9.sewage Treatment Plant

HAMWORTHY WATER
SYSTEMS LTD
STC03-13 Super Trident
Sewage Treatment Unit
GO98559HullS AD0039
FINAL DRAWINGS
HAMWORTHY WATER SYSTEMS LTD

Fleets Corner, Poole, Dorset BH17 0JT, United Kingdom
Tel: +44(0)1202 662600
Fax: +44(0)1202 665444 (Spares & Service)
Fax: +44(0)1202 668793 (Sales)
www.hamworthy.com
Offices, Associate Companies and Agents throughout the world
98559 Final ISS1 04/6

Installation, Commissioning,
SEWAGE TREATMENT PLANT Operating and Maintenance

Manual
Document ID PCH 1602 STC03-13 1P1C
STP Type STC03-13 with 1 Pump 1 Compressor
Issue No. Issue 4 September 2015
IMO Ref: Approved to MEPC 227 (64)
Project
Installation, Commissioning, Operating and Maintenance
Amendment Record
Issue No. ECN No. Description of Change

Chlorination dosing pump was model CONC1601PVT but replaced with
3 N062000
CNPb1601PVT
Suction lances changed from Prominent to Grundfos due to issues with
4 N062113
NC/NO contacts
PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual
Safety and Warnings

The Manufacturer is not responsible for damage if you do not follow all of this documentation.
Warning Instruction markings
WARNING
Warning means there is a risk of personal injury.
WARNING-ELECTRICITY
Electricity warning means there is a risk of personal injury due to electric shocks.
CAUTION
Caution means there is a risk of damaging equipment.
NOTE
Note contains important information or requirements.
DANGER
Danger means immediately imminent danger, death or severe bodily injury.
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.
NOTE
Health and safety act compliance: before operating the equipment, ship’s staff
must be made aware, and ensure compliance with, the health and safety
regulations appropriate to this class of work.
2 Ensure people working with raw sewage are appropriately vaccinated and
wearing/using the correct and appropriate PPE for handling and working with raw
sewage.
3 Work must only be carried out by suitably qualified and competent persons.
4 Before lifting, installing and operating the unit, the instructions detailed below, and also
the accompanying manual must be read.
PCH 1602 STC03-13 1P1C i

5 Ensure that all equipment used for lifting the unit is adequate for the weight.
6 The handling points are situated on top of the tank in all four corners and these must be
used. The hooks of slings must not be fitted directly to lifting eyebolts, lugs & shackles
must be used. For information on correct lifting requirements refer to the general
arrangement drawing or the lifting label on the side of the sewage treatment plant.
7 Before running the unit for the first time, the installation must be thoroughly checked,
taking account of the procedures detailed in this manual Section 4 “Commissioning and
Operation” on page 4–1.
8 The unit must not be run unless all protective guards supplied with the equipment
are in position.
9 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.
DANGER
During a prolonged STP power failure, shut down or loss of aeration for a period
greater than 6 hours, there is a potential for build-up of Hydrogen Sulphide
(H2S), Methane (CH4) or Ammonia (NH3) gas in the tank, the compartment in
which the sewage plant is housed & the vent system. Ensure safety procedures
for hazardous gases or oxygen depletion are carried out before opening the
tanks for maintenance, inspection or during a prolonged period of power failure
or shut down. Care is to be taken when opening the sewage treatment plant tank
compartments or dismantling the vent pipework for maintenance or
refurbishments in case these gases are present. Ensure the inside of the STP, all
pipework and the compartment within which the STP is housed, is certified gas
free prior to commencement of works or entry into the compartment. Ensure
correct PPE is worn, safe working practices are followed and a risk assessment
carried out by ships staff before commencement of any maintenance
procedures on the tank or vent system.
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 in the event of an emergency.
12 Before handling sodium hypochlorite and sodium bisulphite refer to the safety data
sheets in Section 9.1.2 and 9.1.3.
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.
15 Attention is drawn to the following publications:
a “Sewage systems on ships: associated hazards, installation and maintenance”,

