevent burn injuries, keep in mind that the work piece is hot during the welding. Also
beware of hot surfaces after the welding.
Before starting the welding, check that there is no flammable material nearby. Also, make
sure that there are no explosive gases and that the ventilation is sufficient. Keep a foam
extinguisher near the welding location, as welding sparks and hot work pieces always
cause a risk of fire.
A fire watcher should be present whenever welding is being performed. The fire watcher
should be trained to use the fire extinguisher. The fire watch should be maintained for at
least half an hour after completion of welding to extinguish possible smouldering fires.
Take the necessary precautions to prevent equipment damage. Do not place the welding
devices close to power supplies or other electric devices. Always disconnect any sensitive
electronic equipment.
Bellows and flexible hoses must be protected against welding sparks. This can be done
using steel sheets or leather.
Before starting the welding, make sure that the return current cable of the welding device is
connected in a safe and correct way, to prevent personal injury and damage to equipment.

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2. Safety notes Product Manual

2.4 Safety notes for maintenance work GUID-AF4CA6C1-72E0-45DA-9460-49B4A1BC0379

To prevent personal injury, proper safety precautions must be taken when performing
maintenance work on the unit.
● To prevent accidental starting, any component that is to be serviced must be properly
locked and tagged out.
○ The components must be disconnected from the power supply.
○ If the maintenance involves the electrical system, the main switch must be turned off
and secured.
● Protective clothing must always be used when opening any part of the unit.

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 Product Manual 3. Unit description

3. Unit description
The oil mist separator unit is used for removing oil particles from the crankcase ventilation
gas. The oil mist separator is capable of removing 98–99.9% of the oil in the crankcase
gases.

3.1 Design GUID-996B8C64-2143-44B1-A0A2-B9EAD593190D

The central component of the unit is the electrically driven separator, which is mounted on a
steel frame along with the inlet and outlet pipes. The separator consists of a disc stack
made of antistatic carbon fibre reinforced polyamide, which is enclosed in an aluminium
housing.
To improve the separation efficiency, a frequency converter is used for boosting up the
speed of the electrical motor. The gas flow to the separator is adjusted with a throttle valve
in the inlet pipe.
In case of a separator fault or overflow, the air is lead straight to the atmosphere through a
bypass pipe. The bypass pipe is also used for taking balancing air to the separator from the
outlet air pipe.
The oil mist separator unit includes a variable frequency drive for power distribution,
monitoring and control.

(1) Oil mist separator (4) Drain outlet

(2) Throttle valve (5) Clean air outlet
(3) Ventilation air from engine (6) Bypass pipe

Fig 3-1 Oil mist separator flow diagram (single) GUID-F435119D-7D31-4549-B7B3-92F5258E8DF7 v1

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3. Unit description Product Manual

(1) Oil mist separator (4) Drain outlet

(2) Throttle valve (5) Clean air outlet
(3) Ventilation air from engine (6) Bypass pipe

Fig 3-2 Oil mist separator flow diagram (double) GUID-FC8721E4-B6C5-4388-A8C0-CBE858B62FF3 v1

(1) Oil mist separator (3) Variable frequency drive (VFD)

(2) Throttle valve (4) Bypass pipe

Fig 3-3 Component locations (single) GUID-FFDBB6D5-A08D-4B8E-ABC5-955F24BA3A98 v1

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 Product Manual 3. Unit description

3
1

(1) Oil mist separator (3) Variable frequency drive (VFD)

(2) Throttle valve (4) Bypass pipe

Fig 3-4 Component locations (double) GUID-38863390-E52D-427D-85B7-190FB7135CAE v1

3.2 Functional description GUID-09AA5998-45ED-42A4-BC4B-D19AE7BBA3F6

The crankcase gas enters through the inlet at the bottom of the oil mist separator and
passes into the rotating disc stack. The oil mist is separated in the disc stack. The oil drops
are collected on the separator housing inner wall and drained by gravity through the drain
outlet. The clean air is released to atmosphere or back to the inlet of the engine if a closed
configuration is used.

