Technical Manual for Installation Operation & Maintenance Rev.00 – 04/12
SEWAGE WATER TREATMENT PLANT – FACET - STP-2
Serial Nº / Order Nº /
Technical Manual for Installation, Operation & Maintenance
SEWAGE WATER TREATMENT PLANT FACET STP/VTP SERIES
75960000001 Sewage Water Treatment Plant STP.doc/Rev.01 05/11 www.pecofacet.com
FACET Sewage Treatment Plant
1
SAFETY These operating instructions contain basic requirements to be observed during the installation, operation and maintenance of the Sewage Treatment Plant. Therefore, the instructions must be read by the operator responsible of the unit prior to assembly and commissioning, and kept available at the operating site of the Sewage Treatment Plant at all times. 1.1
Risks that may be undergone during the operation of the Sewage Treatment Plant The Sewage Treatment Plant has been fully tested and certified regarding safety, if it were not properly set up or used, risks could arise and result in damage of:
The personnel’s life or their body.
the Sewage Treatment Plant and other installations on board.
the proper operation of the Sewage Treatment Plant.
The personnel responsible for the installation of the Sewage Treatment Plant and/or its electrical and hydraulic systems must
1.2
be duly qualified to carry out their duties
strictly follow the instructions her explained
Labelling of Advice in the Operating Instructions The following warnings are incorporated into these instructions: In these operating instructions safety advice whose non-observance could lead to danger for life or limb is labeled with the following text Danger!!! Safety instructions whose non-observance could jeopardize the machine and its functions are labeled by the word: Warning!!! To indicate practical tips and other important information following text is used in this manual: Important Always comply with instructions mounted directly on the unit, e.g.
rotational direction arrow
fluid connection indicators
and ensure that the information remains legible.
1.3
Personnel Qualifications and Training Personnel charged with operation, maintenance, inspection and assembly must be in possession of the appropriate qualifications for the tasks. The company operating the machine must define exact areas of responsibility, accountabilities and personnel supervision schemes. Personnel lacking the required skills and knowledge must receive training and instruction. If necessary, the operating company may commission the manufacturer/supplier to conduct these training courses. Furthermore, the operating company must ensure that the personnel fully understand the contents of the operating instructions.
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1.4
Security Precautions The following precautions must be taken for the security of the personnel who operate the Sewage Treatment Plant: 1. Precaution must be taken to keep the area around the Sewage Treatment Plant clean to prevent accidents. 2. All product spills must be dried immediately with rags, and these removed to a safe place. 3. Gloves must be used when parts are handled that have been in contact with the fluids handled by the Sewage Treatment Plant. 4. Avoid unnecessary contact of the skin and clothes with the handled fluids. 5. After maintenance or working with the Sewage Treatment Plant, the hands and parts that have been in contact with the fluids must be thoroughly washed. 6. Immediate medical attention must be lent to cuts in the skin, upset stomach, etc., due to possible contacts with the product or to the inhalation of gases. Danger!!! The equipment is normally fed voltages that can cause damage if contact with these lines takes place. Precautions must be taken when opening the Control Panel, since even if the general switch is open there will be tension in the input terminals of the control panel. As a precaution the line that feeds the equipment should be disconnected. Important Security and environmental protection are the responsibility of the user. Facet does not assume any responsibility for the inadequate use of this Sewage Treatment Plant or its use outside the parameters for which it was designed.
7. The Sewage Treatment Plant must be securely installed on a stable, horizontal surface, following it to tip over would endanger life and limb. 1.5
Safety Instructions for equipments installed in explosive atmospheres For skilled electricians and instructed personnel in accordance with national regulation, including the relevant standard and, where applicable, in acc. with IEC 60079-17 on electrical apparatus for explosive atmospheres. 1. The apparatus must not be operated in Zones 0 2. The technical data indicated on the apparatus, in the technical documentation of products, and in the present instructions are t o be observed! 3. Changes of the design and modifications to the apparatus are not permitted! 4. The apparatus shall be operated as intended only in undamaged and perfect conditions! Danger!!! Do not keep these operating instructions inside the enclosures during operation.