Marine Guidance Note MGN 33 (M+F), Marine Safety Agency, UK, August 1997.
b “Working with sewage: The health hazards - A guide for employers”, C13 IND(G)198L
2/96, Health and Safety Executive, UK, February 1996.
ii PCH 1602 STC03-13 1P1C

Table of Contents
Safety and Warnings..............................................................................................................................................i

List of Tables .......................................................................................................................................................vii
List of Figures.......................................................................................................................................................ix
Spare Parts and Service ......................................................................................................................................xi
Wärtsilä Agents and Offices ..............................................................................................................................xii
1. Technical Data ..............................................................................................................................................1–1

1.1. General Technical Data ............................................................................................................................1–1
1.1.1. Sewage Loading Data........................................................................................................................1–1
1.1.2. Sewage Peak Loading Considerations..............................................................................................1–1
1.1.3. Electrical Power Supply .....................................................................................................................1–1
1.1.4. Discharge Pump Ratings ...................................................................................................................1–2
1.1.5. Compressor Electrical Ratings and Duties ........................................................................................1–2
1.1.6. Sewage System Alarm.......................................................................................................................1–2
1.1.7. Vent System Back Pressure ..............................................................................................................1–2
1.1.8. Temperature and Humidity Data........................................................................................................1–2
1.1.9. Requirement for Shipboard Cleaning Chemicals ..............................................................................1–2
1.2. Record of Commissioning Data ...............................................................................................................1–3
2. Introduction ...................................................................................................................................................2–1
2.1. General .....................................................................................................................................................2–1
2.1.1. STC Definition....................................................................................................................................2–1
2.1.2. Nomenclature ....................................................................................................................................2–1
2.2. General Description of STC Unit ..............................................................................................................2–1
2.3. Detailed Description of STC Unit .............................................................................................................2–2
2.3.1. General ..............................................................................................................................................2–2
2.3.2. Aeration Tank.....................................................................................................................................2–3
2.3.3. Settlement Tank.................................................................................................................................2–4
2.3.4. Chlorine Contact Tank (Chlorination).................................................................................................2–4
2.3.5. Chlorination and De-chlorination Dosing Units .................................................................................2–4
2.3.6. Discharge Pump ...............................................................................................................................2–5
2.3.7. Compressor .......................................................................................................................................2–5
2.3.8. Control Philosophy ...........................................................................................................................2–5
2.4. STC System Interface Configurations ......................................................................................................2–6
3. Installation ....................................................................................................................................................3–1
3.1. General Data ............................................................................................................................................3–1
3.1.1. Lifting Operations ..............................................................................................................................3–1
3.1.2. Unit Weights and C of G....................................................................................................................3–3
3.1.3. Installation Position............................................................................................................................3–4
3.2. Further Installation Details .......................................................................................................................3–5
3.2.1. Typical Plant Installation Instructions T0406037A.............................................................................3–5
3.2.2. Vent System Design Recommendations R63262............................................................................3–14
3.2.3. Peak Loading Considerations R63261 ............................................................................................3–16
3.2.4. Grey Water Streams R62742 ...........................................................................................................3–18
3.3. Fitting Instructions for Items Packed Separately for Safe Transit..........................................................3–19
3.4. Compartment Ventilation .......................................................................................................................3–19
3.5. Space for Maintenance ..........................................................................................................................3–19
4. Commissioning and Operation ....................................................................................................................4–1

4.1. Start Up Procedures.................................................................................................................................4–1
PCH 1602 STC03-13 1P1C iii

