PCH1544 PDF

Hamworthy
ST2A ST6A
Super Trident
Sewage Treatment Units
PCH 1544
ISSUE 2 0200
HAMWORTHY KSE LIMITED

Fleets Corner, Poole, Dorset, BH17 0JT, England
Telephone: +44 (0)1202 662600
Facsimile: Spares +44 (0)1202 665444 Sales +44 (0)1202 668793 Service +44 (0)1202 662622
Offices, Associate Companies and Agents throughout the world
Amendment Record
Location
All pages
Page 3- Warning
Page 2
Changes in comparison with previous issue

Change
Converted to electronic format
Updated .
WARNING
1.
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.
2.
Work must only be carried out by suitably qualified and competent persons.
3.
Before lifting, installing and operating the unit, the instructions detailed below, and also the
accompanying manual must be read.
4.
Ensure that all equipment used for lifting the unit is adequate for the weight. The weight is normally
stencilled on the unit and/or stamped on the machine nameplate.
5.
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.
6.
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.
7.
The unit must not be run unless all protective guards supplied with the equipment are in position.
8.
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.
9.
Ensure safety procedures for hazardous gases or oxygen depletion are carried out before opening the
tanks.
10.
Before commencing repair or overhaul a preliminary check of available spares must be made, e.g.
replacement set of joints or jointing material.
11.
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.
12.
Before handling sodium hypochlorite refer to instructions in Section 4.
13.
The equipment should not be installed in an explosive atmosphere.
14.
This equipment is subject to international, European, and national regulations and must be used
accordingly.
Page 3
CONTENTS
SECTION 1 - TECHNICAL DATA ................................................................................................................... 1-1
SECTION 2 - DESCRIPTION ......................................................................................................................... 2-1
2.1
INTRODUCTION .............................................................................................................................. 2-1
2.2
GENERAL......................................................................................................................................... 2-2
2.3
DETAILED DESCRIPTION .............................................................................................................. 2-2
2.3.1
Aeration Compartment .............................................................................................................. 2-2
2.3.2
Settling Compartment................................................................................................................ 2-2
2.3.3
Chlorine Contact Compartment................................................................................................. 2-2
2.3.4
Chlorinator ................................................................................................................................. 2-3
2.3.5
Discharge Pump ........................................................................................................................ 2-3
2.3.6
Air Compressors........................................................................................................................ 2-3
2.3.7
Macerator (Comminutor) (when supplied)................................................................................. 2-3
2.4
Electrical Controls............................................................................................................................. 2-3
2.4.1
General...................................................................................................................................... 2-3
2.4.2
Float Switches ........................................................................................................................... 2-3
2.4.3
Operation................................................................................................................................... 2-3
2.4.4
Remote Emergency Stop .......................................................................................................... 2-4
SECTION 3 - INSTALLATION ........................................................................................................................ 3-1
3.1
GENERAL DATA .............................................................................................................................. 3-1
3.2
RECOMMENDATIONS ON VENT SYSTEM DESIGN .................................................................... 3-5
3.3
FITTING INSTRUCTIONS FOR ITEMS PACKED SEPARATELY FOR SAFE TRANSIT............... 3-6
3.4
COMPARTMENT VENTILATION.....................................................................................................3-6
SECTION 4 - OPERATION............................................................................................................................. 4-1
4.1
HEALTH AND SAFETY INFORMATION.......................................................................................... 4-1
4.2
PREPARATION OF UNIT FOR INITIAL OPERATION .................................................................... 4-3
4.3
DETERMINATION OF RESIDUAL CHLORINE CONTENT............................................................. 4-4
4.3.1
General...................................................................................................................................... 4-4
4.3.2
Sampling Instructions ................................................................................................................ 4-4
4.3.3
Disinfectant Cleaners ................................................................................................................ 4-4
4.3.4
Approved Biological Toilet Cleaners ......................................................................................... 4-4
4.3.5
Approved Descaler .................................................................................................................... 4-4
4.4
DESLUDGING TO AN INCINERATOR ............................................................................................ 4-5
4.4.1
General...................................................................................................................................... 4-5
4.4.2
Using a Sludge Pump................................................................................................................ 4-5
4.4.3
Using the Super Trident Discharge Pump................................................................................. 4-5
4.4.4
Key to Symbols shown on Schematic Drawing A19170 ........................................................... 4-6
SECTION 5 - MAINTENANCE........................................................................................................................ 5-1
5.1
GENERAL......................................................................................................................................... 5-1
5.2
MAINTENANCE SCHEDULE........................................................................................................... 5-1
5.2.1
Weekly....................................................................................................................................... 5-1
5.2.2
Monthly ...................................................................................................................................... 5-2
5.2.3
6 Monthly ................................................................................................................................... 5-2
5.2.4
Annually..................................................................................................................................... 5-2
5.3
CLEANING THE CHLORINATOR....................................................................................................5-2
5.4
DRAIN AND CLEAN UNIT ............................................................................................................... 5-3
5.5
AIR DIFFUSER ASSEMBLIES......................................................................................................... 5-4
5.5.1
General...................................................................................................................................... 5-4
5.5.2
Element Replacement ............................................................................................................... 5-4
5.6
DISCHARGE PUMP ......................................................................................................................... 5-4
5.7
COMPRESSOR................................................................................................................................ 5-4
5.8
MACERATOR................................................................................................................................... 5-4
5.9
RECOMMENDED SPARES LIST .................................................................................................... 5-5
SECTION 6 - DRAWINGS .............................................................................................................................. 6-1
6.1
General Arrangement Drawings ....................................................................................................... 6-1
6.2
Sectional Arrangement Drawings ..................................................................................................... 6-5
6.3
General Arrangement Drawings Sewage Pumps........................................................................ 6-13
6.4
General Arrangement Drawings Macerator................................................................................. 6-17
6.5
Control Panel Layout ...................................................................................................................... 6-19
6.6
Installation Wiring Diagrams........................................................................................................... 6-21
Page 4
6.7
Circuit Diagrams ............................................................................................................................. 6-27
SECTION 7 - DISCHARGE PUMP MAINTENANCE...................................................................................... 7-1
7.1
DISMANTLING PUMP B50 X 50HC ................................................................................................ 7-1
7.2
INSPECTION.................................................................................................................................... 7-1
7.3
ASSEMBLING PUMP B50 X 50HC.................................................................................................. 7-1
7.4
DISMANTLING PUMP B50 X 50HB................................................................................................. 7-2
7.5
INSPECTION.................................................................................................................................... 7-3
7.6
ASSEMBLING PUMP B50 X 50HB.................................................................................................. 7-3
SECTION 8 - AIR COMPRESSOR MAINTENANCE ..................................................................................... 8-1
8.1
PUMP RANGES ............................................................................................................................... 8-1
8.2
DESCRIPTION ................................................................................................................................. 8-1
8.3
SUITABILITY .................................................................................................................................... 8-1
8.4
HANDLING AND SETTING UP (Figures 8.1 and 8.2) ..................................................................... 8-1
8.5
INSTALLATION (Figure 8.1) ............................................................................................................ 8-2
8.6
INITIAL OPERATION (Figure 8.1) ................................................................................................... 8-3
8.7
POTENTIAL RISKS FOR OPERATING PERSONNEL ................................................................... 8-3
8.8
MAINTENANCE AND SERVICING .................................................................................................. 8-3
SECTION 9 - MACERATOR MAINTENANCE ............................................................................................... 9-1
9.1
MACERATOR (COMMINUTOR) ...................................................................................................... 9-1
9.1.1
General...................................................................................................................................... 9-1
9.1.2
Mechanical ................................................................................................................................ 9-1
9.1.3
Electrical .................................................................................................................................... 9-1
9.1.4
Macerator Jams And Cuts Out.................................................................................................. 9-1
9.1.5
Use of Release Bar R197.......................................................................................................... 9-2
9.2
MAINTENANCE INSTRUCTIONS ................................................................................................... 9-2
9.2.1
To Dismantle a 150 Pulveriser Ref. R1537. ....................................................................... 9-2
9.2.2
To Replace the Cutter Ring....................................................................................................... 9-2
9.3
REASSEMBLY ................................................................................................................................. 9-3
9.4
TO REPLACE THE WATER SEAL .................................................................................................. 9-3
9.5
REASSEMBLY ................................................................................................................................. 9-3
9.6
TO REPLACE THE DRIVE END BEARING AND SEALS ............................................................... 9-4
9.7
REASSEMBLY ................................................................................................................................. 9-4
Page 5
FIGURES
Figure 2.1 Schematic Diagram of Sewage Treatment Unit ........................................................................... 2-1
Figure 2.2 Schematic Diagram of Sewage Treatment Unit with Vacuum Toilet System............................... 2-1
Figure 3.1 Typical Super Trident Sewage Treatment Plant Installation ........................................................ 3-2
Figure 3.2 Holding Down Feet ....................................................................................................................... 3-4
Figure 3.3 Discharge Pump Installation ......................................................................................................... 3-6
Figure 4.1 Schematic System Layout Sewage Treatment Unit / Incinerator ................................................. 4-7
Figure 6.1 Control Panel Arrangment Two Compressors & Two Discharge Pumps ................................ 6-19
Figure 8.1 Compressor .................................................................................................................................. 8-1
Figure 8.2 Compressor Interior (1)................................................................................................................. 8-2
Figure 8.5 Compressor Exploded View ...................................................................................................... 8-6
Figure 9.1 General Assembly 150 HVL Pulveriser (DD) R1537 .................................................................... 9-6
Figure 9.2 Water Seal, Drawing R1361 ......................................................................................................... 9-8
Figure 9.3 Spare Parts for BCP Motors .......................................................................................................... 9-9
TABLES
Table 3.1 Key to Typical Installation diagram ................................................................................................ 3-3
Table 5.1 Trouble Shooting Guide ................................................................................................................. 5-1
Table 5.2 Recommended List of Spares........................................................................................................ 5-5
Table 6.1 List of Parts for Drawing D7937 ...................................................................................................... 6-9
Table 7.1 List Of Parts - Pump Type B50 x 50HB (Drawing 5013) and B50 x 50HC (Drawing 5025) .......... 7-7
Table 8.1 Compressor : List of Parts for Figure 8.5 ....................................................................................... 8-7
Table 9.1 List Of Parts General Assembly 150 HVL Pulveriser (DD) ........................................................... 9-7
Table 9.2 List Of Parts for BCP Motor BS Metric Fan Cooled Motor, Cage D Range, R1306.................. 9-9
Page 6
Spare Parts and Service

