HAMWORTHY WASTEWATER SYSTEMS LTD ST3A Super Trident Sewage Treatment Unit GO.93315-01/02 HULL H0307333 FINAL DRAWINGS ISSUE 1/0905 Fleets Corner, Poole, Dorset BH17 OJT, United Kingdom Tel: +44(0)1202 662600 Fax: +44(0)1202 665444 (Spares & Service) Fax: +44(0)1202 668793 (Sales) www.hamworthy.com Offices, Associate Companies and Agents throughout the world Page 1WARNING. 4 10. "1 12, 13, 14, Health and Safety Act Compliance. Before working on this equipment personnel should be made aware of, and ensure compliance with, the Health and Safety Regulations appropriate to this class of work. Work must only be carried out by suitably qualified and competent persons. Before lifting, installing and operating the unit, the instructions detailed below, and also the accompanying manual must be read. Ensure that all equipment used for lifting the unit is adequate for the weight. The weight is normally steneiled on the unit and/or stamped on the machine nameplate. The handling points are indicated on the unit and these must be used. The hooks of slings must not be fitted directly to lifting eyebolts or lugs, shackles must be used. Before running the unit for the first time, the installation must be thoroughly checked and the procedure detailed in Section 4 of this manual under the heading “Preparation for Initial Operation’ referred to. The unit must not be run unless all protective guards supplied with the equipment are in position. Before proceeding with maintenance on the unit, or making adjustments to its connections and fittings, it must be stopped and isolated electrically and mechanically and visible warning notices displayed. Ensure safety procedures for hazardous gases or oxygen depletion are carried out before opening the tanks, Before commencing repair or overhaul a preliminary check of available spares must be made, e.g. replacement set of joints or jointing material Pumps handle various liquids, sometimes not those for which the pump was initially supplied. Know the properties of the liquids that have been pumped, and the actions necessary to make handling safe and in the event of an emergency. Before handling sodium hypochlorite refer to instructions in Section 4 The equipment should not be installed in an explosive atmosphere. This equipment is subject to intemational, European, and national regulations and must be used accordingly. Page 2SUE [1 @ Hamworthy wastewater Systems Limited Hamworthy Acknowledgement Of Order 31 March, 2005 GO 93315,16,17,18,19 & 20-01 QUOTE: £60772 CUSTOMER: 1NEWO26 CONSIGN TO: New Century Shipbuilding Co Ltd WAIGAOQIAO BONDED WAREHOUSE Xingang Port, Jingliang City SHANGHAI Jiangsu Province China 214514 China Customer's Order No: NCS0307333-015, dated 15" November 2004 Destination: Hull H0307333,34,35,36,37 & 38 Owner : Seatramp Tankers Inc PE IT. ED ONE- STSA Super Trident Sewage Treatment Plant suitable for a total estimated daily sewage flow of 4660 litres having @ maximum B.0.D. load of 3.000 kg per day. IMO & MED certified and accepted by USCG for use on non-US flag vessels in US waters. Grey water from low level sinks, showers, etc., can be connected to the final collection tank to enable overboard discharge. (4500 litres/day max) Electrical Supply: 440V/SPR/60HE . Total Operating Electrical Load: 6.3 kW The following equipment is supplied with the Sewage Treatment Plant offered: ‘One — Rotary Vane Air Blower, Electric Motor Driven to aerate and mix through internal fine bubble diffusers. One Effluent Discharge Pump, Electric Motor Driven. * Discharge Pump Capacity: SmThr + Total Head: 18m © Separate hospital water inlet. * Grease Trap (Supplied loose) MATERIALS: ‘The tank construction is a welded mild stee! fabrication fitted with the required pump, compressor and control panel piped and cabled complete. Pump casing — Cast Iron (plastic coated), Impeller - Bronze Mechanical Seal Electric Motor - totally enclosed fan cooled [IP55), squirrel cage, induction motor, continuously rated to BSS000 Part 99 and relevant parts of BS 4999, with Class 'F' insulation suitable for direct on line start 3 level float switch for pump control - polyester resin/polypropyiene ‘Tank Mounted Calcium Hypochlorite tablet dosing chiorinator - polypropylene/PVC Effluent Quality Test Kit for checking residual chlorine level, nominally 5 ppm 10 Kg drum of hypochlorite tablets for use in chiorinator uni[Sse 7 LI GF Hamworthy Wastewater Systems Limited Hamwor Acknowledgement Of Order 31 March, 2005 GO 93315,16,17,18,19 & 20-01 QUOTE: £60772 CUSTOMER: 1NEW026 CONSIGN TO: New Century Shipbuilding Co Ltd WAIGAOQIAO BONDED WAREHOUSE Xingang Port, Jingjiang City SHANGHAI Jiangsu Province China 214514 China Customer's Order No: NCS0307333-015, dated 15" November 2004 Destination: Hull H0307333,34,35,36,37 & 38 Qwner : Seatramp Tankers inc ‘Auto-Control Panel with [P&S enclosure mounted on unit with contactors for air blowers and discharge pump, running pilot lamps 110 volt control circuit transformer, with primary circuit breaker protection control circuit fuses and main motor protection circuit breakers. Connections included for pump float switch control, remote high level alarm and general abnormal alarm. INTERNAL TANK: Corrosion protection shotblast to SA 2.5 and a minimum of two coats of coal tar epoxy paint to give a minimum ‘of 250 dry film thickness. PAINT FINISH:- 1+ Tank External - Finish paint colour LIGHT GREEN TO RAL 6019 2+ Panel RAL7032 3- Blowers Manufacturer's standard 4 Pumps Cast iron (plastic coating). ‘Motor — Manufacturer's Standard colour Carriage: CFR Shanghai ( Ex Waigaogiao bonded warehouse) FAT. Factory Acceptance Test Approvals: Depart of Transport, MED & Works Test Certificates, {IMO & MED approval labels fitted to unit) Terms: irrevocable Letter of Credit confirmed by National Westminster Bank ple, London Handbook: Contract specific manual based on PCH1544 (for ST3A) and PCH 1857 (for pump).SUE | 7 Hamworthy Wastewater Systems Limited Hamworthy Acknowledgement Of Order 31 Merch, 2005 GO 93315,16,17,18,19 & 20-02 QUOTE: E60772 CUSTOMER: 1NEW026 CONSIGN TO: New Century Shipbuilding Co Ltd WAIGAOQIAO BONDED WAREHOUSE Xingang Port, Jingjiang City SHANGHAI Jiangsu Province China 214514 China Customer's Order No: NCS0307333-015, dated 15" November 2004 Destination: Hull H0307333,34,35,36,37 & 38 Owner : Seatramp Tankers Inc ‘ST3A Super Trident Sewage Treatment Plant Recommended Spares One Set Of Spares Comprising:- PUMP: 2 Jacking screws, 1 peel off shim, 1 impeller screw, 1 'O' ring (impeller), 1 'O' ring {So wachor,t mechanical seal, cot motor berngs CONTROL PANEL 1 Triple pole contactor, 1 auxiliary contact, 1 pilot lamp bulb, 2 fuses - § amp, 2 fuses - 2 amp. BLOWER 1 set vanes, 2 inlet filter element, 1 outlet filter element, 2 bearings, 10 spacers, 1 set security rings, 2 tolerance rings, 1 gasket set.ISSUE | 1 Hamworthy Wastewater Systems Limited Hamworthy Acknowledgement Of Order 31 March, 2005 GO 93315,16,17,18,19 & 20 QUOTE: £60772 CUSTOMER: 1NEW026 CONSIGN TO: New Century Shipbuilding Co Ltd WAIGAOQIAO BONDED WAREHOUSE Xingang Port, Jingjiang City SHANGHAI Jiangsu Province China 214514 China Customer's Order No: NCS0307333-015, dated 15" November 2004 Destination: Hull H0307333,34,35,36,37 & 38 Owner: Seatramp Tankers Inc GENERAL ‘The equipment on this contract will be of standard commercial design, with no special materials, material tests, fitings, connections or components being incorporated except as detailed in this Specification. ‘The contract includes for the supply only of the specified items. Installation, interconnecting pipework including valves and other accessories, electrical wiring, etc. will be the responsibilty of the Customer. The equipment on this contract will be supplied in accordance with agreed Contract Terms, including Liquidated damages of 0.5% per week up to a maximum of 5% of contract value (GUARANTEE To cover claims notified within 18 months of the date of commissioning the plant (or of handover of the vessel to the owners) or 24 months from the date of despatch from our Works, whichever is the earlier. ‘This guarantee applies to Hamworthy manufactured items. We wil endeavour to obtain the same terms from our suppliers in respect of bought out items, but where they are not prepared to meet our request, the guarantee ‘covering such bought out components wil be limited to that which we are able to obtain from the supplier. PAINTING ltems will be supplied to Manufacturer's Standard Grade and finish painted to Manufacturer's standard ‘Spectication. PACKAGING AND CONSIGNING The goods on this contract will be securely packaged to export standard suitable for surface freight overseas and delivered CFR Shanghai PortJods, CERTIFICATE OF TYPE APPROVAL ‘This is to certify that Lloyd's Register did undertake the relevant type approval procedures of the equipment detailed below which ‘was found to be in compliance with the essential Pollution Prevention requirements for use on ships and offshore installations classed with Lloyd's Register, and for use on ships and offshore installations when authorised by contracting governments to issue the relevant certificates, licences, permits, etc Manufacturer Hamworthy KSE Ltd, Marine & Offshore Division Address Fleets Comer Poole Dorset, BHIZOT United Kingdom (UK) Type SEWAGE TREATMENT PLANTS. q Description ST 3A Super Trident Specified Standard MBCP.2(V1) The attached Design Appraisal Document forms part of this certificate. This certificate remains valid unless cancelled or revoked, provided the conditions in the attached Design Appraisal Document are complied with and the equipment remains satisfactory in service, Date of sstie 18 December 2003 Expiry date 17 December 2008 Certificate No. SAS Po3o104 Sheet No 1083 ‘Name SJames Surveyor to Lloyd's Register EMEA ‘A Member of the Lloyd's Register Group Note: ‘This certificate is not valid for equipment, the design or manufacture of which has been varied or modified from the specimen tested, The manufacturer should notify Ltoyd’s Register of any modification or changes to the equipment in order to obtain a valid Certificate. ‘THis DOCUMENT IS SUBJECT TO THE PROVISIONS ON THE REVERSELloyd’s Register EMEA fe i 2of 3 Joys itn ston London, EC3M 485 ry AGPSERL tetsrione 070 7423 2940 Fex 020 7397 4246 SAS Po30104 Email [email protected] Taser 1 DESIGN APPRAISAL DOCUMENT. Dae ‘Gas is plore onal an commvaicnone 18 December 2003 ‘TGG/STAT/POL/S} ITA THE WAL. AS PORO104 ‘The undemoted documents have been appraised for compliance with the relevant requirements of International Conventions, and this Design Appraisal Document forms part of the Certificate. APPROVAL DOCUMENTATION ‘The equipment has been examined and satisfactory tested in accordance with the International Maritime Organisation Resolution MEPC.2(V1) to meet the operational requirements referred to in regulation 2C1X@)4H) of Annex IV of the International Convention for the Prevention of Pollution from Ships, 1973/1978, ‘The equipment was tested andl produced an effluent which, on analysis, did not exoved: 250 faecal coliform por 100 miliiire MPN, and a geometric mean of total Suspended Solids of 50 ailligcams per Iitre. Designed hydraulic loading, 9.22 cubic metres per day Designed organiclonding 591 kilograms per day (BOD) ‘This acoeptance is based upon the examination of drawings and on satisfactory test oaried out under the supervision of the Department of transport Marine Directorate on a similar treatment plant having a designed hydraulic loading of 9.36 cubic metres per day and an organic loading of 6.0 kilograms per day Biochemical Oxygen Demand. ‘The control and sensor equipment were tested for shock and vibration. ‘The equipment has been designed: 1) sothat the geometzic mean of the $day Biochemical Oxygen Demand (BODs) does not exceed 50 i) Ae aan dea aa ae CONDITIONS OF: TION A plate or durable label containing data of the manufacturer’s name, type and serial numbers of the equipment, hydraulic loading and data of manufacturer isto be fitted on each unit. A.copy of this cortificate shall be curied onboard any vessel equipped with the deserbed unit ‘THIS DOCUMENT IS SUBJECT TO THE PROVISIONS ON THE REVERSE= Lloyd’s Register EMEA 30f 3 lo S71 Fenchurch Street, London, EC3M 48S Docementanber EBISEET texan 020 7429 2040 tax 0207097 206 SAS Po30104 Email [email protected] al DESIGN APPRAISAL DOCUMENT te Geek ta has on coma 18 December 2003 TGG/STAT/POL/S} CE OF ‘AA Dengwei Road otherwise than in strict CTION Hamworthy KSESuwzhou & © Hamworthy KSE Fleets Corner ‘New District Poole ‘Suzhou 215011 ‘Dorset, BHI7 OjT Jiangsu Province United Kingdom PR China, ‘Sam James: a ‘Tanker and Gas Section Marine Support Group. fers a seme Type. yal Conditions conformity with the said prototype(). ‘This certificate and Design Appraisal Document relates fo type approval, it cerlifis that the prototypels) ofthe Product(s) referred to herein hasfhave been found to mect the applicable design criteria for the use specified herein, 4 does rot mean or imply approval for any other use, nor approval of any products designed or manufactured ‘THIS DOCUMENT IS SUBJECT TO THE PROVISIONS ON THE REVERSERages ane An Executive Agency ofthe Department of Transport, Local Government and the Regions EC TYPE EXAMINATION (MODULE B) CERTIFICATE ‘This isto certify that LLOYDS REGISTER OF SHIPFING, specified as a “notified body” under the terms of The Merchant Shipping (Marine Equipment) Regulations $1. 