4.1.1. General...............................................................................................................................................4–1
4.1.2. Health and Safety Information ...........................................................................................................4–1
4.1.3. Preparation of Unit for Initial Operation .............................................................................................4–2
4.1.4. Setting up Chlorination Dosing Pump ...............................................................................................4–4
4.1.5. Setting up De-chlorination Dosing Pump ..........................................................................................4–5
4.1.6. Setting up Discharge Pump Outlet Gauge Pressure .........................................................................4–7
4.1.7. Dilution Water Requirement for Vacuum Collected Sewage .............................................................4–8
4.2. Process start up Procedures....................................................................................................................4–9
4.3. Schedule of Routine Procedures............................................................................................................4–10
4.3.1. Daily .................................................................................................................................................4–10
4.3.2. Every Three Days .............................................................................................................................4–10
4.3.3. Weekly .............................................................................................................................................4–10
4.3.4. Monthly ............................................................................................................................................4–10
4.3.5. Every 3 months ................................................................................................................................4–10
4.3.6. Daily Log Sheet................................................................................................................................4–11
4.4. Methods for Routine Procedures ...........................................................................................................4–12
4.4.1. De-sludge Operation .......................................................................................................................4–12
4.5. Sampling and Analysis ...........................................................................................................................4–14
4.5.1. STC unit Sampling Points ................................................................................................................4–14
4.5.2. STC unit Routine Analysis ..............................................................................................................4–14
4.6. Unit Shut Down Procedure.....................................................................................................................4–15
4.6.1. General.............................................................................................................................................4–15
4.6.2. Unit shut down for a short period without emptying (Up to 6 Hours)..............................................4–15
4.6.3. Unit shut down for a long period ....................................................................................................4–15
5. Maintenance and Trouble Shooting ............................................................................................................5–1

5.1. Maintenance Schedule ............................................................................................................................5–2
5.1.1. Monthly ..............................................................................................................................................5–2
5.1.2. 3 Monthly ...........................................................................................................................................5–2
5.1.3. Annually .............................................................................................................................................5–2
5.2. Trouble Shooting .....................................................................................................................................5–4
5.3. Specific Maintenance Procedures ...........................................................................................................5–5
5.3.1. Cleaning the Dosing Pump Injectors .................................................................................................5–5
5.3.2. Air Diffuser Assemblies Replacement Procedures ............................................................................5–5
5.3.3. Discharge Pump Maintenance Procedures .......................................................................................5–6
5.3.4. Compressor Maintenance Procedures ..............................................................................................5–6
5.3.5. Removing Dosing Skid ......................................................................................................................5–6
5.3.6. Removing Control Panel ....................................................................................................................5–7
5.3.7. Removing Ruptured Chemical Tank ..................................................................................................5–8
5.3.8. Dosing Pump Head Exploded View for Spares Items .......................................................................5–9
5.4. Recommended Spares List ...................................................................................................................5–11
6. Discharge Pump B50x50HC .........................................................................................................................6–1

6.1. Technical Data..........................................................................................................................................6–2
6.1.1. Standard Discharge Pump Performance ...........................................................................................6–2
6.1.2. Recommended Tightening Torque — Discharge Pump....................................................................6–2
6.1.3. Discharge Pump Motor Speed ..........................................................................................................6–2
6.1.4. General Dimensions...........................................................................................................................6–2
6.1.5. Rotation .............................................................................................................................................6–2
6.1.6. Bearing Lubrication............................................................................................................................6–2
6.1.7. Discharge Pump Weight ....................................................................................................................6–3
6.2. Description ...............................................................................................................................................6–4
6.2.1. General...............................................................................................................................................6–4
6.2.2. Pump Inner Cover ..............................................................................................................................6–4
6.2.3. Pump Casing .....................................................................................................................................6–4
6.2.4. Mechanical Seal.................................................................................................................................6–4
6.2.5. Impeller ..............................................................................................................................................6–4
iv PCH 1602 STC03-13 1P1C

6.3. Installation ................................................................................................................................................6–5

6.3.1. Storage ..............................................................................................................................................6–5
6.3.2. Installation Data – Pump Weight And Dimensions ............................................................................6–5
6.3.3. Installation Procedure ........................................................................................................................6–5
6.4. Operation..................................................................................................................................................6–8
6.4.1. Checks Before Running For The First Time.......................................................................................6–9
6.4.2. Priming...............................................................................................................................................6–9
6.4.3. Starting The Pump.............................................................................................................................6–9
6.4.4. Regulating Flow From Pump – Pumped Media Without Solids ......................................................6–10
6.4.5. Stopping The Pump.........................................................................................................................6–10
6.5. Maintenance...........................................................................................................................................6–11
6.5.1. General ...........................................................................................................................................6–12
6.5.2. Lubrication .......................................................................................................................................6–12
6.5.3. Preparation For Dismantling The Pump...........................................................................................6–12
6.5.4. DISMANTLING PUMP ....................................................................................................................6–13
6.5.5. Inspection ........................................................................................................................................6–13
6.5.6. Assembling Pump............................................................................................................................6–14
6.6. Drawings ................................................................................................................................................6–18
6.6.1. List Of Drawings — Discharge Pump Drawing List .........................................................................6–18
7. Compressor (Type CYBW-25) ......................................................................................................................7–1