Spare Parts can be ordered direct from the following address:
Hamworthy KSE Ltd.
Telephone:
+44 (0)1202 662600
Fleets Corner
Facsimile:
+44 (0)1202 665444
Poole, Dorset
Email:
poolespares@hamworthykse.com
BH17 0JT, 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:
Obtained from machine nameplate
Type and serial number of machine:
Obtained from details in this publication
Item Number and full description of part required:
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:
Facsimile:
Email:
+44 (0)1202 662663

+44 (0)1202 662622
pooleservice@hamworthykse.com
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 Ltd.,

113 Cushman Road, Unit 8,
St. Catherines, Ontario. L2M 6S9
Tel. +1 905 688 4922
Fax. +1 905 688 9028
Norway
Hamworthy KSE A/S,

Joseph Kellers vei 20
Tranby
PO Box 83, N-3401 Lier, Norway
Tel. + 47 32 85 92 00
Fax. + 47 32 85 21 93
China
Hamworthy KSE Shanghai Representative Office,

Room 7-D Yi Dian Plaza,
No. 746 Zhao Jia Bang Road,
Shanghai 200030
Tel. + 86 21 64455665
Fax. + 86 21 64459875
Singapore
Hamworthy KSE PTE Ltd,

15 Benoi Crescent
Singapore 629978
Tel. + 65 261 6066
Fax. + 65 261 6011
Dubai
C/O Aqua Tech,

DY 160/1 Al Jadaf, PO Box 62073
Dubai, UAE
Tel. + 971 4324 0335
Fax. + 971 4324 0336
South Africa
Hamworthy Engineering Africa (Pty)

Ltd
P.O. Box 50435,
Randburg 2125, Johannesburg.
Tel. + 27 11 7923886
Fax. + 27 11 7923889
Holland
Hamworthy KSE BV,

Bristolstraat 1, 3047 A.B.,
Rotterdam, Netherlands
Tel. + 31 10 462 4777
Fax. +31 10 415 9046
U.S.A.
Georgia
Hamworthy KSE Inc.,

1129 Hospital Drive, Suite 3C,
Stockbridge, Georgia 30281.
Tel. +1 770 507 8900
Fax. +1 770 507 8989
India
Hamworthy KSE Pvt Ltd

C-155 Mittal Court, Nariman Point,
Mumbai 400 021 India
Tel. + 91 22 2872394
Fax. + 91 22 2872394
New Jersey
187 Route 34
Matawan, NJ 07747
New Jersey
Tel: + 732 583 5115
Fax: + 732 583 5116
Korea
Hamworthy KSE Korea Ltd.

14th Floor Hyundai Building #1193-5
Choryang 3 dong, Dong-gu,
Pusan, Korea (601-013)
Tel: + 8251 465 8461
Fax: + 8251 463 7498
New Orleans
1418 Edwards Avenue

Suite B
New Orleans
Louisiana 70123
Tel: +1 504 734 5525
Fax: +1 504 734 5716
Page 7
Hamworthy Agents Worldwide

Abu Dhabi
Ali & Sons Co.

Ali & Sons Co. Building
Tourist Club, PO Box 915
Abu Dhabi, U.A.E.
Tel. + 971 2 723900
Fax. + 971 2 723901
Egypt
International Marine Center

PO Box 95 (21321)
Imbrahimieh
Alexandria, Egypt
Tel. + 203 483 6959
Fax. + 203 483 7969
Sultanate
of Oman
Trans-Oceanic Trading Est.

PO Box 4892
Postal Code 112, Ruwi
Sultanate of Oman
Tel. + 968 798503
Fax. + 968 702981
Argentina
Neptune S.A.
Calle Mendoza 3185 - 5 - B
1428 - Buenos Aires
Argentina
Tel. + 54 1 322 6041
Fax. + 54 1 322 5790
France
Etablissements Tiano
2 Bis Rue de la Baume
Paris 75008, France
Tel. + 33 1 4561 9932
Fax. + 33 1 4225 6962
Pakistan
United Traders
Haroon Chambers
Altaf Hussain Road,
Karachi 74000, Pakistan
Tel. + 92 21 241 4916
Fax. + 92 21 241 6862
Australia
Caba (Aust.) Pty. Ltd.

41 Barry Avenue
Mortdale, N.S.W. 2223
Australia
Tel. + 61 29 534 2100
Fax. + 61 29 533 5332
Germany
Wilhelm Rump KG
Buchheisterstrasse 6
20457 Hamburg, Germany
Tel. + 49 40 317842-0
Fax. + 49 40 3194841
Poland
Romac Ltd.
80/463 Gdansk,
Ciolkowskigo 7A/25
Poland
Tel. + 48 58 347203
Fax. + 48 58 3463694
Greece
Alpha Marine Engineering Ltd. Qatar

38 Salaminos
GR 16674 GLYFADA,
Athens Greece
Tel: + 301 89 43 220
Fax. + 301 96 80 210
Al Ahed Trading &

Contracting Company
PO Box 3266, Doha, Qatar
Tel. + 974 414022
Fax. + 974 414021
Aries Industrial Y Naval S.A.

Parque de las Naciones
Edificio Germania
Guzman el Bueno 133
Madrid 28003, Spain
Tel. + 34 91 533 9200
Fax. + 34 91 534 7402
Bangladesh Marinetec Ltd.

30 Agrabad Commercial Area,
PO Box 2018
Bandar, Chittagong
Bangladesh
Tel. + 880 31 502834
Telex: 66466
Brazil
Tridente Brazil
Rua Visconde de Inhuama,
134 GR 1513
Centro - Rio de Janeiro RJ
20091-100, Brazil
Tel. + 55 21 233 1489
Fax. + 55 21 233 7187
Italy
Genoa
S.I.R.N. s.r.l.
22/1 Via Casaregis, 16129
Genoa
Tel. + 39 0 10 586771
Fax. + 39 0 10 542678
Spain
Bulgaria
Dawcul Ltd. Cherni Vrah Bul,

BL NO 4VH A, 1421 Sofia,
Bulgaria
Tel. + 359 2 963 0156
Fax. + 359 2 962 5217
Trieste
22/1 Via Del Lazzaretto

Vecchio,
9.34123, Trieste
Tel. + 39 0 40 304247
Fax. + 39 0 40 308196
Venezuela Oficini Maritima PI. C.A.
Chile
Lanz Y Cia Ltda

Israel
Calle Dr. Barros Borgono 233.
Casilla 16389
Santiago, Chile
Tel. + 56 2 235 2707
Fax. + 56 2 235 7329/1070
B. Sofer & Co. Ltd.

PO Box 221,
Avichail 42910 Israel
Tel. + 972 9882 2319
Fax. + 972 9862 5211
Columbia
Consul Naval Ltda

Kuwait
Edificio Colseguros
Oficina 501
Calle Cochera del Gobernador
Cartagena, Columbia S.A.
Tel. + 575 664 6413
Fax. + 575 664 1640
The Trading & Industrial

Equipment Co. (WLL)
(TIECO),
PO Box 2159,
13022, Safat, Kuwait
Tel. 00965 4810385
Fax. + 965 4810387
Denmark
Berendsen PMC A/S,

Telefonvej 6,
DK 2860 Soborg, Denmark
Tel. + 45 70 21 21 21 ext 421
Fax. + 45 39 54 85 11
Malta
Thos. C. Smith & Co. Ltd.