1999 No, 1957, did undertake the relevant type approval procedures for the equipment identified below which was found to be in compliance with the essential Life Saving Appliance Tequirements of Marine Equipment Directive (MED) 96/98/EC as modified by Commission Directives 98/85/EC, 2001/53/EC, 2002/75/EC and 2002/84/EC subject to any conditions in the Design Appraisal Document attached hereto, Manufacturer Hamworthy KS.E, Address Fleets Corner Poole Dorset, BHI7 OT England Product Type SEWAGE TREATMENT PLANTS Product Description _ ST3A Super Trident Specified Standard = MEPC.2(V1) ‘The attached Design Appraisal Document (schedule) forms part of this certificate. ‘This certificate remains valid unless cancelled or revoked, provided the conditions in the attached schedule are complied with and the equipment remains satisfactory in service. Date of issue 16 December 2003 Expiry date 15 December 2008 Certificate No. ‘MED 0350345 Signed Sheet No of 3 Name — SJames ‘Surveyor to Lloyd's Register LR EC Distinguishing No. 0033 Note: ‘This certificate is not valid for equipment; the design or manufacture of which has been varied or modified from the specimen tested. The manufacturer should notify the notified body named on this certificate of any modification or changes to the equipment in order to obtain a valid Certificate, Subject to compliance withthe conditions Inthe attached Design Appratsl Document (echedu) which fos part ofthis crtiieata and those of Artes 10.1) and 11 of the Dlctiv, the Manufactaer ie allowed to afi the “Mark of Conformity” to the Product described herein YY Lastiwo digit ofyearmari affixed, ‘This certificate is issued under the authority of the MCA. ‘THIS DOCUMENT IS SUBJECT TO THE PROVISIONS ON THE REVERSE ———————7 Lloyd's Register EMEA a3 fee Joys actrees nin ce50 05 [pees ——— eg ISLET — teteptione 020 7423 2940 Fax 020 7397 4246 j MAD IBS EEE Email degestat@ir org enna DESIGN APPRAISAL DOCUMENT Ba Tea ens can hi coma 16 December 2003 TGG/STAT/POL/S) ‘The undemoted documents have been appraised for compliance with the relevant requirements of International Conventions and European Union legislation for the EC Type Examination of Marine Equipment for use on Merchant Ships Registered in the European Econontic Area ‘This Design Appraisal Document (schedule) forms part of the Certificate, OV, TION Drawing number 73580040 ‘The equipment has been examined and satisfactory tested in accordance with the International Maritime Organisation Resolution MEPC2(V1) to meet the operational requirements referred to in regulation ‘3(1Xay(i) of Annex IV of the International Convention for the Prevention of Pollution from Ships, 19/1978, ‘The equipment was tested and produced an effiuent which, on analysis, did not exceed: 250 faecal coliform per 100 millfitre MPN, and a geometric mean of total Suspended Solids of 50 milligrams perlite, Designed hydraulic lading 4.66 cubicmetres per day ‘Designed organic loading 3.0 kilograms per day (BOD) ‘This acceptance is based upon the examination of drawings and on satisfactory test carried out under the supervision of the Department of transport Marine Directorate on a similar treatment plant having designed hydraulic loading of 936 cubic metres per day and an organic loading of 60 kilograms per day Biochemical Oxygen Demand, ‘The control and sensor equipment were tested for shock and vibration. ‘The equipment has been designed: 4) 50 that the geometric mean of the 5-day Biochemical Oxygen Demand (BOD:) does not excued 50 mg/I and i) can operate under conditions of heel of up to 15°, Fomeees ous ope Rapltas of Shipping epee fie: 71 Fer Ste Lancon BCIM ARS ‘THIS DOCUMENT IS SUBJECT TO THE PROVISIONS ON THE REVERSE eeLloyd’s Register EMEA Sot 30f3 Telephone 020 7423 2949 Fax 020 7397 4246 MED 0250545 loyds 71 Fh Se en BOMBS 18 ssa egister Email [email protected] Teemu DESIGN APPRAISAL DOCUMENT Bae ‘Goch iene onl Rar conta 16 December 2008, TGG/STAT/POL/ST NITIONS OF. CAT A plate or durable label containing data of the manufacturer's name, type and serial numbers of the ‘equipment, hydraulicloading and data of manufacturer is tobe fted on each tnt. A copy of this certificate shall be carried onboard any vessel equipped with the described unit. CE OF PRODU Hamworthy KSESwzhou & | Hamworthy KSE ‘7A Dengwei Road Fleets Comer New District Poole Suzhou 215011 Dorset, BHI7 OT Jiangsu Province United Kingdom PRChina, Toya Reais te Sam James Principal Surveyor Tanker and Gas Section Marine Support Group Lloyd's Register EMEA Forces 046 oye Region a Sipping pete le: 7h Fenchwch Sct London BOOM AS ‘THIS DOCUMENT IS SUBJECT TO THE PROVISIONS ON THE REVERSE ——————$—$——CONTENTS SECTION 4 - TECHNICAL DATA. SECTION 2 - DESCRIPTION 2.4 INTRODUCTION... 2.2 GENERAL... 2.3 DETAILED DESCRIPTION. 2.3.1 Aeration Compartment 2.3.2 Settling Compartment... 2.3.3 Chiorine Contact Compartment 2.34 — Chiorinator 2.35 DISCHARGE PUMP. 2.4 Pump Inner Cover... 2.5 Pump Casing wn... 2.6 Mechanical Seal 27 Impeller 2.8 Air Compressor... 29 Electrical Controls... 2.10 Electrical Controls.. 2.101 General 2.10.2 Float Switches 2.10.3 Operation. 240.4 Remote Emergency Stop . SECTION 3 - INSTALLATION 3.1 GENERAL DATA 3.2 RECOMMENDATIONS ON VENT SYSTEM DESIGN... 33 FITTING INSTRUCTIONS FOR ITEMS PACKED SEPARATELY FOR SAFE TRANSIT. 3.4 COMPARTMENT VENTILATION... SECTION 4 - OPERATION. 4.41 HEALTH AND SAFETY INFORMATION... a 42 PREPARATION OF UNIT FOR INITIAL OPERATION...... 43 _ DETERMINATION OF RESIDUAL CHLORINE CONTENT. 43.1 General 43.2 Sampling instructions... 44° Disinfectant Cleaners. 44.1 Approved Biological Toilet Cleaners ... 44.2 __ Approved Descaler..... : 45" DESLUDGING TO AN INCINERATOR ABA General ee 45.2 Using a Siudge Pump... 45.3 Using the Super Trident Discharge Pump. 45.4 Key to Symbols shown on Schematic Drawing Ai9170 SECTION 5 - MAINTENANCE... 5.1 GENERAL. 52 MAINTENANCE SCHEDULE. 5.2.1 Weekly. 522 Monthly conn. 5.2.3 6 Monthly... 524 Annually... ae 53. CLEANING THE CHLORINATOR 5.4 DRAIN AND CLEAN UNIT..... 5.5 _ AIR DIFFUSER ASSEMBLIES. 55.1 General 5 5.5.2 _ Element Replacement. 56 DISCHARGE PUMP. 5.7 COMPRESSOR ..esnsnnennnninininnen 58 RECOMMENDED SPARES LIST vss Pry y yey ppm pps ‘SECTION 6 - DRAWINGS 6.1 General Arrangement Drawings 62 Sectional Arrangement Drawings... 63 Sectional Arrangement List of Parts...6.4 General Arrangement Drawings ~ Sewage PUMPS... 6-8 65 Control Panel Layout 6-10 6.8 _ Installation Wiring Diagrams 11 67 Circuit Diagrams .. ia en SECTION 7 - DISCHARGE PUMP MAINTENANCE wn TA 7.1 PREPERATION FOR DISMANTLING THE PUMP. A 7.2 DISMANTLING PUMP oT 7.3 INSPECTION ener TA 7.4 ASSEMBLING PUMP. 7 7.5. RECOMMENDED TIGHTENING TORQUE 73 SECTION 8 - AIR COMPRESSOR MAINTENANCE, at 8.1 PUMP RANGES... 84 82 DESCRIPTION... . at 8.3 SUITABILITY. Fite at 84 HANDLING AND SETTING Lip (Figures 8.4 and 8.2). a4 85 INSTALLATION (Figure 8.1) Meee eeeinnercce a ee 86 _ INITIAL OPERATION (Figure 8.1)... : 83 87 POTENTIAL RISKS FOR OPERATING PERSONNEL. 83 88 MAINTENANCE AND SERVICING... at 83 Page 4FIGURES Figure 2.1. Schematic Diagram of Sewage Treatment Unit Figure 3.1 Typical Super Tent Sewage Treatment Pant instalation. Figure 3.2 Holding Down Feet... Figure 3.3. Discharge Pump Installation... eee Figure 4.1. Schematic System Layout Sewage Treatment Unit / Incinerator... Figure 6.1 Control Panel Arrangment - Two Compressors & Two Discharge Pumps FIGURE 7.1. IMPELLER SHIMMING cd Figure 8.1 Compressor... Figure 82 Compressor interior (1). Figure 8.3 Compressor Interior (2). Figure 8.4 Compressor Interior (3). Figure 8.5 Compressor ~ Exploded VieW ...sncnnmnmnnnnnnninnnnisennnnnnnnne TABLES Table 3.1. Key to Typical Installation diagram .. ce Table 5.1 Trouble Shooting Guide TABLE 5.2 PUMP FAULT FINDING CHART. TABLE 5.3 MAINTENANCE SCHEDULE. Table 5.4 Recommended List of Spares. Table 6.1 List of Parts for Drawing D7937 Table 7.1 Sectional Arrangement for BSOxS0HC 2-Pole Sewage Pump Drawing D8103. Table 72 hems List for BSDXSOHC 2 Sewage Pump Drawing DETO3. Table 8.1 Compressor : List of Parts for Figure 8.5. Page 5Spare Parts and Service Spare Parts can be ordered direct from the following acdress: Hamworthy Wastewater Systems Lid. Telephone: +44 (0)1202 682600 Fleets Corner Facsimile: +44 (0)1202 685444 Poole, Dorset Emall: [email protected] BH17 OJT, England or from any Hamworthy office or agency throughout the world, When ordering spare parts, the following information is required to ensure that correct parts are supplied: Type and serial number of machine: Obtained from machine nameplate Item Number and full description of part required: Obtained from details in this publication Technical Service and Advice: Technical service and advice can be obtained during normal working hours from the above address, on the following contact numbers Telephone; +44 (0)1202 662663 Facsimile: +44 (0)1202 662622 Email [email protected] or via any of our overseas companies or offices Outside normal working hours a 24 hour emergency facility is available. Initial telephone contact number is England +44 (0)1202 662663 Overseas Hamworthy Offices Canada Hamworthy Canada Lid, Norway Mamworthy AS, 113 Cushman Roed, Unit’, soseph Kelers vei 20 St Catherines, Ontario, 2M 659 Tenby Tei. +1 905 608 4022 PO 80x89, N-3401 Lier, Nomay Fax. +1 905 688 9028 Tel +47 32 85 92.00 Fax +47 92852193 China Hamworthy Shanghat Representative Offce, Singapore Hanworthy PTE Lid, Room 7-0 ¥iDien Paza, 18 Bendi Crescent No. 788 Zhao sia Bang Ross, Singapore 829678 Shanghsi 200030 Tel, +65 251 6086 Tol. +06 21 e4assees Fax +65 261 6011 Fax. +0021 64450075, Dubai CIO Aqua Tech, South Africa Hamworthy Engineering Arca (Pty) DY 160/7 Al Jada, PO Box 62073 ua Dub, UAE P.O. Boxs04ss, Tel. + 971 4326 0335 Randburg 2128, Johannesburg Fax. +971 4328 0398 Te» 2711 7923666 Fox +27 11 7023880 Holland Hamworthy BV, usa, Horworthy Inc. Bistolstaat 1, 3047 AB. Georgia 1129 Hospital Dive, Suto 3C, Roterdam. Netheriands Stockbridge, Georgia 30261 Tel. +31 10462 4777 Tel. +1 770 07 8900 Fax. +31 40 416 6088 Fax +1 770 607 6969 India Hamworthy Pvt Ltd Now Jersey 187 Route 38 (6-185 Mital Cour, Narman Point Matawan, NJ 07747 Mumbai 400 021 ina New Jersey Tel. + 91 22 2672804 Tet +732 583 5118 Fax. +91 22 2072008 Fax +702 869 5110, Korea Hamworthy Korea Lid Now Orieans 1418 Edwards Avenue ‘4th Floor Hyundel Building #1198-5 Suite 8 Ghoryang 3 dong, Done-gu, Now Crteans| Pusan, Korea (601-013) Louisiana 70123 Tel 6251 405 8461 Tel: +1 804 734 8525 Fax: + 8251 469 7408, Fox +1 504 738 5716 Page 6Hamworthy Agents Workiwide Abu Dhabi Al & Sons Co. ‘AB & Sons Co, Bullaing Tourist Clb, BO Box a6 Abu Dhabi, UAE. Tel. + 