@ Manual 445 - G&O Bioreactor

G&O Bioreactor

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

Gertsen & Olufsen A/S Savsvinget 4 DK 2970 Hørsholm Denmark Tel: +45 4576 3600 Fax: +45 4576 1773

G&O Bioreactor

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

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G&O Bioreactor

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G&O Bioreactor

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G&O Bioreactor

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G&O Microbac Bioreactor Manual

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

Gertsen & Olufsen A/S Savsvinget 4 DK 2970 Hørsholm Denmark Tel: +45 4576 3600 Fax: +45 4576 1773 [email protected] www.g-o.dk

G&O Bioreactor

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G&O Bioreactor

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G&O Bioreactor

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G&O Bioreactor

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G&O Bioreactor

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G&O Bioreactor

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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 E-mail address:

FAX: +45-45761773

[email protected]

GERTSEN & OLUFSEN A.S.

01

01.1 01.1.1 01.2

GENERAL DESCRIPTION

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

1


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

3

Designed Hydraulic Load:

74 m /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:

W8

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

2


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 approved according to IMO MEPC 159(55). The G&O STP is a continuation of the well-proven Microbac Bioreactor, which has been on the market for 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 the self-cleaning aeration system provides the required amount of dissolved oxygen for the biomass to feed on 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 normally needed. 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 matrix Settling tank with matrix Clean water tank The inlet mixing tank is optional supply from G&O if case the ship can accommodate this tank within the 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:

Compressor Discharge pump Macerating pump Sludge return pump UV-Steriliser Aerators in the bioreactor Level switches in clean water tank Level 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 un it via the ship air system.

3


Black water and grey water will be let into the inlet mixing tank. The wastewater will be macerated by circulation through the macerator pump. The macerating pump will start/work according to the settings of 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 the effluent and on the surfaces on which biomass is fixed. The wastewater is driven upwards in the adjacent 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 settled sludge back to the influent tank. The installed level switches control the water level in the clean water tank. The discharge pump will start when water reaches “high” and stop when water level reaches “low”. In addition to the high and low 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 fitted components 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 under maceration, 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 t he 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 air compressor.

4


01.3.3 DISCHARGE PUMPS Normally one discharge pump are fitted on the pump manifold installed in front of the plant. Please note 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 the following 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 Bioreactor tank. 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 expected incoming 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.

5


01.3.5 UV-STERILIZER The UV-Sterilizer is installed between the settling tank and the clean water tank and located on the left side 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 be transferred back to the bioreactor tank for further treatment. A sludge return pump, controlled by a timer 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 the installed control cabinet and electrical components.

01.3.8 VACUUM UNIT •

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

6


02.

INSTALLATION

02.1

PREPARATION FOR INSTALLATION ..............................

2

02.2

LIFTING .................................................................................

2

02.3

SPECIAL EQUIPMENT ........................................................

2

02.4

INSTALATION MATERIALS...............................................

2

02.5

FOUNDATION .......................................................................

2

02.6

EXTERNAL CONNECTIONS ...............................................

3

02.7

VALVE SYSTEMS .................................................................

3

02.8

DISCHARGE PIPE LINE FROM PLANT. ...........................

3

02.9

VENTING PIPE LINE FROM PLANT .................................

3

02.10 EMERGENCY OVERFLOW PIPE LINE .............................

3

02.11 ELECTRICAL AND ALARM SYSTEM ...............................

4

02.12 GREASE TRAP (Optional) ....................................................

4

1

GERTSEN & OLUFSEN A.S. 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 all tanks 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.

2

GERTSEN & OLUFSEN A.S. 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 LINE In 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.

3

GERTSEN & OLUFSEN A.S. 02.11 ELECTRICAL AND ALARM SYSTEM The main components on the Sewage Treatment Plant have the following power consumption: Electric equipment Air compressor Discharge pump Macerating pump Sludge return pump UV sterilizer

Power consumption at rated voltage KDT3.60 3,0 kW; KDT3.80 3,5 kW; KDT3.100 6,4 kW; KDT3.140 9,3 kW 2,60 kW 2,60 kW 0,66 kW W5 0,23 kW; W8 0,365 kW

Vacuum system: Vacuumarator

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 o f 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 nozzle cleaning, 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.

4

GERTSEN & OLUFSEN A.S. 03

OPERATION/MAINTENANCE

NOTICE ......................................................................................

03.1

GENERAL

03.2

PREPARATION FOR FIRST START UP .................................................. 3

03.3

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

03.4

START UP – GREASE TRAP

03.5

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

03.6

SLUDGE

03.7

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

03.8

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

03.9

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

(optional).....................................................

REMOVAL ....................................................................................

Appendix 1:

INSPECTION OF

Appendix 2:

UV-UNIT...........................................................................................

Appendix 3:

DISASSEMBLING OF

4

6

COMPRESSOR ................................................. 9 12

PUMPS ..................................................... 21

Appendix 4: ASSEMBLING OF PUMPS............................................................ Exploded drawing for pumps Appendix 5:

2

27

SLUDGE RETURN PUMP (optional). ............................................ 34

1

GERTSEN & OLUFSEN A.S. 03.1

GENERAL NOTICE

Sewage Treatment Plant is designed for treatment of grey waste water from wash basins / floor drains and black waste water 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 to the panel internals. A detailed local procedure must be established to secure cut-off of electrical power supply to the Sewage Treatment Plant prior to commencement of service activities involving opening of the lo cal electrical panel and/or entry to electrical 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 Plant The 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 Treatment Plant. 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 the oxygen concentration and supply. It is recommended to carry detectors for CO an H2S gasses, and have a safty person outside the tanks if help needed.

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 BR37000 BR46250 BR55500 BR64750 BR74000

T3 6 min. T1 3 min(tr ). each 30 min(ta). T3 8 min. T1 4 min(tr ). each 30 min(ta). T3 10 min. T1 5 min(tr ). each 30 min(ta). T3 12 min. T1 6 min(tr ). each 30 min(ta). T3 14 min. T1 7 min(tr ). each 30 min(ta). 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 expected incoming 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 prevent water standing in air supply pipe line. Turn main switch to “off”. Close all inlet valves.

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 p osition “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 and discharge 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: 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 o 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 let to 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.