7.1. General .....................................................................................................................................................7–1
7.1.1. Applications .......................................................................................................................................7–1
7.1.2. Model Number Description................................................................................................................7–1
7.2. Main performance index ..........................................................................................................................7–1
7.2.1. Table of Main Compressor Performance Parameters (Table 7–1 on page 7–5)................................7–1
7.2.2. Performance Curve (Fig 7–1 on page 7–6) ........................................................................................7–1
7.3. General Introduction (With General Arrangement Drawing Enclosed) .....................................................7–2
7.3.1. Assembling and Disassembling of Compressor Model CYBW-25....................................................7–2
7.4. Installation and start-up ...........................................................................................................................7–4
7.5. Operation and maintenance .....................................................................................................................7–5
7.6. Storage and handling ...............................................................................................................................7–5
7.7. Operating Instructions for the Compressor Motor ...................................................................................7–7
7.7.1. General ..............................................................................................................................................7–7
7.7.2. Preparations Before Installing the Compressor Motor ......................................................................7–7
7.7.3. Compressor Motor Installation ..........................................................................................................7–7
7.7.4. Test Run of the Compressor Motor ...................................................................................................7–7
7.7.5. Maintenance, Overhaul and Storage .................................................................................................7–8
7.7.6. Drying the Compressor Motor ...........................................................................................................7–9
7.7.7. Troubleshooting Compressor Motor Faults.......................................................................................7–9
8. Key Components...........................................................................................................................................8–1
8.1. Chlorination Dosing Pump .......................................................................................................................8–1
8.2. De-chlorination Dosing Pump ................................................................................................................8–34
8.3. De-chlorination Dosing Rate Against Discharge Pump Pressure ..........................................................8–56
8.4. Dosing Pumps – Suction Lines ..............................................................................................................8–57
9. Documents and Drawings............................................................................................................................9–1

9.1. Health and Safety .....................................................................................................................................9–1
9.1.1. DPD No. 4 Tablets .............................................................................................................................9–1
9.1.2. Sodium Bisulphite (De-chlorination): Document SDS S011 ..............................................................9–2
9.1.3. Sodium Hypochlorite (Chlorination): Document SDS S024.............................................................9–12
9.2. General Arrangement and P&I Drawings................................................................................................9–29
9.3. Sectional Arrangements .........................................................................................................................9–33
9.4. Electrical Drawings.................................................................................................................................9–42
PCH 1602 STC03-13 1P1C v

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vi PCH 1602 STC03-13 1P1C

List of Tables
Table 1–1 Sewage Loading Table ...................................................................................................................1–1

