@ manual 445 - g&o bioreactor

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G&O Bioreactor

Gertsen & Olufsen A/S

Savsvinget 4

DK 2970 Hørsholm

Denmark

Tel: +45 4576 3600

Fax: +45 4576 1773

[email protected]

www.g-o.dk

Service Manual

TMS AVR-3BR74000-V-BS / Plant 445


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G&O Bioreactor

G&O Bioreactor

G&O Bioreactor

G&O Bioreactor

G&O Bioreactor

G&O Bioreactor

G&O Bioreactor

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Projekt TMS AVR-3 Anlæg 74000-V-BS No. 445

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G&O Microbac Bioreactor

Gertsen & Olufsen A/SSavsvinget 4DK 2970 HørsholmDenmarkTel: +45 4576 3600Fax: +45 4576 [email protected]

G&O Microbac Bioreactor

Gertsen & Olufsen A/SSavsvinget 4DK 2970 HørsholmDenmarkTel: +45 4576 3600Fax: +45 4576 [email protected]

Manual

TMS AVR-3

BR74000-V-BS / Plant 445

Manual

TMS AVR-3

BR74000-V-BS / Plant 445


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OPERATION & MAINTENANCE MANUAL

REVISION R01

CERTIFICATION DATA BOOK

G&O SEWAGE TREATMENT PLANT TYPE 74000-V-BS

PLANT NO.: 445

FOR

AVR-3

CHAPTER 01 GENERAL DESCRIPTION

CHAPTER 02 INSTALLATION

CHAPTER 03 OPERATION/MAINTENANCE

CHAPTER 04 COMPONENT DESCRIPTION

CHAPTER 05 TROUBLE SHOOTING

CHAPTER 06 RECOMMENDED SPARE PARTS

CHAPTER 07 DRAWINGS

CHAPTER 08 CERTIFICATES

CHAPTER 09 VACUUM UNIT

GERTSEN & OLUFSEN A.S. SAVSVINGET 4

DK-2979 HØRSHOLM

DENMARK

TEL.: +45-45763600 FAX: +45-45761773

E-mail address: [email protected]


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GERTSEN & OLUFSEN A.S.

1

01 GENERAL DESCRIPTION

01.1

VESSEL PARTICULARS ...................................................... 2

01.1.1

PARTICULARS SEWAGE TREATMENT PLANT .......... 2

01.2 DESCRIPTION OF THE SYSTEM ....................................... 3

01.2.1 GENERAL .............................................................................. 3

01.2.2 SYSTEM .................................................................................. 3

01.3

SYSTEM BUILD UP .............................................................. 4

01.3.1 TANK SYSTEM

......................................................................

4

01.3.2 AIR SUPPLY ........................................................................... 4

01.3.3 DISCHARGE PUMPS ............................................................ 5

01.3.4 MACERATING PUMP ........................................................... 5

01.3.5 UV-STERILIZER ................................................................... 6

01.3.6 SLUDGE RETURN AIRLIFT SYSTEM

................................

6

01.3.7 CONTROL CABINET ............................................................ 6

01.3.8 VACUUM UNIT ...................................................................... 6


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01.1 VESSEL PARTICULARS

Hull number: 445

Yard / Owner: TMS ARV-3

Delivery Date of Plant: 02-07-2012

01.1.1 PARTICULARS SEWAGE TREATMENT PLANT

Designed Hydraulic Load: 74 m3/day

Designed Organic Load: 30,0 kg BOD5/day

Compressor (optional): Becker DT 3.140

Discharge Pump: Orpu Orcut ES 130

Macerating Pump: Orpu Orcut 135/4

UV-Sterilizer: W 8

Level Switches: Pepperl+Fuchs LFL2

Solenoid valve: Danfoss EV 220B 6B

Dry weight: 5800 kgs approx.

Operation weight: 38700 kgs approx.

Plant Dimensions See Chapter 07 – Drawings

Vacuum unit (optional): See chapter 9


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01.2 DESCRIPTION OF THE SYSTEM

01.2.1 GENERAL

The G&O Sewage Treatment Plant(STP) is a biological sewage treatment plant working on the fixed bed principle, constructed to meet the rules and regulations described in Marpol 73/78 and approvedaccording to IMO MEPC 159(55).

The G&O STP is a continuation of the well-proven Microbac Bioreactor, which has been on the marketfor more than 15 years and has been constantly improved.

The G&O STP is an aerated submerged fixed film unit with a unique proprietary aeration system that provides major advantages to the operator. There are no moving parts inside the bioreactor and theself-cleaning aeration system provides the required amount of dissolved oxygen for the biomass to feedon and degrade the waste.For sewage treatment, the bioreactor needs no nutrient addition or pH-correction, and chemicals are not

needed, hence there is no added costs or environmental problems associated with the use of chemicals.

The bioreactor will accept all wastewaters produced in the accommodation, including combination of black, gray and galley water. Depending of the quality of the galley water, a grease trap is normallyneeded. Waste from food grinder is not accepted as waste water.

01.2.2 SYSTEM

The installed plant is built up as follows;

Inlet mixing tank (optional see below)

Bioreactor with matrixSettling tank with matrix

Clean water tank

The inlet mixing tank is optional supply from G&O if case the ship can accommodate this tank withinthe ship.Please see General arrangement drawing in Chapter 07 for further details.

With the following components see chapter 07 or chapter 01.1.1 for details:

CompressorDischarge pump

Macerating pumpSludge return pumpUV-SteriliserAerators in the bioreactor

Level switches in clean water tankLevel switch in inlet mixing tank

Depending of customer request further component can be fitted/omitted:- Standby pumps as to customers specification.- Compressor in case the customer don’t want to supply the unit via the ship air system.


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Black water and grey water will be let into the inlet mixing tank. The wastewater will be macerated bycirculation through the macerator pump. The macerating pump will start/work according to the settingsof the timer if the liquid level is higher than the installed low level switch.The macerator pump is controlled by the timer in order to ensure a even flow to the bioreactor which

contains a Polypropylene cross fluted structured matrix as its media, on which the degrading bacterial biomass adheres and rapidly grows. This matrix is manufactured so that constant intermixing of the

wastewater occurs in each vertical column of the media, ensuring maximum contact between theeffluent and on the surfaces on which biomass is fixed. The wastewater is driven upwards in theadjacent column. In this way, the effluent moves in a serpentine fashion through the whole of the

bioreactor to ensure the maximum contact time and optimum biological treatment.

Treated waste water from the bioreactor is directed to the settling tank where treated water is led in below the installed matrix in order to ensure separation of water and solids(if any) and flow, by gravity,through the installed UV-Steriliser to the clean water tank.Connected to the settling tank is the sludge return system, which periodically transfers the settledsludge back to the influent tank.

The installed level switches control the water level in the clean water tank. The discharge pump willstart when water reaches “high” and stop when water level reaches “low”. In addition to the high andlow level switches, a High-High level switch is installed. Should water level reach this switch, a

common alarm signal is set in order to alert the crew for further action.

01.3 SYSTEM BUILD UP

The G&O STP is connected to the vessels piping and electrical systems. Description of fittedcomponents to the plant is described in Chapter 04 – Component description.

01.3.1 TANK SYSTEM

The tanks(Bioreactor/Settling/Clean water – inlet mixing tank is optional) are built together to one

compact unit, interconnected with necessary piping/overflows for flow of wastewater undermaceration, treatment, settling of sludge, flow of treated water, air transport and venting.

01.3.2 AIR SUPPLY

The air supply to the plant has the following functions;

- to supply necessary air to the air diffusers.

The plant will be supplied whit air from a compressor or external air supply.

In addition to/or as substitute for the compressor it is possible to use vessels air system, and a air pressure regulator is fitted to ensure the right amount of air.

See Chapter 03 and 04 – Component description for technical details and operation of the aircompressor.


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01.3.3 DISCHARGE PUMPS

Normally one discharge pump are fitted on the pump manifold installed in front of the plant. Pleasenote that some customers specifies an additional discharge pump.During normal operation the pump are discharging treated water from the clean water tank.The installed level switches controls the pump functions;

- High-level switch activated Discharge pump start- Low level switch activated Discharge pump stop

The discharge pump are also able, when operated in manual mode, to discharge water/sludge from thefollowing tanks;

- Inlet mixing tank(optional).

- Bioreactor tank.- Settling tank.

See Chapter 03 and 04 – Component description for technical details and operation of the pump.

01.3.4 MACERATING PUMP

The macerating pump can be fitted in one of the following two ways:- Fitted in front of the plant connected to the inlet mixing tank.- Option, fitted inside the inlet mixing tank, special submerged pump.