5. The tasks of inspections in explosive atmospheres have to be done by “qualified” personnel in accordance with the Electrotechnical Low Voltage Regulations. It is recommended follow the instructions indicated in IEC 60079-17.
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6. A qualified “electrician” may only carry out repairs the effects of explosion protection, and subsequently will have to be checked by an «expert» 7. Improper operations can invalidate the guarantee! 8. The national safety rules and regulations for prevention of accidents and the following safety instructions described in theses operating instructions, will have to be observed 9. The respective national regulations as well as the general rules of engineering which apply to the installation and operation of explosive atmospheres protected apparatus will have to be observed Danger!!! The opening of enclosures always shall be without voltage!
10. Mounting the selected cable entries (cableglands or seals according needs) in accordance with the type and dimensions of the cable, following their manufacturer instructions. Danger!!! The flameproof enclosures are well closed when all of their screws closing the flange joint are perfectly tighten and their gaps are ≤0.2mm
11. The selected cable entries have to be a minimum protection mode EExd IIB. 12. Unused cable entries have to be closed by a correspondent certified blanking plug with a minimum protection mode EExd IIB. 13. Connect the apparatus in accordance with their technical product documentation of the supplied apparatus. 14. The flameproof joints have to be cleaned, undamaged, without corrosion and perfect greased. 15. Exd enclosures damaged or with corrosion can minimize their mechanical resistance. 16. The flameproof joints of these apparatus have to be greased permanently in order to ensure its protection against corrosion, water intake and size up problems. Clean rest of grease and corrosion with no sharp metallic devices that can damage the surface of the joints and grease the joints using appropriate thermally and chemically stable grease with a drop point > 200ºC. 17. If necessary change the supplied screws closing the enclosure (cover to body) pay attention to use a screw with identical dimensions an resistance > 65 kg/mm2. 18. The cable glands must be well tightened and without corrosion. 19. The cables must be well tightened to their cable glands which must be of adequate size. 20. When seals are installed the internal sealing shall be in perfect conditions to ensure the sealing of the cables. 21. The repair tasks shall be carried out according the standard IEC 60079-19 and in compliance with respective national regulations.
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FACET Sewage Treatment Plant
2
INTRODUCTION 2.1
Description. This Manual gives instructions for the installation, operation and maintenance of the Sewage Water Treatment Plant Facet STP/VTP
2.2
Purpose. To give the user the necessary instructions for its continuous and trouble-free operation, and the procedures and tests to detect failures and correct them in the less possible time. This manual is valid for all the Facet STP/VTP Systems.
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GENERAL INSTRUCTIONS 3.1
Purpose of the Equipment. To treat the black sewage waters from ships, according to international criteria and recommendations (U.S.C.G., IMO, RINA, etc.).
3.2
Recommendations •
The efficiency of the Unit is mainly determined by the periodic performance of the tests and maintenance operations described in Table 6 Periodic Maintenance page 20. An adequate maintenance of the Unit will avoid failures and unpleasant smells.
•
In case of detecting an unpleasant smell it is recommended to check the aeration system of the unit. See Paragraphs 7.3 page 16 and 0 page 20.
•
Regulations require treatment of black waters only. Therefore gray waters may be discharged directly without passing through the unit, obtaining a considerable reduction on its size. Warning!!!
When equipment has been handled and you have been in contact with the waters to be treated, it is important to wash hands thoroughly and apply a disinfectant. Avoid at all times splashing on eyes and prolonged vapor inhalation. Beware to disconnect the unit before any operation on it or in any of its electrical components.
•
Facet Ibérica, S.A. recommends the installation of a by-pass in the unit, by means of manual valves, that may allow for isolation in case of failure or revision. The Unit can only be by-passed if the ship is in international waters, following the closing procedure described in Paragraph 11.1 page 26.
•
Vertical motion of the vessel can result in extremely high local high-loading, due to the mass of the contained liquid. For this reason, adequate support must be provided for the Unit, preventing permanent deformation and/or fracture. See Paragraph 0
•
Installation page 15.