Table 1–2 Discharge Pump Ratings................................................................................................................1–2
Table 1–3 Compressor Electrical Ratings and Duties (50/60Hz) ....................................................................1–2
Table 1–4 Record of Commissioning Data .....................................................................................................1–3
Table 2–1 Compressor Types and Manuals for each Sewage Plant Type .....................................................2–5
Table 3–1 Minimum Apex Height for 4 Point Pyramid Lift ..............................................................................3–2
Table 3–2 Minimum Chain Leg Ratings ..........................................................................................................3–2
Table 3–3 Plant Weights and Centres of Gravity ............................................................................................3–4
Table 4–1 Chlorination Dosing Requirement (Over 10 Minute Period) ...........................................................4–4
Table 4–2 Chlorination Dosing Pump Settings ...............................................................................................4–4
Table 4–3 De-chlorination Dosing Requirement .............................................................................................4–6
Table 4–4 De-chlorination Dosing Pump Settings ..........................................................................................4–6
Table 4–5 Alternate De-chlorination Dosing Pump Settings for Different Pump
Delivery Pressures – Medium Head Pump .....................................................................................4–7
Delivery Pressures – High Head Pump...........................................................................................4–7
Table 4–7 Maximum Dilution Water Dosing Rates..........................................................................................4–9
Table 4–8 Estimated De-sludge Volume from Each De-sludge Operation ...................................................4–13
Table 5–1 STC Trouble Shooting Guide .........................................................................................................5–4
Table 5–2 Recommended List of Spares ......................................................................................................5–12
Table 6–1 Standard Discharge Pump Performance........................................................................................6–2
Table 6–2 Recommended Tightening Torque — Discharge Pump ................................................................6–2
Table 6–3 Discharge Pump Motor Speed .......................................................................................................6–2
Table 6–4 Discharge Pump Weight.................................................................................................................6–3
Table 6–5 Discharge Pump Maintenance Schedule .....................................................................................6–16
Table 6–6 Discharge Pump Fault Finding Chart ...........................................................................................6–17
Table 6–7 List Of Drawings — Discharge Pump...........................................................................................6–18
Table 6–8 Items List for B50x50HC 2-Pole Sewage Pump Drawing D8103, Issue 1 ...................................6–20
Table 7–1 Table of Main Compressor Performance Parameters ....................................................................7–5
Table 7–2 Troubleshooting Compressor Motor Faults ...................................................................................7–9
Table 9–1 Product DPD No.4 Tablets .............................................................................................................9–1
Table 9–2 General Arrangement and P&I Drawings......................................................................................9–29
Table 9–3 Sectional Arrangements ...............................................................................................................9–33
Table 9–4 Circuit Diagram.............................................................................................................................9–42
Table 9–5 Installation Wiring Diagram...........................................................................................................9–42
PCH 1602 STC03-13 1P1C vii

viii PCH 1602 STC03-13 1P1C

List of Figures
Fig 2–1 Typical 3D Cut-Away drawing of the Sewage Treatment Plant (STCXX-00036).................................2–2
Fig 2–2 Generic process diagram of the sewage treatment plant (STCXX-00006)..........................................2–3
Fig 3–1 Typical 4 Point Pyramid Lift Set Up.....................................................................................................3–2
Fig 3–2 Lifting Angle & Apex height Restrictions .............................................................................................3–3
Fig 3–3 Centre of Gravity Datum......................................................................................................................3–3
Fig 4–1 Chlorination Dosing Pump Control......................................................................................................4–5
Fig 4–2 De-chlorination Dosing Pump Control.................................................................................................4–6
Fig 4–3 De-chlorination Dosing Pump Alternate Settings for Different Discharge Pressures..........................4–8
Fig 5–1 Chlorination Dosing Pump Liquid End Spares – CNPb1602PVT (STC03-13).....................................5–9
Fig 5–2 De-chlorination Dosing Pump Liquid End Spares – CONC0806PP2 ................................................5–10
Fig 6–1 Discharge Pump Impeller Shimming .................................................................................................6–15
Fig 7–1 Compressor Performance Curve — CYBW-25 ...................................................................................7–6
Fig 7–2 CYBW-25 Compressor General Arrangement Drawing ....................................................................7–10
Fig 8–1 Chlorination and De-chlorination Pump Suction Line .......................................................................8–57
PCH 1602 STC03-13 1P1C ix

x PCH 1602 STC03-13 1P1C

Installation, Operating and Maintenance Manual
Spare Parts and Service

Spare Parts can be ordered direct from the following address:
Wartsila Water Systems Ltd. Telephone: +44 (0)1202 662600

Fleets Corner
Poole, Dorset Facsimile: +44 (0)1202 665444
BH17 0JT Email: pse@wartsila.com
England
or via any Wärtsilä office or agency throughout the world, listed below.
NOTE
When ordering spare parts, remember to always provide the Type and serial
number of the machine, the item number and full description of the part required.
This will ensure the correct spare part is supplied.
CAUTION
Only approved or original Wartsila Water Systems Ltd spare parts should be
used when maintaining this equipment. Failure to comply with this could result in
any warranty package supplied with this unit being rendered void, irreversible
damage to the unit and/or serious injury to the operator.
When ordering spare parts, the following information is required to ensure that correct parts
are supplied:
Type and serial number of machine: Obtained from machine nameplate