The macerating pump mixes and macerates the incoming raw sewage, before it enters the Bioreactortank.The pump can be operated in auto or manual mode.In auto mode pump functions are controlled by a timer in the control cabinet and the installed level

switches in the inlet mixing tank. The low level switch protects the pump from dry running when the pump is in auto mode.

- Low level switch activated Macerating pump start by timer adjustment- High level switch Macerating pump start

Please note that when the pump is operated in manual mode the function of the level switches is by- passed.

Time settings for the macerator pump are preset and only intended as a guide to handle the expectedincoming hydraulic flow of sewage water, the time settings are to be adjusted after exsiting conditions

if necessary.

See Chapter 03 and 04 – Component Description for technical details and operation of the pump.


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01.3.5 UV-STERILIZER

The UV-Sterilizer is installed between the settling tank and the clean water tank and located on the leftside of the plant.Water flows by gravity from the settling tank up through the UV-Sterilizer to the clean water tank.

See Chapter 03 and 04 – Component description for technical details and operation of the

UV-Sterilizer.

01.3.6 SLUDGE RETURN SYSTEM

The sludge returns pipe is fitted to the bottom of the settling tank. Periodically, sludge will betransferred back to the bioreactor tank for further treatment. A sludge return pump, controlled by atimer in the control cabinet, operates the system.

The system can also be operated in manual mode, and here the timer function is by-passed.

See Chapter 03 and 04 - Component description for technical details for installed sludge return pump.

01.3.7 CONTROL CABINET

The control cabinet is installed on the front of the plant. The control cabinet operates automatically the

following;

- functions in the G&O STP- function of the discharge system.- function of the macerating system- function of the sludge return system.

-

function of UV-unit- function of the high level alarm.

- function of alarm for component failure.- function of pre alarm for UV-unit

- function of vacuum pumps/alarm, only vacuum systems

See Chapter 07 - Drawings for component description for technical details and specification for theinstalled control cabinet and electrical components.

01.3.8 VACUUM UNIT

• For sewage system with vacuum unit see chapter 9, or enclosed documents foradditional Vacuum equipment.


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02.1 PREPARATION FOR INSTALLATION

Prior to installation of the Sewage Treatment Plant, all wrappings and other packing / sealing materials

must be fully removed.

A complete check of the plant integrity should be carried out prior to start of installation activities.

02.2 LIFTING

The Sewage Treatment Plant is designed for a 4 point lift in accordance with the document Slinging /

Lifting Arrangement; ref. Handling & Shipping Procedure.

02.3 SPECIAL EQUIPMENT

No special tooling or equipment is required for the installation of the Sewage Treatment Plant.

02.4 INSTALATION MATERIALS

Unless specifically agreed otherwise, G&O do not supply any materials required for installation.

02.5 FOUNDATION

It must be ensured that the supporting/underlying deck or platform structure will provide proper and

sufficient support for the sewage treatment plant.

For sewage treatment plants designed for bolting to the supporting structure, all intended bolts must be

fitted to ensure a sufficient mechanical strength of the attachment.

For sewage treatment plants to be welded to the supporting deck structure, the site welding must be

continuous and fully sealing the plant to the deck structure to prevent accumulation of water / other

liquids and substances underneath the plant.

IMPORTANT NOTE:

• For sewage treatment plants manufactured in carbon steel and internally coated for corrosion

protection, no welding must be carried out on any part of the plant that may conduct excessive

heat to the tank internal coating. Failure to do so may permanently damage the internal

coating and will invalidate the manufacturers guarantee.

• For welding of internally coated plants to the deck structure, it is advised to fill water in alltanks to a level of approximately 0.5 m prior to any welding is initiated. During welding

extreme care must be exercised to control the heat conducted to the internal coating.


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02.6 EXTERNAL CONNECTIONS

See component list in chapter 07.

02.7 VALVE SYSTEMS

The following valves are Yard supply:

Valve

Inlet valve (Black water)

Inlet valve(Grey water)

Water inlet valve

No return Valve, discharge pump

Sampling valve(Treated water)

Valves for Grease trap(if fitted)

02.8 DISCHARGE PIPE LINE FROM PLANT.

If the Sewage Treatment Plant discharge level is above outside discharge level, install a water trap in

the discharge pipe, water trap highest point should be over the High Alarm level switch in clean water

tank.

For system mounted with two discharge pumps it is recommended to install non-return valves in the

discharge pipe line for both pumps.

02.9 VENTING PIPE LINE FROM PLANT

To ensure the proper function of the venting line, it is very important that it is routed into free air as

directly as possible as a continuously rising pipe. As such negative elevation and water traps must be

avoided and the use of 90⁰ pipe bends should be kept to an absolute minimum. Drain valves must be

installed in critical locations.

02.10 EMERGENCY OVERFLOW PIPE LINEIn case a dedicated overflow line is to be installed and this is not routed to a closed tank or into a

closed piping system or similar, a water trap must be fitted to eliminate foul smelling. The water trap

must be equipped with a water supply suitable for filling of the water trap.


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02.11 ELECTRICAL AND ALARM SYSTEM

The main components on the Sewage Treatment Plant have the following power consumption:

Electric equipment Power consumption at rated voltage

Air compressor KDT3.60 3,0 kW; KDT3.80 3,5 kW; KDT3.100 6,4 kW; KDT3.140 9,3 kW

Discharge pump 2,60 kW

Macerating pump

Sludge return pump

2,60 kW

0,66 kW

UV sterilizer

Vacuum system:

Vacuumarator

W5 0,23 kW; W8 0,365 kW

MBA 25 3,45 kW; MBA 65 6,3 kW

Rated Voltage: 380-480 V 50/60 Hz voltage to be defined upon order.

Optional 690 V 50 Hz / 690 V 60 Hz

Please see electric drawing for further details in Chapter 07 – Drawings.

Visual indications for electrical components failure, high level and pre alarm for UV-unit, alarms on

front on Control Panel.

Vacuum systems are additional equipped with vacuum alarm.

Control Panel Interface connections:

- Common alarm.

- Vacuum alarm (vacuum system)

- Emergency Shut Down

- Power supply to the control panel

02.12 GREASE TRAP (Optional)

The grease trap must be installed horizontally in the galley water drain line. Make sure that a pipe of

approx. one meter is installed horizontally on the inlet side to ensure stabilization of flow; grease trap

is to be installed above level of Sewage treatment plant to ensure natural flow by gravity through

grease trap. The grease trap must be installed as close as possible to the galley area. In another case the

grease can block the galley water drain line. Make sure space for opening the grease trap and remove

the collected grease, is available at location of installation. Shut off valves must be installed on inlet

and outlet side of the grease trap. We recommend also installation of a by – pass valve, to be operated

during cleaning of grease trap. A shut off valve must be installed in the drain line from the grease trap.

Drain line to be connected to the caisson. The venting from the grease trap must go to free air to avoid

smell from the drain line. If grease trap is mounted with ½” water connection for filling/spray nozzlecleaning, it is recommended to install a quick coupling for dismantling the water connection when

maintenance of the grease trap/spray nozzle is needed.

.

For installation also see Installation diagram and P & ID drawing.


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GERTSEN& OLUFSEN A.S.

03 OPERATION/MAINTENANCE

03.1 GENERAL NOTICE ...................................................................................... 2

03.2 PREPARATION FOR FIRST STARTUP .................................................. 3

03.3 START UP – BIOREACTOR ....................................................................... 4

03.4 START UP – GREASE TRAP (optional)..................................................... 4

03.5 ROUTINE OPERATION/MAINTENANCE .............................................. 5

03.6 SLUDGE REMOVAL .................................................................................... 6

03.7 BIOREACTOR SEEDING AND START UP ............................................. 7

03.8 BIOREACTOR SHUT DOWN FOR STAND BY. ..................................... 8

03.9 SUBMERGED FIXED FILM UNITS .......................................................... 8

Appendix 1: INSPECTION OF COMPRESSOR ................................................. 9

Appendix 2: UV-UNIT........................................................................................... 12

Appendix 3: DISASSEMBLING OF PUMPS ..................................................... 21

Appendix 4: ASSEMBLING OF PUMPS............................................................ 27

Exploded drawing for pumps

Appendix 5: SLUDGE RETURN PUMP (optional)............................................. 34

1


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03.1 GENERAL NOTICE

Sewage Treatment Plant is designed for treatment of grey waste water from wash basins / floor drains and black wastewater from toilets and must be operated in strict accordance with the design specifications.