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3. Unit description Product Manual

(1) Ventilation air from engine

(2) Drain outlet
(3) Clean air outlet

Fig 3-5 Operating principle GUID-3FE99606-407A-4921-A92F-857A326BD86A v1

3.3 Control GUID-DC617785-CAC9-46E6-BEBE-66E7EA40FD16

The oil mist separator is normally started and stopped automatically according to the
engine operation. The separator can be controlled manually from the local control panel.
The manual control is mainly used for test and maintenance purposes.
The variable frequency drive (VFD) includes the frequency converter for the separator motor
speed control, the local control panel and a safety switch. The local control panel consists
of a keypad and a display. Remote control for automatic operation is set from the control
panel. The separator can always be stopped from the local control panel but the start
button functions only when the separator is set for local control. The safety switch can be
used as a local emergency stop.

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 Product Manual 4. Installation

4. Installation

4.1 Product handling GUID-16CED2AA-9955-4CAF-A224-516F814EBEB1

To prevent accidents, appropriate safety precautions must always be taken when handling
the product. This includes the use of personal protective equipment, such as safety shoes
and hard hat.

NOTE
The transportation and lifting must be done only by authorized persons who
have received adequate training.

4.1.1 Unpacking and inspection GUID-C3112DF2-6EBA-4476-B11B-495C33A8C30B

The unit can be delivered in a container or a wooden crate.

The container or crate can be lifted and moved with a crane. The crate can also be
transported with a forklift truck, provided that a truck with sufficient capacity is available.

NOTE
If the unit will be stored outdoors, keep the container or crate unopened until it
is time for the installation or inspection of the delivery.

For information about the weight of the unit, refer to the dimensional drawing.

4.1.1.1 Inspecting the delivery

GUID-8516BB88-F45F-4A67-A7E4-957484435154

When the equipment has arrived to the site, it should be checked for transport damage or
missing parts.

Procedure

1 Check the delivery against the packing list, to make sure that all parts are included.
Make sure that all pipes and other components that were dismounted for the transport are
included in the delivery.

2 Make a visual inspection of the equipment for signs of transport damage.

Check that any temporary fastening and locking devices are intact, and that all protective
covers are in place and undamaged.

3 If transport damage is found or suspected, make a thorough inspection and

immediately issue a failure report.
Consider that the process of delivering replacement parts may be time-consuming.

Postrequisites
If the equipment will be stored outdoors before the installation, it must be repacked after
the inspection.

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4. Installation Product Manual

4.1.1.2 Inspecting the pipes

GUID-CF54D05A-E282-4B5F-B4C2-1A5629575CDC

Before the installation, the pipe systems must be inspected for rust or impurities.

Procedure

1 Remove the counter flanges and the protection plates of the pipes.

2 Inspect the pipes visually to check that they are clean on the inside.

3 Put the counter flanges and the protection plates back in place.

Postrequisites
If heavy rust or large impurities are found, the pipes must be mechanically cleaned or, in
worst case, chemically pickled or sandblasted before the installation. A separate flushing is
also needed. Contact Wärtsilä for further advice.

4.1.2 Storing the unit after the inspection GUID-1540CA3A-6CAD-4AF6-9CF3-A26BADA28AB8

During storage, the unit must be protected from rain, heavy dust and other unfavourable
conditions.
● If possible, store the unit indoors in the container or crate until it is time for the
installation.
● Keep the container or crate unopened if the unit must be stored outdoors for a
long period of time.
If the unit was delivered in a wooden crate, cover it by a tarpaulin.
● Make sure that the unit is not subjected to excessive vibration.

4.1.3 Lifting a load GUID-C632AEAF-E97B-4769-9FC9-B765E9A48D56

Same lifting guidelines apply to the module and all components heavy enough to warrant
the use of lifting equipment.
● Make sure that the capacity of the lifting device is sufficient before starting to lift
the load.
For information about the weight and the centre of gravity, refer to the dimensional
drawing of the unit.
● Lift the load carefully, avoiding rapid movements or jerks that may damage the
equipment.
○ Do not lift the load higher than necessary.