4


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 the optical 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 and letting 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”, and replace 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 filling material with clean water, inspect fixed film units (see 3.9) fill plant with clean water. Remove inspection hatch clean water tank, clean if necessary. Open grease trap for complete cleaning, fill with fresh water. STP with compressor G&O delivery Check 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 sludge return 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

5


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 running as 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 d epending on how much load the Grease trap is subjected to.

-

-

Manual cleaning: Grease is to be removed manually by opening of the top cover (see drawing in chapter 7) at the outlet side of the 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 AND STARTED AGAIN.

6


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 odours that these produce, are reduced. The bacteria in MDS-PAK create a bio film inside the pipe work/tank system and degrade the waste, cleaning the system and preventing the build up of sludge and deposits. The biological activity in the marine sewage treatment plant is greatly increased, so the plant can thus handle more waste. The Malodour in toilet areas and scruppers, normally associated with overload or blocked systems, are reduced . Note! Re-circulated toilet paper should be avoided, as th is type contains plastic, which will not b e 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 soluble small 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 REACTIVATION Ineffective sewage treatment can be reactivated by dosing 4-8 bags of MDS-PAK into the sewage tank via the nearest toilet. 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 water are not self producing and the present of the enzymes will depend of the quality of the incoming sewage water, to obtain the 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.

7


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 is strongly 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 fixed film units are recommended once a year in connection with the 12 month cleaning of the sewage plant. The fixed film unit 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 see condition.

8

GERTSEN & OLUFSEN A.S. 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 every 3000 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. Please read 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:

9

GERTSEN & OLUFSEN A.S. Minimum vane length: Type DT 3.60 DT 3.80 DT 3.100 DT 3.140

Minimum length (mm) 21 26 26 31

We commend to log the vane length at least at every 3000 operating hours as to the recommendations from the compressor manufacturer. However if the compressor is working under high temperatures and/or in dirty air which clogs up the filters frequently then 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 crew onboard.

10


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 concerning compressor problems or maintenance.

11


UV-UNIT

Controls : This will switch the UV unit on or off. : Shows actual status of UV unit. : Step through the menu with three buttons.

On/Off Switch Display Menu 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 as soon as the temperature drops below 35ºC. Lamp off, temp too high (optional); if the temperature rises above 35ºC (lamp off type) or 50ºC (flush valve type) the lamp will be switched off automatically. If the temperature drops below 50ºC the lamp will be switched on automatically. UV pre alarm (optional); if the UV intensity drops below 70% a UV pre-alarm is generated. Quartz sleeve cleaning or lamp replacement is required soon. UV low (optional); if the UV intensity drops below 50% a UV low alarm is generated. Quartz sleeve cleaning or lamp replacement is required. Effective disinfection is not guaranteed.

12


Menu Controls 

• •





• • • • •

Increment value Change option Decrement value Change option Enter menu Enter change mode Accept changed parameter

Enter menu: • Press  button Next menu item: • Press  button Previous menu item: Press  button • Change value / enter change mode: • Press  button Increment value / change option: • Press  button Decrement value / change option: Press  button •

General: • •

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 with the  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 life lamps). 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.

13

GERTSEN & OLUFSEN A.S. “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 OFF Press  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:

Temperature option

UV option

Al arm co nd it io ns:

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 correct disinfection 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).

14

GERTSEN & OLUFSEN A.S. Maintenance General

In general the UV unit requires only minimal maintenance. A regular visual check of the operation of the UV lamp 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 is operational 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 a long 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 handling them 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 other marks). 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 in to the quartz sleeve as this • may 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.

15

GERTSEN & OLUFSEN A.S. Removal of th e UV lamp

Step 1. Release the cable gland by turning it anti-clockwise.

If the cable can be moved easily, the cable gland is loose enough.

Step 2. Release the locking plug by turning it anti clockwise.

Check that the lamp cable is not twisting!! Important: Prevent unscrewing of the reactor plug!

Step 3. Take out the UV lamp carefully.

Do not touch lamp with bare hands, ware gloves Take care, the UV lamp can still be hot!

Step 4. Disconnect the connector from the UV lamp.

Do not drop the UV lamp into the sleeve!

16

GERTSEN & OLUFSEN A.S. Installing the UV lamp Step 1. Check if the spring is inside the quartz sleeve, and insert the lamp carefully.

Do not touch the UV lamp with bare hands, ware gloves.

Step 2. Place the connector on the UV lamp end.

Do not drop the UV lamp into the quartz sleeve!

Step 3. Hand tighten the locking plug. (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 UVC radiation and subsequently adversely affects disinfection. If a light covering of scale is present on the quartz 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 used during this operation. See: Quartz change procedure.

17


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 sleeve through 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 UV lamp” section Step 2. Release the reactor plug by turning it anti-clockwise.

Step 3. Remove the locking sleeve and o-ring.

Step 4. Carefully remove the quartz sleeve care fully.

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

Step 5. Clean the quartz sleeve with clean piece of cloth and proprietary descaler or similar.

Do not use an aggressive cleaning method. This will damage the sleeve.

18

GERTSEN & OLUFSEN A.S. Installing the quartz sleeve Step 1. Carefully insert the quartz sleeve in the UV chamber.

Take care to prevent breakage!

Step 2. Ensure that the sleeve is in the correct position through the flow plate.

Step 3. Fit a new o-ring and replace the locking sleeve (with the internal chamfer side towards the o-ring).

Step 4. Re-fit the reactor plug by turning it clockwise and hand tighten. Re-pressurise the chamber and check for leaks.

Never touch the quartz sleeve with bare hands, ware gloves

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

19

Use the gloves provided.

GERTSEN & OLUFSEN A.S. Logbook

UV unit serial number: ………………………………. Installation date ……………………………………

Options:  Temperature

Sensor Dump (with solenoid controlled dump valve)

 Temperature

Sensor Safety (‘Lamp-Off’ type)

 UV

Sensor Wiper System

Date

 Quartz

System Hour counter

Lamp Hour counter *

0

9000 or 16000

Ac ti on Installed

*Depending of type of lamp

20

Sleeve

Carr ied out by


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 crowbar Mallet Special tool: rotor disk puller including mandrel. 1 Hex. nuts (pos. no. 28) and spring lock washer (pos no. 30) is loosened and removed. Intake (pos. no. 27) is then removed. NOTE: Remember to mark the intake in order to fit it back in the right position. Intake pos. no. 27.