Proper earthing connection of the Sewage Treatment Plant skid must be ensured prior to connection to electrical power

supply.Electrical panel doors must be properly secured / locked after start-up to avoid un-authorised / un-intentional access tothe panel internals.A detailed local procedure must be established to secure cut-off of electrical power supply to the Sewage TreatmentPlant prior to commencement of service activities involving opening of the local electrical panel and/or entry toelectrical components on the plant.

Similarly, detailed local procedures must be established for other relevant maintenance / service activities. No alterations of the mechanical design and/or electrical and instrument components and connections on Sewage

Treatment Plant should be carried out without the prior written consent of the manufacturer.

Any such alterations will immediately invalidate all the manufacturer’s warranty obligations and the product liability.

Operational Precautions

Use of re-circulated toilet paper should not be used, as this may contain plastic materials that are not degradable in the biological process in the Sewage Treatment PlantThe following cleaning agents and substances should not be directed to the Sewage Treatment Plant:

• Organic solvents

• Strong acids and alkalis

• Biocides

• Medicine

• Paint

• Oil

• Petrol

• Toxic substances

• Salt

• Large quantities of detergents

• Large quantities of ammonia

• Large quantities of sulphate

Use of above materials will seriously deteriorate the performance of the biological process in the Sewage TreatmentPlant.For cleaning of toilets and bathroom areas it is recommended only to use products compatible with the biological

cleaning process in the Sewage Treatment Plant.

Safety instructions

When working at or in the sewage treatment plant be aware that bacteria and viruses are present. According to the work

done on the plant use protective glasses, clothes, gloves and rubber boots where necessary.Good personal hygiene and proper precaution minimize health risk.If entering the tank area take precautions for working in close areas. Ventilate the tanks, measure and secure theoxygen concentration and supply. It is recommended to carry detectors for CO an H2S gasses, and have a safty personoutside the tanks if help needed.


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03.2 PREPARATION FOR FIRST START UP

Fill up of the G&O STP (Sewage Treatment Plant) by carry out the following steps

Turn main switch to “Off”.

- Turn switches for compressor, discharge pump, sludge return and macerating pump to “Off”- Close all discharge pump suction valves- Turn switch for UV-sterilizer to “Off “- Open the valve for UV-Sterilizer- Connect the flush water line to flushing water inlet (Please note that it is also possible to fill the STP via the

inspection hatch on top of the Bioreactor tank)

- Check/Adjust timer settings for the Sludge return system, T2 set to 5 minutes (tr ) per 30 minutes (ta).- Check/adjust timer settings for the macerating pump, T3 and T1 is set to the values according to the table.-

• BR27750 T3 6 min. T1 3 min(tr ). each 30 min(ta).




• BR64750 T3 14 min. T1 7 min(tr ). each 30 min(ta).• BR74000 T3 16 min. T1 8 min(tr ). each 30 min(ta).

- All time settings for the macerator pump are preset and only intended as a guide to handle the expectedincoming hydraulic flow of sewage water, the time settings to be adjusted after exsiting conditions if

necessary.

Check that all delivery valves after the discharge pump are opened!

- Turn main switch to “On”- Start filling the sewage plant with water by opening the discharges valves for the inlet tank and the Bioreactor- The settling and the clean water tanks will be filled via internal connections- When high level alarm (clean water tank) appears on the control panel, switch off the water filling.- Close the discharge suction valve for the Bioreactor and the inlet tanks.

DURING RUNNING OF THE PUMPS, CHECK FOR RIGHT ROTATION DIRECTION OF PUMP MOTORS

BEFORE SWITCHING ON PUMPS AFTER A LONG STAND-STILL THEN ALL PUMPS MUST BE

CHECKED FOR FREE ROTATION BY ROTATING THE MOTOR SHAFT BY HAND.

- Open air inlet aeration valves- Connect air supply, open for external air or turn switch for compressor to “On”.

ENSURE THAT THE COMPRESSOR ROTATES IN RIGHT DIRECTION BY BUILD UP THE PRESSURE

QUICKLY AS IT CAN, IF OPERATED IN WRONG DIRECTION CAN CREATE A VACUUM AND END UP

WATER FILLED WITH WATER FROM THE BIOREACTOR TANK AND CAUSE BREAK DOWN OF THE

COMPRESSOR.

• For sewage system with vacuum unit see chapter 9

THE VACUUM PUMPS MUST NEVER BE STARTED OR OPERATED WITHOUT SUFFICIENT

PRE-FILING OG WATER IN SUCTION CHAMBER

- Close air supply or turn switch for compressor to “off”, make sure to close air inlet aeration valves to preventwater standing in air supply pipe line.

- Turn main switch to “off”.- Close all inlet valves.


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03.3 START UP – BIOREACTOR

When the G&O STP is filled with clean water then begin start up of the bioreactor tank by carry out the following steps:

- Check the control panel. (The main switch positioned in “Off”)

- Check air supply, open valve for external air supply or set the switch for compressor in position “On”- Check that switch for sludge return is in position ”Auto”- Check that discharge pump is in position “Auto”. (Remember to check all suction and discharge valves for the

pump are open)- Check that macerating pump is in position “Auto”. (Remember to check all suction and discharge valves for

the pump are open)

- For vacuum systems: Check that vacuum pumps are in position “Auto”. (Remember to check all suction anddischarge valves for the pumps are open and suction chamber is pre-filled with water)

- Ensure that discharge valves from bioreactor tank and settling tank are closed.- Ensure that discharge valve from clean water tank and UV-sterilizer is open.- Keep the UV-sterilizer switch in position “Off “- Turn main switch to “On”- Check of UV-sterilizer:

o Check that no water leaks are observed on the UV-Sterilizer.o Turn UV-sterilizer switch to “ON”.o Control LED “Lamp on” on UV-sterilizer panel is lit.o On some models it is possible to visual confirm that the lamp is lit via the optical ring at the end of

the lamp connectors.- After check of UV-sterilizer, turn switch to “Off”.- Check correct flow rate for macerating pump.- For vacuum systems: Check vacuum in suction line.- Add Biotal MDS-PAK- After sewage water is fed to the STP the turn UV-steriliser switch to “On”.

The Bioreactor is now operating in automatic mode.

03.4 START UP – GREASE TRAP (optional)

The Grease trap is optional equipment and if fitted positioned in the Grey water line from the Galley or other room

where grease are a component in the waste water. Waste from food grinders in galley are NOT recommended to be letto the bioreactor.

The ideal temperature for separation is 30-35 ⁰C.

For grease trap equipped with heating element the temperature range is 30–85 ⁰C.

Thermal safety release set to 110 ⁰C, reset by removing the lid of the socket and press the reset button in the upper part

of the thermostat.

Please refer to P&ID drawing for position and the drawing of grease trap connections in chapter 7 – Drawings.

- Inlet and outlet valves to be opened.(normally not a part of G&O supply)- By-pass and drain valve to be closed.(normally not a part of G&O supply)- Check that the Grease trap is ventilated.- Fill the grease trap with fresh water.


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03.5 ROUTINE OPERATION/MAINTENANCE


When operating in AUTO MODE:

Check daily

Reset alarms, no light in common alarms.Check air supply

Check tanks, piping and pumps for leakages.

Check UV-sterilizer for operation, faint purple/blue light is visible through theoptical ring on the end of the lamp

WARNING

NEVER LOOK AT DIRECTLY AN UV-LAMP WITHOUT USING

PROTECTION GOGGLES!

Check weekly

Check full air flow through air membranes by closing one of the inlet valves andletting the full flow through one membrane for approx. 30 sec. and vice versa. Do

this twice.

Add bacteria as described in “Bioreactor seeding and start up”

Check every 2 weeks

De sludge the bioreactor tank and settling tank using the discharge pump.

(See 03.6 “Sludge removal” on following pages).

Check monthly

Check function of all alarms.

Control running hour for UV-sterilizer on UV- lamp display

Inspection of UV Quartz sleeve(See Appendix 2)

STP with compressor G&O delivery.

Check filter in air compressor and replace/clean if necessary(See Appendix 1 and spare part list in chapter 6)

Empty and clean grease trap, fill with fresh water.

(See 03.6 “Sludge removal” on following pages).Check every 3 months

STP with compressor G&O delivery.

Check measurement of compressor vanes, fill out “Vanes measurement log”, andreplace vanes if necessary.(See Appendix 1 and spare part list in chapter 6)

Check every 12 months

Shut down air supply

De sludge Bioreactor, inlet- and settling tanks, remove hatches and flush the fillingmaterial with clean water, inspect fixed film units (see 3.9) fill plant with cleanwater.