WARNING
Risk of crushing. Always make sure that nobody is under the lifted load.

○ The load must always be well balanced during the lifting.

● Make sure that the load is properly supported if it is necessary to work under the
load.

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 Product Manual 4. Installation

4.1.3.1 Lifting with a crane

GUID-4A1EA308-FEBC-42C6-A13F-77609AA075D0

Procedure

1 Inspect the lifting lugs on the load.

a Make sure that the lifting lugs are correctly attached to the load.

b Check that there are no cracks in the welds around the lugs.

2 Inspect the lifting ropes.

a Check that the ropes are in perfect condition.

b Make sure that the ropes are strong enough.

3 Attach the lifting ropes or chains to the lifting lugs on the load.
● Use spreaders as required, to ensure that the required lifting angle is obtained.

CAUTION
The lifting ropes must not press against any part of the load when it is lifted.

● The lifting ropes must carry the load evenly. To maintain horizontal balance of the load,
the ropes must be adjusted so that the load is lifted up straight.

CAUTION
The ropes must not get twisted.

4 Before lifting the load from the floor, tighten the lifting ropes by lifting them with the
crane.
Check that the lines and hooks are securely fastened, and that the lines are straight and
equally tightened.

5 Lift the load carefully in position.

4.2 Planning the installation work GUID-DE8DCEDD-1B40-45F2-A387-33B8C14C5690

Before starting the installation work, make sure that all necessary preparations have been
made.
● Make sure that all installation workers are familiar with the drawings and details.
● Make sure that the assembly plan is completed and accepted.
● Make sure that the constructions are strong enough to carry the expected load.
● Check that all needed parts have arrived and are identified.
● Check that bolts, nuts and washers of the right size are available.
● Make sure that the necessary lifting equipment and tools are available and have
been inspected.

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4. Installation Product Manual

4.2.1 Installation environment GUID-3C0E94A7-7834-48EC-910F-BA4C7C5DABFD

The unit must be placed so that it is accessible for supervision and service, and work can
be performed around the unit.

NOTE
To enable the disk stack to be removed, a service space of at least the same
height as the separator is required above the unit.

4.3 Installing the oil mist separator unit GUID-B094106C-6845-4D4A-B228-8D6DED12C5EB

CAUTION
Make sure that the module is properly earthed when performing any welding
work.

The following documents are needed when installing the module:

● Master layout drawings
● Location plan drawings
● System flow diagram
● Dimensional drawings of the unit.
For more detailed instructions on performing the individual installation tasks, refer to the
corresponding sections of this manual.

Procedure

1 Lift the unit in position.

Refer to the master layout drawing for the location of the unit.

2 Fasten the unit in place.

3 Lift the separator disc stack and motor assembly into the separator housing.
Use eye bolts fastened to the plate between the motor and the disc stack when lifting.

4 Fasten the separator disc stack and motor assembly to the separator housing.

5 Install the external pipes.

a Install the inlet pipe between the engine crankcase outlet and the unit inlet.

b Install the clean air outlet pipe.

If the unit is installed indoors, the outlet pipe must be led out.

c Install the drain pipe.

Make sure that the pipe is installed with a continuous downward slope from the unit.
Refer to the main flow diagram of the lubricating oil system for the outlet connection of
the pipe.

6 Check that the position of the variable frequency drive (VFD) is suitable.
The VFD must be accessible and there must be enough free space around it. Refer to the
manufacturer’s documentation for free space requirements.

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 Product Manual 4. Installation

The VFD can be moved into optional location if required. Refer to the dimensional drawing
for the optional VFD positions.

7 Install the electrical system.

a Connect the earthing cables.

b Connect the power supply and control cables.

4.4 Installation of pipes GUID-BACB6430-3D49-416C-9440-2665CEA41773

The pipes can be installed when the units have been mounted in their final positions.