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4
GENERAL DESCRIPTION 4.1
Description The Facet STP / VTP Unit is a treatment system comprised of a tank divided by bulkheads in several deposits interconnected by pipes, and with an air supply system for the liquid recirculation and reactivation of aerobic biological reactions. It also includes a chlorine injection system as disinfection in the last stage. The description and function of each of the components is given in the following paragraphs. 4.1.1. Tank Made of mild steel plate including all baffles, pipes and bulkheads, whose water-tightness is verified by hydrostatic pressure tests. The surfaces are protected by Epoxy paints according to a special treatment. Can be supplied in modules adaptable on board. It is internally divided into three compartments. According to their order of process sequence they are: A. Aeration Chamber B. Clarifier Chamber C. Disinfection / discharge Chamber Covers and hatches have been provided for cleaning and checking operations. Figure 1 Elements
Chlorine Tank Tanque de cloro
Disinfection Chamber Chamber Cámara de Desinfección
Air from Ship
Metering Pump Optional
Y1
Clarification chamber Cámara Decantació
Dosing Valve
Aeration Chamber Cámara Aireación
Control Panel
Sewage Inlet Entrada Aguas Negras
Biofilm Discharge Pump Bomba Descarga
Gravity Discharge Descarga Por Gravedad
Client Supply
Blower Soplante
Client Supply
Overboard Al mar
Sewage treatment unit Facet STP / VTP Planta de Tratamiento de Aguas Fecales Facet STP / VTP
To IMO Flange A Brida IMO
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4.1.2. Biofilm The Biofilm Media Cassettes are a patented fixed film system which are submerged in the aeration chamber, and provide a large surface area for entrapment and holding of waste water digesting microbes. 4.1.3. Aeration System 1.
The Aeration System is comprised of the necessary pipes, valves and interconnections for the distribution and control of the air flow supplied to the diffusers and to the sludge return line. The air is used to obtain agitation in the Aeration Chamber, activating the oxygen transfer for the biological reduction and to generate flow for the transfer recycling of activated sludge.
2.
Facet offers two possible configurations for the air supply: Use the compressed air system of the ship. In this case a regulation valve will be provided to reduce the air pressure as well as a protection filter. The unit may be equipped with a/two blower/s. It is recommended to provide a connection with the air of the ship in case there is a failure in the blower. In this case the pressure is automatically regulated. The air flow is regulated manually by valves in the distribution pipe. Figure 2 Elements (continuation)
Sludge return valve Válvula retorno de lodos
Aeration Chamber Cámara de aireación
Blower Soplante
Clarifier Chamber Cámara de Decantación
Control Panel Panel de control
Disinfection Chamber Cámara de Desinfección
Discharge Pump Bomba de Descarga
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4.1.4. Chlorination System The Chlorination System is designed to attain the destruction of the coliform bacteria on the influent coming from the Clarifier Chamber. It is comprised of a storage tank fabricated in polyethylene containing the Hypochlorite solution. The disinfectant discharge system may be supplied in two ways:
With variable flow chlorine dosing pump to obtain the Hypochlorite solution required on the effluent.
Dosing by gravity regulated by a dosing valve.
The complete equipment is externally located to allow for ease of access in case of repair or inspection. 4.1.5. Discharge System It may be made in three different ways depending on the location of the Unit on board.
Discharge by gravity.
Discharge by one (or two) centrifugal pumps that directly suction from the Chlorine Contact Chamber.
Installation of a pumping station with one (or two) submersible pumps. The Unit will discharge by gravity to this tank.
The two last systems are provided with level detectors for the automatic operation of the pumps. 4.1.6. Control Panel Includes the required components for the necessary for the operation of the elements valves, sensors, etc.), including the required may be directly installed over the Unit or in any
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energy control and supply installed in the Unit (motors, protections and securities. It other place as convenient.
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5
SPECIAL TOOLS AND TEST EQUIPMENT 5.1
General. This section contains a list of those special items of equipment and supplies required to operate and maintain the Unit. Standard items are not included in this section.