5 pcs. hex. nut pos. no. 28 + 5 pcs. spring lock washer pos. no. 30

2 Hex. socket screws (pos. no. 35) and spring lock washer (pos. no. 36) is loosened and removed. The knife (pos. no. 32) is then lifted via the grub screws (pos. no. 34) Knife pos. no. 32

4 pcs. Hex. socket screw pos. no. 35 + 4 pcs. spring lock washer pos. no. 36 Grub screw pos. no. 34

21

GERTSEN & OLUFSEN A.S. 3 Hex. nut (pos. no. 22) is loosened and removed. 5 pcs. hex. nut pos. no. 22

Housing cover pos. no. 20

4 Housing cover (pos. no. 20) is removed and grub screw (pos. no. 21) is loosened and removed. 5 pcs. grub screw pos. no. 21

22

GERTSEN & OLUFSEN A.S. 5 The cutter (pos. no. 33) is loosened by means 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 screw driver (or similar) is able to enter the rotor disk, all the way to the shaft in order to keep the rotor disk in same position. Cutter pos. no. 33

6 Hex. nut (pos. no. 25) is loosened and removed together with rotor disk holding disk (pos. no. 26) Use a box wrench or a stiff Allan key, the screw is secured with loctite.

23

GERTSEN & OLUFSEN A.S. 7 Fit the mandrel for the rotor disk puller (special tool) Mandrel

Rotor disk pos. no. 18

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

24

GERTSEN & OLUFSEN A.S. 9 Feather key (pos. no. 14) is loosened and removed from shaft (pos. no. 3)

10 The rotating part of the end-face seal (pos no. 23) is loosened and removed by means of two screw drivers or similar tool. NOTE: It is very important that the shaft surface is smooth and without any sharp edges before removing the stationary part of the end-face seal as this can cut the oring inside the end-face seal. If rotating part of end face seal is stuck, go to no. 11 and remove the seal by gently lift the pump housing e.g. use a tree leg puller.

Rotating part of the end-face seal pos. no. 23

25

GERTSEN & OLUFSEN A.S. 11 Hex. screws (pos. no. 15) and spring lock washers (pos. no. 16) is loosened and removed. Pump housing (pos. no. 19) is then removed together with the stationary part for the end-face seal (pos. no. 23) Pump housing pos. no. 19

4 pcs. Hex. screws pos. no. 15 + 4 pcs. spring lock washers pos no. 16

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

26


ASSEMBLING OF PUMPS

Assembly of ORPU pump. Tools to be used: Combination wrench size 13 and 17 mm Allan key size 4 and 5 mm Screw driver or crowbar Rubber (plastic) mallet Special tool: Sleeve for end-face seal, Fitting tool for end-face seal, Fitting tool for rotor disk and a piece of paper. 1 Apply lubricant on sealing surface on pump skirt (pos. no. 4) Fit pump housing (pos. no. 19) with the discharge flange facing away from the motor feet. Pump skirt pos. no. 4

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

27

GERTSEN & OLUFSEN A.S. 3 Fit the stationary part for the end-face seal (pos. no. 23) by pressing it into the pump housing. NOTE: It is very important to protect the sealing surface and to press it into correct position using fitting tool for end-face seal.

Washer for the end-face seal (pos. no. 23)

Stationary part for the endface seal (pos. no. 23) Rotating part for the endface seal (pos. no. 23) 4 Fit the sleeve for end-face seal onto shaft before fitting the end-face seal.

28

GERTSEN & OLUFSEN A.S. 5 Fit the rotating part of end-face seal (remember to fit the two sealing faces towards each other) and press it down using the fitting tool for end-face seal in order to ensure that it is positioned correct.

6 Sleeve for end-face seal is removed from shaft and washer for end-face seal is fitted and apply grease or similar in order to keep it in position during pump assembly. 7 Fit feather key (pos. no. 14). Feather key (pos. no. 14)

29

GERTSEN & OLUFSEN A.S. 8 Grease or lubricating pasta is applied onto shaft in order to avoid the rotor disk to seize up on the shaft.

9 Rotor disk is fitted using the fitting tool for rotor disk in order to ensure that the rotor disk is pressed all the way down and hereby into correct position. Fitting tool for rotor disk

30

GERTSEN & OLUFSEN A.S. 10 Rotor disk holding disk (pos. no. 26) and Hexagon screw (pos. no. 25) add a little loctite, is fitted and tightened.

11 Grease or lubricating pasta is applied onto thread of the cutter (pos. no. 33). The cutter is tightened using an Allan key and rotor disk is kept in position using a screw driver (or similar). NOTE: It is very important that the screw driver (or similar) is able to enter the rotor disk, all the way to the shaft, in order to keep the rotor disk in same position.

12 The O-ring (pos. no. 24) is fitted into groove using a small amount of grease or lubricating pasta. Also the sealing surfaces are well greased.

31

GERTSEN & OLUFSEN A.S. 13 The knife (pos. no. 32) is fitted onto the housing cover (pos. no. 20). A plastic or rubber mallet can be used. NOTE: It is very important that both parts are cleaned and all sealing surfaces are well greased with grease or lubricating pasta before assembly.

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

32

GERTSEN & OLUFSEN A.S. 15 4 pieces of Hexagon socket screws (pos. no. 35) and spring lock washers (pos. no. 36) are fitted along with 4 pieces of grub screws (pos. no. 34) but not tightened. Also the 5 pieces of grub screws (pos. no. 21) are fitted and tightened. Hexagon nuts (pos. no. 22) are fitted but not tightened.

Grub screw pos. no. 34

Grub screw pos. no. 21 + Hex. nuts pos. no. 22. 4 pcs. Hex. socket screw pos. no. 35 + 4 pcs. spring lock washer pos. no. 36

16 Adjustment of cutter system: Step 1: Hexagon nuts (pos. no. 22) are slightly tightened. Step 2: Hexagon socket screws (pos. no. 35) are slightly tightened. Step 3: Grub screws (pos. no. 34) are adjusted so they just touch the housing cover (pos. no. 20) Step 4: Hexagon socket screws (pos. no. 35) are loosened again. Step 5: Grub screws (pos. no. 34) are tightened/turned 20 to 25 minutes (equals 120 to 150 degrees) Step 6: Hexagon socket screws (pos. no. 35) are tightened properly. Step 7: A pieces of paper (1/10 mm) is used as feeler gauge in order to center the cutter system why it has to fit in between the knife and cutter all the way round. If any adjustment is needed then use a rubber or plastic mallet on the housing cover. Repeat this until the cutter system is centered. Step 8: When cutter system is centered the hexagon nuts (pos. no. 22) are tightened properly.