12 St Christopher Street
Valetta, Malta
Tel. + 356 625071
Fax. + 356 247182
Ecuador
Sertemar Ltd. El Oro 1303 Y

Guaranda, PO Box 5899
Guayaquil, Ecuador S.A.
Tel. + 593 4 345105/340325
Telex. 043741 AM BU SL
New
Zealand
Caba (New Zealand) Ltd

37 Clyde Street
Whangarei, New Zealand
Tel. + 64 94 383661
Fax. + 64 94 30854
Edif Torre La Previsora

Piso 7, Sabana Grande
Aptdo 60710, Caracas 1060A
Venezuela
Tel. + 58 2 7817897
Fax. + 58 2 781 9457
V11
Page 8
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 9
Page 10
SECTION 1 - TECHNICAL DATA

Electrical Power Supply
ST2A to ST6A
380 - 440V, 3 phase, 50/60 Hz
Control Voltage
110V A.C.
Discharge Pump Motor Ratings

ST2A to ST6A
Close coupled B50 x 50HC
2.4 kW
Belt driven B50 x 50HB
8.0 KW
Compressor Motor Ratings

ST2A
0.65 kW
ST3A
0.9 kW
ST4A
0.9 kW
ST6A
1.8 kW
Macerator Motor Rating

Macerator Motor Rating
2.2 kW
Discharge Pump Duty

3
B50 x 50HC - Low head
10 m /hr at 8m head
B50 x 50HB - High head
10 m /hr at 26m head
Compressor Duty
3
ST2A
0.5 bar - 15 m /hr
ST3A
0.55 bar - 22 m /hr
ST4A
0.5 bar - 27 m /hr
ST6A
0.5 bar - 41 m /hr
3
3
Macerator duty
Macerator duty
5.5 m /hr
High Level Alarm

High Level Alarm
Volt free normally closed 500W
Vent System Back Pressure

Vent System Back Pressure
15mm w.g. (max.)
Page 1-1
Loading Data
3
Designed Hydraulic Flow m /day

Max. Hydraulic flow, l/h
3
Min. Hydraulic flow, m /day
Max. duration of max. flow, h
Designed BOD5 Loading, kg/day
Page 1-2
ST2A
3.12
202
1.56
1
2.00
ST3A
4.66
306
2.33
1
3.00
ST4A
6.01
388
3.01
1
3.85
ST6A
9.36
660
4.68
1
6.00
SECTION 2 - DESCRIPTION
2.1
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 flexible
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 requirement considerable installation space
and long lengths of piping.
Figure 2.1 Schematic Diagram of Sewage Treatment Unit
Figure 2.2 Schematic Diagram of Sewage Treatment Unit with Vacuum Toilet System
Page 2-1
2.2
GENERAL
Basically the Super Trident Sewage Treatment unit comprises a tank, divided into three water tight
compartments - an aeration compartment, a settling 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 settling compartment where the aerobic bacteria
floc, 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.
2.3
2.3.1
DETAILED DESCRIPTION
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.
Air 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 settling compartment the bacteria settle out and are returned to the aeration compartment by the airlift
tube. This takes its supply from the bottom of the compartment and discharges to the aeration compartment,
via a visual indicator pipe which enables a check to be made on the sludge return. The settling 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 air lift. The effluent enters the compartment through a stilling 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 bacteria.
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
Chlorinator
1. 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 effluent 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 effluent.
2. Liquid Disinfection (when fitted). This comprises a reservoir, dosing pump and controls to adjust the
flow of disinfectant depending on test results (see Section 4)
2.3.5
Discharge Pump
This is a separate motor driven unit and two types are available. A close coupled non self-priming unit
suitable for low heads where the impeller is mounted on the motor shaft; a non-self priming unit for high head
duties which is belt driven. The pump rotating element can be withdrawn without disturbing the pipework.
2.3.6
Air Compressors.
One rotary vane air compressor is fitted as standard, with a second standby unit available as an option.
2.3.7
Macerator (Comminutor) (when supplied).
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.
2.4
2.4.1
Electrical Controls
General
The rotary air compressor motors are operated by manual switches on the control panel. When a discharge
pump is supplied it is controlled by float switches fitted in the final effluent tank with an overriding
HAND/AUTO switch on the control panel.
2.4.2
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(s), and the upper float operates the high level alarm
circuit should the level rise above normal.
2.4.3
Operation
When the system is fitted with a discharge pump and the control switch is in the AUTO position, the typical
sequence of 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.
Page 2-3
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 until the control switch is moved to OFF.
When dual pumps are supplied the second pump is typically a standby unit, however if requested the
sequence of operation may be arranged for lead follow or parallel operation to suit special on-board
conditions.
A control panel General Arrangement drawing including control switch layout is included in Section 6.5 and a
circuit wiring diagram is shown in Section 6.7.
2.4.4
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
3.1
GENERAL DATA
The unit should be installed in a position where it is as level as possible when the ship or 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 longest 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 a 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.
All valves. 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.
5.
Discharge pumps and air blowers for maintenance.
6.
Float switch assembly.
The following pipe connections 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 filling 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 tank side. Can be piped to bilge via 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
Figure 3.1 Typical Super Trident Sewage Treatment Plant Installation

Page 3-2
Table 3.1 Key to Typical Installation diagram

A*
Isolating Valves
B*
Limited low level waste water disinfecting inlet (grey water)
Disinfection tank
Tablet disinfection feed tubes
Emergency Overflow Connection
Level Control Switch for disinfection contact tank
Emergency Air Inlet Connection (if single compressor fitted).
Rotary Air Compressor
Control panel for sewage treatment tank
Sea water supply for initial filling and cleaning. (Use clean sea water or freshwater not
harbour water)
Discharge Pump
Standby Discharge Pump (When ordered)
Overboard discharge
Aeration Tank
Sample / Sludge incinerator / Recirculation Connection
Settling/clarifier Tank
Q*
Soil inlet (black water)
R*
Vent to Funnel or Mast
Branch above max. water line (prevents system back-up)
T*
Storm Valve
Overboard By-pass connections must be fitted on soil and grey water lines, as indicated
Typical Installation
Macerator (when ordered). A sump should be fitted for protection against metal objects.
Grease trap (when ordered)
Notes to Figure 3.1:

1.
Items marked thus * NOT Hamworthy supply.
2.
Grey Water Waste Drains. Discharge directly overboard in accordance with I.M.O. Regulations. A
limited quantity of grey water meeting I.M.O. sewage effluent standards from sources below the water
line may be piped into the disinfection tank. (not galley sinks, garbage disposal 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.
3.
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. If it 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.
Page 3-3
4.
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
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.
5.
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. If the available level is
less than this a back-up will occur in the system until the required head is available. If emergency
overflow is below maximum water level, then connect to bilge including a U trap of 200mm to prevent
venting.
6.
Dual pump set. This can be supplied to give a standby pump, ready piped in.
7.
Syphon Prevention. If top of tank is above light draught water line then pump discharge line must be
looped above top of tank and a connection taken from the top of the loop to a point in the air vent
above the discharge head of the pump.
8.
Galley Waste. This should be led directly overboard. If it is intended to connect into the black soil
water inlet of the sewage unit Hamworthy must be consulted, as size of unit will be affected and a grease
trap must be fitted. DO NOT connect to the Grey Waste Water disinfecting inlet.
9.
Asiatic type constant flushing toilets. These will affect size of unit. Consult Hamworthy.
10.
Low Flush Sewage Delivery Systems (e.g. Vacuum). The concentrated black water soil from this
type of system must be diluted to facilitate the biological treatment. Dilution should be with clean sea
water but it may be possible to use some grey water subject to surfactant content /use of anti-foaming
dosing equipment. Dilution water should be added to the aeration tank or a feed tank prior to the
treatment unit, at a constant rate to prevent shock loading. Consult Hamworthy.
11.
Ultra-Violet Sterilisation. An optional unit can be supplied where final disinfectant discharge is
unacceptable. No grey water must be directed to the disinfecting tank when the treatment unit is
installed with a UV unit.
NOTE: This equipment can be supplied to meet the requirements of the Environment of Canada Great Lake
Regulations.
12.
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 as 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
Page 3-4
3.2
RECOMMENDATIONS ON VENT SYSTEM DESIGN
1.
The vent pipe run should be to the funnel or mast using the minimum number of bends.
2.
Bends should be long radius type, where possible.
3.
Negative gradients on horizontal runs are to be avoided and listing of vessel should be taken into
account.
4.
U trap drains should be added where water traps could occur in the main line.
5.
Flame traps are not required, but if fitted should be sized to not increase the overall pressure drop
above the stated limit and should be regularly cleaned.
6.
Vent fans can be supplied by Hamworthy for system back pressures above the stated limits.
7.
Odour extraction fans can be supplied by Hamworthy when exhausting to sensitive areas.
8.
Water traps should be fitted to the treatment unit overflow and any grey water inlets with a minimum of
80 mm to prevent venting into compartments.
9.
Water closets, urinals etc. must have a water seal 30 mm greater (or more) than vent back pressure.
10.
When coupling any other vent pipework into the sewage vent system its effect must be taken into
account on the overall pressure drop.
Particularly, a vacuum sewage collect system vent which will approximately double the air flow rate of
the treatment plant, also creating very high peaks as each water closet flush will induce 60 litres of air
in 3 - 4 seconds.
11.
The total system back pressure should be typically not above 15 mm water gauge with the following
air flows:
Unit Size
Vent Design Air Flow
Vent Connection Nominal Diameter
Standard Tank (M3/hour)
Standard Tank (mm)
Ejectors fitted (mm)
ST2A
13
50
80
ST3A
18
50
80
ST4A
24
50
80
ST6A
40
50
80
Page 3-5
Figure 3.3 Discharge Pump Installation