Remove inspection hatch clean water tank, clean if necessary.

Open grease trap for complete cleaning, fill with fresh water.

STP with compressor G&O deliveryCheck vanes and filters, replace if necessary.(See Appendix 1and spare part list in chapter 6)

Clean all piping in sludge return system, flush with clean water by activate sludgereturn in manual mode.

Check/clean restrictor in pipeline from macerator pump.

Start air supply and check aeration system.

Check function of the solenoid valve.

Disassembly UV-sterilizer and replace UV lamp and O-ring if needed –recommended after 9000 hours, clean/replace quarts sleeve.(See Appendix 2 and spare part list in chapter 6)

Add bacteria as described in “Bioreactor seeding and start up”

Close inspection hatch

For new upstart follow start up procedure


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03.6 SLUDGE REMOVAL

In the first two months manual sludge removal is not necessary.

After two months then following manual sludge removal is recommended every two weeks:(The frequency of sludge removal is determined by the sludge accumulation depending of the quality and the load of the

sewage water.)Bioreactor:

- Close discharge valve from clean water tank.- Open discharge valve from bioreactor tank.- Switch off air supply, remove inspection hatch, discharge sludge/water from the Bioreactor to 10-15 cm under

top of filling material by turning discharge pump switch to position “Man”.- Turn discharge pump switch to “Off”- Close discharge valve from bioreactor tank.- Inspection off Bioreactor, see below.- Replace inspection hatch.- Start air supply.- Open discharge valve from settling tank.- Turn discharge pump switch to “Man”

- Discharge sludge/water from settling tank, empty the tank make sure the discharge pump is not dry runningas this could make serious damage to the pump.- Open inspection hatch and wash down the filling material, discharge water as above.

(Washing down settle tank should be done every week or more frequently if large accumulations of sludge.)- Turn discharge pump switch to “Off”- Close discharge valve from settling tank.- Open discharge valve from clean water tank.- Turn discharge pump switch to“Auto” and make sure the discharge pump is bled.

IMPORTANT!

DISCHARGE OF SLUDGE FROM THE PLANT MUST NOT TAKE PLACE WHEN THE VESSEL IS

WITHIN 12 NAUTICAL MILES FROM THE NEAREST LAND.

Inspection of Bioreactor

In connexion with the two weeks sludge removal, a visual check of the inside of the Bioreactor could be carried out.The Biofilm in the filling material should be sensed as a thin mucous/greasy layer in the aerated zones.

Start air supply, to be observed - bubbles in surface in aerated zones, seen as a “boiling” surface.

Sludge removal from Grease Trap(optional)

In general the grease trap requires only minimal maintenance.We recommend and removing grease and solids at least ones a month depending on how much load the Grease trap issubjected to.

Manual cleaning:

- Grease is to be removed manually by opening of the top cover (see drawing in chapter 7) at the outlet side ofthe grease trap.

- Solids are to be removed by drainage using the drain valve (see drawing in chapter 7).- After drainage clean the grease trap, flush with hot water and drain.

Spray nozzle cleaning:- Open drain valve (see drawing in chapter 7) start spray nozzle cleaning, hot water to be preferred.

When cleaning by spray nozzle, it is recommended to inspect grease trap at least 4 times a year, including

inspection and cleaning of spray nozzle.

IF THE GREASE TRAP IS SUBJECTED TO POOR OR LACK OF MAINTENANCE THE GREASE WILL

THEN END UP IN THE STP AND CAUSE LOSS OF CAPACITY.

IN WORSE CASE THE STP WILL STOP FUNCTIONING AND NEEDS TO BE TOTALLY CLEANED ANDSTARTED AGAIN.


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03.7 BIOREACTOR SEEDING AND START UP

BIOREACTOR SEEDING AND START UP

Biotal MDS-PAK

PRODUCT DESCRIPTION

MDS-PAK organic water treatment is designed to keep marine sanitation devices, holding tanks and sanitary systems

operating at peak efficiency.MDS-PAK is formulated with a synergistic blend of Bacillus strains to digest sewage, grease, fats, starch and other

organic compounds. The degradation of paper, protein and waste product residuals is greatly increased, and the odoursthat these produce, are reduced.

The bacteria in MDS-PAK create a bio film inside the pipe work/tank system and degrade the waste, cleaning thesystem and preventing the build up of sludge and deposits. The biological activity in the marine sewage treatment plantis greatly increased, so the plant can thus handle more waste. The Malodour in toilet areas and scruppers, normallyassociated with overload or blocked systems, are reduced .

Note!Re-circulated toilet paper should be avoided, as this type contains plastic, which will not be broken down in the biological process.

APPLICATION

Biotal MDS-PAK 3000 organic waste treatment is available in 10 kg. (22 lb.) Kegs each containing 88 water solublesmall bags.

DOSING INSTRUCTIONS

Direct dosing to the sewage treatment plant or via the nearest toilet will greatly enhance the biological activity and keep

the plant operating efficiency.

START UP or REACTIVATIONIneffective sewage treatment can be reactivated by dosing 4-8 bags of MDS-PAK into the sewage tank via the nearesttoilet. The MDS-PAK bags should be dissolved in 4-8 litters of warm water and allowed to stand for 10-15 minutes before being flushed down the toilet to reach the tank.

MAINTENANCE

The MDS-PAK contain enzymes which are naturally present in the sewage water, these enzymes in the sewage waterare not self producing and the present of the enzymes will depend of the quality of the incoming sewage water, to obtainthe best performance for the degradation of the waste products we recommend to add MDS-PAK waste water treatment,to keep a optimum quantity of enzymes.

For a vessel with a crew of up to 50 people, 1 bag should be dosed weekly via the nearest toilet.Place the bag in the toilet, leave for 10-15 minutes then flush the toilet.


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03.8 BIOREACTOR SHUT DOWN FOR STAND BY.

The sewage treatment plant is capable to stay on “stand by” for one week if aeration is retained, after one week it isstrongly recommended to shot down and clean the plant for new start up.

For shut down of sewage treatment plant, all equipment are to be turned to “Off” position. Emptying all the tanks by

manual running of discharge pump. Flush the tanks, pipes and pumps with clean water for removing of sludge.Fill the tanks with water for conservation. It is important to keep the filling material under water.Turn off the main switch.Close all inlet valves

The plant is now ready to start up, follow the start up procedure.

03.9 SUBMERGED FIXED FILM UNITS

The submerged fixed film units condition depends of the quality of the incoming sewage water, which could cause blockage, create scaling or attach the plastic media etc and weather and sea influence. A visual inspection of the fixedfilm units are recommended once a year in connection with the 12 month cleaning of the sewage plant. The fixed filmunit shall appear with no damage or blockage in the channels.Wash down the fixed film units and ensure that no blockage occurs in the units, damaged units to be replaced.

Expected life time for submerge fixed film units is 8 to 10 years depending of load and quality of sewage water and seecondition.


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Appendix 1: INSPECTION OF COMPRESSOR

To achieve proper and secure operation of the compressor, it is very important to inspect the length of the vanes every3000 operational hours.

The vanes are subject to wear due to abrasion from the walls of the enclosure.

Running the compressor with vanes below the minimum length can cause serious damage to the compressor. Pleaseread below for minimum vane length for each compressor type..

In Order to gain access to the compressor vanes then please look below

For type KDT 3.60, 3.80, 3.100 and 3.140:


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Minimum vane length:

Type Minimum length (mm)

DT 3.60 21

DT 3.80 26

DT 3.100 26

DT 3.140 31

We commend to log the vane length at least at every 3000 operating hours as to the recommendations from thecompressor manufacturer.However if the compressor is working under high temperatures and/or in dirty air which clogs up the filters frequentlythen the vanes has to be inspected at shorter intervals than 3000 hours.

Please look at next page for an example on a vane measurement log sheet which can be copied and used by the crewonboard.


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Measurement log for compressor vanes:

Vane 1 2 3 4 5 6 7 Signature and date

Please enclosure copy of compressor vane measurement log if contact is made to G & O regarding questions concerningcompressor problems or maintenance.


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Appendix 2: UV-UNIT

Controls

On/Off Switch : This will switch the UV unit on or off.

Display : Shows actual status of UV unit.Menu buttons : Step through the menu with three buttons.

Display

Menu buttons

On/Off switch

Display messages:

• Lamp defect.

• Hours pre alarm; 730 operation hours to go before lamp life time is over.

• Hours main alarm; lamp life expired.