Allan key is used to turn cutter in order to check the clearance with a piece of paper

If the paper doesn’t fit, the mallet is used in the opposite side in order to adjust the clearance.

33

Spare part set BR.2000 Mechanical seal Angular ball bearing O-ring 24x6 O-ring 80x3 O-ring 185x3 O-ring 185x3

Item No. 23 Item No. 6 Item No. 7 Item No. 37 Item No. 24 Item No. 31


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

1


04.1

AIR COMPRESSOR

One of the following air compressors is installed on the sewage treatment plant according to chapter 01.1.1: Maker:

Protection class:

Becker KDT3.60 F IP55




Motor 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 3,0 80

1465-1780 3,5 85

1465-1780 6,4 129

Type: Insulation class:

kW: Weight:

04.2

DISCHARGE PUMP

The following discharge pump are installed on the sewage treatment plant: Maker: Type: Insulation class: Protection class: Flow: Delivery head: Motor voltage: Rotation speed: Normal power consumption: Pump housing/impeller: Weight:

04.3

Orpu Orcut 130 F IP55 3 0-16 m /h 28-0 m 400/690-480 V 50/60 Hz 3460 rpm 2.60 kW GG 25 46 kg

MACERATOR PUMP

The following macerator pump is installed on the sewage treatment plant: Maker: Type: Insulation class: Protection class: Flow: Delivery head: Motor voltage: Rotation speed: Normal power consumption: Pump housing/impeller: Weight:

ORPU Orcut 130 F IP55 0-16 m3/h 28-0 m 400/690-480 V 50/60 Hz 3460 rpm 2,6 kW GG 25 46 kg

2

1465-1780 9,3 140


04.4

UV -STERILIZER

One of the following UV sterilizer is installed on the sewage treatment plant according to chapter 01.1.1: Maker: Type: Power supply: Protection class: Lamp consumption: Flow 60% transmission Expected life time of lamp:

04.5

Van Remmen W5 230Vac 50/60Hz IP55 0,23 kW 6,2 m3 16000

Van Remmen W8 230Vac 50/60Hz IP55 0,365 kW 9,2 m3 16000

LEVEL SWITCHES

The following level switches are installed on the sewage treatment plant: Maker: Type: Max voltage:

04.6

Pepperl+Fuchs LFL2 250 V

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:

04.7

•

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

VACUUM UNIT


3


05 05.1

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

1

GERTSEN & OLUFSEN A.S. 05.1 TROUBLE SHOOTING Discharge pump does not start / Common Alarm to ECR / High Level Alarm:

1. 2. 3.

Reset alarm by pressing reset alarm on control panel. Start discharge pump in manual mode and empty clean water tank. If the pump is running check the high level switch – replace if needed. 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. 2.

Immediately switch to OFF. Check low level switch – replace if needed.

Discharge pump is running but not pumping:

1.

2. 3. 4. 5.

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) Check all inlet/outled valves. Check water level in the tank. Bleed the pump. Check impeller – replace if needed

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

1. 2. 3.

4.

Check timer settings – adjust/replace timer if needed. Start macerator pump in manual mode. If the pump is running, Check the high level switch – replace if needed. Check the low level switch – replace if needed. 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.


Macerating pump does not stop:

1. 2.

Check timer settings – adjust/replace timer if needed. Check high level switch in inlet tank.

2


Macerating pump is running but not pumping:

1.

2. 3. 4. 5.


Overflow in STP:

1. 2. 3. 4.

Check that the discharge valve on clean water tank is open. Check function of level switches. Check if discharge/macerator pump is in auto mode. Check discharge/macerator pump as mention above.

Air Compressor does not work:

1. 2. 3.

Check power supply to compressor. Check air filter on compressor – replace if needed Check vanes in compressor – replace if needed


Air Compressor running, but insufficient capacity:

1.

2. 3.

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) Check filters on compressor – replace if needed. Check vanes in compressor – replace if needed.

Sludge pump does not start:

1. 2. 3. 4.

Check timer settings – adjust/replace timer if needed. Start sludge return pump in manual mode. If the pump is running, Check timer replace if needed. 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.


Sludge return pump does not stop:

3.

Check timer settings – adjust/replace timer if needed.

3


Sludge return pump is running but not pumping:

1.

2. 3. 4. 5.


UV-sterilizer does not work:

1. 2.

3.

Check power supply to UV sterilizer. If power supply is ok and lamp is not lit then check Lamp starter. If unit is overheated. Loose lamp connection/wire. Internal fuse. Replace lamp (9000 operating hours)

4


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 dains lead to sewage treatment plant. Foul smelling from Bioreactor:

1. 2.

Air supply to bioreactor missing. 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.


5


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

1

GERTSEN & OLUFSEN A.S. 06.1 SPARE PARTS FOR COMPRESSOR See component list chapter 07 or chapter 01.1.1 for the installed equiptment. KDT 3.60- KDT 3.80 Article number Quantity BR.3012 2 pcs BR.3028 1 sets BR.3014 1 set

Description Filter Filter Vanes

Remarks Pos 68 Pos 91 1 set consist of 4 vanes

DT 3.100 – KDT 3.140 Article number Quantity BR.3012 2 pcs BR.3029 1 pcs BR.3027 1 sets

Description Filter Filter Vanes

Remarks Pos 68 Pos 91 1 set consists of 4 vanes

06.2 SPARE PARTS FOR DISCHARGE/MACERATOR PUMP Discharge and Macerator pump ES 130 Article number Quantity Description BR.2000 1 Wearing part set

Article number BR. 2020

Quantity 1 pcs.