71 2723900 Fax. +971 2729901 Argentina Neptune SA Cale Mencoza 3185 -5°- 8 1428 - Buenos Altes Argentina Tal. + 54 1 322 6081 Fax. +84 1.822 8790 (Cate (Aust) Ply. Lt, 43 Barry Avenue Mortdale, NSW. 2223 Austala Tel, + 61 29538 2100 Fax. +61 29 599 5332 Marinetec Ls, 30 Agrabad Commercial Area, POBox 2018 Bandar, Chitagong Bangladesh Tel 880 31 502854 Telex: 65466 Australia Bangladesh ‘Tridente Brazil Rus Visconde de Inhuama, 134-GR 1519 Centro Rio de Janeio ~RJ 2081-100, Brazil Tel, + 8521233 1480 Fax, +85.21 293 7187 Daweul Ltd, Chem Veah Bul, BLNO4VH A. 1421 Sofi, Bulgaria Tel, + 359 2 083 0186 Fax, +3592 062 5217 Brazil Bulgaria Lanz ¥ Cia Lida Calle Dr. Barcot Borgono 233, Casita 16389) Santiago, Chile Tel. + 582.295 2707 Fx, +86 2 236 7329/1070 ‘Consul Naval Lida Edificio Colseguros Oficina 501 Calle Cochera del Gobecrador Cartagena, Columbia S.A Tel +575 664 8473 Fax, +875 686 1640 Berendsen PMC A/S, Telefonve; 6, Dk 2860 Soborg, Denmark Tel +45 702121 21 ent 42 Fax, + 45-39 64 85 11 ‘Sortemer Lig. E1 Oro 1303 ¥ Guaranda, PO Box 8800 Guayaquil. Ecuador S.A ‘Tel +990 4 945108/540925 Telex, 049741 AM BU SL. Chile Columbia Denmark Ecuador Eoypt France Germany Greece Italy Genoa Trieste Israel Kuwait Maita New Zealand Ineratone Manne Comer Sultanate Tne usec Tadhg Sat 0x95 (21321 0% Imbrehimien OF Oman postal Code 112, Raw ‘Alexandia. Eoypt Suitanate of Oman “el. +209 483 €959 Tol. +968 798603 Fax. + 203 483 7969 Fax. + 966 702961 Etebicsements Tiano Pakistan Urites Traders 2 Bis Rue cela Baume Harcon Chambers Paris 75008, France Altaf Hussain Rood, Tel+ 331 dst 9952 Karechi 74000, Pakistan Fax, #38 14225 6062 Tel. + 0224 241 4016 Fax. +92 21 241 6862 Wiheim Rump KS Poland — Romac Lic Buchheistestrasse 6 801483 Gdansk, 20887 Hamburg, Germany Giolkowekigo 70/26 Tel + 40.40 3178420 Poiand Fax. + 49-40 3194064 Tel + 48 $8 347208, Fax. + 48 58 3463604 ‘pha Marine Engineering Ltd. Qatar Al Aned Trading & 58 Sslaminos Contracting Company ‘GR 16574 GLYFADA, PO Box 3266, Doha, Qatar Attens Greece, Tel +974 s14022 Tels +307 89 43 220 Fox. + 974 414021 Fax, +301 96 60 210 SIRN Sct Spain Aves Industral Y Naval S.A. 22) Vie Casaresis, 16128 Parque de ies Naciones| Genoa Edie Gormania Tol. +300 10 886771 Guzman @ Bueno 133 Fax, #3900 10 542678, Mears 26008, Spain Tel. #34 91853 9200 Fax, +34 91 834 7402 2211 ViaDelLazzaretto Venezuela Ofcin Mastima PI. C.A Vecchio, 9.24128, Trieste Tel +39 040 304247 Fax +390 40 308108 Edit Tore La Previsora Piso 7, Sabana Grande ‘Aptéo 60710, Caracas 1060A Venezuela Te +882 7817897 Fax, + 582 781 9457 B, Sofer & Co. Lid PO Box 224 ‘Aichi 2010 israel ‘Tel +972 9882 2519 Fax. + 972 9862 5211 ‘The Trading & Industrial Equipment Co. (WL) (TECO}, PO Box 2159, 19022, Safat, Kuwait Tel 06965 4810385 Fax, + 965 4810367 ‘Thos. ©. Smith & Co. Lt. 42 St Christopher Street Valetta, Mata Tel +356 625071 Fax, + 356 247182 (Gaba (New Zealand) Lic 37 Clyde Siroot Whangarei, New Zealand Tel +64 9438366 Fax. + 64.94 00854 Page 7CAUTION NOTICE TO ALL USERS OF HAMWORTHY EQUIPMENT SPARE PARTS Please ensure that only original spare parts are used Machines have failed as a direct result of using non-original spare parts. Warranty claims may be invalidated if non-original parts are used. The use of non-original parts can be dangerous. Statutory rights are not affected. Page &ir DUTT TECHNICAL SPECIFICATION - SPARES & TOOLS LIST [°° HAMWORTHY UNIT: DISCHARGE PUMP TOOLS SesnSaecsceseesenessnna asl SUPPLY_] NO. NAME, SKETCH Se} wmrra Bee ae Bees JACKING SCREW O.15KG ' » 32521346 I 7 2 em 2 [ena 1 [arose PUMP SPARES KIT ASSEMBLY NUMBER: 73478000 SS] DATE DRAWN PS lowe JJH ro ADB [x © _HAMWORTHY ENGINEERING LIMITED 1998AURUEUUL | CONTROL PANEL SPARES FOR 110 VOLTS ia HAMWORTHY (UNIT: ST2a - sT6a SHEET i Se is ‘SUPPLY No. NAME SKETCH Se) water Bos =e gz5 31 + lo —— 2 FUSE LINK » a (5 AMP) -| - 2) 2/8 £18 giR a Wl a = 2 31 nN j=" 1 ip > FUSE LINK ols «2 AMP) ne - 2|u/8 Nia B19 a < 5 37 g a u LA] | ile AUXILIARY 0°90 | a < CONTACT e| Io - - LE e{s °° Slo | SSESEEES! EE v y | 23 I < ~ I oo | a 70 ia 45| | a fe | = a of] a m0 CONTACTOR ll tte 2 Fi © = - lho g | | + 2 Tat | | | 1 [ens | i SS [pate - RaW | PS | orc JuH | are | ADB SL © HAMWORTHY ENGINEERING LIMITED 1998TTY [oO Paes es FoR w vas HAMWORTHY | UNIT: Stea = STSa SEET 3 “SETS are SUPPLY NO, NAME, SKETCH S=) meter, Beis ae Bess 27 S a o BULB | tee See 1/8 5 8 t a BOX 204 128 CALL SPARES | [= 7 R CONTAINED a 6 WITHIN> 3 - - 1; a m © o CONTROL PANEL SPARES KIT ASSEMBLY NUMBER: 78013208 co 1 [arse 18S [DATE pRAWW PS cK JJH ar ADB SL © HAMWORTHY ENGINEERING LIMITED 1998RIETSCHLE DLT 25 SPARES re HAMWORTHY |UNIT:s734 7 ST4a BLOWER SPARES SHEET T SHEETS 2 = Tawar Te NO. NAME SKETCH Be) wera (ghee a BS eoh= as ‘ CARBON cE wT BLADE | = | carson | € 33 FILTER CARTRIDGE - PAPER (PAPER> 040 94 FILTER COMPRESSOR SPARES KIT ASSEMBLY NUMBER: 49950558 CARTRIDGE - | ste |! (METAL) el 26a 28 BALL BEARING aS _ 1 230 eer 7 aa 3s Dare Raid giz Ld PS TOLERANCE lene RING - : 1 JJH are ADB SL © HAMWORTHY ENGINEERING LIMITED 19987 DUENRRUUUL RIETSCHLE DLT 25 SPARES : 68. HAMWORTHY | UNIT:ST34 / ST4A BLOWER SPARES: SHEET = SHEETS 2 ce SUPPLY Ls NO. ‘at se gal fe HE SKETCH BS) trem. gle fe at Jose ao a SPACER BEARING () - - 1 COMPRESSOR SPARES KIT ASSEMBLY NUMBER: 49950558 er 1 [evs iss [DATE DRAW PS lonK JJH APP ADB SL © _HAMWORTHY ENGINEERING LIMITED 1998nl : “DUPLED PUMP SPARES CLASS-B a HAMWORTHY UNIT: MEDIUM HEAD (DISCHARGE PUMP? Sees SHEETS _ SUPPLY, NO. NAME SKETCH BS] water ble iil BEES oe 9 eee Fo Ser 2 PEEL OFF SHIM _| 225 = | 5/%oZ jit S| ene g eed oO ote od : je x @ 32 7 3 0127 8 : 12 a |. | TAB WASHER Zu 6/% “4 a NX |e B) 2g |B )s o xU oO Zz a | a a | a ai 54 19 a u wu a i i a) IMPELLER } 8] as His SCREW BS) 4. fila] | / 275 am) MLO au, o | ee < any a 4) a | = Q | *O" RING 5 e % | Pa um 1) wea a za @ = aa soe ¢ Tarai ss [pare [Raw NHS len NHS are NHS | SL © HAMWORTHY ENGINEERING LTD 1998HH CLOSE COUPLED PUMP SPARES CLASS-B Ga ree eee HAMWORTHY [UNIT MEDIUM HEAD (DISCHARGE PUMP? leer ee faa SUPPLY NO NAME SKETCH EE) wren Boe | rie BEES o 245 6 ao g | wae | 1g QO” RING CASING | BER s S| fem i/o ray Hr D ia Zan ¥ © £ 66 | © x < oO NS wy]. MECHANICAL SEAL z 3 | | KRUTATING PART) n «| a Siw | 7 Tt} a 1/3} S| 5 cj) la }S 5 < jv |Z a | >| a} a i 70 | 10 9 ” lal MECHANICAL SEAL i g iS]5 STATIONARY 2 yi Q]Y PaRT> é G a iS) ig oO a 50 | |& a a) a = rs oO Theea os pare fpeAwa NHS io NHS ae NHS SL © WAMWORTHY ENGINEERING LTD 1998Tn CLOSE COUPLED PUMP MOTOR SPARES CLASS~ABC (ea. HAMWORTHY |UNIT: MEDIUM HEAD (DISCHARGE PUMP? SfEET SHEETS NO. NAME SKETCH ee MATERIAL fe a SEs S @ 3 DE. MOTOR g B BEARING = 6307 ez 0 +e 3 < eer 16 nN = o | |= NDE. MOTOR g - |1/8 BEARING 3 3 6206 22 q | [38 baa + = [ona [2 [ea Thies PUMP SPARES KIT ASSEMBLY NUMBER: 73478042 iS [DATE BRAWN NHS. KK | NHS | APP NHS. LSE © HAMWORTHY ENGINEERING LIMITED 1998SECTION 1 - TECHNICAL DATA Electrical Power Supply ST3A __ | 440V, 3 phase, 60 Hz rol Voltage: IOV AC. Discharge Pump Motor Ratings ‘STSA Close coupled B50x50 MED 60Hz | 44 KW Compressor Motor Ratings ST3A 0.9 KW. Discharge Pump Duty Close coupled B50x50 MED 60Hz 8 méihr at 18m head Pump Motor Speed GOHZ ole) Compressor Duty "3525 revimi ST3A 0.55 bar - 22 m'/hr High Level Alarm High Level Alarm, Volt free normally closed 500W Vent System Back Pressure Vent System Back Pressure 1mm wg. (max.) ‘Temperature and Humidity Data Operating Ambient Temperature 0° (min) to 45°C. (max) Operating Relative Humidity ‘Maximum 95% Page 1-1Page 1-2 Loading Data ST3A Designed Hydraulic Flow m'/day 4.66 Max. Hydraulic flow, Uh 306 Min, Hydraulic flow, m'/day 2.33 Max. duration of max. flow, h 4 Designed BOD, Loading, ko/day 3.00SECTION 2 - DESCRIPTION 24 INTRODUCTION ‘The Hamworthy Super Trident Sewage Treatment unit is a self contained system for the treatment of sewage from ships or rigs before it is discharged overboard and so prevent the pollution of harbour and coastal waters and inland waterways. The system uses the aerobic principle of sewage digestion, coupled with treatment of the final effluent, and is generally accepted as the most compact, efficient and fiexible system for use on board ship. The Super Trident will operate satisfactorily on salt, fresh or brackish flushing water. ‘The system is ideal for ship installation as, if necessary, a number of small units can be arranged to suit ‘accommodation requirements rather than one large installation requiring considerable installation space and Jong lengths of piping, 7G Lad ocHRee Ne eversoueo Figure 2.1. Schematic Diagram of Sewage Treatment Unit Page 2-122 GENERAL Basically the Super Trident Sewage Treatment unit comprises a tank, divided into three water tight ‘compartments - an aeration compartment, a setting compartment, and a chlorine contact compartment. The incoming sewage enters the aeration compartment, where it is digested by aerobic bacteria and micro ‘organisms which are promoted in the sewage itself by the addition of atmospheric oxygen. From the aeration compartment the sewage flows into the setting compartment where the aerobic bacteria fioc, known as activated sludge, is settled out producing a clear effluent which passes through a chlorinator and into the chlorine contact compartment before being finally discharged, 23 DETAILED DESCRIPTION 2.3.1 Aeration Compartment In this compartment of the treatment unit, aerobic bacteria, that is those bodies requiring dissolved oxygen to exist, reduce the influent waste material which mainly comprises Carbon, Oxygen, Hydrogen, Nitrogen and Sulphur into Carbon Dioxide, Water and new bacteria cells. The Carbon Dioxide is emitted throughout the vent system whilst the water together with the bacteria cells are displaced into the settling compartment. Ar is supplied to the sewage from a rotary compressor through a number of fine bubble diffusers, located at the bottom of the tank but removable from the side for ease of maintenance. The air provides the life giving oxygen to the aerobic organisms and also keeps the contents of the tank intimately mixed with the incoming raw sewage and the returned settled activated sludge. 2.3.2 Settling Compartment In the setting compartment the bacteria settie out and are returned to the aeration compartment by the airlift tude. This takes its supply from the bottom of the compartment and discharges to the aeration compartment, via a visual indicator pipe which enables @ check to be made on the sludge return. The setting compartment of the unit is of the hopper type. The sloping sides prevent the sludge from accumulating and direct it to the suction side of the airlift. The effluent enters the compartment through a stiling chamber and rises through the clarifier, to discharge to the chlorine contact compartment through a weir at the top of the clarifier, A surface skimmer is provided to skim off and return surface debris back to the aeration tank - a second airlift is used for this purpose. 2.3.3 Chlorine Contact Compartment The effluent is stored in this compartment after chlorination to allow time for the chlorine to kill off any harmful bacteri (On units fitted with a discharge pump two level regulators (or float switches) are fitted to control the operation of the pump, see Electrical Controls. ‘An additional float switch is fitted which operates an alarm signal should the level rise above the normal “high” position. ‘An emergency overflow pipe connection is also provided through which only treated effluent can pass. Page 2-22.3.4 Chiorinator 4. Tablet disinfection (standard). This is of the flow-through type and all of the effluent passes over the specially formulated tablets and absorbs the required amount of chlorine before flowing into the chlorine contact tank. ‘One or two tubes depending upon test results (see Section 4 - Determination of Residual Chlorine Content) are filled with tablets and placed in position in the chlorinator with the cut-away sections at the lower end. The effiuent flows around and past the lower end of the tube and comes into contact with the tablets, ‘At the outlet end of the chlorinator is a control weir arranged so that as the effluent flow increases the level rises and more tablets come into contact with the effluent. In this way the chlorine uptake is always sufficient for sterilisation of the effiuent.) 