Table 4-1 Plant installation instructions for external piping

Piping/ducting supports WDAAA116756

Cleaning and flushing of external piping WDAAA116767

4.4.1 Installing the external pipes GUID-49200211-66D6-479A-83C1-A16868D49304

Prerequisites
Before the pipes are installed, the units to be connected must be mounted in their final
positions.
The pipe connections on the unit are supplied with the necessary counter flanges.
● Make sure that pipes of the correct size and material are used.
● Make sure that the pipes are properly supported and fitted without tension.
All possible piping loads – such as the weight of the filled pipe and the thermal
expansion – must be taken into account.
● Clean and flush the pipes properly before connecting them, to remove any dirt.
● Keep the protective covers of the pipe connections in place until the pipes are
connected.

NOTE
Be careful not to let any dirt into the pipes during the installation.

● Tack weld the pipes to the flanges when the pipes are in position.
Remove the pipes for the final welding.
● Make sure that the gaskets of the flange connections are properly mounted and
that the bolts are tightened to the correct torque.

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4. Installation Product Manual

4.4.2 Pipe connections on the oil mist separator unit GUID-127EBCCD-687C-41C1-A367-4A667EA1A242

R1

C 701

Fig 4-1 Pipe connections on the oil mist separator unit (single) GUID-BA0F5CAE-ADBF-45CD-A065-

BA0C72E8058C v1

R1

701
C

Fig 4-2 Pipe connections on the oil mist separator unit (double) GUID-C9BE1662-6351-49A9-A698-

E859D8E47545 v1

Table 4-2 Pipe connections on the oil mist separator unit

Description Dimension
701 Ventilation air from engine DN150

C Drain outlet DN25

R1 Clean air outlet DN150

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 Product Manual 4. Installation

4.5 Electrical installation GUID-FC8F2138-9A81-44D1-8E46-47E6646C849C

NOTE
All electrical installation work must be done by certified electricians.

4.5.1 Earthing the unit GUID-0892D832-3F71-4697-A060-3E9A839984E8

The unit must be properly earthed before connecting the power supply to the variable
frequency drive.
● Connect the earthing cable from the dedicated earthing point of the separator
housing to the unit frame.
● Connect the earthing cable from the dedicated earthing point of the unit frame to
the plant’s earthing bar.
Refer to the earthing layout drawings of the plant.

4.5.2 Connecting the power supply and control cables GUID-30C0249E-900A-4951-B9CE-9414B016678A

Prerequisites
The oil mist separator unit is connected to the external power supply and control systems
through the variable frequency drive (VFD). Before connecting the cables, make sure that
the VFD is securely mounted.
When connecting the power supply and control cables, refer to the applicable electrical
drawings, cable lists and wiring diagrams.

WARNING - ELECTRICITY
Risk of electric shock. Do not switch on the power until all electrical connections
are ready and in accordance with the electrical drawings.

Procedure

1 Connect the power supply cable to the VFD.

2 Connect the power supply cable from the VFD to the separator motor.
3 Connect the control cable and the signal cable from the auxiliary control panel
(BJA0_1) to the VFD.

4.6 Finalizing the installation

4.6.1 Touch-up and repair painting GUID-0D9B1D43-CEC6-4B34-BA90-E3F9C19701C0

The steel structures are protected from corrosion by a protective coating. Any damaged
coating must be carefully repaired to maintain the level of corrosion protection.
Touch-up painting is generally used for repairing damaged paintwork. Repair painting
involving more surface treatment is used when damage is seen on a bare steel surface, for
instance at welding seams. The size of the damaged area shall also be considered when
determining which painting method is suitable.

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Detailed instructions for touch-up and repair painting are given in a separate chapter in the
plant installation instructions.

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 Product Manual 5. Commissioning

5. Commissioning
The commissioning procedures are performed to validate and document that the system is
correctly designed and installed, and that the equipment operates correctly. The
commissioning process includes checks to be made during the installation of the
equipment, as well as inspections and function tests to be performed after the installation.