3.3
FITTING INSTRUCTIONS FOR ITEMS PACKED SEPARATELY FOR SAFE TRANSIT
1.
Pump assembly complete with motor. (when supplied loose). This requires bolting to the deck. Pipe
strains must be avoided when making suction and delivery connections. Wiring is required between
the pump motor and electric control panel. A wiring diagram is permanently attached to the inside of
the control panel cover. A General Arrangement drawing is included in Section 6.3.
2.
Chlorinator 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 air
(See Technical Data, Section 1 for flow rate).
Page 3-6
SECTION 4 - OPERATION
4.1
HEALTH AND SAFETY INFORMATION
Personnel:
Protection
Safety glasses and gloves should be worn when taking samples,

refilling chlorine tablet tubes and general maintenance of the system.
Product:
DPD No. 4 Tablets
Application:
For water testing applications only.
Composition:
Tablets containing less than 1% diethyl-p-phenylene diamine sulphate in

formulation with buffer, boric acid, borates, potassium iodide, stabilisers and
tableting aids.
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.
Shelf Life:
1 years unopened at 30C and relative humidity of 80%.
Handling:
Use only as instructed. Avoid handling whenever possible. Wash hands after
use. Not to be taken.
Transport:
Not regulated.
In case of contact with

skin/eyes
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 tetrachloroglycoluril (75%)

and inerts (25%)
Properties:
White tablets. Oxidising agent. Corrosive.
Hazards:
Do not mix or contaminate calcium 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.
Storage:
Prevent any hot or burning material such as a lighted cigarette from

falling into any container of tablets.
Keep in a cool (20 - 23C) dry place in the original container. Always
replace 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 55C.
Shelf Life:
Un-opened
12 months at 23C
6 months at 30C
3 months at 45C
Handling:
Do not allow contact with eyes, skin, mucous membranes or clothing. It

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 fire.
In case of contact with eyes/skin, flood with plenty of water. OBTAIN MEDICAL ATTENTION
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.
In case of fire, drench with water and cool the surrounding area with water.
Page 4-2
4.2
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, except standby compressor delivery valve.
Close control panel isolator. Switch the service compressor on and check for correct rotation by
placing a hand over the inlet. Suction effect indicates correct rotation. Check operation of relief valve
by closing compressor discharge valve. Open compressor discharge valve to check that relief valve
reseats. Repeat this for standby air compressor (if fitted).
2.
With duty compressor running, partially fill unit with water to cover diffusers. Open valves to diffusers,
close valves to air lifts and confirm air to each diffuser. Select auto and No. 1 duty discharge pump on
panel.
3.
Close all side hatches on tank, close valves 1, 3, 4 and 6. Open valves 2 and 5 and fill 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 4 and 6 of duty
discharge pump.
4.
Check that liquid is flowing through the visual indicator pipe in the sludge return line. The air flow is
controlled by the air valve and should be set, during normal operation, to give as high a sludge return
as possible whilst ensuring that the liquor does not become clear. If this happens the airlift should be
reduced until the return is seen to darken again. Following initial filling 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 air lift can empty skimmer. Adjust valve only when water is in skimmer tray, i.e. when
being fed.
5.
Partially fill disinfectant contact tank and prime discharge pump(s).
6.
Check pump rotation and selector switch operation (dual pumps).
7.
Check operation of pumps from float switch when in AUTO.
8.
Fill contact tank and check time required to discharge contents. Check for signs of cavitation.
9.
Check that water is not pumped from syphon vent in discharge pipe.
10.
Check operation of macerator (when fitted).
11.
Close up tank.
12.
Fill chlorinator tubes with tablets if in restricted waters (when fitted). Approximately 2.5 kg of tablets
are required to fill one tube.
13.
Check air pressure above liquid in aeration tank with manometer. Not to be more than 15mm (H20)
with blower running.
14.
Open raw sewage and grey water (when fitted) inlet valve(s) to put unit on line.
15.
Refer to sample procedures, operation and maintenance requirements including desludging.
Page 4-3
4.3
4.3.1
DETERMINATION OF RESIDUAL CHLORINE CONTENT

General
A chlorine test is supplied so that the residual chlorine content of the treated sewage effluent may be
determined. A sample of this effluent 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 stirrer.
T9201005).
3.
Make comparison.
(Replacement tablets Pt. No.
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 chlorinator 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 hypochlorite 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.
If liquid disinfection is fitted adjust the dosing pump flow to achieve 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.
4.3.3
Disinfectant Cleaners
Disinfectant toilet cleaners used in large quantities can be detrimental to biological treatment plants. They
should be used very sparingly.
4.3.4
Approved Biological Toilet Cleaners
Gamlen Gamazyme TD500 (liquid)

Gamlen Gamazyme 700FN (powder)
Ubichem Actizyme
Arrow Tolette
4.3.5
Approved Descaler
Gamlen Darentab 664
Page 4-4
4.4
4.4.1
1.
DESLUDGING TO AN INCINERATOR
General
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 it is not possible, however, the sludge from the Super Trident should be removed daily in the
quantities shown for the unit in use.
ST2A
45 Litres
ST3A
65 Litres
ST4A
90 Litres
ST6A
135 Litres
A 1" BSP connection is provided on the Super Trident for this purpose and the sludge can then be
pumped direct into the sludge 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.
4.4.2
When removing sludge daily 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 little
until a constant reading is obtained. Alternatively, if the suspended solids are decreasing the sludge
quantity should be reduced.
Using a Sludge Pump
A small positive displacement pump (with 1" B.S.P. connections) can be supplied for desludging 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 control panels so that
the desludging operation can be carried out in a position where the sludge tank level indicator can be
observed.
4.4.3
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 sludge tank level. In this way, desludging of the Super Trident can be carried out without the problem
of overfilling the sludge tank.
The quantities shown in paragraph 2 must still 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
4.4.4
Key to Symbols shown on Schematic Drawing A19170

A.
Super Trident Discharge Pump for discharge of effluent and desludging overboard.
B.
Super Trident Unit
C.
Macerator must be fitted when desludging to Incinerator
D.
Sludge burner connection 1/2" B.S.P.
E.
Incinerator unit
F.
Sludge burner metering pump
G.
Incinerator sludge tank
H.
Engine room sludge transfer pump
J.
Engine room sludge tank
K.
Alternative desludging. Metered quantity daily by sewage sludge transfer pump to

incinerator sludge tank. The operation must be carried out daily in the following
approximate quantities.
ST2A
45 Litres
ST3A
65 Litres
ST4A
90 Litres
ST6A
135 Litres
Key to symbols in Figure 4.1.

* These items and all pipework are not HamworthyKSE 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
Page 4-8
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
Tank overflow.
High level alarm.
Noxious odour emissions.
Cause
Remedy
Pump failure.
Check electrical circuit.
Blockage.
Check for pipe blockage.
Excessive input.
Check for leaking flush valves on

w.c.s.
Anaerobic condition within the

tank.
Ensure compressor is operating

correctly. Check sludge return
air-lifts are working. Check
aeration tank air diffusers for
blockage.
High sludge level in aeration tank. Check desludging requirement.

Lack of oxygen.
Check compressors diffusers,

filters and valve positions.
Low, micro-organism levels.
Eliminate disinfectant cleaners

from system.
Effluent quality poor.