2.3.5 DISCHARGE PUMP These pumps are horizontal close coupled centrifugal units with a 2-bladed open impeller of the non-clog type. They are designed for capacities up to 40 m’/h and operate at 2-pole motor speeds. The medium head pump is suitable for heads up to 18 metres. The high head pump is suitable for heads up to 25 metres. The pumps are particularly suited for effluent discharge, sump drainage and handling dirty water containing solids up to 25mm. diameter. 2.4 Pump Inner Cover The inner cover is bolted onto the electric motor and houses the mechanical seal. 2.5 Pump Casing The pump casing is bolted to the inner cover and incorporates the suction branch which is in-line with the motor shaft, and the discharge branch which is arranged at right angles with the suction branch. 2.6 Mechanical Seal The mechanical seal arrangement comprises two besic parts, a stationary seal ring, located in the pump cover, and a rotating seal ring, carried on the impeller hub. A spring maintains pressure between the seal faces, and lubrication is by the pumped fluid, Circulation passages are arranged to maintain flow rate and prevent the accumulation of sediment 2.7 Impeller ‘The impeller is keyed to the motor shaft and retained by @ screw and lockwasher. A shim Is fitted at the bottom of the impeller hub to permit the running clearance to be correctly set between the impeller and inner cover. 2.8 Air Compressor One rotary vane air compressor is fitted as standard. 2.9 Electrical Controls The macerator is a separate electric motor driven unit situated in the sewage treatment tank. The purpose of the unit is to break up the incoming solids and accelerate subsequent digestion. A General Arrangement drawing is included in Section 6.4. Page 2-3240 Electrical Controls 2.10.1 General The rotary air compressor motors are operated by manual switches on the control panel. When @ discharge pump is supplied it is controlled by float switches fitted in the final effiuent tank with an overriding HAND/AUTO switch on the control panel. 2.10.2 Float Switches ‘These are of the magnetic reed type with three floats mounted on a common stem and wired to the control panel, The two lower floats operate the discharge pump, and the upper float operates the high level alarm Circuit should the level rise above normal. 2.10.3 Operation When the system is fitted with a discharge pump and the control switch is in the AUTO position, the typical sequence af operation is as follows’ When the liquid reaches the “High” level float switch, the pump motor is started and the liquid begins to discharge from the compartment. The pump continues to run until the liquid drops to the level of the "Low" level float switch when the motor is switched off. Should the "High’ level alarm float switch fail to operate for any reason, the level of the liquid will reach the "High" level alarm float switch, and actuate the alarm circuit When the control switch is moved to the HAND position and the ON push-button switch is operated the pump motor will run, to empty the tank for draining or cleaning unti the control switch is moved to OFF. A control panel General Arrangement drawing including control switch layout is included in Section 6.5 and @ Circuit wiring diagram is shown in Section 6.7. 2.10.46 Remote Emergency Stop Terminals are provided in the control panel for customer supply and connection of a remote stay put type emergency stop button. Operation of the button will prevent all pumps and compressors from running. If the Compressor is stopped for a prolonged period the loss of process air may result in anaerobic conditions. To prevent this occurring, either an emergency oil free air supply must be fitted, taken from the ships air system or the unit must be emptied and flushed out as detailed in Section 5. Page 2-4SECTION 3 - INSTALLATION 31 GENERAL DATA The unit should be installed in a position where it is as level as possible when the ship of rig is in its normal position. Bolt holes are provided in the baseplate of the unit for fixing. It is recommended that the Super Trident Is installed with the jongest side in a fore and aft direction to minimise the effect of rolling motion. ‘The maximum angle of roll or pitch at which the unit will function satisfactorily is 15° either side of the vertical To facilitate periodic maintenance and for use in an emergency, a direct overboard by-pass of the unit must be provided. Galley waste water which meets solids discharge standards can be led, via @ grease trap, to the waste water mains. Where solids are disposed of by macerator/garbage disposal unit, Hamworthy must be consulted. CAUTION: Welding must not be carried out on the tank surfaces or the internal coating will be destroyed. The incoming electrical control terminals are clearly marked in the control panel. ‘An installation wiring diagram is included in Section 6.6. The following should be read in conjunction with the General Arrangement drawing supplied with the equipment, or as part of the contract documentation. A General Arrangement drawing is included in Section 6.1 for reference purposes only, but this may not fully represent the installation, Access to the following items must be arranged: 1. Electric Control Panel. Switches are mounted on the outside of the door. The open door dimension is, stated on the General Arrangement drawing 2. Chlorinator. Tablets are to be added as necessary. See Section 4 - Determination of Residual Chlorine Content. 3. Allvalves. Required to be operated during cleaning. 4, Rectangular and circular covers in the top and sides of the units. During servicing of the aerators and internal examination after annual cleaning these are removed, ischarge pump and air blower for maintenance. 6. Float switch assembly, The following pipe connec NS are required to the unit 1, Raw sewage inlet 2, Gas vent to atmosphere. 3. Overboard discharge connection (from pump discharge) and one sea water filing connection. 4, Inlet for water from sinks, showers, etc., that cannot gravitate directly overboard, 5. Emergency overflow connection. It is important that the pipe does not rise above the height of the boss on the tenk side. Can be piped to bilge vie a water trap, or directly overboard, or into a storage tank. 6. Recirculation line, 25mm flexible hose (for cleaning). With due consideration of the foregoing, i.e. access required to various items and all pipe connections to be made, the tank and pump can be positioned to suit the space available. Page 3-1Y Peteed ansvattactons Figure 3.1 Typical Super Trident Sewage Treatment Plant Installation Page 3-2Table 3.1. Key to Typical Installation diagram a Isolating Valves 7 Br Limited low level waste water disinfecting inlet (grey water) c Disinfection tank +H ef D Tablet disinfection feed tubes i 7 E Emergency Overflow Connection c F Level Control Switch for disinfection contact tank SG Emergency Air inlet Connection (if single compressor fitted). 4 Rotary Air Compressor i Control panel for sewage treatment tank J ‘Sea water supply for initial filing and cleaning, (Use clean sea water or freshwater ~ not harbour water) K_ Discharge Pump iM Overboard discharge a i N Aeration Tank Be | ° ‘Sample / Sludge incinerator / Recirculation Connection P Settling/clarfier Tank a Soil inlet (black water) R Vent to Funnel or Mast Ss Branch above max. water line (prevents system back-up) Tr ‘Storm Valve U ~__ | Overboard By-pass connections must be fited on soll and grey water nes, as indicated [v_ ‘Typical installation el x Grease Trap (When Ordered) 7 Notes to Figure 3.1 1 2, lems marked thus * NOT Hamworthy supply. Grey Water Waste Drains. Discharge directly overboard in accordance with I.M.O. Regulations. A limited quantity of grey water meeting |.M.O. sewage effluent standards from sources below the water line may be piped into the disinfection tank. (not galley sinks, garbage disposel units or laundry). NOTE: Sink waste, etc., should pass through a de-greasing unit and solids should not be present. Water traps are necessary on all sinks, showers, etc. Grey water must be piped separately from Black water soil mains. A by-pass line must be fitted. Black Water Soil Mains. These are for handling the waste from water closets and urinals. An overboard by-pass line must be fitted. A Hamworthy transfer unit can be used if the final soil pipe position is below the sewage treatment plant. A macerator is recommended where larger material is likely to be present and on passenger vessels and ferries. fit is required to combine the waste mains and soil main, Hamworthy must be advised at an early stage as the size of the unit will usually be affected, Black Soil Line Falls. This should be a minimum of 10mm per 300mm run after allowing for the worst trim conditions. Non-return valves or valves which could cause a flow restriction should not be fitted. Vent, Carbon dioxide is formed during the aerobic process of waste treatment, This has no odour, is non-toxic, non-flammable and is released to atmosphere with saturated excess air which is not used in the stabilisation process. It is important that no liquid pockets can form to impede the free run of the Page 3-3gases. A centrifugal fan can be supplied by Hamworthy for difficult pipe arrangements that would give more than 15mm water gauge back pressure. A separate guide for vent pipes is available from Hamworthy. Flame traps, if required by local regulations, must be generously sized to meet the vent requirements between maintenance periods. Emergency overflow from Disinfection Tank. Connection must be 1.5m above water level to ensure that the discharge non-return valves can be lifted and flow take place. f the available level is less than this a back-up will occur in the system until the required head is available. If emergency overfiow is below maximum water level, then connect to bilge inoluding a "U trap of 200mm to prevent venting. ‘Syphon Prevention. if top of tank is above light draught water line then pump discharge line must be looped above top of tank and 2 connection taken from the top of the loop to a point in the air vent above the discharge head of the pump. Galley Waste. This should be led directly overboard. If itis intended to connect into the black soil water inlet of the sewage unit Hamworthy must be consuited, as size of unit will be affected and a grease trap must be fitted. DO NOT connect to the Grey Waste Water disinfecting inlet NOTE: This equipment can be supplied to meet the requirements of the Environment of Canada Great Lake 8 32 Regulations. Fixings. The holding down bolt dimensions are shown on the General Arrangement Drawing. ‘Supporting steelwork must span the base length on the edges and the centre line 2s shown in the following sketch, The holding down feet may be welded to the support structure but DO NOT weld to the tank sides or base as the internal protective coating will be destroyed. Packers to be used as required. Figure 3.2 Holding Down Feet RECOMMENDATIONS ON VENT SYSTEM DESIGN The vent pipe run should be to the funnel or mast using the minimum number of bends. Bends should be long radius type, where possible. Ensure that the vent pipe continuously rises from the Sewage Treatment Plant to the vent discharge point so that condensate can drain back to the sewage treatment plant and that listing of vessel is taken into account, Facilities to enable draining of the vent pipe should be added where unavoidable water traps could occur in the vent line. Eg. fit adequate depth water sealing U-traps with isolating valves. Good vent design and choice of vent discharge position can avoid the need for equipment which can: a) Create back pressure on the vent system b) Require excessive maintenance to ensure a low back pressure is maintained Page 3-4Eg. Flame traps, filters, fans etc. All waste water inlets, Water Closets (W. C.), urinals, etc connected to the sewage treatment plant, its feed or vent pipe-work must have a device fitted to prevent venting from the vent pipe into compartments e.g. water seal of at least 30mm greater depth than the vent back pressure. Listing etc of vessel is to be taken into account. The sewage treatment plant overflow and any other connection to the system terminating within the vessel should be fitted with a similar device, When coupling any other vent pipe-work into the sewage vent system or fiting a vacuum sewage collection system to the sewage treatment plant its effect must be taken into account on the overall vent pressure drop. This is particularly the case with vacuurn sewage collection systems, which will increase the air flow rate from the sewage treatment plant, also creating surges as each W. C. flush will induce approximately 60 litres of air in 3-4 seconds. (Allow for potential peak flushing rates by increasing the air flow rate from the sewage treatment plant according to the number of vacuum producing units venting into the sewage treatment plant & their air pumping capacity.) The total system back pressure should therefore typically not be above 15mm water gauge with the following air flows: UNIT SIZE | MAXIMUM TYPICAL VENT DESIGN] TYPICAL VENT CONNECTION NUMBER OF AIR FLOW (m°th). NOM. DIA. (mm) st vacuum | STANDARD | VACUUM | STANDARD VACUUM. RT UNITS TANKONLY | SYSTEM | TANK ONLY ‘SYSTEM ASSUMED | (novec. Units) | FITTED | (no vac. Units) FITTED 3A. 2 18 58. 