Remarks 1 Mechanical seal 1 Angular ball bearing 1 O-ring 24x6 1 O-ring 80x3 1 O-ring 185x3 1 O-ring 185x3

Description Special pump tool for disassembling and assembling

Remarks Rotor disk puller incl. mandrel Sleeve for end face seal Fitting 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 Article number Quantity BR.2039 1 pcs BR.2040 1 pcs BR.2041 1 pcs BR.2042 1 pcs BR.2043 1 pcs BR.2044 1 pcs

Description Mechanical seal Bearing non drive side Bearing drive side Impeller nut Labyrinth ring Gasket

2

Remarks Pos. 433 Pos. 320.1 Pos. 320.2 Pos. 920 Pos. 423 Pos. 433

GERTSEN & OLUFSEN A.S. 06.4 SPARE PARTS FOR UV STERILIZER See component list chapter 07 or chapter 01.1.1 for the installed equiptment. W5 Article number BR.7150 BR.7151 BR.7152

Quantity 1 pcs. 1 pcs. 1 pcs.

Description UV-lamp Quartz sleeve Coupling complete 25mm

BR.7153

1 pcs

Lamp support spring

W8 Article number

Description

BR.7157 BR.7159 BR.7152

Quantit y 1 pcs. 1 pcs. 1 pcs.

BR.7153

1 pcs

Lamp support spring

Remarks

1 Locking sleeve 1 Reactor plug 1Transparent sleeve 1 O-ring 28x3,5 1 O-ring 41x1,78

Remarks

UV-lamp Quartz sleeve Coupling complete 28mm

1 Locking sleeve 1 Reactor plug 1Transparent sleeve 1 O-ring 28x3,5 1 O-ring 41x1,78

06.5 SPARE PARTS FOR LEVEL SWITCH Article number BR.6001

Quantity 1 pcs.

Description Level switch complete

Remarks 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 Article number BR.10009

Quantity 1 set

Description Spare part kit

Remarks Shaft seal, sealing ring, rubber flap, split sleeve and O-rings.

65 MB-A Article number BR.10010

Quantity 1 set

Description Spare part kit

Remarks Shaft seal, sealing ring, rubber flap, V-ring, split sleeve and O-rings.

3


07

DRAWINGS Description P&I DIAGRAM GENERAL ARRANGEMENT COMPONENT LIST ELECTRICAL DRAWING INSTALLATION DIAGRAM

1

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN

GERTSEN & OLUFSEN


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 )


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 )

1

Painting Specification - Protective Coatings Customer:

NVG.

Date: Januar 2012.

Project:

Schmidt Marine- El aps. Tanks outside.

Area:

Black steel.

Pretreatment:

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 to ISO 8501-1. Clean the surface for impurities.

Product no. and name 7802 SigmaFast 205 7524 SigmaDur 520

Prepared by: Johnny Yssing

Filmthickness Dryfilm Wetfilm µ µ

Re-coating Intverval at 20°C n. ax.

Shade

Vol. Sol.

Div Ral / NCS

70

80

1 14

4 hrs

6 mth.

91-92

Div Ral / NCS

57

60 140 14

1 05 2 19

6 hrs

non e

21-06

Thinner

Remark: 1. 2. 3. 4.

31 17 0 37

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

Sigma Coatings and Amercoat are brands of PP G Industries

“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 shall be the competent court of 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.” 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 SPRL/BVBA´s guarantee for the quality of our products, and that specification, datasheets and advice, are given in accordance to the best of our knowledge and know-how.

PPG Coatings SPRL/BVBA. Tweemontstraat 104BE-2100 Deurne-Antwerpen

SQP PC UK.xls

05-01-2012


NVG.

Date: Januar 2012.

Project:

Schmidt Marine- El aps. Tanks inside.

Area:

Black steel.

Pretreatment:

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 a roughness corresponding to 50-100 my. Clean the surface.

Product no. and name 7409 Sigma Phenguard 930 (Primer) 7448 Sigmaguard 790 (HS) 7448 Sigmaguard 790 (HS)


Shade

Vol. Sol.



Thinner

Offwhite

66

100

152

36 hrs

21 days

91-92

Greenish grey

86

100

116

16 hrs

5 days

91-92

Greenish grey

86

100 300

116 384

16 hrs

5 days

91-92

Remark: 1. 2. 3. 4.

31 17 0 37

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


“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 shall be the competent court of 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.” 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 SPRL/BVBA´s guarantee for the


NVG.

Date: Januar 2012.

Project:

Schmidt Marine- El aps. Tanks inside.

Area:

Black steel.

Pretreatment:

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 a roughness corresponding to 50-100 my. Clean the surface.

Product no. and name 7409 Sigma Phenguard 930 (Primer) 7448 Sigmaguard 790 (HS) 7448 Sigmaguard 790 (HS)


Shade

Vol. Sol.



Thinner

Offwhite

66

100

152

36 hrs

21 days

91-92

Greenish grey

86

100

116

16 hrs

5 days

91-92

Greenish grey

86

100 300

116 384

16 hrs

5 days

91-92

Remark: 1. 2. 3. 4.

31 17 0 37

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


“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 shall be the competent court of 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.” 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 SPRL/BVBA´s guarantee for the quality of our products, and that specification, datasheets and advice, are given in accordance to the best of our knowledge and know-how.

SQP PC UK.xls

PPG Coatings SPRL/BVBA. Tweemontstraat 104BE-2100 Deurne-Antwerpen

05-01-2012


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

1

Operation & Maintenance

Jets Vacuumarator

Principle & Function

DATA SHEET NO. 2106 - 28.02.2008 Page 1 of 1

Mode of Operation The Jets Vacuumarator's main function is to create vacuum in the piping system.The Vacuumarator is a screw pump with a built-on macerator. The principle of operation is a helical rotor running in a cylindrical housing, which together with two end plates forms the pump body. When the Vacuumarator is in operation, a liquid ring is created round the rotor. The depth of the liquid ring is governed by the size of the opening in the end plate on the pressure side. This opening is arranged so that the created liquid ring will be touching the rotor hub on one side and the rotor tips on the other. This arrangement creates a series of progressive crescent shaped cavities travelling from suction to pressure side. Air, sewage and water is pulled into those cavities and transported through the vacuumarator. The sewage is macerated by the built-on macerator before it enters the pump body.