• Flush active (optional); if the temperature rises above 35ºC the dump valve will be activated for 10 seconds

(flush time). After 60 seconds waiting time the dump valve is activated again. This sequence will stop assoon as the temperature drops below 35ºC.

• Lamp off, temp too high (optional); if the temperature rises above 35ºC (lamp off type) or 50ºC (flush valvetype) the lamp will be switched off automatically. If the temperature drops below 50ºC the lamp will beswitched on automatically.

• UV pre alarm (optional); if the UV intensity drops below 70% a UV pre-alarm is generated. Quartz sleevecleaning or lamp replacement is required soon.

• UV low (optional); if the UV intensity drops below 50% a UV low alarm is generated. Quartz sleevecleaning or lamp replacement is required. Effective disinfection is not guaranteed.


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Menu Controls

• Increment value

• Change option

• Decrement value• Change option

• Enter menu

• Enter change mode

• Accept changed parameter

Enter menu:

• Press buttonNext menu item:

• Press buttonPrevious menu item:

• Press buttonChange value / enter change mode:

• Press buttonIncrement value / change option:

• Press buttonDecrement value / change option:

• Press buttonGeneral:

• At value changes keep button pressed for faster changes.

• All changes and setups are stored when leaving the menu. If you stop pressing any of the control buttons for

longer than 5 seconds, the menu will revert back to the default screen automatically.

Menu structure

Operation screen:

Remaining lamp hours, warnings and errors, UV intensity (optional)

Menu items:1. “Starts” - Number of lamp starts.2. “Sysstarts” - Number of system starts.3. “SystemHrs” - Number of system hours.4. “Language”:

Press button for entering change mode.

Choose language (change with and button). Provisional only English available.Press button to confirm.5. “Lamp power & Software version”.6. “UV calibration” (optional):

Press button to enter the calibration mode.Change the calibration value with or button (default 110%)Press button to activate the calibration.“Are you sure?” Press button for YES, press button for NO.Press button to activate above choice.

7. “Alarm settings” (Password protected: 8131):Press button to enter the alarm settings menu.Press the button and button to enter the password. Confirm each number withthe button.

• “Max lamp life” - Lamp life time in hours:Press button for entering change mode.Change the value with or button (default 9000hrs for standard lamps, 16000 hrs for long lifelamps).Press button to confirm.

• “Hours pre alarm” - Lamp hours left when the pre alarm is activated:Press button for entering change mode.Change the value with or button (default 730hrs).Press button to confirm.

• “Hours main alarm” - Lamp hours left when the main alarm is activated:Press button for entering change mode.Change the value with or button (default 0hrs).Press button to confirm.


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Temperatureoption

“Temp pre alarm” - Lamp out type: too high temperature pre-alarm, lamp ON.Flush valve type: Temperature too high, flush valve activated.Press button for entering change mode.Change the value with or button (default: lamp out type 30ºC, flush valve type 35ºC).Press button to confirm.“Temp main alarm” - Lamp out type: too high temperature main alarm, lamp turns

OFF

Flush valve type: Temperature too high, flush valve de-activated, lamp turns OFFPress button for entering change mode.Change the value with or button (default: lamp out type 35ºC, flush valve type 50ºC).Press button to confirm.“Flush time”:Press button for entering change mode.Change the value with or button (default 10s).Press button to confirm.“Waiting time” i.e. the time before the controller re-check the temperature again:Press button for entering change mode.Change the value with or button (default 60s).Press button to confirm.“UV pre alarm”:

Press button for entering change mode.Change the value with or button (default 70%).Press button to confirm.“UV main alarm”:Press button for entering change mode.Change the value with or button (default 50%).Press button to confirm.“Exit”:Press button to exit the alarm settings menu.“Reset” - Reset the lamp hours left and lamp starts:

Alarm condit ions:

The UV unit can activate 2 different alarms: a pre alarm and a main alarm.

Pre alarm:

• A beep every 30 sec.

• Pre alarm relay contacts activated.

• Will be generated for any of the following reasons:

• 730 lamp hours are left.

• UV intensity is lower than 70% (if UV sensor is fitted).

Main alarm:

• A beep every 5 sec.

• Pre alarm relay contacts activated.

• Main alarm relay contacts activated.

• Will be generated for any of the following reasons:

• UV lamp life expired, the level of UV-C being emitted by the lamps is insufficient to ensure correctdisinfection and the lamp must be replaced.

• Lamp defect.

• Temperature is equal or above 35ºC/50ºC(if temperature sensor is fitted).

• UV intensity is lower than 50% (if UV sensor is fitted).

UV option


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Maintenance

General

In general the UV unit requires only minimal maintenance. A regular visual check of the operation of the UVlamp is generally all that is required. If the UV unit is equipped with an external alarm a visual check is maybe

less important.

In case of a failure of the UV unit, alternative means of water disinfection should be used until the UV unit isoperational again.

• Do not use alternative makes of UV lamp. Effective disinfection is not guaranteed and it may cause damage to

electrical components and cause a safety hazard.

• Maintenance should only be performed once the unit has been electrically and hydraulically isolated.

• Wear suitable personal protective equipment during maintenance.

Replacing the UV lamp

UV lamp replacement must take place with a maximum interval of 8000 hours (or 16000 hours in case of along life lamp). After this period the level of UV-C being emitted by the lamps is insufficient to ensure correct

disinfection and the lamps must be replaced.

Never touch the UV lamp with bare hands. Remove any finger marks with a soft cloth and industrial alcohol(or similar). Wear gloves or use protective materials when handling UV lamps to prevent contamination of the

lamp surface. UV lamps are fragile, support the UV lamp always with two hands. Take care when handlingthem to avoid breakage. Breakage of the UV lamp or the quartz sleeve is not covered by the warranty.

It is recommended to remove, check and clean the quartz sleeve during the replacement of the UV lamp. The

quartz sleeve o-ring seal should also be replaced.

Lamp change procedure

To gain access to the lamp, loosen the locking (outer) section of the cable gland on top of the locking plug (1) before the locking plug (2) is unscrewed. Prevent unscrewing of the reactor plug (5).

Installation of the UV lamp:

• Before the installation of the UV lamp, the lamp should be checked for surface contamination (dirt or othermarks). These should be removed using a soft cloth and industrial alcohol (or similar).

• Insert the lamp support spring(10) into the quartz sleeve (if not already present).

• Insert the UV lamp nearly all the way into the chamber. Do not drop the lamp into the quartz sleeve as thismay cause breakage of the UV lamp and/or quartz sleeve.

• Connect the lamp to the 4 pin connector.

• Re-fit the locking plug, hand tight is sufficient. Feed the UV lamp as far as possible into the quartz sleeve by using the lamp cable. Re-tighten the cable gland.

Removal of the UV lamp is a reversal of the above procedure.Whenever a new lamp is placed, reset the hour counter. (see Menu structure).

End of useful li fe/Disposal

UV lamps are to be disposed of as special waste in the same manner as fluorescent lamps. This should be

carried out in accordance with the local environmental regulations or by an authorised disposal company. If in

doubt, contact your supplier for advice.


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Removal of the UV lamp

Step 1.Release the cable gland byturning it anti-clockwise.

If the cable can be movedeasily, the cable gland is

loose enough.

Step 2. Release the locking plugby turning it anti clockwise.

Check that the lamp cableis not twisting!!

Important:Prevent unscrewing of the

reactor plug!

Step 3.Take out the UV lampcarefully.

Do not touch lamp withbare hands, ware gloves

Take care, the UV lampcan still be hot!

Step 4.Disconnect the connectorfrom the UV lamp.

Do not drop the UV lampinto the sleeve!


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Installing the UV lamp

Step 1.Check if the spring is insidethe quartz sleeve, andinsert the lamp carefully.

Do not touch the UV lampwith bare hands, ware

gloves.

Step 2.Place the connector on theUV lamp end. Do not drop the UV lamp

into the quartz sleeve!

Step 3.Hand tighten the lockingplug. (clockwise)

Step 4.Tighten the cable gland.(clockwise)

Do not over tighten!!

Quartz sleeve cleaning

If there is hardness in the water a scale deposit may be formed on the quartz sleeve. This obstructs the UV-C radiation and subsequently adversely affects disinfection. If a light covering of scale is present on thequartz sleeve, carefully clean the quartz sleeve with a proprietary descaler or industrial acid e.g. citric acid.Ensure that the correct safety measures are taken and the correct personal protective equipment is usedduring this operation.

See: Quartz change procedure.


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Quartz change procedure

Installing new quartz sleeves

• Before use, the quartz sleeve should be cleaned using a clean cloth and industrial alcohol (or similar).