50 80 @ 10. " Where two sizes are shown the first is the tank connection size. It is recommended that the vent be increased to at least the second size as close to tank as is reasonably practicable. Flame traps are not normally required at the end of the vent, but if fitted should be sized so as not to increase the overall pressure drop above the required limit when dirty and should be regularly maintained. Where choice of vent discharge location is restricted to sensitive areas & odour extraction filters are required contact Hamworthy to discuss potential vent fiter options. if fitted they should be sized to not increase the overall pressure drop above the required limit when dirty and should be regularly maintained, In the last resort, where system back -pressures cannot mest the required limits, contact Hamworthy to discuss potential vent fan options. Page 3-5dann Wie See rea warea, (of HARBOUR Mat. a 7 SETTLING TANG eerie AeRATION Tae SE course tamc—el ole | pur ®, Rp ered oyERBOARD ra 7 SISSHANE negyecuLarin 4 SHIPYARD CONNECTION DETAILS SINGLE DISCHARGE PUMP Figure 3.3. Discharge Pump Installation 3.3. FITTING INSTRUCTIONS FOR ITEMS PACKED SEPARATELY FOR SAFE TRANSIT Chilorinator tablet tubes. These are mounted in the chlorinator in the position shown on the General Arrangement drawing 3.4 COMPARTMENT VENTILATION Ensure that the compartment containing the Sewage Treatment plant has an unrestricted supply of clean sir (See Technical Data, Section 1 for fow rate). Page 3-6SECTION 4 - OPERATION 4.1 HEALTH AND SAFETY INFORMATION Personnel: Safety glasses and gloves should be worn when taking samples, Protection refiling chlorine tablet tubes and general maintenance of the system, Application: For water testing applications only. Properties: White tablets. Non-combustible. Corrosive if dissolved in water to give slightly acidic solution. Hazards: Of low toxicity. Minimal hazard during normal handling and use as directed. Storage: Store in original containers. Keep dry. Keep away from children, Sheff Life: 11% years unopened at 30°C and relative humidity of 80%, Mi . Use only as instructed. Avoid handling whenever possible. Wash hands after fandling: use, Not to be taken. Transport: Not regulated. In case of contact with skinleyes Wash with plenty of water If swallowed Give plenty of water to drink. OBTAIN MEDICAL ATTENTION. In case of spillage Sweep up and wash away with water In case of fire Water and all extinguishers may be used. Tablets are non-combustible. Page 4-1Product: Calcium hypochlorite mixture tablets Application: Disinfection and sanitisation of effluent ‘Composition: Calcium hypochlorite hydraed and 1, 3, 4, 6 tetrachloroglycoluri (75%) and inerts (25%) Properties: Hazards: Storage: White tablets. Oxidising agent. Corrosive. Do not mix or contaminate caiciurn hypochlorite tablets with any other suppliers or any foreign materials such as grease, oil, lubricants, solvents, acids, alkalis, soap products, paint products, household products, pool chemicals, vinegar, garbage, beverages, pine, dirty rags etc. Contamination or mixing with these types of chemical and products ‘may result in fire or explosion. The fire can be of great intensity | Chlorine gas may also be produced. Prevent any hot or burning material such as a lighted cigarette from falling into any container of tablets. Keep in a coo! (20 - 23°C) dry place in the original container. Always repiace cover. Do not store in any other container. Do not re-use empty container. Wash thoroughly with water and discard clean container in a safe place. Do not expose to temperatures above 56°C. Sheff Life: Unopened 12 months at 23°C | 6 months at 30°C | 3 months at 45°C \ soa | Handling: Do not allow contact with eyes, skin, mucous membranes or clothing. tt may produce severe chemical burns. Harmful or fatal if swallowed, Handle containers with care. Do not drop, roll or skid, Keep upright. Handle calcium hypochlorite tablets only with clean, dry hands, rubber gloves or metal utensils. Any contamination may result in fre. | In case of fire, drench with water and cool the surrounding area with water. In case of contact with eyesiskin, flood with plenty of water IMMEDIATELY for eyes. Obtain medical attention for skin if irritation persists. If swallowed, feed bread soaked in milk, followed by olive oil or cooking oil. DO NOT INDUCE VOMITING. OBTAIN MEDICAL ATTENTION IMMEDIATELY. In case of spillage, dispose of with large amounts of water. Page 4-2 OBTAIN MEDICAL ATTENTION42 PREPARATION OF UNIT FOR INITIAL OPERATION (For Valve number positions see Section 3 - Discharge Pump Installation) 1 Ensure that all valves in the air supply lines are open. Close control panel isolator. Switch the service compressor on and check for correct rotation by placing a hand over the inlet. Suction effect incicates, correct rotation. Check operation of relief valve by closing compressor discharge valve. Open compressor discharge valve to check that relief valve reseats. With duty compressor running, partially fill unit with water to cover diffusers. Open valves to diffusers, close valves to air lfts and confirm air to each diffuser. Select auto and No. 4 duty discharge pump on panel. Close all side hatches on tank, close valves 1, 3 and 6. Open valves 2 and 5 and fil unit with clean sea water or fresh water until water flows over skimmer, and through chlorinator. Check for leaks at covers. Close valves 2, 5 and 7 (when fitted), open 3 and soil inlet valve, together with 6 of duty discharge pump. Check that liquid is flowing through the visual indicator pipe in the sludge return line. The ait flow is controlled by the air valve and should be set, during normal operation, to give as high a sludge return a possible whilst ensuring that the liquor does not become clear. If this happens the aitit should be reduced until the return is seen to darken again. Following inital filing the airflow should be set to give the minimum liquid flow and then be gradually increased in line with the above instructions as the solids content of the unit increases, The skimmer airlift should be adjusted to give the minimum reliable liquid flow. NOTE: Skimmer airlift can empty skimmer. Adjust valve only when water is in skimmer tray, i.e. when 40. "1 12. 13, 14, being fed. Partially fil disinfectant contact tank and prime discharge pum. Check pump rotation Check operation of pump from float switch when in “AUTO" Fill contact tank and check time required to discharge contents, Check for signs of cavitation. Check that water is not pumped from syphon vent in discharge pipe. Close up tank. Fil chlorinator tubes with tablets if in restricted waters . Approximately 2.5 kg of tablets are required to fill one tube. Check air pressure above liquid in aeration tank with manometer. Not to be more than 15mm (H,0) with blower running. Open raw sewage and grey water (when fitted) inlet valve(s) to put unit on line, Refer to sample procedures, operation and maintenance requirements including destudging, Page 4-34.3 DETERMINATION OF RESIDUAL CHLORINE CONTENT 4.3.4 General A chiorine test is supplied so that the residual chlorine content of the treated sewage effluent may be determined. A sample of this effiuent is obtained by way of the sampling valve. Full instructions for carrying out the test are supplied with the kit which consists of the following items: 1 Colour Comparator 50 D.P.D. Test Tablets in 5 foil packets (10 per packet) HP & C No. T9201005 1 Cleaning Brush 1 Stirrer 4.3.2 Sampling instructions Ensure tubes are clean then: 1. Fill the middle and right hand chambers with sample up to line. 2. Add D.P.D. tablets to right hand chamber and crush with stirer. (Replacement tablets Pt. No. 79201005), 3. Make comparison, ‘The typical chlorine residual should be between 4 ppm and 6 ppm. ‘There is no upper limit but should the residual be above 6 ppm use only one chiorinator tablet tube. Should the residual be consistently below 1 ppm then the disinfecting effect may not be sufficient. Check that both the sample tablets and calcium hypochiorite tablets are within their shelf life and if grey water is being fed to the chlorine contact tank, check that the maximum daily flow does not exceed twice the designed daily black water flow specified in section 1. I liquid disinfection is fitted adjust the dosing pump flow to achiave a 5 ppm residual, NOTE: In waters not covered by regulations, the chlorination tablets are not necessary. Average usage is 2 grammes per person per day. 4.4 Disinfectant Cleaners Disinfectant tollet cleaners used in large quantities can be detrimental to biological treatment plants. They should be used very sparingly, 4.4.1 Approved Biological Toilet Cleaners Gamlen Gamazyme TD500 (liquid) Gamlen Gamazyme 700FN (powder) Ubichern Actizyme Arrow Tolette 44.2 Approved Descaler Gamilen Darentab 664 Page 4-44.8 DESLUDGING TO AN INCINERATOR, 48.1 General 1. Sludge from the Super Trident can be disposed of to the Hamworthy Neptune Incinerator, but it should be noted that the water content of the sludge is in excess of 99% and hence fuel will be used just to evaporate this water. It is therefore an advantage to desludge the Super Trident in the normal way at sea when outside restricted waters. 2. — When itis not possible, however, the sludge from the Super Trident should be removed daily in the quantities shown for the unit in use. [st3a___ [65 Litres | A 1" BSP connection is provided on the Super Trident for this purpose and the sludge can then be Pumped direct into the siudge tank provided with the incinerator. In this way the small quantity of sewage sludge will be mixed with waste oil and incinerated without using fuel. 3. When removing sludge dally in the quantity shown for the Super Trident, the suspended solids reading for the aeration tank should remain constant and should be checked approximately twice a week. If the suspended solids are increasing, then the quantities of sludge removed should be increased a litle unt a constant reading is obtained. Alternatively, i the suspended solids are decreasing the sludge quantity should be reduced 48.2 Using a Sludge Pump A small posttive displacement pump (with 1” B.S.P. connections) can be supplied for desiudging the Super Trident. The starter provided is fitted with an adjustable time switch which will run the sludge pump for sufficient time to remove the correct quantity of sludge. The time switch should be adjusted to achieve the correct desludging rate. It is recommended that the starter is fitted adjacent to the Incinerator and sludge tank contro! panels so that the desludging operation can be carried out in a position where the sludge tank level indicator can be observed. 