The macerator consists of one rotating knife fixed to the shaft and one stationary knife fixed to the suction chamber . In order to provide sufficient liquid level at the time when the Vacuumarator is starting, and thus securing the initial priming of the screw pump, a vacuumaratortank is mounted on the outlet pipe of the Vacuumarator. This is done for all types of Vacuumarator except for the Vacuumarator Jets 10N Tand 15MB/15MB-D, where the 50mm pipe on the outlet pipe functions as a tank to ensure return water. How to fill water into the vacuumarator prior to start or after service: Unscrew plug on side of suction chamber, one of the plugs. Fill fresh water through the plug hole up to plug hole level. Level may be c ontrolled by looking through the suction c hamber cover. Refit plug.

Discharge (Outlet)/ Return water Suction (Inlet) ↓

↑ Pump Housing

Macerator

Liquid ring

Note: Changes without prior notice

www.jets.no

Rotor

Vacuumarator Jets 65MBA

Vacuumarator


The patented Jets Vacuumarator - creates vacuum - macerates sewage - pumps sewage Designed for direct connection to any kind of sewage treatment plant. Outlet can also be connected to gravity piping or holding tank. Safe operation is secured by black water from the t oilets.

Technical Data: Capacity:................................................................................................................................... 60r m3/hr Flushing Capacity at 50 Hz: ............................................................................................. 520 fushes/hr Flushing Capacity at 60 Hz: ............................................................................................. 600 fushes/hr Outside Dimensions:....................................................................................818x263x336 mm (LxWxH) Electric Motor:........................................................................................................ MEZ 7BA 132 S0 2K Pump Casing Material .....................................................................................................Stainless steel Rotor Housing Material: .................................................................................... Stainless steel AISI 316 Pump Rotor Material: ..........................................................................................................Ni-Al Bronze Pump Knives Material: ...................................................................................... Stainless steel AISI 420 Pump Shaft Material: ........................................................................................ Stainless steel AISI 316 Connection Inlet: .................................................................................................................DN65, PN10 Connection Outlet: ..............................................................................................................DN50, PN10 Connection Return water: ................................................................................ 1/2´´ BSP inside threads Total Weight: .................................................................................................................................. 97 kg

Part No. Jets 65MBA Voltage/Frequency 230-380/50, 255-440/60

02A065001

690/60

02A065002

690/50

02A065003


www.jets.no

Part No.

Vacuumarator Jets 65MBA

Vacuumarator


Dimensions 65MBA 381,5 69,5

312 8 , 3 1

DN65

DN50

5 3 3

20,5

151,5

4 2 3

282 433,5

220 267

799

Operating Data: 50Hz

60Hz

Speed (nom.): ........................................................... 2.895 RPM .........................................3.494 RPM Power Connections (nom.): .............................3x400V / 3x230V ...............................................3x440V Power Output (nom.): .......................................................5,5kW ................................................6,3 kW Current Consumption (230V): ........................................... 18,7 A Current Consumption (400V): ........................................... 10,7 A Current Consumption (440V): ....................................................................................................... 11,2 A For other voltages: ......................................................................................... See Data Sheet No, 3123

70

Capacity 400V/50Hz 5,5kW AIR

60 50

7,0

70

6,0

60

5,0

m³/h

4,0 kW

m³/h

m³/h

6,0

50

40

.

5,0

40 4,0 kW

m³/h

30

30 3,0

kW

20

0 -0,1

-0,2

-0,3

-0,4

-0,5

-0,6

-0,7

-0,8

-0,9

. .

kW

.

0

-1

-0,1

-0,2

-0,3

-0,4

-0,6

-0,7

-0,8

-0,9

-1,0

65MBA Kurver Engelsk

Capacity 400V/50Hz 5,5kW WATER

Capacity 440V/60Hz 6,3kW WATER

14

10

10

8

8

kW

6

6 kW

4

2

m³/h

10

m³/h

12

m³/h

4

-0,5 bar

10 m³/h

8

kW

8 6

6 4

4

2

0

2 0

1

2

3

4

5

6

7

8

mH2O

www.jets.no

:

1,0 0,0

65MBA Kurver Engelsk

12

:

2,0

bar

14

3,0

.:

.

10

1,0 0

I

20

2,0

10

7,0

Capacity 440V/60Hz 6,3kW AIR

9

10 11 12 13 14 15

0

2 0

1

2

3

4

5

6

7

8

mH2O

9

10 11 12 13 14 15

kW

El.motor for Jets 65MBA

El.motor


Dimensions MEZ 7BA 132S02K

All dimensions in mm

Technical Data: Type:...................................................................................................................... MEZ 7BA 132 S0 2K Outside Dimensions: .....................................................................................619x263x336mm (LxWxH) Number of Poles: ..................................................................................................................................2 Mounting: ..........................................................................Special flange and foot mounting (IEC-72-1) Frame Size: ....................................................................................................................132 (IEC-72-1) Enclosure: ..............................................................................................................IP 55 (DIN IEC 34-6) Insulation Class: ...................................................................................................................................F Material, Housing: .....................................................................................................................Cast iron Material, fan Cover: ........................................................................................................................Steel Material, Ventilator: .................................................................................................... Fibre-glass plastic Terminal Box: ..............................................................................Top mounted, turnable in 900 intervals Cable Conduit: ............................................................................................ Threaded holes for 2 x M32 Cooling: ........................................................................................................ Self ventilating /air cooling Total Weight: .................................................................................................................................. 52 kg

Operating Data: Voltage (V) ................... 230............. 400 ............. 415 ............. 440 ............. 660 ............. 690 .............690 Frequence (Hz).............. 50 ............... 50 ............... 50 ............... 60 ............... 50 ............... 50 ...............60 Speed (Rpm) ............ 2.895.......... 2.895 .......... 2.895 .......... 3.495 ..........2.895 ..........2.895 ..........3.495 Power (kW) ................... 5,5 .............. 5,5 .............. 5,5 .............. 6,3 .............. 5,5 .............. 5,5 ..............6,3 Main current (Amp) ..... 18,7............ 10,8 ............ 10,4 ............... 12 .............. 6,5 .............. 6,3 ..............7,2 Efficiency (%)................. 82 ............... 82 ............... 82 ............... 83 ............... 82 ............... 82 ...............83 Duty ............................... S1 ............... S1 ...............S1 ...............S1 ...............S1 .............. S1 .............. S1 Cos ϕ ........................... 0,9 .............. 0,9 .............. 0,9 ............ 0,89 .............. 0,9 .............. 0,9 ............0,89 Connection ......................D .................Y .................Y .................Y .................Y .................Y ................ Y Part. No. ............ 031226200 ... 031226200....031226202....031226200 ...031226203 ... 031226204 ... 031226201


www.jets.no

DATA SHEET NO.