(Note: Allow 14 days conditioning Sludge not returning from settling Check air lifts are working,
tank or skimmer.
adjusted to give required flow.
period from initial start-up).
Foaming in aeration tank and up

vent line.
5.2
5.2.1
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.
Use low foam cleaners and

Excessive use of cleaning agents. prevent emptying of cleaners
buckets down w.c.s.
MAINTENANCE SCHEDULE
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 Chlorine 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.
Page 5-1
5.2.2
Monthly
Change over from the duty to the standby air compressor. Ensure that the delivery valve is open before
operating change over switch and then close delivery valve on unit not running.
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 ml 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 switch 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 settling 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.
7.
Refill unit with clean fresh or sea water and select valves for normal running.
8.
Select the discharge pump control panel switches to AUTO.
5.2.3
6 Monthly
Examine filter cartridges fitted to the aeration compressor and replace if dirty. (These may be cleaned by
blowing compressed air from the inside of the cartridge outwards in an emergency). Check the functioning
of the non-return 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 pumps and air blowers for wear. Replace aerator air diffuser elements.
2
NOTE: If air pressure rises above 0.2 bar (3 lbf/in ) above original commissioning pressure at any time,
check both filter cartridges and aerators and replace as necessary.
5.3
CLEANING THE CHLORINATOR
The chlorinator 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 stiff brush (NOT WIRE).
CAUTION:
Page 5-2
1.
Never use water above 65C (150F) in this chlorinator. To do so may result in
damage.
2.
Use only the recommended tablets as supplied initially with the unit.
5.4
DRAIN AND CLEAN UNIT
Safety Notes:
1.
Never leave the Trident sewage treatment unit full of sewage without the air compressors running.
2.
To completely shut-down, drain and clean as shown below and leave empty, or alternatively refill with
clean water and ready for use.
3.
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.
Close the valves on the raw sewage and waste water inlet lines, or alternatively, ensure that the
connected appliances are not used.
2.
Select the discharge pump control panel switch to OFF.
3.
Close valve numbers 1, 2 and 5.
4.
Open valve numbers 3, 4 and 6.
5.
Select HAND on the control panel switch to operate the discharge pump.
6.
Pump or drain the chlorine contact tank contents overboard.
7.
Close valve number 3 and open valve number 2.
8.
Pump or drain the aeration compartment contents overboard.
9.
When the aeration compartment is empty, close valve number 2.
10.
Open valve number 1 and empty the settling tank.
11.
Close valves 4 and 6 and open valves 1, 2 and 3, refill unit through valve 5 taking care not to over
pressurise the tank.
12.
Where a recirculation line has been fitted, Super Chlorinate the unit before entering the tank, close
valves 2, 3 and 5 and open valves 3, 4, 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.
13.
Inspect the internal coating and recoat as necessary with a high grade coal tar epoxy.
14.
Examine the inspection cover joints for serviceability and renew if necessary. Refit the joints and
covers.
15.
Inspect the filter periodically. This can be cleaned in situ with a hose or removed from the tank and
cleaned.
NOTE: When a standby discharge pump is fitted, refer to Section 3 - Discharge Pump Installation and
ensure that the appropriate suction and delivery valves serving the pump in use are open and
those serving the standby pump are closed.
Page 5-3
5.5
5.5.1
AIR DIFFUSER ASSEMBLIES

General
The air diffuser elements are made from a 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
2
reading rises 0.2 bar (3lbf/in ) above original commissioning pressure, or the air pressure relief valve is
blowing. Ensure that the air filter cartridges are clean and that the air lift 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
A complete pump and motor can be provided as standard spares for a single discharge pump arrangement,
so that should trouble be experienced with this relatively small item it can be quickly remedied without
interfering with the normal operation of the unit.
For dual discharge pump system, the standby pump serves as a spare in case of difficulty.
Before dismantling the pump it is recommended that it be thoroughly flushed. 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
so that should trouble be experienced with this relatively small item it can be quickly remedied without
interfering with the normal operation of the unit.
For dual compressor systems, the standby compressor serves as a spare in case of difficulty.
Maintenance instructions are included in Section 8.
5.8
MACERATOR
Maintenance instructions are included in Section 9.
Page 5-4
5.9
RECOMMENDED SPARES LIST

Table 5.2 Recommended List of Spares
Item
Description
Impeller screw
Peel off shim
Pump
Mechanical seal
Tab washer
Carbon blades
Filter elements
Compressor
Set of bearings
Set of spacers and tolerance rings
Contactor
Auxiliary contact lamp
Controls
2 x 5A fuses
2 x 2A fuses
Sampling kit
Lovibond tablets
Chlorine tablets
Drum of tablets
Page 5-5
Page 5-6
SECTION 6 - DRAWINGS
6.1
General Arrangement Drawings
Page 6-1
Page 6-2
Page 6-3
Page 6-4
6.2
Sectional Arrangement Drawings
Page 6-5
Page 6-6
Page 6-7
Page 6-8
Table 6.1 List of Parts for Drawing D7937

ITEM
001
002
003
004
008
009
010
012
013
014
018
019
020
021
022
023
025
026
027
028
029
031
034
036
039
040
043
050
051
054
055
056
057
065
068
069
070
071
072
073
074
075
076
077
078
079
080
081
082
139
140
144
146
147
DESCRIPTION
TANK SUB-ASSEMBLY
AIR COMPRESSOR
CONTROL PANEL
LEVEL SWITCH
BLANK FLANGE
FLANGE
DISCHARGE PUMP
JOINT,50NB
JOINT
NUT & BOLT
CHLORINATOR
COVER
JOINT-FITTERS CUT
LABEL
NAMEPLATE
M8 STIFF NUT
HEXAGON SCREWS
LABEL WARNING WELDING
3/8" ST.ST. WASHER, EN58.
NAME PLATE
LABEL
CABLE
NAMEPLATE
TERMINAL TAG PANEL
JOINT WASHER FIBRE
FLEXIBLE CONDUIT
CABLE TIE
CONDUIT ELBOW
ADAPTOR
LABEL
LABEL
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.
HEXAGON BOLT
BOLT
HEX NUT,M16 ZINC PLATED
BOLT
1.1/2"NB POLYURETHANE DUCTING
HOSE
REINFORCED PVC HOSE
HOSE CLIP
M STUD ELBOW BSP BR
FERRULE
Page 6-9
ITEM
150
156
158
162
163
164
165
169
170
174
179
180
184
185
201
202
203
204
205
206
207
244
245
246
247
270
271
272
273
274
275
276
277
278
279
280
281
282
283
289
291
293
294
295
296
297
300
301
302
303
304
305
306
307
308
309
320
Page 6-10
DESCRIPTION
DIFFUSER HOLDER
DIFFUSER ELEMENT
COMPOSITE UNION
FLEXIBLE HOSE
HOSE CLIP
BULKHEAD CONNECTION
1/2"OD NYLON TUBE
DIFFUSER DOWNTUBE
ABS.BS5391 DN15X21.3 CL.T
AIR LIFT TUBE
SURFACE SKIMMER
SEALING RING
REDUCING ELBOW
PIPE
TEE, PVC
REDUCING BUSH
TUBE, PVC
TUBE, PVC
FLEXIBLE HOSE
HOSE CLIPS
HOSE CLIPS
LABEL
LABEL
LABEL
LABEL
STIFFNUT, M6
SPRING WASHER, M6 , ZN PLT
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,3/4"
PLUG,3/4"
NON-RETURN VALVE,3/4"
GAUGE ADAPTOR
PRESSURE GAUGE
ELBOW,1/2"
COVER, (ST2A DUAL COMP ONLY)
'P' CLIP
NUT,M5
WASHER,M5
HOSE CONNECTOR,3/4"BSPx3/4"NB
CONDUIT ADAPTER
JOINT
JOINT
HEX NUT M8 ZINC PLATED
FILTER SCREEN, ST2A
ITEM
321
322
323
325
326
330
331
335
340
341
342
350
351
360
361
370
371
372
373
374
375
376
377
378
379
380
DESCRIPTION
FILTER SCREEN, ST3A
FILTER SCREEN, ST4A
FILTER SCREEN, ST6A
BALL VALVE 1"BSP
BALL VALVE 1/2"BSP
HEX SCREW M6 X 16MM LG ZINC
PLATED
JOINT
JOINT-FITTERS CUT
JOINT-FITTERS CUT
1/2" BSP BACKING NUT
BSP BACKING NUT DURAPIPE
ELBOW,3/4"
ELBOW,3/4"
CABLE MARKER NUMBER '3'
CABLE 2.5MM
CABLE MARKER LETTER 'U'
CABLE MARKER LETTER 'V'
CABLE MARKER LETTER 'W'
CABLE MARKER LETTER 'X'
TERMINAL TAG PANEL
Page 6-11
Page 6-12
6.3
General Arrangement Drawings Sewage Pumps
Page 6-13
Page 6-14
Page 6-15
Page 6-16
6.4
General Arrangement Drawings Macerator
Page 6-17
Page 6-18
6.5
Control Panel Layout
Figure 6.1 Control Panel Arrangment Two Compressors & Two Discharge Pumps
Page 6-19
Page 6-20
6.6
Installation Wiring Diagrams
Page 6-21
Page 6-22
Page 6-23
Page 6-24
Page 6-25
Page 6-26
6.7
Circuit Diagrams
Page 6-27
Page 6-28
Page 6-29
Page 6-30
Page 6-31
Page 6-32
Page 6-33
Page 6-34
Page 6-35
Page 6-36
SECTION 7 - DISCHARGE PUMP MAINTENANCE