45.3 Using the Super Trident Discharge Pump ‘The Super Trident discharge pump can be used to desludge to the incinerator sludge tank but, due to the large capacity of the pump, care must be taken not to overfill the sludge tank Volt free contacts are available on the level switches in the sludge tank control panel and it is strongly recommended that these are used to provide a remote indication adjacent to the Super Trident control panel, of the siudge tank level. In this way, desiudging of the Super Trident can be carried out without the problem of overfiling the sludge tank. The quantities shown in paragraph 2 must stil be adhered to, but to simplify the operation the desludging can be carried out twice a week instead of daily. To desludge, close valve number 3 and open valve number 1 (refer to section 3 - Discharge Pump Installation) and switch discharge pump to manual and allow pump to run for two minutes or until sludge tank is full. Then stop the discharge pump and close the valve, Page 4-54.5.4 Key to Symbols shown on Schematic Drawing A19170 ‘Super Trident Discharge Pump for discharge of effluent and desludging overboard, ‘Super Trident Unit Macerator must be fitted when desludging to Incinerator ‘Sludge burner connection 1/2" B.S.P. Incinerator unit Sludge burner metering pump Incinerator sludge tank Engine room sludge transfer pump Engine room sludge tank ale|z|o|n|mlolo|a/> Alternative desludging. Metered quantity daily by sewage sludge trensfer pump to incinerator sludge tank. The operation must be carried out daily in the following approximate quantities ST3A 65 Litres Key to symbols in Figure 4.1. * These items and all pipework are not Hamworthy Wastewater Systems Ltd supply. + Macerator and Pump are not Hamworthy supply unless specially ordered. Page 4-6Figure 4.1. Schematic System Layout Sewage Treatment Unit / Incinerator Drawing No. A19170 Iss.2 Page 4-7SECTION 5 - MAINTENANCE 5.1 GENERAL ‘The item numbers in the text refer to the item numbers called up on the appropriate Sectional Arrangement included in Section 6.2. When ordering spare parts or in any correspondence the unit number stamped on the nameplate must be quoted. Please also give the drawing and item number and full description of the item required as quoted on the appropriate List of Parts and Sectional Arrangement drawing, Table 5.1 Trouble Shooting Guide Problem Cause Remedy Tank overfiow. Pump failure. \Check electrical circuit. High level alarm, Blockage. \Check for pipe blockage. Excessive input. ‘Check for leaking flush valves on wes. Noxious odour emissions. |Anaerobic condition within the tank, Ensure compressor is operating correctly. Check sludge return airifts are working. Check zeration tank air diffusers for blockage. Effluent quality poor. |(Note: Allow 14 days conditioning period from initial start-up). Lack of oxygen. igh sludge level in aeration tank. Check desludging requirement. Check compressors diffusers, Ifters and valve positions. Low, micro-organism levels. Eliminate disinfectant cleaners from system, ‘Sludge not returning from setting tank or skimmer. (Check air lifts are working, adjusted to give required flow. Excessive hydraulic throughout. (Check for leaking flush valves on \w.c.s and urinals. ‘Scum build up on surface in settling tank. Check air lifts operational, clear ‘scum from settling tank, pump out and clean settling tank. Foaming in aeration tank and up vent line. Excessive use of cleaning agents. Use low foam cleaners and prevent emptying of cleaners: buckets down w.c.s. Page 5-1TABLE §.2 PUMP FAULT FINDING CHART Fault Cause Remedy Delivery valve closed. ‘Open vaive. ‘Suction valve closed ‘Open suction vaive. No Discharge Blocked suction pipework ‘Clean suction pipework Water level beyond maximum lit | Change the set up to Improve of pump. suction head. ‘Ailend to joints and glands in Air leaks or upturned loops in Reduced and/or irregular suction system and check run of suction pipework. Discharge Pipe for loops. Choked impeller Dismantie and clean. Valve or non-return valve partially | Aitend to vaive or non-return Reduced Output and High closed. valve. Temperature ‘Actual total head exceeds max. | Consult our Technical Department generated by pump. giving full particulars, Pump Absorbing Excessive Power | Worn motor bearing. Renew bearing 5.2 MAINTENANCE SCHEDULE 5.2.1 Weekly When in controlled waters replenish the supply of tablets in the Chlorinator. Fill tubes completely and replace cap. Use only recommended tablets and never allow the level to fall below % full. Check also the air supply pressure gauge reading and that activated sludge is being returned through the transparent pipe on top of the tank. The cock valve should be carefully adjusted to give the required flow. Check the chlorine content of the effluent. (See section 4 - Determination of Residual Chiorine Content) Coarse screen filter to be inspected and any plastic bags or other debris etc. to be removed. Access to screen is obtained through inspection cover. 5.22 Monthly Check the contents of the aeration compartment for quantity of suspended solids using the graduated cylinder supplied. Fill the cylinder to 100 ml level and allow to stand for 30 minutes. if the level of the settled sludge is above the 60 mi level, the unit must be partially desludged as detailed below, when not in controlled waters or to a shore facility. 1. Close the valves on the raw sewage and waste water inlet lines and open the overboard by-pass valves. 2. Select the discharge pump control panel switches to OFF. 3. Close valve number 3 and open valve number 2. 4. Select HAND on the control panel swit to operate duty discharge pump. 5. Run the discharge pump until approximately 50% of the aeration tank contents have been discharged. 6 Remove cover in the top of the aeration tank and check that the screen below is clear, also remove the cover in the top of the setting tank and check the surface is clear of scum. If scum is present hose down the surface or pump out and clean settling tank as necessary. Page 5-27. Refill unit with clean fresh or sea water and select valves for normal running. 8 Select the discharge pump control pane! switches to AUTO. 5.2.3 6 Monthly Examine filter cartridges fited to the aeration compressor and replace if diy. (These may be cleaned by blowing compressed air from the inside of the cartridge outwards in an emergency). Check the functioning (of the non-retum valve fitted to the air line. 5.2.4 Annually Drain and clean all compartments of the unit and inspect and repair any damaged coating. Inspect the discharge pump and air blower for wear. Replace aerator air diffuser elements. NOTE: If air pressure rises above 0.2 bar (3 Ibfiin’) above original commissioning pressure at any time, ‘check both fier cartridges and aerators and replace as necessary. 5.3 CLEANING THE CHLORINATOR ‘The chiorinator must be cleaned periodically, at intervals determined by the characteristics of the water used, and the amount of mineral deposits accumulated on all contacted surfaces. Should it be required to clean the unit before all the tablets have been dissolved, the tablets must be removed and all surfaces must be washed and cleaned with a stif brush (NOT WIRE). CAUTION: 1. Never use water above 65°C (150°F) in this chiorinator, To do so may result in damage. 2. Use only the recommended tablets as supplied initially with the unit, Page 5-35.4 DRAIN AND CLEAN UNIT Safety Notes: 4 2 Never leave the Trident sewage treatment unit full of sewage without the air compressors running. To completely shut-down, drain and clean as shown below and leave empty, or alternatively refill with clean water and ready for use. Never enter a sewage treatment unit unless it is thoroughly cleaned out, with all inspection covers removed, or breathing apparatus is worn. During these operations the pump should not be allowed to run dry for extended periods. Refer to the notes regarding valve numbers in Section 3 for discharge pump installation, 1 10. 1". 12, 13, 14. 15. Close the valves on the raw sewage and waste water inlet lines, or alternatively, ensure that the connected appliances are not used. Select the discharge pump control panel switch to OFF. Close valve numbers 1, 2 and 5. ‘Open vaive numbers 3 and 6. ‘Select HAND on the control panel switch to operate the discharge pump. Pump or drain the chlorine contact tank contents overboard. Close valve number 3 and open vaive number 2. Pump or drain the aeration compartment contents overboard. When the aeration compartment is empty, close valve number 2. Open valve number 1 and empty the settling tank. Close valve 6 and open valves 1, 2 and 3, refil unit through valve 5 taking care not to over pressurise the tank, Where a recirculation line has been fitted, Super Chiorinate the unit before entering the tank, close valves 2, 3 and 5 and open valves 3, 6 and 7. Start discharge pump, circulate tank contents for approximately 30 minutes. Then close valve 1 and open valve 3. Circulate for a further 30 minutes. After circulation pump out unit as previously described, Inspect the internal coating and recoat as necessary with a high grade coal tar epoxy. Examine the inspection cover joints for serviceability and renew if necessary. Refit the joints and covers, Inspect the filter periodically. This can be cleaned in situ with a hose or removed from the tank and cleaned. Page 5-45&5 AIR DIFFUSER ASSEMBLIES 5.5.1 General ‘The air diffuser elements are made from @ porous ceramic material and must be handled with care to avoid breakages. The diffuser elements must be replaced annually or at any time when the pressure gauge reading rises 0.2 bar (3ibffin’) above original commissioning pressure, or the air pressure relief valve is blowing. Ensure that the air filter cartridges are clean and that the air lft valves are adjusted to give the required flow. 5.5.2 Element Replacement This must normally be carried out during annual servicing with the tank empty. Remove respective side manhole cover and disconnect running union located immediately inside cover. Lift out diffuser assembly complete. Remove wingnut and washer and withdraw ceramic element. Fit a new element taking care that the rubber washers are in place at either end. Replace the wingnut taking care not to overtighten. Replace diffuser assembly in the tank taking care to locate spigot in the bracket in the bottom of the tank Replace manhole cover. 5.6 DISCHARGE PUMP WARNING: 4. BEFORE PROCEEDING WITH MAINTENANCE OF THE PUMP, IT MUST BE STOPPED AND ISOLATED ELECTRICALLY AND MECHANICALLY AND VISIBLE WARNING NOTICES DISPLAYED. SOME UNITS MAY BE ON AUTOMATIC STANDBY DUTIES. ISOLATORS MAY BE REMOTE FROM THE PUMP. IN THESE CASES EXTRA CARE IS NECESSARY TO BE ABSOLUTELY SURE THAT ISOLATION OF THE UNIT IS COMPLETE. 2. PUMPS HANDLE VARIOUS LIQUIDS, SOMETIMES NOT THOSE FOR WHICH ‘THE PUMP WAS INITIALLY SUPPLIED. KNOW THE PROPERTIES OF THE LIQUIDS THAT HAVE BEEN PUMPED, TAKE ANY ACTIONS NECESSARY TO MAKE SAFE AND BE AWARE OF THE RECOMMENDED PROCEDURES TO FOLLOW IN THE EVENT OF AN EMERGENCY. 3. HEALTH AND SAFETY ACT REQUIREMENTS COMPLIANCE: BEFORE WORKING ON THIS EQUIPMENT PERSONNEL MUST BE MADE AWARE OF, AND ENSURE COMPLIANCE WITH, THE HEALTH AND SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF WORK. 4. ONLY ADEQUATELY QUALIFIED PERSONNEL FAMILIAR WITH THIS TYPE OF EQUIPMENT SHOULD CARRY OUT MAINTENANCE OR ADJUSTMENTS. 5. DO NOT ATTEMPT TO REPAIR OR OVERHAUL THE PUMP UNTIL THIS INSTRUCTION BOOK HAS BEEN STUDIED. 6, BEFORE COMMENCING ANY WORK A CHECK OF AVAILABLE SPARES SHOULD BE MADE, E.G. REPLACEMENT OF O-RINGS, JOINTS, SEALS. 