5.2
Special Tools. No special tools are required. Maintenance of the equipment is limited to inspection, fluid sampling, adjustment, cleaning; component replacement or such minor repairs as can be effected using common tools. The only special supply required is a dilute Sodium Hypochlorite solution at 5,25%, or common bleach.
5.3
Test Equipment. Comprises three phases: o
pH Test.
o
Determination of dissolved oxygen.
o
Determination of the chlorine amount.
These tests are made on the effluent according to Section 9.4 page 21.
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INSTALLATION 6.1
Preparation. According to the Unit’s General Dimensions drawings, the site location, inlet/outlet connections, discharge and vents required will be determined, as well as clearances required for hatch and cover removal. A sewage by-pass to the Unit is recommended for the discharge of sewage waters directly to the sea (only in areas where it is permitted by applicable regulations), considering the position of the flotation line of the ship. (See drawing 3153730)
6.2
Installation. After the site has been selected, a level mounting must be provided to assure proper operation. The Unit must be fastened securely in place for a long, continuous troublefree operation. Warning!!! Vertical motion of the vessel can result in extremely high local loading due to the mass of the contained liquid. For this reason, adequate support must be provided to prevent permanent deformation and/or fracture..
1. A convenient support for the Chlorine Tank must be included with easy access for filling and for washing down easily. 2. In the case of the Unit being fed by gravity, the installation of a trap at the inlet is recommended to avoid air flow towards washbasins and toilets.
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START UP OF THE UNIT 7.1
Preparation. Remove all hatches and visually check for foreign objects that may be present. If necessary clean the Unit with water. Do not use cleaning agents other than those recommended. Check all mechanical components assuring cleanliness of the lines and proper lubrication of the blower, (oil and grease) chlorine dosing mechanism (oil) and discharge pumps. Check all piping to detect cracks or breaks incurred during shipping.
7.2
Fill Make certain the inlet valve to the Unit is open and the by-pass is closed. Open the Aeration Chamber Access Hatch and proceed as indicated below.
TABLE 2 POSITION OF VALVES TO FILL THE UNIT Description of valves position
Condition
Overboard Discharge
Closed
Diffuser Air Valve
Closed
Sludge Return Air Valve
Closed
Equalizing Valve
Open
Sampling Valve
Open
Fill Unit, with the same water (salt or fresh) as used in the vessel's sanitary system, until water flows freely from the Equalizing Valve of the Clarifier Chamber. Close this valve and continue filling until the liquid flows through the Sampling Valve, close this valve and shut-off water supply. 7.3
Air Supply Air is supplied to the Unit by vessel air or by a unit blower air system (See Section 0 page 12). Whichever system is used, proceed as follows:
TABLE 3 ADJUSTMENT OF AIR SUPPLY VALVES Condition Description
Vessel Air
Unit Air
Diffuser Air Valve
Open 75º
Open 75º
Sludge Return Air Valve
Open 45º
Open 45º
Vessel's Air Stop Valve
Open
Closed
Pressure Regulator
5-7 PSI 2
Blower Oil Level 1 Blower Air Stop Valve
1
Blower 1 1 2
Closed
Open
Off
On
On Units so equipped See Appendix A
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Blower
FACET Sewage Treatment Plant
When adjusting Diffuser Air Valve, note the liquid agitation state in the Aeration Chamber. The correct agitation should be brisk, surface breaking without violent or excessive splashing. Adjust sludge return air valves so that liquid discharge from the return line fills approximately 1/3 of the inside diameter of pipe outlet. A solenoid valve is installed on all units to allow regulation of air supply to the sludge return line. The operation of this valve is discontinuous, its working cycle is determined by a timer in the control system. This timer may be adjusted to operate the solenoid valve at the start up of the Unit, to regulate the air flow or when it is necessary to check the sludge return flow. This periodical operation has as a consequence a better and more effective sludge decanting with the result of less turbulence and agitation in the Clarifier Chamber. 7.4
Chlorine System. Fill the Chlorine Tank with a solution of: one (1) part 5.25% Sodium Hypochlorite and ten (10) parts of fresh water. Set Injection Pump control indicator to the correct position and operate as follows:
TABLE 4 ADJUSTMENT OF CHLORINE SYSTEM VALVES Description
7.5
Condition Injection Pump
Injection by gravity
Injection Pump
On
-
Heater System (If installed)
Operative
Operative
Injection Valve
-
Open
Discharge System
Operative / Auto
Operative / Auto
Final Preparation. With the Sewage By-pass Valve still open flush all bowls and check for free flow out of the overboard discharge port, then close the Sewage By-pass Valve and open Sewage Inlet Valve. Unit is now ready for use.