7.1
DISMANTLING PUMP B50 X 50HC
Refer to Sectional Arrangement Drawing D5025, on Page 7-5.

1.
Remove the bolts securing the electric motor to its seating, and the nuts, washers and bolts securing
the inner cover to the casing.
2.
Withdraw the motor and pump from the casing and remove O-ring seal.
3.
Bend back the locking tab washer and remove the impeller screw, tab washer and O-ring.
4.
Turn the impeller so that the jacking screw holes are horizontal, as shown on the Sectional
Arrangement Drawing D5025, and screw the two jacking screws to withdraw the impeller.
5.
Withdraw the stationary part of the mechanical seal from the inner cover and the rotating part from the
impeller.
6.
Remove the nuts and spring washers and remove the inner cover from the electric motor.
7.
Remove the peel-off shim and the liquid thrower.
7.2
INSPECTION
Thoroughly clean and examine all components for corrosion, cracks, wear or any other damage and renew
any parts found to be defective. If the mechanical seal faces are damaged, the complete seal assembly
must be renewed. The O-ring seals and tab washer must be replaced with new ones.
Check the worn clearance between the impeller vane and the internal machined face of the casing adjacent
to the suction branch bore. For optimum performance the maximum permissible limit of wear is 1.27mm.
7.3
ASSEMBLING PUMP B50 X 50HC
If stud is removed from the motor shaft, the stud threads must be coated with Loctite Stud Lock before it is
screwed back into the motor shaft.
Position the liquid thrower on the motor shaft and the inner cover on the motor. Fit the spring washers and
nuts.
1.
To determine the amount of shimming required between the impeller and motor shaft:
a.
Position a new peel-off shim in the bore of the impeller.
b.
Line up the keyway in the impeller with the key in the motor shaft and press the impeller onto
the shaft at the same time guiding the liquid thrower onto the impeller hub.
c.
Place the tab washer on the impeller screw and fit the screw on the stud; fully tighten the screw
but do not lock it at this stage.
d.
With the aid of a set of feeler gauges, measure the gap between the rudimentary vanes at the
back of the impeller and the inner cover. This dimension should be 0.457 +/- 0.076mm (0.018
+/- 0.003 in.). Subtract 0.457mm (0.018 in.) from the measurement obtained. The resultant
figure is the amount of shimming that it is required to remove from the peel-off shim.
NOTE: Each lamination of shim is 0.076mm (0.003 in)
e.g. Clearance measured 0.762mm (0.030 in)
Deduct:
0.457mm (0.018 in)
0.305mm (0.012 in)
Page 7-1
Therefore the amount of laminations to be removed from the shim is 0.305mm (0.012 in) or 4
laminations. A new shim is 20 laminations or 1.524mm (0.060 in) thick.
e.
Remove the impeller screw and tab washer and withdraw the impeller as detailed in Dismantling
Pump, sub-para. 4.
f.
Remove the peel-off shim from the bore of the impeller and remove the number of laminations
determined in (d) above.
2.
Smear the inside of the impeller bore with grease and fit two new O-ring seals in the grooves.
3.
Position the stationary part of the mechanical seal in the inner cover and the rotating part on the hub
of the impeller.
4.
Fit the peel-off shim in position in the bore of the impeller and line up the keyway in the impeller with
the key in the motor shaft and press the impeller onto the shaft at the same time sliding the liquid
thrower onto the hub.
5.
Secure the impeller with the impeller screw and tab washer. Lock the screw with the tab washer.
6.
Place a new O-ring seal on the inner cover and position the motor and pump assembly on its
mounting and secure that inner cover to the casing with bolts, washers and nuts.
7.
Fit the bolts and washers securing the motor to its mounting.
7.4
DISMANTLING PUMP B50 X 50HB
Refer to Sectional Arrangement Drawing D5013 on Page 7-6.

1.
Remove the two bolts and belt guard.
2.
Slacken off the nuts securing the electric motor to the base plate and release the tension on the drive
timing belt sufficiently to remove the belt.
3.
Remove the nuts, washers and bolts securing the inner cover to the casing.
4.
Take out the setscrews and washers securing the pump bearing housing to the baseplate and remove
the pump assembly from the baseplate.
5.
Remove O-ring seal and bend back the locking tab of the tab washer, unscrew the impeller screw and
remove the tab washer and O-ring.
6.
Turn the impeller so that the jacking screw holes are on the horizontal centre line, as shown on the
Sectional Arrangement drawing D5013, and screw in the two jacking screws to withdraw the impeller.
7.
Withdraw the rotating part of the mechanical seal and the two O-ring seals from the impeller and the
stationary part of the mechanical seal from the inner cover.
8.
Remove the nuts and spring washers securing the inner cover to the bearing housing and remove the
inner cover.
9.
Remove the liquid thrower from the pump shaft.
10.
Slacken off the three screws securing the pump pulley to the pump shaft and withdraw the pulley.
11.
Take out the screws and remove two bearing covers.
12.
Remove the impeller key and pulley key.
Page 7-2
13.
Press the pump shaft, together with the pulley end ball bearing, out of the bearing housing. The ball
bearing can then be pressed off the shaft, and the impeller end ball bearing can be pressed out of the
bearing housing.
NOTE: It is not necessary to remove the circlip if the bearing is pressed out towards the impeller end of the
housing.
7.5
INSPECTION
Thoroughly clean and examine all components for corrosion, cracks, wear or any other damage and renew
any parts found to be defective. If the mechanical seal faces are damaged, the complete seal assembly
must be renewed. The O-ring seals and tab washer must be replaced with new ones.
Check the worn clearance between the impeller vane and the internal machined face of the casing adjacent
to the suction branch bore. For optimum performance the maximum permissible limit of wear is 1.02mm.
7.6
ASSEMBLING PUMP B50 X 50HB
If the studs are removed from the tee nuts the stud threads must be coated with Loctite Stud Lock before
they are screwed back onto the tee nuts.
1.
Press ball bearing into the impeller end of the bearing housing and fit the bearing cover and retaining
screws.
2.
Press the other ball bearing onto the shaft and press the shaft and bearing into the bearing housing.
Fit the outer bearing cover and retaining screws.
3.
Fit key to the pump shaft and press the pump pulley onto the pump shaft and tighten the three
retaining screws.
4.
Place the liquid thrower on the pump shaft and secure the inner cover to the bearing housing with
spring washers and nuts.
5.
Fit the impeller key to the pump shaft.
6.
When assembling a pump, it is necessary to determine the amount of shimming required between the
end of the pump shaft and the impeller. To do this, position a new peel-off shim in the bore of the
impeller and:
a.
Line up the keyway in the impeller with the key in the pump shaft and press the impeller onto
the shaft at the same time guiding the liquid thrower onto the impeller hub.
b.
Place the tab washer on the impeller screw and fit the screw on to the stud; fully tighten the
screw but do not lock it at this stage.
c.
With the aid of a set of feeler gauges, measure the gap between the rudimentary vanes at the
back of the impeller and the inner cover. This dimension should be 0.305+/- 0.076mm (0.012
+/- 0.003 in). Subtract 0.305mm (0.012 in.) from the measurement obtained. The resultant
figure is the amount of shimming that is required to remove from the peel off shim.
NOTE: Each lamination of shim is 0.076 mm (0.003 in)
e.g. clearance measured
Deduct
0.762 mm (0.030 in)

0.305 mm (0.012 in)
0.457 mm (0.018 in)
Therefore the amount of lamination to be removed from the shim is 0.457mm (0.018 in) or 6
laminations. A new shim is 10 laminations or 0.762 mm (0.030 in.) thick.
d.
Remove the impeller screw and tab washer and withdraw the impeller as detailed in Dismantling
Pump sub-para 4.
Page 7-3
e.
Remove the peel-off shim from the bore of the impeller and remove the number of laminations
determined in (c) above.
7.
Smear the inside of the impeller bore with grease and fit two new O-ring seals in the grooves.
8.
Position the stationary part of the mechanical seal in the inner cover and the rotating part on the hub
of the impeller.
9.
Fit the peel-off shim in position in the bore of the impeller and line up the keyway in the impeller with
the key in the pump shaft and press the impeller onto shaft at the same time sliding the liquid thrower
onto the hub.
10.
Secure the impeller with the tab washer and screw. Lock the screw with the tab washer.
11.
Fit a new O-ring seal on the inner cover and position the pump assembly on the baseplate. Secure
the inner cover to the casing with bolts, washers and nuts and the bearing housing to the baseplate
with set screws and washers.
12.
Fit the timing belt on the pulley and adjust the belt tension, by moving the electric motor so that a force
of 4.5 kg (10 lb) applied on the belt at mid-span produces a deflection of 5mm (3/16 in). Tighten the
nuts securing the motor to the baseplate.
13.
Place the belt guard in position and fit the retaining setscrews.
Page 7-4
Page 7-5
Page 7-6
Table 7.1 List Of Parts - Pump Type B50 x 50HB (Drawing 5013) and B50 x 50HC (Drawing 5025)
Item
No.
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
20
21
22
23
24
25
27
28
29
30
31
32
33
34
35
36
38
50
51
52
53
54
58
59
60
61
Description
Casing
Inner Cover (B50 x 50HC)
Inner Cover (B50 x 50HB)
Impeller
Bearing Housing
Shaft
Impeller Screw
Bearing Cover
Liquid Thrower
Peel-off Shim
Ball Bearing
Circlip
O-ring - (Impeller)
O-ring - (Casing)
Crane Mechanical Seal Type 2 BR3C3/N
Tab Washer
Screw
Bolt
Nut (B50 x 50HB)
Nut (B50 x 50HC)
Stud
Stud
Nut
Spring Washer
Spring Washer
Plug
Joint
Stud
Nut
Key - (Impeller)
Key - (Pump Pulley)
Setscrew
Washer
Stud
Tee Nut
Setscrew
Motor
Timing Belt
Taper Lock Bush
Taper Lock Bush
Taper Lock Bush
Pump Pulley
Motor Pulley
Baseplate
Guard
Qty
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
6
6
13
6
3
4
4
3
4
1
1
4
4
1
1
4
6
4
4
2
1
1
1
1
1
1
1
1
1
Page 7-7
Page 7-8
SECTION 8 - AIR COMPRESSOR MAINTENANCE
Figure 8.1 Compressor