Item Number and full description of part required: Obtained from details in this publication
Technical Service and Advice:

Technical service and advice can be obtained during normal working hours from the above
address on the contact numbers shown, or via email pooleservice@Wartsila.com, or via any
Wartsila office or agency throughout the world, listed below. Outside normal working hours a
24 hour emergency facility is available. Initial telephone contact number is:
+44 (0) 1202 662600.
NOTE
When requesting technical advice or making a warranty claim, remember to
always provide the type and serial number of the machine, the year of
manufacture and full description of the equipment.
PCH 1602 STC03-13 1P1C xi

Installation, Operating and Maintenance
Wärtsilä Agents and Offices
Wärtsilä Netherlands B.V.

Havenstraat 21, 3115 HC Schiedam, The Netherlands
Contact: Sjoerd Boersma
Benelux
Tel: +31 10 42 77 100
Fax: +31 10 426 4571
Email: partsales.benelux@wartsila.com
Tridente Brasil
Rua da Assembléia, 10 Gr. 3302, Centro, Rio de Janeiro, Brasil
Contact: Mr J A Gomes
Brazil Tel: + 55 21 2233 1489
Fax: + 55 21 2516 7543
Mobile: + 55 21 9983 3190
Email: Info@Tridente.Com.Br
Marine & Offshore Canada
9 Keefer Road, St. Catharines, ON L2M 7N9, Canada
Contact: Mr Roger McNeill
Canada Tel: + 1 905 688 4922
Fax: + 1 905 688 9028
Mobile: + 1 905 933 6985
Email: service@marineandoffshore.com
Wärtsilä Shanghai Service.
Building 11, No.170 Jin Feng Road, Pudong
China New District, Shanghai 201201, P.R.China
Tel: +86 21 5858 5500
Fax: +86 21 5858 9331
Wärtsilä China Ltd - Dalian Branch
Office 606 Building B. Dalian International
Ocean Building, No.11 Yu Guang Street,
China Zhongshan District, Dalian,
Liaoning Province 116001 P.R. China
Tel: +86 411 8230 9819
Fax: +86 411 8230 9829
Wärtsilä China Ltd - Guangzhou Branch
Room 910, Fuying Building, No. 166
Changgand Rd, Haizhu district,
China
510250 Guangzhou, P.R. China
Tel: +86 20 8435 1719
Fax: +86 20 8435 1695
xii PCH 1602 STC03-13 1P1C

Soritecna Srl
Via Cassa Di Risparmio 6 34121 Trieste, Italy
Contact: Ms Annamaria Zangrilli
Italy Tel: + 39 040 365508
Fax: + 39 040 368982
Mobile: + 39 335 693 3399
Email: Info@Soritecna.It
Wärtsilä Korea Ltd
15-36, Gangbyeon-daero 456 beon-gil
Sasang-gu, Busan
Korea South Korea
Tel: +82 51 329 0500
Fax: +82 51 324 4349
E-mail: weksales@wartsila.com
Wärtsilä Finland Oy
Ship Power & Services Office Helsinki
John Stenbergin ranta 2 P.O.Box 196,
Finland FI-00531 Helsinki, Finland
Tel: +358 10 709 0000
Fax: +358 10 709 5722 (Ship Power)
Fax: +358 10 709 5700 (Services)
Wilhelm Rump Kg
Witternstrasse 20, 21107 Hamburg, Germany
Contact: Mr. Hubertus Rump
Germany Tel: + 49 40 317 8420
Fax: + 49 40 319 4841
Mobile: + 49 17 174 51599
Email: Info@Rump-Kg.De
Wärtsilä Serck Como GmbH
Pankower Str. 16-18, 21502 Geesthacht,
Germany
Germany Tel: +49 4152 805-0
Fax: +49 4152 805-105
E-mail: wsc.aftersales@wartsila.com
E-mail: wsc.sales@wartsila.com
Marine & Industrial Systems Ltd
4-6 Efplias Street, Gr 185 37, Piraeus Greece,
Contact: Mr Angelo Macris
Greece Tel: + 30 210 428 2826
Fax: + 30 210 418 3627
Mobile: + 30 694 483 0087
Email: Am@Misltd.Gr
PCH 1602 STC03-13 1P1C xiii

Olio Resources Sdn. Bhd.