5.1 Inspecting the installation GUID-CF23982F-C98F-495C-8A69-E7114E8249FA

The factory acceptance test (FAT) reports are prepared by the equipment supplier before
the delivery. To verify that the module is correctly installed, additional inspections and tests
must be carried out during and after the installation.
After the installation, inspect the whole system to ensure that the installation is complete
and that all stages of the installation have been correctly performed.
● Check that the module and all connections have been installed according to the
flow diagram.
● Check that the module is correctly positioned and properly fastened.
● Check that the piping has been correctly installed.

a Check that the protective covers have been removed.

b Check that all pipe connections are sealed and tight.

c Check that there is no visible tension on the pipes, and that the pipes are
properly supported.

d Check that the oil outlet pipe is installed with a continuous downward slope
from the oil mist separator unit.
● Check that all bolts are tightened to the correct torque.
● Check that any required touch-up painting has been performed.
● Check that all electrical cables are correctly installed and connected.

a Check that the cables are pulled and connected according to the electrical
drawings.

b Check that the cables are properly fastened and supported.

c Check the cable continuity and make sure that the insulation is not damaged.

5.2 Adjusting the throttle valve GUID-F6A68C37-BFA9-415B-8C59-09CE2E7DA093

Procedure

1 Start the separator.

2 Open the throttle valve.

3 Run the engine at 100% output.

4 Open the bypass pipe coupling.

a Remove the pipe clamps on the flexible coupling.

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b Push the rubber hose on the bypass pipe upwards to free the opening in the intake
pipe.

c Cover the upper bypass pipe end to prevent gases from the separator escaping
through the pipe during the throttle valve adjustment.

5 Close the throttle valve slowly until visible smoke starts to emerge from the opening
on the lower bypass pipe.

6 Open the inlet valve 2.5 degrees from the point the smoke starts to emerge.

7 Lock the throttle valve locking screw and remove the handle to prevent accidental
change in valve position.

8 Lubricate the inside surface of the rubber hose using e.g. engine lubricating oil or
similar to prevent sticking.

9 Mount the rubber hose on the bypass pipe back to its original position and fasten the
pipe clamps.

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 Product Manual 6. Operation

6. Operation

6.1 Start and stop GUID-3AE78515-66DC-4290-8914-117313AA9D89

The measures to take at startup depend on the state of the equipment. If the engine is
stopped for a brief period only, some of the auxiliary units may be kept in automatic
operation during the stop. Starting after a prolonged stop requires more preparations and
manual operation. The following main operating states are distinguished:

In operation The plant is in operation or on standby, controlled by the control

system. The engine may be running or temporarily stopped. When
the engine is stopped, the auxiliary systems remain filled and are
ready for engine startup. Some units are started and stopped
automatically by the control system.
Maintenance The engine is stopped for maintenance. The state of the auxiliary
stop systems depends on the nature of the maintenance work that is to
be performed. Some auxiliary units may be kept in operation if they
are not affected by the maintenance. The fuel and compressed air
supplies are typically shut off for safety reasons.
Prolonged stop The engine is shut down for a prolonged time. The auxiliary systems
are stopped. The fuel and compressed air supplies are shut off. The
units are disconnected from the power supply and the control
system.

6.1.1 Starting the oil mist separator unit GUID-8DE308A6-8407-471C-85F5-7EE4164BEB5F

The oil mist separator starts and stops automatically according to the engine operation
when set for remote control.

Procedure

1 Make a visual check of the oil mist separator unit, to ensure that it is ready for
operation.

2 Turn on the safety switch on the VFD.

3 Set the oil mist separator for remote control from the VFD.
Refer to the original equipment manufacturer’s documentation.

4 Check the operation of the oil mist separator once the engine is running.

a Check the unit and pipe connections for leaks.

b Check the oil mist separator for abnormal vibration and noise.
Some vibration is normal during the starting cycle when the separator passes through its
critical speeds.

6.1.1.1 Starting after a prolonged stop

GUID-C82042BA-3A2E-4245-83B7-9597DC16564F

When starting the unit for the first time or after a prolonged stop, inspect it thoroughly to
verify that all components are in working order.