Troubleshooting & Repair

2168 ISSUE C

Vacuumarator type Jets 65MBA

Maintenance Job

Data Sheet No

Clean connection pipe for pressure switches by letting in air

Drawing No

Part No

Piping Diagram

Check function pressure switches

3103

Reset pressure switches* (*if needed)

3103

Replace shaft seal Vacuumarator and El Motor

Change bearings on electric motors

Interval

Comments

Daily

032300100

Daily

Piping Diagram

032300100

Monthly

2149 3123 2155

32020-02A 32026-031

038225700 037224200

2 years/ 6000 hours or if water leakages should occur during running.

See Data Sheet 2155 for disassembly and assembly of Vacuumarator Jets 65MBA

3123 2155

32026-031

038226600 and 038223800

2 years/ 6000 hours

See Data Sheet 2155 for disassembly and assembly of Vacuumarator Jets 65MBA

DATA SHEET NO.

Troubleshooting & Repair

2168 ISSUE C

Vacuumarator type Jets 65MBA Additional Information on Maintenance and Repair Problem

Causes

Action

Data Sheet Drawing/Part No.

Low vacuum

Lack of sealing liquid to Vacuumarators

Check that Vacuumarator has water during operation

2149,2106

Leaks in vacuum pipes

Check for leaks and repair

Piping Diagram and Vacuum Piping Guide

Macerator clogged

Remove blockage

32020-02A/ 02A25512

Clogged pipes

Remove blockage

Piping Diagram and Vacuum Piping Guide

Water leakage from vacuumarator

Defective shaft seals

Ckeck and replace shaft seals

32020-02A 32026-031 038225700 037224200

Frequent start and stop of Vacuumarator

Leakage in vacuum pipes

Check for leakage and repair

Piping Diagram

Leakage caused by insufficient closing of Flap Valve (Vacuumarator's non-return valve)

Check flap valve and clean surface of valve

32020-02A/ 037302100

Motor protection relay tripped

Check causes for overload and repair

El Diagram

Overload electrical motor Running time alarm* (*If installed)

Running time of Check for leakages Vacuumarator in pipe system and has extended repair preadjusted time in Time Relay

El Diagram

JETS VACUUM AS P.O.Box 14 N-6069 Hareid, Norway Tel.: +47 70 03 91 00

DATA SHEET NO.

2155

Disassembly & Assembly Instruction Vacuumarator 65MBA S CHEDULED

MAINTENANCE

Replace the Shaft Seals every 24 th. month or after 6000 working hours whichever occurs first.

ISSUE A

2. Remove the suction chamber No. 023280040 by means of a rubber mallet. 3. Unscrew the screw 13 mm in centre of the macerator, by means of a socket wrench. Then remove the macerator.

W ARNING

4. Unscrew and remove stay bolts No. 036202011.

Be sure the electricity supply has been switched off before working on the Vacuumarator.

5. Remove end plate No. 02A265106.

Be aware of the nature of the liquid and take the necessary precautions.

7. Remove macerator bushing No. 02A265104 and rotor No. 02A265101.

Unscrew plug No.020202900 and empty the pump of liquid.

8. Remove pressure chamber No. 02A265109 by means of a rubber mallet.

6. Remove rotor housing No. 02A265102.

A. DISASSEMBLY: The references are located in drawing 32020-02A Vacuumarator Jets 65MBA Part Drawing. All parts must be marked before disassembly to ensure reassembled in the correct order and angle position. The disassembly process shall always be carried out from the suction side of the pump i.e. opposite the motor. Dismount pump from bed plate. During disassembly/ assembly the Vacuumarator should be in upright position. 1. Unscrew 4 sylinder screws No. 036207621

C. ASSEMBLY: The assembly process takes place in the opposite order. Ensure that all parts are perfectly clean, especially all recesses where O-rings are used, before the assembly process is carried out. 1. Use liquid soap when fitting the shaft seal No. 038225700. 2. Always use new O-rings.

JETS VACUUM AS P.O. Box 14 N-6069 Hareid, Norway Tel: +47 70 03 91 00 Fax: +47 70 03 91 01

1

2

3

4

5

Flange For Shaft Seal 02A265108

Flap Valve Body 023280061

A

6

A

O-Ring 037219270

Rubber Flap 037302100 Plate For Flap Valve 023280091

Flap Valve Complete 023280060

Nut M6 x 16 036232920

Macerator 02A265112 B

B

Nut for Flap valve 02A265100 Shaft Seal ø40 038225701

Flange 02A265110

Pressure Chamber 02A265109 O-Ring 037219280

Plug 3/8" 021217000 Distance Sleeve 02A265105 O-Ring 037219261 Rotor Housing 02A265102

C

Key 02A265113

O-Ring 037219261

Suction Chamber 023280040 O-Ring 037219260 Suction Chamber Cover 023280050

D Nut M6 036901200

Set screw 036202401

Stay Bolt 036202011 Plug 1/2" 020202900

Rotor 02A265115 C

N

Updated part no

25.09.2007 MG

M

Removed Dripflange and V-ring

16.05.2007 Rhu

L

Revised part name V-ring

16.01.2007 RHU

K

ADD NEW PART "DRIPFLANGE"

06.04.2006 RoL

J

CHANGED SOME PART. NAME

01.12.2006 RoL

I

CHANGED P.NO. ON SCREWS ON SUCTION CHAMBER06.06.2005 TG

H

ADD PART NO. FOR "FLAP VALVE COMPLETE"

G

ADD "THROW OFF RING"

10.09.2003 RoL

A

Original Drawing

22.08.2001 RoL Date

Description

Rev. Title

End Plate Suct. Chamber 02A265106 Maserator Bushing N-6069 HAREID Tel. +47 70 03 91 00 02A265104

O-Ring 037219220 Cylinder Screw 036207621

28.02.2005 RoL

Designed by

TM

VACUUMARATOR JETS 65MBA

Scale

Sign

22.08.2001 RoL

D

%

PART DRAWING

Fax. +47 70 03 91 01 E.Mail [email protected]