Level 3A, Work @ Clearwater, Off Jalan Semantan,
Changkat Semantan, Damansara Heights, 50490 Kuala Lumpur
Malaysia Contact: Halim Zainal Abidin
Tel +603 2095 1800
Fax +603 2095 2800
Email: operations@olio.com.my
Wärtsilä Moss AS
Værftsgata 13
PO Box 1053, 1510 Moss, Norway
Norway
Tel: +47 69 27 99 00
Fax: +47 69 25 45 78
E-mail: moss@hamworthy.com
Wärtsilä Pumps Pte Ltd
15 Benoi Crescent, 629978 Singapore,
Singapore
Singapore
Tel: +65 6261 6066
Fax: +65 6261 6011
Email: sgpumpssales@wartsila.com
Wärtsilä Sweden AB
Services Office Gothenburg
Götaverksgatan 10, P.O.Box 8006
Sweden
402 77 Gothenburg, Sweden
Tel: +46 31 744 4600
Fax: +46 31 744 4670
Wärtsilä Hamworthy Middle East FZE
P.O. Box 120691, W/H P6-86, SAIF Zone,
Sharjah, United Arab Emirates
UAE
Tel: +971 655 74806
Fax: +971 655 74807
Email: whme@wartsila.com
Wärtsilä Water Systems Ltd
Fleets Corner, Poole Dorset BH17 0JT,
United Kingdom
UK Tel: +44 1202 662600
Fax: +44 1202 668793
Email: wastewater@wartsila.com
Email: poolespares.enquiries@wartsila.com
Wärtsilä North America, Inc.
Branch Office Ft. Lauderdale
2900 SW 42nd Street, FL 33312
USA Ft. Lauderdale, USA
Contact: Gysette Medina
Tel: +1 954 327 4700
Fax: +1 954 327 4773
xiv PCH 1602 STC03-13 1P1C

Koastal Industries Pte . Ltd.

Ho Chi Minh City Liason Office 18 Truong Son, Tan Bnh District, Ho Chi Minh City,
Vietnam
Contact: Mr Ting Teck Jin
Vietnam
Tel: + 84‐8‐8488990
Fax: + 84‐8‐8488991
Mobile: + 84-903-811588
Email: Tingtj@Koastal.Com
PCH 1602 STC03-13 1P1C xv

xvi PCH 1602 STC03-13 1P1C

Wartsila Ref:
TECHNICAL DATA SHEET – SEWAGE TREATMENT PLANT

SELECTION CRITERIA
No. of People : 30
Waste streams being treated : Black water and Gray water
Volume of black water to be treated : 15 Litres/person/day BOD load: 35 g/person/day
Volume of gray water to be treated 135 Litres/person/day BOD load: 65 g/person/day
Collection System : Black water Vacuum , Gray water Gravity
Effluent Quality : IMO MARPOL Annex IV tested to MEPC.227(64)
SEWAGE TREATMENT PLANT SELECTION / DATA

Model : STC03-13
Process : Biological / Activated Sludge
Certified Flow : 4,660 Litres/day
Certified BOD Load : 3.0 Kg/day
Certified Peak Flow : 5.10 Litres/minute
CONSTRUCTION
Tank : Welded mild steel
Flange standard : BS 4504/DIN ND 16
Internal Paint System : Two component ,high build epoxy..
External Paint System : Wartsila standard enamel. International Interlac 665
Final Colour : RAL6021
Connection Sizes : Gray water Inlet – 150mm; Hospital Inlet – 100mm;Vaccum Inlets-65 mm ,
Vent – 80mm; Overflow – 50mm; Pump Discharge – 50mm; Filling/Cleaning –
50mm ,Emergency air connection.
ELECTRICAL SUPPLY : 440 volts, 3 phase, 60 Hz.
DISCHARGE PUMP
Quantity : One
Type : B50x50HC Centrifugal, open blade impeller for solids handling
Material : Cast iron casing (plastic coated); bronze impeller
Capacity : 8m³/hr @ 18m total head
Motor : 4.4kW, IP55, class F insulation, IEC frame
AERATION BLOWER
Quantity : One
Type : Rotary Vane
Capacity : 15m³/hr @ 0.5 bar
Motor : 0.65kW, IP54, class F insulation, IEC frame
CHLORINATION DOSING PUMP