8.1
PUMP RANGES
These operating instructions concern the following dry running rotary vane compressors: Models DLT 6 to
DLT 40.
3
They have nominal capacities of 6, 10, 15, 25 and 40 m /hr 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 filtered
by a built-in micro-fine filter. Excess carbon dust from the carbon blades is also filtered on the exhaust side
by built-in filters. The compressor unit is encased in a rugged black plastic sound enclosure. The cooling
fan for the DLT is located inside the sound enclosure. On sizes 15, 25 and 40 with the larger motor the
compressed air is cooled by an aftercooler. Both the motor and compressor have a common shaft.
Pressure can be adjusted to the required levels, however, they are limited to 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 40C. For temperatures outside
this range please contact Hamworthy.
These dry running compressors are suitable for use with air of a relative humidity of 30 to 90%.
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 a minimum space of 30 cm in front of exhaust grid (G), suction grid (G1) and housing cover
(b) for servicing. The cooling air entries (E) and the cooling air exists (F) must have a minimum distance of
10cm from any obstruction. The discharged cooling air must not be re-circulated.
Page 8-1
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 fitting anti-vibration mounts. This range of compressors
are almost vibration free in operation.
8.5
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.
1.
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 (unless a special plug connection is fitted). Check the electrical
data of the motor for compatibility with your available 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.
It is recommended that motor starters should be used that are fitted with a 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.
Figure 8.2 Compressor Interior (1)
Page 8-2

8.6
INITIAL OPERATION (Figure 8.1)
1.
Initially switch the compressor on and off for a 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 a 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.
8.8
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 a 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 (e) 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
Page 8-3
if the cartridges are cleaned their separating efficiency deteriorates.

exchanging the cartridges every six months.
We would therefore recommend
Changing the filters:

Screw off exhaust grid (G). Remove screwed cover(s) and milled knob (m). Pull filter 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 6 25 have 6 blades whilst the DLT 40 has 7 blades. The blades have a low but
permanent wear factor.
DLT 6, DLT 10 and DLT 15: first check after 7,000 operating hours, thereafter every 1,000 operating hours.
DLT 25 and DLT 40: first check after 5,000 operating hours, thereafter every 1,000 operating hours.
Screw off exhaust grid (G). Screw off housing cover (b) from housing. Remove blades (d) for inspection. All
blades must have a minimum height (X):
Model
X (minimum height)
DLT6
20 mm
DLT 10
20 mm
DLT 15
24 mm
DLT 25
24 mm
DLT 40
35 mm
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 blades clean out the housing and the rotor slots with compressed air. Place the blades
with the radius outwards (Y) so that the bevel is in the direction of rotation (01) and corresponds with the
radius of the housing (Z).
Fix end cover (b) and exhaust grid (G). Before restarting the pump check free movement of the blades by
turning the motor cooling fan before refitting the cooling grid (G1).
Page 8-4
TROUBLE SHOOTING
1
Motor starter cuts out compressor
1.1
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 trip (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.
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.
2.4
Blades are damaged.
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 small.
Compressor operates at an abnormally high temperature:
4.1
Ambient or suction temperature too high.
4.2
Cooling air flow is restricted.
4.3
Problem as per 1.5 and 1.6.
Unit emits abnormal noise:
5.1
The compressor cylinder is worn.

Solution: send your complete unit off for repair to Hamworthy.
5.2
The regulating valve 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 6 DLT 40
Basic Parts
1
Housing
Rotor
Blade
Disc
Disc
Spring shim
Hexagon head screw
End cover
Threaded pin
10
Spring
11
Filter cartridge complete
12
Filter cartridge complete
13
Milled knob
22
Disc
Connection Cover
30
31
Connection cover
D
32
33
Sealing ring
Supporting Ring
Deep groove ball bearing
36
Rubber foot
37
Rubber foot
38
Hexhead screw
39
Rubber foot
40
Foot
41
Mounting
42
Lifting eye
Drive
45
Motor (3~)
46
Motor (1~)
47
Drive shaft (3~)
48
Drive shaft (1~)
49
50
Deep groove ball bearing

Condensor
Cooling
55
Fan
56
Fan hub
57
Tolerance ring
58
Air guiding plate
59
Disc
Page 8-7
Compressed air aftercooling (DLT-15-40)

60
Cooling segment
61
Pipe
62
Pipe
63
Fitting
Box
70
Lower part
71
Side part
72
Side part
73
Threaded pin
74
Upper part
75
Exhaust grid
76
Suction grid
77
Buffer
Labels
80
Data plate
Assembly parts
90
91
Connection nipple
D
92
93
Sealing ring
Screwed ring
Sealing ring
95
Pressure regulating valve
96
Screwed cover
97
Silencer
201-208
Screws
To order please indicate:

Model:
Serial Number:
Item Number:
Motor (kW, V, Hz)
KEY
V = Fast wearing parts
D = Seals
Page 8-8
SECTION 9 - MACERATOR MAINTENANCE

9.1
9.1.1
MACERATOR (COMMINUTOR)
General
The following items of routine maintenance and inspection must be carried out to ensure the correct
functioning of the unit on a day to day basis.
1.
Check all safety interlocks.
2.
At the end of each day run the machine under no load conditions to clear any residue. Wipe down all
external surfaces and leave the unit clean.
Preventative maintenance is more economical than remedial maintenance and accordingly it is

recommended that the unit is subjected to a regular service schedule carried out 3 times a year at
approximately four monthly periods.
9.1.2
Mechanical
1.
Check to ensure no leakage from the main seals.
2.
Check wear on cutter ring/impeller.
3.
Check impeller rotates freely with no vibration.
4.
Inspect and tighten nuts and bolts as necessary.
9.1.3
Electrical
1.
Check operating contactors functioning correctly.
2.
Check overload units operating and correctly set.
3.
Check all interlocks are operating correctly.
4.
Each end bracket motor is provided with a plugged drain hole. Periodically remove plugs and allow
any accumulated moisture to drain away. Replace plugs.
9.1.4
Macerator Jams And Cuts Out.
If the macerator jams and cuts out close down the system and isolate the electrical supply.
1.
To release a jammed impeller remove the red plate on the body of the unit (two screws) and using the
bar provided turn the release gear to free the impeller and cutter ring.
2.
Remove the cause of the obstruction. If necessary disconnect the canopy flange to obtain access to
the grinding compartment.
3.
Refit canopy flange and release gear cover plate.
4.
Close isolator switch and reinstate electrical supply.
Page 9-1
9.1.5
Use of Release Bar R197.
If the disposer jams and cuts out:

1.
Press stop button and isolate power supply.
2.
Release the impeller plate by means of the release bar.
3.
Remove the cause of the jam in the grinding chamber.
4.
Close isolator switch and restart machine.
9.2
MAINTENANCE INSTRUCTIONS
9.2.1
To Dismantle a 150 Pulveriser Ref. R1537.
Electrically isolate the machine from the mains supply and turn off the water supply where fitted.
1.
Disconnect the unit from the installation at the inlet canopy (11), at the outlet flange and motor bolts if
horizontally mounted.
2.
The unit may now be lifted away and placed in a convenient position for servicing or dismantling.
9.2.2
To Replace the Cutter Ring
From the non-drive end remove:

1.
The bolt assemblies (2, 3 and 4) which secure the canopy (11) to the pulveriser head (8).
2.
Canopy (11).
3.
Upper support ring (5).
4.
Cutter ring (6).
5.
Lower support ring (7).
Examine the cutter ring for signs of damage or wear and replace it if necessary. New support rings MUST
be fitted on assembly.
Page 9-2
9.3
REASSEMBLY
Fit the two new support rings (5 and 7) to the cutter ring (6) and lightly grease the outside diameters.
Replace:
1.
Cutter ring assembly in position ensuring that the support rings are properly seated.
2.
Canopy (11) and secure it to the pulveriser head with the bolt assemblies (2, 3 and 4).
3.
Check the concentricity of the cutter ring by rotating the impeller (18) by hand and check the gap
between the cutter ring and impeller. Should readjustment be necessary insert a screwdriver between
the cutter ring and impeller and ease the cutter ring over. Replace the unit.
9.4
TO REPLACE THE WATER SEAL
Canopy already removed.