7. BEFORE ATTEMPTING TO DISMANTLE THE PUMP, ENSURE THAT THE PUMP SUCTION AND DELIVERY VALVES ARE CLOSED AND THAT THE CASING DRAIN PLUG IS REMOVED. Page 5-5TABLE 5.3 MAINTENANCE SCHEDULE Every Year or 8,000 Every 4 Years or _ peter hrs 20,000 Hrs Inspect x “O-Ring Seals Replace: inspect x Mechanical Seais Replace x Pump Casing Inspect x Impeller Key Inspect x NOTE: 1. Where running hours and time are quoted, the shorter period is the criterion if the component is a dynamic part. 2. Allclearances and parts should be checked as routine if the unit is dismantled for any reason 3. This table is for guidance only and indicates the minimurn recommended schedule. This may be varied where, for specific conditions, operating experience indicates that a difference schedule would be beneficiat ‘A complete pump and motor can be provided as standard spares for a single discharge pump arrangement, 50 that should trouble be experienced with this relatively small item it can be quickly remedied without interfering with the normal operation of the unit. Dismantling and reassembly instructions are included in Section 7. NOTE: There is no need to disturb pipework to remove rotating parts. 5.7 COMPRESSOR ‘A complete compressor and motor can be provided as standard spares for a single compressor arrangement 0 that should trouble be experienced with this relatively small item it can be quickly remedied without interfering with the normal operation of the unit. Maintenance instructions are included in Section 8. Page 5-65.8 RECOMMENDED SPARES LIST Table 5.4 Recommended List of Spares Description Pump Impelter screw Peel off shim Mechanical seal ‘Tab washer Compressor Carbon blades Filter elements Set of bearings Set of spacers and tolerance rings Controls Contactor ‘Auxiliary contact lamp 2x 5A fuses 2x 2A fuses Sampling kit Test Lovibond tablets Measuring Cylinder Chlorine tablets Drum of tablets Page 5-7SECTION 6 - DRAWINGS. 6.1 General Arrangement Drawings Page 6-1eo TLL ov Sv, a nouoahd eavacins > re I rat Oe), + aoe fin Vo ue Tat HRS ORL Na es un SESH APH i poe seseo “| tes cusses BAR BY “| 9619S 6209st qauimn opanions sneoumen @ REL meaawes ev Q''g O12 NO_S3¥LN39 420 O3oveS-1NO3 ¥i0 81 S310H_- 8 Vid/0 O82 X 3u0e UNION G21 “91 GN NIC ONY (3}uL3Ai £79) Nd POSPSE OL SUVL30 HIM “SONY TS “UL ASSION oss 193990701 SSOB. 084 * PKG oe wae cate meee — me ae fe = 6 Gg c 6L Sd WNS2I OL afl Bue He TRG > FS = SA TROT Owe am owin a 282 = 17 DRSSNIONG AALBOWNY arte aad eT a . ‘62 Sectional Arrangement Drawings Page 6-2== ~ ss. ¥ Mowe No HEA zl Page 6-3oun, eowresea a Prem Fok 4 mame B DUAL OONPRESEOR A FIPEWORK FOR ST2A AAD STA i i i i Spree it Page 6-463 Sectional Arrangement List of Parts Table 6.1 List of Parts for Drawing D7937 Trem 001 [DESCRIPTION TANK SUB-ASSEMBLY 002 ‘AIR COMPRESSOR. (003 ‘CONTROL PANEL LEVEL SWITCH BLANK FLANGE. FLANGE, [DISCHARGE PUMP JOINT SONB- ‘JOINT NUT & BOLT ‘CHLORINATOR ‘COVER JOINT-FITTERS CUT LABI NAMEPLATE M8 STIFF NUT HEXAGON SCREWS _ LABEL WARNING WELDING ‘318" ST.ST. WASHER, ENS8. NAME PLATE LABEL, ‘CABLE NAMEPLATE TERMINAL TAG PANEL FLEXIBLE CONDUIT JOINT WASHER FIBRE. (CABLE TIE ‘CONDUIT ELBOW ADAPTOR, LABEL (ABEL, NAMEPLATE RING TYPE CABLE TERMINAL M5. CABLE 2.5MM SHIM MANIFOLD MANIFOLD GATE VALVE 2 IN ‘VALVE BUTTERFLY WAFER PUMP MOUNTING MOTOR SUPPORT, TRIDENT TANKS, UNION STRAIGHT M10 X 25 HEX SCREW. B.M.S. WASHER, M10 CAD PLATED. B.M.S, WASHER, M16 CAD PLATED. HEXAGON BOLT BOLT HEX NUT,MA6 ZINC PLATED. BOLT 4.1/2°NB POLYURETHANE DUCTING HOSE. REINFORCED PVC HOSE Page 6-5Page 6-6 DESCRIPTION HOSE CLIP M STUD ELBOW BSP BR FERRULE DIFFUSER HOLDER DIFFUSER ELEMENT ‘COMPOSITE UNION FLEXIBLE HOSE, HOSE CLIP BULKHEAD CONNECTION | 1/2"OD NYLON TUBE DIFFUSER DOWNTUBE ‘ABS,BS5391 DN15X21.3 CLT AIRLIFT TUBE ‘SURFACE SKIMMER SEALING RING. REDUCING ELBOW PIPE ‘TEE, PVC REDUCING BUSH TUBE, PVC TUBE, PVC. HOSE CLIPS HOSE CLIPS, B.M.S. WASHER, M6 CAD PLATED ELBOW 1/2" HOSE CONNECTOR.3/4 HOSE, RUBBER, 3/4" HOSE CLIP BALL VALVE, 3/4" [NIPPLE 3/4 TEE,3/ PLUG.3/8" NON-RETURN VALVE,3/2" _ ‘GAUGE ADAPTOR PRESSURE GAUGE ELBOW, 1/2"_ _ 23 Cue 294 NUT.MB 205 | WASHER. MS 298 [HOSE CONNECTOR 3/4 BSPx3/4°NB [207 | CONDUIT ADAPTER. ‘300 | JOINT JOINT. HEX NUT,M12 ZINC PLATED: HEX NUT M8 ZINC PLATED. HEX NUT,M16 ZINC PLATED HEX NUT,M20 ZINC PLATED. B.M.S. WASHER, M12 CAD PLATED. B.M.S. WASHER, M8 CAD PLATED.ITEM | DESCRIPTION 308 | B.M.S. WASHER, Mi6 CAD PLATED. ‘309 | B.M.S. WASHER, M20 CAD PLATED. '320___| FILTER SCREEN, ST2A, 321__| FILTER SCREEN, ST3A 322___| FILTER SCREEN, STAA 323 FILTER SCREEN, S' 325 | BALL VALVE 1°BSP 326 | BALL VALVE 172°BSP 330 | HEX SCREW M6 X 16MMLG ZINC PLATED, 331 BMS. WASHER, M6 GAD PLATED. 336 | JOINT 340 __| JOINT-FITTERS CUT. 341 | B.M.S. WASHER, M8 CAD PLATED. ‘342 | JOINT-FITTERS CUT '350___| 1/2" BSP BACKING NUT. 351___| BSP BACKING NUT DURAPIPE 360 | ELBOW, 3/4" 361 | ELBOW, 3/4" 370___ | CABLE MARKER NUMBER 3 371 | CABLE 2.5MIM. ‘372___| CABLE MARKER LETTER U" 373 | CABLE MARKER LETTER 'V. 374 | CABLE MARKER LETTER W 375___| CABLE MARKER NUMBER 4 376 | CABLE MARKER NUMBER 377__| CABLE MARKER NUMBER '378___| CABLE MARKER LETTER ° 379___| CABLE MARKER NUMBER 380 | TERMINAL TAG PANEL, Page 6-76.4 General Arrangement Drawings ~ Sewage Pumps Page 6-8SNIONS_ AHLWOMAVE Page 6-965 Control Panel Layout $00 “82 3 250 3 a . = ee MOUNTING HOLES 6 10.5 4 1 | naa HAMWORTHY eoemensen | gant 09 625, a Figure 6.1 Control Panel Arrangment ~ Two Compressors & Two Discharge Pumps Page 6-106.6 _ Installation Wiring Diagrams Page 6-11ww eas Pm wes miele wae mary as Mivonuion oda adi baie “ava TOMINOD WL Wve Hava a1 o3193NNBS Se EL Sas SL Ave S3NI1 N3IGLE NI NAOHS St ONtUIM SuBHOUSNIZ 3unionats G1 g3xt3 sinanoa “aanea1s ond ETRE SAR! oh hal WR eT ost f SS: BESO) Ai lah tess fe oF Gav nail ond aUbo HONE ISVS) SEG Haye weit Sar « m0 No 4360 = Fe eh -p hom ~ 2 SSH) auisn gina samnasie Q)—aeaerE ay notO SHEL SBS ada on ri ey. ane ot 35079 g 7 FE fA aa 8t SINR SR yOLOn aOsssadwO2 (GK -APATAT I aT NOLLVOIONT SNINNAS 3LONSY eee WTS PMN, SHO gD = ¢ s34Q034 40 x T - 2 5 RE | cots 73037 ADT ang 97757 m : A alas Sobers € J SSNIDaIAWE BdAL“TAdkw LS ote] 2,9 SR sade gE tas i ws gSGRARL MSIE WO oD ga (Wale T3A37 BOIK WHS fn - A - Sass" S1avinad > Lape a ga A EPC SEP LPL THRs aN Z SORE SAS x gum st x . fan sasans suse Sse FAONY “anv 7OaINOD a Ts IH, “a Tu S| Z609L4 — a om ys aan aH vam uval aNd DURE BY SOD : 7 aT ~ Be = wae nv AT Hila aNeoTaL ES. 7 ee eon TT it 39 skivont nota =a sonata67 Circuit Diagrams Page 6-12wv so wr eee wtuldeo 05 dase ain Asi He a 4 ION S351 BION a3 a) seen] | [OIF zs er ee OF ah oe “uw yours Ze0st3 9 6 O 9 L 2) WVADWIT INDEED ANd SONFHOST azenny Twa) ON ONY BOSSHUdHOO INO HLM Tree ‘aL 35% AHLZONAVHE AIND INGRUVRAL GOVMES “NCRAL, Wels =esige | SJ NOTES ies | | 1. CUSTOMERS REMOTE HIGH LEVEL ALARM TO BE CONNECTED Bl222| oH TO TERMINALS 1X & 2x ( CONTACTS OPEN ON RISING LEVEL ) g/2a2 4 2, REMOTE COMPRESSOR MOTOR RUNNING INDICATOR TO BE Bag) Or] CONNECTED TO TERMINALS OX Se 4x wi2er| OI 3.REMOVE_ LINK ‘A’ TO CONNECT A REMOTE EMERGENCY, 2223) Or ie STAY-PUT TYPE PUSHBUTTON BETWEEN TERMINALS 7 & 8 IgE [ssl | scustovers REMOTE COMMON THERWAL/MAGNETIC OVERLOAD ALARM 2 3g phd) TO BE CONNECTED TO TERMINALS 5X & 6X (CONTACTS OPEN ON FAULT) Sy | Sympocs DESCRIPTION | 82 | (ev3z LC-CONTACTOR, 1-REFERENCE NUMBER IN CIRCUIT/ ie] HBS NUMBER OF MAIN CONTACTS/NUMBER OF AUXILIARY CONTACTS I] SS FL SA 3 #65 FI-FUSE REFERENCE NUMBER, SA-FUSE AMP. RATING | 28° | ——— | contact NorMaLLy OPEN = een oo CONTACT NORMALLY CLOSED | BE | asov soy a) EZ ] ESS | 28 [Coy | SINGLE PHASE TRANSFORMER gs 380V)| 24V ( PRIMARY TAPPED 380, 415, 440 & 460 VOLTS.) © Hee : ( SECONDARY TAPPED 24 & 110 VOLTS ) ala See ee a] b> p> SIGNAL LAMP Lt — COMPRESSOR RUNNING ( GREEN ) au Sel Rane L2 = DISCHARGE PUMP RUNNING ( GREEN ) Le fs} 1S) ~s i [ela] 2) C zl, Jal | © THREE POLE ISOLATOR SWITCH l-¢ aA | E 5 eae pe E}.|3 a ISOLATOR AUXILIARY CONTACT EARLY BREAK ( N.O.) z = epeceeuate LSH — LEVEL SWITCH HIGH LEVEL CONTROL g ee eee CONTACTS CLOSE ON RISING LEVEL sap 1 CONTACTS oy ae MTEVEL SWITCH LOW LEVEL. CONTROL = CONTACTS CLOSE ON RISING LEVEL g t LEVEL SWITCH, LsHa — LEVEL SWTOH HIGH LEVEL ALARM = Toes cuosep J” CONTACTS OPEN ON RISING LEVEL. Zi ie od SELECTOR \. Si - COMPRESSOR ON/OFF SELECTION 3 le + 4 SWITCHES f° $2 — DISCHARGE PUMP AUTO/OFF /MANUAL SELECTION a 2 le alg ® THREE PHASE ELECTRIC MOTOR a\z gle ua Lk = UNK ‘A’ REFERENCE NUMBER IN.CIRCUIT = cote AUXILIARY TRIP CONTACT ON CIRCUIT BREAKER. é — —— | deNoTES wRING EXTERNAL TO CONTROL PANEL. 8 5 AAVSECTION 7 - DISCHARGE PUMP MAINTENANCE 7.4 PREPERATION FOR DISMANTLING THE PUMP REFER TO SECTIONAL ARRANGEMENT DRAWING D8103, on Pago 7-5. 1, Ensure that the electrical power supply to the motor is switched off. 2, Shut the suction and delivery valves in the system pipelines, 3, Remove the drain plug (27) and joint washer (28) from the pump casing. 7.2. DISMANTLING PUMP REFER TO SECTIONAL ARRANGEMENT DRAWING 08103 1, Remove the bolts securing the electric motor to its seating and the nuts (20), washers (34) and bolts (19) ‘securing the inner cover to the casing. 2. Withdraw the motor and pump from the casing and remove the ‘O-ring seal (15) 3, Bend back the locking tab washer (17) and remove the impeller screw (8), tab washer and ‘O-ring (14), 4, Tum the impetier (5) so that the jacking screw holes are horizontal, as shown on the Sectional Arrangement drawing, and screw in the two jacking screws to withdraw the impeller. 5. Withdraw the stationary part of the mechanical seal (16) from the inner cover (2) and the rotating part from the impeller. 6. Remove the nuts (23) and spring washers (25) and remove the inner cover from the efectric motor. 7. Remove the peel-off shim (11) and the liquid thrower (10). 7.3 INSPECTION Thoroughly clean and exarnine all components for corrosion, cracks, wear or any other damage and renew any parts found defective. If the mechanical seal faces are damaged, the complete seal assembly must be renewed. The ‘O'-ring seals (14, 15) and tab washer (17) must be replaced with new ones. 7.4 ASSEMBLING PUMP 1. Position the liquid thrower on the motor shaft and the inner cover on the motor. Fit the spring washers (25) and nuts (23). 2. Impeller Shimming: To determine the amount of shimming required between the impeller and motor shaft: 2) Position 2 new peel-off shim (11) in the bore of the impeller (5) (do not fit mechanical seal at this stage). b) Line up the keyway in the impelier with the key in the motor shaft and push the impeller onto the shaft, ©) Place the tab washer (17) on the impeller screw (8) and fit the screw into the tapped hole in the end of the motor shaft. Fully tighten the screw but do not lock itat this stage. d) With the aid of feeler gauges, measure the clearance between the rudimentary vanes at the back of the impeller and the inner cover (see figure below). This dimension should be 0.457mm + 0.076mm Page 7-1(0.018 + 0.003 in), Subtract 0.457mm (0.018 in.) from the measurement obtained. The resultant figure is the amount of shimming which needs to be removed from the peel-off shim. eg ‘Clearance 0.991 mm (0.039 in) ‘Deduct required clearance. 0.610 mm (0.024 in) ‘Total to be removed from shim (0.381 mm (0.015 in) Note: Each lamination of shim is 0.076 mm (0.003 in) Therefore, the amount of laminations to be removed from the shim is 0.381 mm (0.015 in) or five laminations, A new peel-off shim is 20 laminations or 1.524 mm (0,060 in) thick 1 CLEARANCE he FIGURE 7.1 IMPELLER SHIMMING Page 7-2€) Ensure that the end of the motor shaft key does not protrude beyond the end of the motor shaft or the peel-off shim pack will be fouled. f) Remove the impeller screw and tab washer and withdraw the impeller from the motor shaft. 6) Remove the peel-off shim from the bore of the impeller and remove the number of laminations determined in (d) above. ‘Smear the inside of the impeller bore with grease Fit the mechanical seal as follows: 2) Ensure the ceramic seat is fully inserted into the cup rubber. Lubricate the outside diameter of the Cup rubber and also the bore of the recess in the inner cover, which locates the stationary seat, with soft hand soap and water. b) Feed the cup rubber and ceramic seat into the recess and press into position ensuring an even pressure over the whole of the ceramic seat face. Make sure that the cup rubber and seat are pressed fully home. ©) Stand the pump, less casing and impeller, vertically with the impeller end of the shaft uppermost. 