• Slide the sealing o-ring(7) down from the open end by about 5 cm.

• Gently insert the quartz sleeve into the chamber with the closed end first. Gently slide the quartz sleevethrough the hole in the flow management plate until it meets the bottom support pin.

• Press the locking sleeve (6) onto the o-ring (ensure that the chamfer is facing the o-ring).

• Hand tighten the reactor plug (5) (clockwise).

• Fill the chamber with water and slowly increase the water pressure.

• Check for leakage and retighten the reactor plug, if required.

• Insert the lamp support spring(10).

• Carefully insert the UV lamp (see procedure for changing UV-lamps).

Removal of the quartz sleeve is a reversal of the above procedure.

Removal and cleaning of the quartz sleeve

Step 1.Remove the UV lamp as described in the “installing UVlamp” section

Step 2.Release the reactor plug byturning it anti-clockwise.

Step 3. Remove the locking sleeveand o-ring.

Step 4.Carefully remove the

quartz sleeve care fully. Do not touch the quartzsleeve with bare hands,ware gloves.

Step 5.Clean the quartz sleevewith clean piece of clothand proprietary descaler orsimilar.

Do not use an aggressivecleaning method. This willdamage the sleeve.


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Installing the quartz sleeve

Step 1.Carefully insert the quartzsleeve in the UV chamber. Take care to prevent

breakage!

Step 2.Ensure that the sleeve is inthe correct position throughthe flow plate.

Step 3.Fit a new o-ring andreplace the locking sleeve(with the internal chamferside towards the o-ring).

Step 4.Re-fit the reactor plug byturning it clockwise andhand tighten. Re-pressurisethe chamber and check forleaks.

Never touch the quartzsleeve with bare hands,

ware gloves

Step 5.Install the de UV-lamp as described in the“Installing UV lamp” section.

Use the gloves provided.


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Logbook

UV unit serial number: ……………………………….

Installation date ……………………………………

Options: Temperature Sensor Dump Temperature Sensor Safety(with solenoid controlled dump valve) (‘Lamp-Off’ type)

UV Sensor Quartz SleeveWiper System

Date

SystemHourcounter

LampHourcounter *

Action Carr iedout by

0 9000 or16000 Installed

*Depending of type of lamp


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Appendix 3: DISASSEMBLING OF PUMPS

Disassembly of ORPU pump.

Tools to be used:Combination wrench size 13 and 17 mm Allan key/box wrench size 4, 5 and 14 mm

Screw driver or crowbarMalletSpecial tool: rotor disk puller includingmandrel.

1Hex. nuts (pos. no. 28) and spring lockwasher (pos no. 30) is loosened andremoved. Intake (pos. no. 27) is thenremoved.NOTE: Remember to mark the intake inorder to fit it back in the right position.

2Hex. socket screws (pos. no. 35) and springlock washer (pos. no. 36) is loosened andremoved. The knife (pos. no. 32) is thenlifted via the grub screws (pos. no. 34)

Knife pos.no. 32

4 pcs. Hex. socketscrew pos. no. 35 + 4pcs. spring lockwasher pos. no. 36

5 pcs. hex. nut pos.no. 28+ 5 pcs. spring lockwasher pos. no. 30

Intake pos. no. 27.

Grub screwpos. no. 34


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3Hex. nut (pos. no. 22) is loosened andremoved.

4Housing cover (pos. no. 20) is removed andgrub screw (pos. no. 21) is loosened andremoved.

5 pcs. hex.nut pos. no.

22

5 pcs. grubscrew pos.no. 21

Housingcover pos.no. 20


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5The cutter (pos. no. 33) is loosened bymeans of an Allan key and a screw driver(or similar) in order to hold the rotor disk(pos. no. 18) while loosening the cutter.NOTE: It is very important that the screwdriver (or similar) is able to enter the rotor

disk, all the way to the shaft in order tokeep the rotor disk in same position.

6Hex. nut (pos. no. 25) is loosened andremoved together with rotor disk holdingdisk (pos. no. 26)Use a box wrench or a stiff Allan key, thescrew is secured with loctite.

Cutter pos.no. 33


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7Fit the mandrel for the rotor disk puller(special tool)

8Fit the rotor disk puller (special tool) into therotor disk (pos. no. 18) and pull it off theshaft (pos. no. 3) with an Allan key andspanner.

Mandrel

Rotor diskpos. no. 18

Rotor diskpuller

(specialtool)


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9Feather key (pos. no. 14) is loosened andremoved from shaft (pos. no. 3)

10The rotating part of the end-face seal (posno. 23) is loosened and removed by meansof two screw drivers or similar tool.NOTE: It is very important that the shaftsurface is smooth and without any sharpedges before removing the stationary partof the end-face seal as this can cut the o-ring inside the end-face seal.

If rotating part of end face seal is stuck, goto no. 11 and remove the seal by gently liftthe pump housing e.g. use a tree leg puller.

Rotating part of theend-face seal pos.no. 23


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11Hex. screws (pos. no. 15) and spring lockwashers (pos. no. 16) is loosened andremoved. Pump housing (pos. no. 19) isthen removed together with the stationarypart for the end-face seal (pos. no. 23)

4 pcs. Hex. screwspos. no. 15 + 4 pcs.spring lock washerspos no. 16

Pumphousingpos. no. 19

The stationary partfor the end-face seal(pos. no. 23)


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Appendix 4: ASSEMBLING OF PUMPS

Assembly of ORPU pump.

Tools to be used:Combination wrench size 13 and 17 mm

Allan key size 4 and 5 mmScrew driver or crowbarRubber (plastic) malletSpecial tool: Sleeve for end-face seal,Fitting tool for end-face seal, Fitting tool forrotor disk and a piece of paper.

1 Apply lubricant on sealing surface on pumpskirt (pos. no. 4) Fit pump housing (pos. no.19) with the discharge flange facing awayfrom the motor feet.

2Fit spring lock washers (pos. no. 16) andtighten hex. nuts (pos. no. 15)

Pump skirtpos. no. 4


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3Fit the stationary part for the end-face seal(pos. no. 23) by pressing it into the pumphousing.NOTE: It is very important to protect thesealing surface and to press it into correctposition using fitting tool for end-face seal.

4Fit the sleeve for end-face seal onto shaft

before fitting the end-face seal.

Stationary partfor the end-face seal (pos.no. 23)

Rotating partfor the end-face seal (pos.no. 23)

Washer for theend-face seal(pos. no. 23)


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5Fit the rotating part of end-face seal(remember to fit the two sealing facestowards each other) and press it downusing the fitting tool for end-face seal inorder to ensure that it is positioned correct.

6Sleeve for end-face seal is removed fromshaft and washer for end-face seal is fittedand apply grease or similar in order to keepit in position during pump assembly.

7Fit feather key (pos. no. 14).

Feather key(pos. no. 14)


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8Grease or lubricating pasta is applied ontoshaft in order to avoid the rotor disk toseize up on the shaft.

9Rotor disk is fitted using the fitting tool forrotor disk in order to ensure that the rotordisk is pressed all the way down andhereby into correct position.

Fitting tool forrotor disk


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10Rotor disk holding disk (pos. no. 26) andHexagon screw (pos. no. 25) add a littleloctite, is fitted and tightened.

11Grease or lubricating pasta is applied ontothread of the cutter (pos. no. 33). Thecutter is tightened using an Allan key androtor disk is kept in position using a screwdriver (or similar).NOTE: It is very important that the screwdriver (or similar) is able to enter the rotordisk, all the way to the shaft, in order to

keep the rotor disk in same position.

12The O-ring (pos. no. 24) is fitted intogroove using a small amount of grease orlubricating pasta. Also the sealing surfacesare well greased.


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13The knife (pos. no. 32) is fitted onto thehousing cover (pos. no. 20). A plastic orrubber mallet can be used.NOTE: It is very important that both partsare cleaned and all sealing surfaces arewell greased with grease or lubricating

pasta before assembly.

14The housing cover with knife is fitted ontopump housing (pos. no. 19).