Release the tab washer (21) by straightening or cutting through the tab. Unscrew and remove:
1.
Nose cone (22).
2.
Tab washer (21).
3.
O-rings (20).
Remove the two impeller plug screws and, using suitable bolts in the holes thus vacated, withdraw the
impeller (18). When available the Haigh Impeller Extractor Plate may be used for this purpose (further
details available on request). Whenever an extractor tool is used a thread protector MUST be placed over
the end of the shaft. In all probability at least one part of the seal will be withdrawn with the impeller.
Remove all the seal components from either the impeller or the pulveriser head and examine each
component carefully to ensure that they are not worn or damaged in any way. If any ONE component is
worn or damaged it is advisable to replace the WHOLE seal assembly.
Before attempting to fit a new seal assembly ensure that all seal components and housings are absolutely
clean and damage free. Great care must be exercised when handling O-rings as even a hair line scratch
may negate their use. Check O-ring (10) and replace if required before seal replacement.
9.5
REASSEMBLY
Replace the seal components in the seal cage on the impeller shank. Fit the impeller and seal over the drive
shaft and press it down until the impeller locates against the O-ring (10).
Replace:
1.
O-rings (20).
2.
Tab washer (21).
3.
Nose cone (22)
Fasten the nose cone down securely and lock it with the tab washer (21). Replace the impeller plug screws.
Refit the canopy and replace the unit.
Page 9-3
9.6
TO REPLACE THE DRIVE END BEARING AND SEALS
Refer to the previous test To Replace the Water Seal and then proceed as follows:
Remove:
1.
Bolts (12) with washers (13 and 14).
2.
Pulveriser head (8).
3.
Locking set screws (16) from the shank of the release gear (15).
4.
Shaft keys (24).
5.
Shaft sealing O-ring (10) and withdraw the release gear (15) from the shaft (39).
6.
Counter sunk screws (36) from the bearing housing (23) and, using the same screws in the tapped
holes provided, jack out the bearing housing together with:
a.
b.
Outer race of the roller bearing (33)

Top shaft seal (34)
7.
The inner race of the roller bearing from the shaft together with the upper spacing piece (38).
8.
Nuts and washers (31 and 32) which secure the drive end adaptor place (37) to the motor (29) and
with a soft mallet tap the end of the shaft until the adaptor place is free.
a.
b.
From the adaptor plate remove the lower shaft seal (34).
From the bearing place remove:
1.
2.
The outer race of the roller bearing by utilising the punch holes provided.
Top shaft seal (34).
The whole unit is now dismantled, examine each component for any signs of damage or wear and replace
them as necessary. After stripping always fit NEW shaft seals. Ensure that all components are absolutely
clean before commencing assembly.
9.7
REASSEMBLY
1.
Fit a new lower shaft seal to the adaptor plate.
2.
Fit a new top shaft seal to the bearing housing.
3.
Fit the outer race of roller bearing (33) to the bearing housing.
Replace:
1.
Adaptor place (37) to motor (29) and secure with nuts and washers (31 and 32).
2.
Inner race of roller bearing (33) and pack with grease. (Recommended lubricant Shell Alvania R.A.
grease).
3.
Bearing housing (complete with top shaft seal and outer bearing race). Secure with countersunk
screws (36).
4.
Upper spacing piece (38).
5.
Release gear (15) and secure in position with locking set screws (16) ensuring that they are correctly
located in the dimples provided in the shaft.
Page 9-4
6.
O-ring (10). (Fit new one if required).
7.
Shaft keys (24).
8.
Pulveriser head (8) and secure with bolts and washers (12, 13 and 14).
Refer to previous texts to refit other assemblies and replace the unit.
Ensure that adequate grease has been pre-packed in reservoir around the bearing (33) before the unit is put
back into service.
Page 9-5
Figure 9.1 General Assembly 150 HVL Pulveriser (DD) R1537
Page 9-6
Table 9.1 List Of Parts General Assembly 150 HVL Pulveriser (DD)
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
DESCRIPTION
O-ring
Bolt
Spring washer
Plain washer
Upper cutter support ring
Cutter ring
Lower cutter support ring
Pulveriser head
Water seal assembly
O-ring
Canopy
Bolt
Spring washer
Plain washer
Release gear
Socket set screw
Plug
Impeller assembly
Shaft sealing plug
O-ring
Tab washer
Nose cone
Bearing housing
Key
Set screw
Aperture cover
Filtramatic Identification plate
Drive screw
Motor sub-assembly
Stud
Nut
Spring washer
Roller bearing
Shaft seal
Lower spacing piece
Countersunk screw
Adaptor plate
Top spacing piece
Shaft extension
QTY
1
6
6
6
1
1
1
1
1
1
1
3
3
3
1
2
1
1
1
2
1
1
1
2
4
2
1
4
1
4
4
4
1
2
1
4
1
1
1
Page 9-7
Figure 9.2 Water Seal, Drawing R1361
Page 9-8
Figure 9.3 Spare Parts for BCP Motors
Table 9.2 List Of Parts for BCP Motor BS Metric Fan Cooled Motor, Cage D Range, R1306
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Endshield, D.E.
Grease Nipple
Grease Relief Screw
Endshield Securing Bolt
Preloading Washer
Bearing, D.E.
False Bearing Shoulder (where fitted)
Flume, D.E. and N.D.E
Rotor on Shaft (state polarity)
Drain Plug
Yoke with or without feet
Eyebolt
Fixed Bearing Cup
Bearing N.D.E.
Seeger Circlip
Endshield, N.D.E
Cap Securing Screw
Fan & Fixing Pin
Fan Cover
Lubricator Extension
Terminal Box Cover & Fixing Screws
Terminal Box Cover Gasket
Terminal Board & Fixing Screws
Terminal Box
Terminal Box Gasket
Raceway Cover Plate & fixing Screws
Raceway Cover Plate Gasket
D Flange Endshield, D.E. & fixing studs
C Flange Endshield, D.E.
Page 9-9
Page 9-10

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Hamworthy

HAMWORTHY KSE LIMITED

Changes in comparison with previous issue

Before handling sodium hypochlorite refer to instructions in Section 4.

The equipment should not be installed in an explosive atmosphere.

Spare Parts and Service

+44 (0)1202 662663

or via any of our overseas companies or offices

Hamworthy Canada Ltd.,

Hamworthy KSE A/S,

Hamworthy KSE Shanghai Representative Office,

Hamworthy KSE PTE Ltd,

C/O Aqua Tech,

Hamworthy Engineering Africa (Pty)

Hamworthy KSE BV,

Hamworthy KSE Inc.,

Hamworthy KSE Pvt Ltd

Hamworthy KSE Korea Ltd.

1418 Edwards Avenue

Hamworthy Agents Worldwide

Ali & Sons Co.

International Marine Center

Trans-Oceanic Trading Est.

Caba (Aust.) Pty. Ltd.

Alpha Marine Engineering Ltd. Qatar

Al Ahed Trading &

Aries Industrial Y Naval S.A.

Bangladesh Marinetec Ltd.

Dawcul Ltd. Cherni Vrah Bul,

22/1 Via Del Lazzaretto

Venezuela Oficini Maritima PI. C.A.

Lanz Y Cia Ltda

B. Sofer & Co. Ltd.

Consul Naval Ltda

The Trading & Industrial

Berendsen PMC A/S,

Thos. C. Smith & Co. Ltd.

Sertemar Ltd. El Oro 1303 Y

Caba (New Zealand) Ltd

Edif Torre La Previsora

Machines have failed as a direct result of using non-original spare parts.

SECTION 1 - TECHNICAL DATA

SECTION 1 - TECHNICAL DATA

380 - 440V, 3 phase, 50/60 Hz

Discharge Pump Motor Ratings

Belt driven B50 x 50HB

Compressor Motor Ratings

Macerator Motor Rating

Discharge Pump Duty

B50 x 50HC - Low head

B50 x 50HB - High head

10 m /hr at 26m head

0.5 bar - 15 m /hr

0.55 bar - 22 m /hr

0.5 bar - 27 m /hr

0.5 bar - 41 m /hr

High Level Alarm

Volt free normally closed 500W

Vent System Back Pressure

15mm w.g. (max.)

SECTION 1 - TECHNICAL DATA

Designed Hydraulic Flow m /day