4) Lubricate the bore of the bellows with soft hand soap and water. ©) Apply soft hand soap and water to the outside diameter of the impeller hub, and pass the bellows of the mechanical seal carefully over the taper on the hub (rubber end first) until the bellows contacts the hub shoulder. ) Ensure that the impeller adjusting peel-off shim (11) is in position on the shaft end, ) Line up the keyway in the impeller hub with the shaft key, locate the bore of the hub with the shaft end and push the impeller fully onto the shaft. Carefully position the liquid thrower on the impeller hub. Secure the impeller with the impeller screw (8) and tab washer (17). Lock the screw with the tab washer. Note: Installation of the seal unit, to its working length, should be completed with 15 minutes to ensure that the bellows is correctly positioned before it permanently grips the impeller hub. Place a new ‘O'-ring seal (15) on the inner cover (2) and position the motor and pump assembly on its ‘mounting and secure the inner cover to the casing with bolts (19), washers (34), and nuts (20). 8. Fit the bolts and washers securing the motor to its mounting. 7.8 RECOMMENDED TIGHTENING TORQUE Impeller Screw (item 8) 3.0kgm ‘Stud and Nut (Item 22 and 23) 5.0 kgm Bolt and Nut (Item 19 and 20) 3.0 kam Page 7-3Table 7.1 Sectional Arrangement for B50x50HC 2-Pole Sewage Pump Drawing D8103 ousos xaos ome aE OMaOS pane IEE Ton SME Hn aN HD AH Page 7-4Table 7.2 Items List for B50x50HC 2-Pole Sewage Pump Drawing D8103 ITEM | DESCRIPTION ‘MATERIAL ary. 1 | Pump Casing [B'S.1452 Grade 250 7 2 [Inner Gover (B.S.1452 Grade 250 4 5___| Impeller B.S.1400 ABI 7 8 | Impeller Screw [BS.970431520___ i 40 [ Liquid Thrower ‘Oi Resisting Rubber 1 11__| Pest-off Shim [Brass 4 14__ [O-ring (impeller) | Nitrile Synthetic Rubber 4 48 | 'O-ring (casing) | Nitrite Synthetic Rubber 1 46 | Mechanical Seal Carbon/Ceramic/Nitrle/3 1688 1 47 | Tab Washer [Monel 1 19__| Bolt THIS. Grade 6.8 6 20 Nut THTS. Grade 8.8 6 22 | Sud Mild Steel Grade 4.8 4 23 Nut Mild Steel Grade 4.8 4 25 | Spring Washer [Spring Stee! 4 26 | Namepiate [Aluminium 4 27. Brass 3 28 Copper 3 29 Mild Stee! Grade 4.8 4 30 Mild Steel Grade 4.8 4 31 [Key Steet 1 34 Mild Steel 6 [39 | Mild Steel 2 50 1 Page 7-5SECTION 8 - AIR COMPRESSOR MAINTENANCE G, °. Figure 8.1 Compressor 8.1 PUMP RANGES ‘These operating instructions concem the following dry running rotary vane compressors: Model DLT 25, ‘They have nominal capacities of 25 m°thr operating on 50 cycles. The pressure limits (bar) are indicated on the data plate (N), 8.2 DESCRIPTION All models are complete with a pressure connection and a silencer on the inlet. All the air handled is fitered by a built-in micro-fine fiter. Excess carbon dust from the carbon blades is also filtered on the exhaust side by builtin fiers. The compressor unit is encased in @ rugged black plastic sound enclosure. The cooling fan for the DLT is located inside the sound enclosure. On size 25 with the larger motor the compressed air is ‘cooled by an after-cooler, Both the motor and compressor have a common shaft. Pressure can be adjusted to the required levels, however, they are limited fo a maximum point 8.3 SUITABILITY “The units DLT produce pressure up to the maximum limits, which are shown at the data plate (N). They may be operated continuously. CAUTION: The ambient and suction temperatures must be between 5 and 40°C. For temperatures outside this range please contact Hamworthy. CAUTION: No dangerous mixture (i.e. flammable or explosive gases or vapours), no extremely humid air, water vapour, aggressive gases or traces of oil and grease can be handled, CAUTION: For all applications where an unplanned shut down of the compressor could possible cause harm to persons or installations, a corresponding safety backup system must be installed. 8.4 HANDLING AND SETTING UP (Figures 8.1 and 8.2) ‘There must be @ minimum space of 30 om in front of exhaust grid (G), suotion grid (G;) and housing cover (b) for servicing. ‘The cooling air entries (E) and the cooling air exists (F) must have @ minimum distance of ‘10cm from any obstruction. The discharged cooling air must not be re-circulated. Page &1When the compressors are installed on a solid base, they do not need to be fixed down. If the compressors are installed on a base plate we would recommend fiting anti-vibration mounts, This range of compressors are almost vibration free in operation. &5 INSTALLATION (Figure 8.1) CAUTION: The Compressors may not be operated without the standard pressure regulating and limiting valves fitted so that the maximum pressure is not exceeded (see data plate) For operating and installation follow any relevant national standards that are in operation, 4. Pressure connection at (B). CAUTION: Long and/or small bore pipework should be avoided as this tends to reduce the capacity of the compressor. 2. The electrical data can be found on the data plate (N) or the motor data plate, The motors correspond to DIN/VDE 0530 and have IP 54 protection and insulation class F. The connection diagram can be found in the terminal box on the motor (uniess a special plug connection is fitted). Check the electrical data of the motor for compatibility with your avaliable supply (voltage, frequency, permissible current etc.) 3. Connect the motor via motor starter. It is advisable to use thermal overload motor starters to protect the motor and wiring. All cabling used on starters should be secured with good quality cable clamps. {tis recommended that motor starters should be used that are fitted with @ time delayed trip resulting from running beyond the amperage setting. When the unit is started cold overamperage may occur for a short time, CAUTION: The electrical installation may only be made by a qualified electrician under the observance of EN 60204, ‘The main switch must be planned through the operator. igure 8.2 Compressor Interi (ay Page 8-2Figure 8.3 Compressor Interior (2) 8.6 INITIAL OPERATION (Figure 8.1) 1. Initially switch the compressor on and off for @ few seconds to check the direction of rotation against the direction arrow (0), NOTE: On this initial start the pressure pipework should not be connected. If the compressor runs backwards with the pipework connected @ pressure could build up within the housing which could result in damaged rotor blades. 2. Connect the pressure pipe at (B). CAUTION: For pipework longer than 3m we recommend using non-return valves (ZRK), to avoid reverse rotation when the units are switched off. 3, The requested pressure ranges can be adjusted by turning the pressure regulating valve (D) according to the symbols on the top of the regulating valve. 8.7 POTENTIAL RISKS FOR OPERATING PERSONNEL, Noise emission: The worst noise levels taking into consideration direction and intensity measured according to DIN 45635 part 3 (as per 3. GSGV), are shown in the table at the back. When working permanently in the vicinity of an operating compressor, we recommend wearing ear protection to avoid any damage to hearing. 88 MAINTENANCE AND SERVICING ‘When maintaining these units and having such situations where personnel could be hurt by moving parts or by live electrical parts, the compressor must be isolated by totally disconnecting the electrical supply. It Is imperative that the unit cannot be re-started during the maintenance operation. Do not maintain a compressor that is at its normal operating temperature as there is @ danger from hot parts. 1. Lubrication The DLT compressors have bearings that are greased for life. They need not be serviced. 2. Air filtration (Figure 8.2 and Figure 8.3 CAUTION: The capacity of the compressor can become reduced if the air inlet filters are not maintained correctly, The filter cartridges (2) on the inlet (f) for compressed air have to be cleaned depending on the amount of contamination. This is achieved by blowing compressed air from the inside of the cartridge outwards. Even if the cartridges are cleaned their separating efficiency deteriorates. We would therefore recommend exchanging the cartridges every six months, Page 8-3Changing the fiters: ‘Screw off exhaust grid (G). Remove screwed cover(s) and milled knob (m). Pull fiter cartridges (e) and (f) off and clean or exchange. Re-assemble in reverse order. 3. Blades (Figure 8.2 and Figure 8.4) Checking blades: DLT 25 nas 6 blades. The blades have a low but permanent wear factor. DLT 25: first check after 5,000 operating hours, thereafter every 1,000 operating hours. ‘Screw off exhaust grid (G). Screw off housing caver (b) from housing. Remove blades (d) for inspection. All blades must have a minimum height (X): Model X (minimum height) DLT 26 24mm CAUTION: Blades must be changed completely. Changing Blades: If the minimum height is reached, then the whole set of blades should be changed Before fitting new biades clean out the housing and the rotor slots with compressed air. Place the blades with the radius outwards (¥) so that the bevel is in the direction of rotation (0,) and corresponds with the radius of the housing (2). ix end cover (b) and exhaust grid (G). Before restarting the pump check free movement of the blades by 19 the motor cooling fan before refitting the cooling grid (G:) tu Figure 8.4 Compressor interior (3) Page 8-4‘TROUBLE SHOOTING Motor starter cuts out compressor 44 ‘Check that incoming voltage and frequency corresponds with the motor data plate. 1.2_| Check the connections on the motor terminal block. 1.3 _[ Incorrect setting on the motor starter. 1.4 | Motor starter trips too fast. Solution: Use a motor starter with a time delay trio (version as per IEC 947-4). 1.5 _| Filter cartridges on the exhaust side are contaminated. 1.6 _| The regulating valve is dirty causing excess pressure. 2__ | insufficient pressure capacity: 2.1 | inlet and/or exhaust filters are obscured. 2.2 _| Pressure pipework is too long or too small. 2.3 _| Leak on the compressor or on the system. 24 | Blades are damaged. 3__| Compressor does not reach the required pressure: 3.1_| Leaks on the compressor or on the system. 3.2 _| Blades are damaged. 3.3 _| Motor rating selected too smal 4 _| Compressor operates at an abnormally high temperatur 4.1__| Ambient or suction temperature too high 42_| Cooling air flow is restricted 43 _| Problem as per 1.5 and 1.6. 5 _| Unit emits abnormal noise: 5:1 | The compressor oylinder is worn Solution: send your complete unit off for repair to Harnworthy. 52 | The regulating vaive is noisy. Solution: replace valve, 5.3 _| Blades are damaged. Page 8-5Figure 8.5 Compressor - Exploded View Page 8-6Table 8.1 Compressor : List of Parts for Figure 8.5 DLT 25 Basic Parts 1 Housing 2 Rotor 3 [Blade H 4 Disc 5 | |bisc 6 Spring shim 7 Hexagon head screw 8 End cover 9 Threaded pin 10 Soring 4 Filter cartridge complete 12 Filter cartridge complete 13 Milled knob 2 Dise Be Connection Cover e 30 Connection cover i a Sealing ring 82 Supporting Ring 33 Deep groove ball bearing 36 Rubber foot Ed Rubber foot 38 Hexhead screw [39 Rubber foot ct 40 Foot | a Mounting | 42 Lifting eye | Drive 45 Motor (3~) 46 Motor (1~) 47 Drive shaft (3~) 48 Drive shaft (1~) 49 Deep groove ball bearing 56 Fan hub 57 Tolerance ring 58 Air guiding plate 59 Disc Page 8-7[Compressed air after-cooling (OLT-25) 60 Cooling segment 7 ol Pipe 2 Pipe 63 Fitting Box 7o_ | Lower part a Side part [ "7 Side part 73 Threaded pin 74 |_| Upper part 75 Exhaust grid _76 Suction grid a Buffer | Labels 80 Data plato ‘Assembly parts 90 |_| Connection nipple | D | Sealing ing 92 |_| Screwed ring 9% | D | Sealingring 95_| _| Pressure regulating valve 96 Screwed cover {or 7 _| [201-208 To order please indicate: Model: Serial Number: Item Number: Motor (kW, V, Hz) KEY \V = Fast wearing parts D = Seals Page 8-8