Part no.:

WWW.JETS.NO

02A100101

Material:

Weight:

Drawing no

36 Kg

32020-02A.idw

1

2

3

4

5

6

1

2

3

4

5

6

Spacer Sleeve 031226900 A

A

Ball Bearing 038226000 Key 022222150 Shaft 02A265107

Terminal Box 031225700

Ball Bearing 038223800 Sealing Ring 037224200 B

B Motor Flange 02A265103

Endshield 031225130 Hex Screw M8x30 din933 036202200

Stator See Table

C

Fan 031225120

Fan cover 031225110

C

Circlip 037227100

V-ring 038399550 Dripflange 02A265116

D

4 Pcs. Socket Head Screw M8x50 Din912 12,9 036503410

Part No. El.Motor Jets 65MBA Voltage/ Frequency Part No. Stator No. 031226200 031225103 380/50 / 440/60 031226201 031225104 690/60 031226204 031225105 690/50

G

Revised Title

11.06.2007 rhu

F

Added parts v-ring and dripflange

16.05.2007 Rhu

E

Added Table

17.11.2006 RHU

D

Added part No.

C

Added Part No.

13.12.02

RL

24.09.2002 RL

B

Description for Hex. Screw

13.09.2001 RL

A

Original Drawing

30.08.2001 RL

Rev.

Date

Description

Title

Designed by

TM

MOTOR 7BA132S02K

Checked by Scale

30.08.01

Sign

RoL

D

1

2

3

4

5

6

Spacer Sleeve 031226900 A

A

Ball Bearing 038226000 Key 022222150 Shaft 02A265107

Terminal Box 031225700

Ball Bearing 038223800 Sealing Ring 037224200 B

B Motor Flange 02A265103

Endshield 031225130 Hex Screw M8x30 din933 036202200

Fan 031225120

Stator See Table

C

Fan cover 031225110

C

Circlip 037227100

V-ring 038399550 Dripflange 02A265116 4 Pcs. Socket Head Screw M8x50 Din912 12,9 036503410

D

Part No. El.Motor Jets 65MBA Voltage/ Frequency Part No. Stator No. 031226200 031225103 380/50 / 440/60 031226201 031225104 690/60 031226204 031225105 690/50

G

Revised Title

11.06.2007 rhu

F

Added parts v-ring and dripflange

16.05.2007 Rhu

E

Added Table

17.11.2006 RHU

D

Added part No.

C

Added Part No.

13.12.02

B

Description for Hex. Screw

13.09.2001 RL

A

Original Drawing

30.08.2001 RL Date

Description

Rev. Title

Designed by

TM

WWW.JETS.NO

1

M y ar n e I n d u s t r i o m r å d e , N -6 0 6 0 H a er i d N o r w a y T e .l + 4 7 7 0 0 3 9 1 0 0 . F a x + 4 7 7 0 0 3 9 1 0 1 .E -m a i : l p o s t @ j e t s .n o

w w w . j e t s .n o

2

3

4

Scale

Material

Sign

RoL

D

%

Project no

PART DRAWING Part no.

30.08.01

Checked by

MOTOR 7BA132S02K N-6069 HAREID Tel. +47 70 03 91 00 Fax. +47 70 03 91 01 E.Mail [email protected]

RL

24.09.2002 RL

Weight

Drawing no

32026-031.idw

See Table

5

6

O p e ar t oi n & M a i n et n a n c e

M y ar n e I n d u s t r i o m r å d e , N -6 0 6 0 H a er i d N o r w a y T e .l + 4 7 7 0 0 3 9 1 0 0 . F a x + 4 7 7 0 0 3 9 1 0 1 .E -m a i l : p o s t @ j e t s .n o

w w w . j e t s .n o

O p e ar t oi n & M a i n et n a n c e

5 7

Pressure switch

Installation


Technical data Type:.......................................................................................................... Danfoss RT121 (-1 to 0 bar) Ambient temperature: ........................................................................................................-40 to +70°C. Pressure connection temperature:...................................................................................... max. 150°C. Enclosure:................................................................................... IP 66 acc. to IEC 529 and DIN 40050. Cable entry: .................................................Two Pg 13,5 entries for cable diameters from 5 to 14 mm. Pipe connection: ........................................................................................................................ 3/8" RG

Switch, Contact load, Alternating current:

AC1 (ohmic): ........................................................................................................................ 10 A, 380 V AC3 (motor): .......................................................................................................................... 4 A, 380 V AC11 (coils): ...................... .................................................................................................... 3 A, 380 V Direct current: ..................................................................................................................... 12 W, 220 V

El. connection:

Start and stop: ............................................................................................................. Terminal 1 and 4 Alarm low vacuum: ....................... ............................................................................... Terminal 1 and 2

Pressure switch

Installation


Technical data Type:.......................................................................................................... Danfoss RT121 (-1 to 0 bar) Ambient temperature: ........................................................................................................-40 to +70°C. Pressure connection temperature:...................................................................................... max. 150°C. Enclosure:................................................................................... IP 66 acc. to IEC 529 and DIN 40050. Cable entry: .................................................Two Pg 13,5 entries for cable diameters from 5 to 14 mm. Pipe connection: ........................................................................................................................ 3/8" RG

Switch, Contact load, Alternating current:

AC1 (ohmic): ........................................................................................................................ 10 A, 380 V AC3 (motor): .......................................................................................................................... 4 A, 380 V AC11 (coils): ...................... .................................................................................................... 3 A, 380 V Direct current: ..................................................................................................................... 12 W, 220 V

El. connection:

Start and stop: ............................................................................................................. Terminal 1 and 4 Alarm low vacuum: ....................... ............................................................................... Terminal 1 and 2

Setting The pressure switches shall be adjusted to recommended setpoints, see table below. See also: Data sheet no. 3105 1. Regulator 2. Differential setting disc

Setpoints: Start of pump: - 40 kPa ( % vacuum) Stop of pump: - 55 kPa ( % vacuum) Alarm low vacuum: - 25 kPa ( % vacuum)

ATTENTION: Please note that the mentioned minus kPa in this instruction is only related to t he marked scale value plate on the Danfoss RT121 Pressure Switch, and not to kPa standard in general.


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