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CAUTION
Do not use the unit if it appears damaged.

● Check the oil mist separator for damage and make sure that it is securely fastened.
● Check the electrical connections for broken cables, insulation damage or loose
contacts.
● Check the unit and the pipe connections for signs of leakage.
Retighten or change seals as necessary. Be careful not to overtighten.
● Check the rotation direction of the oil mist separator motor if it is started for the
first time.

6.1.1.2 Starting after maintenance work

GUID-33D62447-4798-4E37-A0FF-D382B5861D0D

When starting the unit after maintenance work, make sure that all components that have
been serviced during the stoppage are correctly assembled and ready for operation.
● Check that all tools and loose parts have been removed.
● Check that no components are still locked or tagged out for maintenance.
● Check the rotation direction of the oil mist separator motor if the power cables
have been disconnected during the stoppage.

6.2 Performing the regular inspections GUID-6E623BF8-2EC1-40E9-8A1F-BA6E9DE84853

To keep the oil mist separator unit in working order, it must be inspected and serviced on a
regular basis.
● Inspect the piping for leaks, broken or loose flanges, etc.
● Check the separator for noise and vibration.
● Check all electrical connections for insulation damage or loose contacts.

6.3 Abnormal operation GUID-02652CE3-A14F-4D50-BB9D-24D15F70E93B

During operation, pay attention to any indications of problems in the system, such as:
● emerging smoke
● excessive vibration
● strange sounds or smells
● leakage.
If any abnormal operating conditions are detected, stop the unit and investigate the cause.

6.3.1 Leakage GUID-608D3D19-0C02-437A-9B46-1D063C916AEE

The unit and the pipe connections should be inspected for leaks on a regular basis. Pay
attention to signs of leakage when the unit is in operation.
If leaks are found, stop the unit until the cause of the situation has been investigated and
the leak repaired. Any abnormal leaks, even small ones, should be repaired as soon as
possible. The area must be properly cleaned after collecting any leaked oil.
To prevent leaks, replace worn seals and other components as necessary in connection
with the scheduled maintenance work.

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 Product Manual 6. Operation

6.4 Alarms and faults

6.4.1 Oil mist separator not running alarm GUID-157CD4E1-01AB-4F1A-A5D6-E083AF1F1E5B

An oil mist separator not running alarm is activated in the plant control system if the
separator is not running when the engine is running.
If the alarm is activated, check the following:
● Check that the separator is set for remote control.
● Check that the safety switch on the VFD is switched on.
● Check the VFD panel for fault messages. Close the throttle valve if the separator has
stopped due to a fault.

6.4.2 Variable frequency drive faults GUID-74737DDA-CB2A-4F2F-9451-A119040D1C0D

The variable frequency drive shows a notification on the display when an unusual operating
condition is detected by the control system. Shown will be the code, the name and a short
description of the problem.
The notifications vary in consequence and required action. Faults make the drive stop and
require reset of the drive. Alarms inform of unusual operating conditions but the drive will
continue running. Info may require resetting but do not affect the functioning of the drive.
Refer to the VFD documentation for more detailed instructions on managing the faults.

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 Product Manual 7. Maintenance

7. Maintenance
The maintenance comprises regular inspections, preventive maintenance and replacement
of worn or damaged parts. The maintenance must be carefully done at the right intervals,
which partly depend on the running time and other operating conditions. All maintenance
activities shall be recorded along with the reason for the maintenance.

NOTE
For information about maintenance intervals and instructions on performing the
maintenance tasks, refer to the plant maintenance manual for auxiliary
equipment and to the manuals issued by the original equipment manufacturers.

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 Wärtsilä is a global leader in complete lifecycle power solutions for the marine and energy markets.
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and economic performance of the vessels and power plants of its customers. Wärtsilä is listed on the
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See also www.wartsila.com

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24hrs Phone +358 10 709 080
Switchboard +358 10 709 0000
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