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04. COMPONENT DESCRIPTION

04.1

AIR COMPRESSOR ................................................................... 2

04.2 DISCHARGE PUMP ................................................................... 2

04.3 MACERATOR PUMP ................................................................. 2

04.4 UV -STERILIZER ....................................................................... 3

04.5 LEVEL SWITCHES .................................................................... 3

04.6

SLUDGE RETURN PUMP ......................................................... 3

04.7 VACUUM UNIT ........................................................................... 3


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04.1 AIR COMPRESSOR

One of the following air compressors is installed on the sewage treatment plant

according to chapter 01.1.1:

Maker: Becker Becker Becker BeckerType: KDT3.60 KDT3.80 KDT3.100 KDT3.140Insulation class: F F F FProtection class: IP55 IP55 IP55 IP55Motor voltage: 190-255/330-440 50Hz

190-290/330-500 60Hz 190-255/330-440 50Hz

190-290/330-500 60Hz

340-430/588-745 50Hz

340-500/588-866 60Hz

340-430/588-745 50Hz

340-500/588-866 60Hz Speed: 1465-1780 1465-1780 1465-1780 1465-1780kW: 3,0 3,5 6,4 9,3Weight: 80 85 129 140

04.2 DISCHARGE PUMP

The following discharge pump are installed on the sewage treatment plant:

Maker: Orpu

Type: Orcut 130

Insulation class: F

Protection class: IP55

Flow:

Delivery head:

0-16 m3/h

28-0 m

Motor voltage: 400/690-480 V 50/60 Hz

Rotation speed: 3460 rpm

Normal power consumption: 2.60 kW

Pump housing/impeller: GG 25

Weight: 46 kg

04.3 MACERATOR PUMP

The following macerator pump is installed on the sewage treatment plant:

Maker: ORPU

Type: Orcut 130

Insulation class: F

Protection class: IP55

Flow:

Delivery head:

0-16 m3/h

28-0 m

Motor voltage: 400/690-480 V 50/60 Hz

Rotation speed: 3460 rpm

Normal power consumption: 2,6 kW

Pump housing/impeller: GG 25

Weight: 46 kg


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04.4 UV -STERILIZER

One of the following UV sterilizer is installed on the sewage treatment plant

according to chapter 01.1.1:

Maker: Van Remmen Van Remmen

Type: W5 W8

Power supply: 230Vac 50/60Hz 230Vac 50/60Hz

Protection class: IP55 IP55

Lamp consumption: 0,23 kW 0,365 kW

Flow 60% transmission 6,2 m3 9,2 m3

Expected life time of

lamp:

16000 16000

04.5 LEVEL SWITCHES

The following level switches are installed on the sewage treatment plant:

Maker: Pepperl+Fuchs

Type: LFL2

Max voltage: 250 V

04.6 SLUDGE RETURN PUMP

The following sludge return pump is installed on the sewage treatment plant

Maker:

Type:

Insulation class:

Protection class:

Flow:

Delivery head:

Motor voltage:

Rotation speed:

Motor consumption:

Pump casing:

housing/impeller:

Weight: Noise Level:

Herborner Unipump

0,75/K25-1-100-V-W1

F

IP55

0,6 m3/h

3.0/4,4 m

400/440 V 50/60 Hz

1500/1800 rpm

0,66 kW

GG 25

GG 25

26 kg

04.7 VACUUM UNIT



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05 TROUBLE SHOOTING

05.1 TROUBLE SHOOTING .............................................................. 2


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05.1 TROUBLE SHOOTING

Discharge pump does not start / Common Alarm to ECR / High Level Alarm:

1. Reset alarm by pressing reset alarm on control panel.

2. Start discharge pump in manual mode and empty clean water tank.

If the pump is running check the high level switch – replace if needed.

3. If the pump is not running,

Check power supply to motor.

Check for clogged pump.

Check Contactor and thermal protection – replace if needed.

Check insulation on motor winding – replace if needed.

WARNING

THINK SAFETY WHEN WORKING WITH ELECTRICAL COMPONENTS.

Discharge pump does not stop:

1. Immediately switch to OFF.

2. Check low level switch – replace if needed.

Discharge pump is running but not pumping:

1. Pump rotates in wrong direction(initial start) – stop immediately - change

one of the phases on power cable(remember to check the other

pumps/Compressor also)

2. Check all inlet/outled valves.

3. Check water level in the tank.

4. Bleed the pump.

5. Check impeller – replace if needed

Macerating pump does not start / Common Alarm to ECR / High Level Alarm:

1. Check timer settings – adjust/replace timer if needed.

2. Start macerator pump in manual mode.

3. If the pump is running,

Check the high level switch – replace if needed.

Check the low level switch – replace if needed.


Check power supply to motor.

Check for clogged pump.



WARNING


Macerating pump does not stop:


2. Check high level switch in inlet tank.


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Macerating pump is running but not pumping:




2. Check all inlet/outled valves.3. Check water level in the tank.

4. Bleed the pump.


Overflow in STP:

1. Check that the discharge valve on clean water tank is open.

2. Check function of level switches.

3. Check if discharge/macerator pump is in auto mode.

4. Check discharge/macerator pump as mention above.

Air Compressor does not work:

1. Check power supply to compressor.

2. Check air filter on compressor – replace if needed

3. Check vanes in compressor – replace if needed

WARNING


Air Compressor running, but insufficient capacity:

1. Compressor rotates in wrong direction(initial start) – stop immediately as

water can enter the compressor - change one of the phases on power

cable(remember to check the pumps also)

2. Check filters on compressor – replace if needed.

3. Check vanes in compressor – replace if needed.

Sludge pump does not start:


2. Start sludge return pump in manual mode.

3. If the pump is running,

Check timer replace if needed.


Check power supply to motor.Check for clogged pump.



WARNING


Sludge return pump does not stop:



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Sludge return pump is running but not pumping:




2. Check all inlet/outled valves.3. Check water level in the tank.

4. Bleed the pump.


UV-sterilizer does not work:

1. Check power supply to UV sterilizer.

2. If power supply is ok and lamp is not lit then check

Lamp starter.

If unit is overheated.

Loose lamp connection/wire.

Internal fuse.

3. Replace lamp (9000 operating hours)


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Foam in the STP:

1. Unbalance between biofilm and sewage water, normally when the plant is

started up.

2. To much use of soap/cleaning devices, choose detergents with low foaming

properties for cleaning and/or do not empty used cleaning water in dainslead to sewage treatment plant.

Foul smelling from Bioreactor:

1. Air supply to bioreactor missing.

2. Bacteria killed.

(Brown sludge: Indicate normal Bacteria life)

(Black sludge: Bacteria killed,- check chemicals used for general cleaning)

CONTACT GERTSEN & OLUFSEN A/S. FOR FURTHER ACTION.

For sewage system with vacuum unit see chapter 9


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06 RECOMMENDED SPARE PARTS

06.1

SPARE PARTS FOR COMPRESSOR ..................................... 2

06.2

SPARE PARTS FOR DISCHARGE/MACERATOR PUMP.. 2

06.3 SPARE PARTS FOR SLUDGE RETURN SYSTEM .............. 2

06.4 SPARE PARTS FOR UV STERILIZER ................................... 3

06.5

SPARE PARTS FOR LEVEL SWITCH ................................... 3

06.6

VACUUM UNIT (OPTIONAL) .................................................. 3


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06.1 SPARE PARTS FOR COMPRESSORSee component list chapter 07 or chapter 01.1.1 for the installed equiptment.

KDT 3.60- KDT 3.80

Article number Quantity Description Remarks

BR.3012 2 pcs Filter Pos 68BR.3028 1 sets Filter Pos 91

BR.3014 1 set Vanes 1 set consist of 4 vanes

DT 3.100 – KDT 3.140


BR.3012 2 pcs Filter Pos 68

BR.3029 1 pcs Filter Pos 91

BR.3027 1 sets Vanes 1 set consists of 4 vanes

06.2 SPARE PARTS FOR DISCHARGE/MACERATOR PUMP

Discharge and Macerator pump ES 130Article number Quantity Description Remarks

BR.2000 1 Wearing part set 1 Mechanical seal

1 Angular ball bearing

1 O-ring 24x6

1 O-ring 80x3

1 O-ring 185x3

1 O-ring 185x3


BR. 2020 1 pcs. Special pump tool for

disassembling andassembling

Rotor disk puller incl. mandrel

Sleeve for end face sealFitting tool for end face sleeve

Fitting tool for rotor disk

06.3 SPARE PARTS FOR SLUDGE RETURN SYSTEM

0,75/K25-1-100-F-V-W1


BR.2039 1 pcs Mechanical seal Pos. 433

BR.2040 1 pcs Bearing non drive side Pos. 320.1

BR.2041 1 pcs Bearing drive side Pos. 320.2

BR.2042 1 pcs Impeller nut Pos. 920

BR.2043 1 pcs Labyrinth ring Pos. 423BR.2044 1 pcs Gasket Pos. 433


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06.4 SPARE PARTS FOR UV STERILIZERSee component list chapter 07 or chapter 01.1.1 for the installed equiptment.