7.6
Start-up Operation.
TABLE 5 START-UP OPERATION. General
Valves
Control Panel
Hatches and covers
Closed
Chlorine tank
Full
Air supply
On
Influent Inlet
Open
By-pass
Closed
Discharge system
Open
Electrical supply
On
Discharge pumps
Automatic
Injection pump
On
Blower
On
Sludge return
Automatic
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OPERATION 8.1
Operation 1. Sewage waters are introduced into the Aeration Chamber. The biological reduction process is initiated here. 2. The influent containing aerobic bacteria and the organic compounds that serve as food for them, enter a turbulent environment, rich in oxygen. The air under pressure is introduced through stainless steel diffusers located near the bottom of the Aeration Chamber. Small bubbles of air are generated which create the agitation necessary to mechanically reduce solids to small particles, increasing the contact surface between the bacteria and the oxygen incorporated. This way the bio-reduction of solids is produced, loosening carbon dioxide and other simple compounds.
Sewage Water Treatment Plant Facet STP / VTP
Inlet
Aeration Chamber
Biofilm
Clarification Chamber
Chlorination Chamber
Active Sludge
Air Supply
Clean Liquid
Overboard Discharge
e n o n i i r t c o l e h y n C I
Sludge Return
Figure 3 Block Diagram
3. During this process, the bacteria form small loose colonies or flocs around small particles of organic material in suspension and pass the Clarifier Chamber through a baffled transfer port located between the two chambers. 4. The Clarifier Chamber is completely filled with liquid (having evacuated of all air by the equalizing valve, during the filling operation) and operates under hydrostatic pressure due to the level difference between the Aeration Chamber and the Clarifier Chamber. This results in a more effective sludge decanting, rich in bacteria concentration, referred to as activated sludge. The liquid in the top part of the clarifier tank passes through a manifold to the Chlorine Contact Chamber, as the last stage. 5. The activated sludge is periodically re-circulated to the Aeration Chamber, according to the signal sent by the timer to the solenoid valve. The recirculation velocity may be regulated by air valves depending on the variations in crew size. The need for this regulation will be detected with the BDO analysis of the outlet.
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6. In the Aeration chamber are submerged the Biofilm Media Cassettes designed to maximize treatment capacity. Its installation ensures maximum exposure of activated sludge to the waste stream. The activated sludge adheres to the media while digesting waste from plant production effluent streams. The result is a resident population of biomass that removes BOD and COD from the wastewater or in nutrient applications will nitrify ammonia or remove total nitrogen. 7. The remaining clear liquid passes through the manifold towards the final disinfection on the Chlorine Contact Chamber. This step also serves to control the liquid level in the Aeration Chamber. The manifold should be wide enough to avoid blockage or flow reductions. 8. The chlorine solution is added to the Chlorine Contact Chamber. The chlorine injection must be a continuous operation. 9. After the chlorination stage the flow is sent to the sea by gravity or by pumps. 10. In total, the system is an assembly of pipes, baffles and deposits aimed to obtain a biological reduction of solids, a physical separation and finally, disinfection. 8.2
Appearance of the Equipment operating correctly. 1. Aeration Chamber - air bubbles rising. Fluid color is brown with little or no foam. Approximately 6.0 p.p.m. dissolved oxygen. (See paragraph 9.4 page 21). 2. Chlorine Contact Chamber. No solids. Approximately 2.0 p.p.m. dissolved oxygen and 1.0 p.p.m. chlorine residue.
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