W 5


BR.7150 1 pcs. UV-lampBR.7151 1 pcs. Quartz sleeve

BR.7152 1 pcs. Coupling complete 25mm 1 Locking sleeve

1 Reactor plug

1Transparent sleeve

1 O-ring 28x3,5

1 O-ring 41x1,78

BR.7153 1 pcs Lamp support spring

W 8

Article number Quantit

y

Description Remarks

BR.7157 1 pcs. UV-lampBR.7159 1 pcs. Quartz sleeve

BR.7152 1 pcs. Coupling complete 28mm 1 Locking sleeve

1 Reactor plug

1Transparent sleeve

1 O-ring 28x3,5

1 O-ring 41x1,78

BR.7153 1 pcs Lamp support spring

06.5 SPARE PARTS FOR LEVEL SWITCH


BR.6001 1 pcs. Level switch complete LF2-CK-U

06.6 VACUUM UNIT (OPTIONAL)See component list chapter 07 or chapter 01.1.1 for the installed equiptment.

25 MB-A


BR.10009 1 set Spare part kit Shaft seal, sealing ring, rubber flap, split sleeve

and O-rings.

65 MB-A


BR.10010 1 set Spare part kit Shaft seal, sealing ring, rubber flap, V-ring, split

sleeve and O-rings.


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07 DRAWINGS

Description

P&I DIAGRAM

GENERAL ARRANGEMENT

COMPONENT LIST

ELECTRICAL DRAWING

INSTALLATION DIAGRAM


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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GERTSEN & OLUFSEN


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1

08 CERTIFICATES

DECLARATION OF CONFORMITY

EC TYPE-EXAMINATION CERTIFICATE FOR G&O

BIOREACTOR, ISSUED BY “DET NORSKE VERITAS”

G&O LEAKAGE TEST CERTIFICATE

PAINT SPECIFICATION ( OPTIONAL )


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Vol. Sol. Dryfilm Wetfilm µ µ n.

7802 Div Ral / NCS 70 80 114 4 hrs

7524 Div Ral / NCS 57 60 105 6 hrs 140 219

Date:

Area: Black steel.

Pretreatment:

Januar 2012.

at 20°C

SigmaFast 205

SigmaDur 520

ShadeProduct no. and name

Customer: NVG.

Project: Schmidt Marine- El aps. Tanks outside.

Painting Specification - Protective Coatings

Oil and grease is removed by emulsifier, followed by highpressure freshwater hosing to remove salts and other impurities. The surface is blasted to Sa 2½ according t

surface for impurities.

Johnny YssingPrepared by:

Filmthickness Re-coating Int

1. 31

2. 17

3. 0

4. 37

PPG Coatings SPRL/BVBA hereby draws the attention to, that PPG Coatings SPRL/BVBA in connection with inspection and technical advice, does not take over the full responsibility of the surface treatment. PPG Coatings

quality of our products, and that specification, datasheets and advice, are given in accordance to the best of our knowledge and know-how.

“All relations with third parties shall be governed by PPG Coatings SPRL/BVBA´s general Conditions of sale. Third party conditions are excluded. The conditions contain a jurisdiction whereas the country court in Charleroi sh

jurisdiction (Court District of Charleroi, Avenue General M ichel, 6000 Charleroi, Belgium). Please r efer to the PPG Coatings SPRL/BVBA´s terms and conditions of sale.”

Remark:

It is highly recommended to consult relevant technical- and safety datasheets before the job is begun.

Above mentioned system applies according to demands in ISO 12944-5 corrossionscategori C3 Medium.

Stripecoating is carried out on weldingseams, holes as well as areas difficult to reach.

For runnig maintance and/or repair of evt. montage damage refur to repair maintance guide. Sigma Coatings and Amercoat are b

SQP PC UK.xls PPG Coatings SPRL/BVBA.Tweemontstraat 104BE-2100 Deurne-Antwerpen


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Vol. Sol. Dryfilm Wetfilm µ µ n.

7409 Offwhite 66 100 152 36 hrs

7448 Greenish grey 86 100 116 16 hrs7448 Greenish grey 86 100 116 16 hrs

300 384

Date:

Area: Black steel.

Pretreatment:

Januar 2012.

at 20°C

Sigma Phenguard 930 (Primer)

Sigmaguard 790 (HS)Sigmaguard 790 (HS)

ShadeProduct no. and name

Customer: NVG.

Project: Schmidt Marine- El aps. Tanks inside.

Painting Specification - Protective Coatings

Oil and grease is removed by emulsifier, followed by HPFW hosing to remove salts and impurities. The surface is sandblasted to Sa 2½ according to ISO 8501-1, with

50-100 my. Clean the surface.

Johnny YssingPrepared by:

Filmthickness Re-coating Int

1. 31

2. 17

3. 0

4. 37

PPG Coatings SPRL/BVBA hereby draws the attention to, that PPG Coatings SPRL/BVBA in connection with inspection and technical advice, does not take over the full responsibility of the surface treatment. PPG Coatings

quality of our products, and that specification, datasheets and advice, are given in accordance to the best of our knowledge and know-how.

“All relations with third parties shall be governed by PPG Coatings SPRL/BVBA´s general Conditions of sale. Third party conditions are excluded. The conditions contain a jurisdiction whereas the country court in Charleroi sh

jurisdiction (Court District of Charleroi, Avenue General M ichel, 6000 Charleroi, Belgium). Please r efer to the PPG Coatings SPRL/BVBA´s terms and conditions of sale.”

Remark:

It is highly recommended to consult relevant technical- and safety datasheets before the job is begun.

Stripecoating is carried out on weldingseams, holes as well as areas difficult to reach.

For runnig maintance and/or repair of evt. montage damage refur to repair maintance guide. Sigma Coatings and Amercoat are b

SQP PC UK.xls PPG Coatings SPRL/BVBA.Tweemontstraat 104BE-2100 Deurne-Antwerpen


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09 VACUUM UNIT OPERATION & MAINTENANCE

INSTALLATION

SANITARY SYSTEM

MODE OF OPERATION VACUUMARATOR

DATA SHEET VACUUMARATOR

DATA SHEET EL MOTOR

OPERATION - VACUUM UNIT

TROUBLESHOOTING & REPAIR

DISASSEMBLY & ASSEMBLY INSTRUCTION

DRAWINGS

INSTRUCTION FOR VACUUM SWITCHES


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Installation

ets

™

acuumarator™

pump

T

SHEET NO. 2108 - 01.01. 2009 Page 1

f

1

Vacuum unit

When designing the installation of the vacuum unit, it

is important to provide sufficient space for inspection

and maintenance. Install shut-off valves included

in

Jets™

supply) according to piping diagram. Each

pump

is

supplied with vibration dampers. Flexible

joints included in Jets™ supply) must be used when

connecting the pump s suction and pressure side.

The pump must

be

located to avoid head loss

on

outlet pipe. Height of outlet pipe should

be

kept

at

a minimum, preferably less than 2 meters, because

increased height of outlet pipe will reduce vacuum

capacity of pump.

If increased height

is

needed, please contact Jets™

Vacuum Technical Oepartment.

Sewage

treatment plant

If connected to a sewage treatment plant, the

discharge pipe s) from lhe pump s) IS connected to

the plant.

See

SewageTreatment Plant Instruction

Manual.

Integrated holding tank

Connected to an integrated holding tank, connections

for pumps must be made according to Technical

Manual.

Level switches for

controlof

discharge pump s)

must be instalied according to drawing

in

Technical

Manual.

Fresh water supply

Fresh water supply may be connected to the suction

chamber on each pump to flush and clean when

neccessary and to fill the pump with water atter

service.

How to fill water into the pump:

Unscrew plug*

on

side of suction chamber**, one

of the plugs. Fill fresh water through the plug hole

up to

pi

ug hole level. Level may be controlled by

looking through the suction chamber cover ***. Refit

plug.

Please n tice

For pump Jets™15M/15MB and Jets™15MB-0:

To keep sufficient priming of the pump, outlet pipe

should be at least 1 m long in vertical direction.

Rotation the Jets™

Vacuumarator™ pump

The correct rotation

is

indicated with an arrow on the

pump housing. The rotation of the pump is always

clockwise seen from the motor fan end.

Prior to checking the rotation, make sure that the

pump

is

filled with liquid.

Starting

up

the pumps without liquid will damage the

shatt seals.

Jets™

Vacuumarator™

Owg**

Pl

@ manual 445 - g&o bioreactor

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