Quantity : One
Type / Container : Solenoid diaphragm / 10 litre HDPE
DE-CHLORINATION DOSING PUMP

Quantity : One
Type / Container : Solenoid diaphragm / 10 litre HDPE
CONTROL PANEL
Enclosure : IP55 steel, stove enamel painted grey (RAL7035), door interlocked isolator
Control Circuit Transformer : 220/24vac
Lamps : Power available (white), blower running, pump running (green), Common
Alarm, Dosing Tank low level alarm (red)
Volt free contacts (for remote monitoring) : Blower running, pump running, System Healthy
Monitoring of remote volt free contacts : Emergency stop
Cable glands for yard power/alarm cables : Yes ,provide that shipyard advise size and number in return comments
INSTRUMENTATION / FITTINGS
1 x Blower air pressure gauge, liquid filled, stainless steel case, kPa/bar/kg/cm²triple scale
1 x 3 level float switch for discharge pump control. ABS floats, polyester terminal box
1x Air flow meter for calibration of Returned Activated Sludge
Loose Supply
1x Efficient quality lest kit for residual chorine and measuring cylinder for suspended solids
1X Set of mating flanges
1x Grease Trap
1 x Emergency air reduce valve
CERTIFICATES
Works Test Certificate
IMO & MED Type Approval. USCG accept IMO type approved plant for non-US flag vessels in US waters.
Installation, Commissioning, Operating and Maintenance Manual 1. Technical Data
1. Technical Data
NOTE
Wärtsilä reserve the right to update the Technical data in Section 1 of this
instruction manual at our sole discretion. Thus, such information may be
changed or updated without prior notice.
1.1 General Technical Data

1.1.1 Sewage Loading Data
Table 1–1 Sewage Loading Table
Organic Loading Rate Hydraulic Loading Rate

Sewage Plant Type BOD(5) (kg/24hrs) (lit/24hrs)
[Notes 1 to 3] [Notes 1 to 3]
STC03-13 3.000 4,660
Notes
[1] All waste & process flows, e.g. conditioning water, added to the aeration compartment, must be
considered. Also see Section 3.2.1, 3.2.3 and 3.2.4 for more information on other waste flows and
their limitations.
[2] Wastes containing any substance in a concentration which will inhibit or kill bacteria or other micro-
organisms must not be allowed to enter the Aeration compartment of the unit.
[3] Wastes containing any substance in a concentration that will attack the tank internals must not be
allowed to enter any compartment of the unit.
1.1.2 Sewage Peak Loading Considerations

See Section 3.2.3 “Peak Loading Considerations R63261” on page 3–16 for more information.
1.1.3 Electrical Power Supply

See relevant Circuit Diagram in Section 9.4 “Electrical Drawings” on page 9–42.
PCH 1602 STC03-13 1P1C 1–1

1. Technical Data Installation, Commissioning, Operating and Maintenance
1.1.4 Discharge Pump Ratings

Table 1–2 Discharge Pump Ratings
Sewage
Plant Type Pump Type Motor Ratings Pump Duties
STC03-13 Close coupled B50x50 Medium Head (18m) 50Hz 4.0 kW 8 m³/hr at 18m head
STC03-13 Close coupled B50x50 Medium Head (18m) 60Hz 4.4 kW 8 m³/hr at 18m head
STC03-13 Close coupled B50x50 High Head (25m) 50/60Hz 5.2 kW 8 m³/hr at 25m head
1.1.5 Compressor Electrical Ratings and Duties

Table 1–3 Compressor Electrical Ratings and Duties (50/60Hz)
Sewage Plant Type Frequency (Hz) Motor Rating (kW) Compressor Duties.
STC03-13 50 1.1 0.5 bar – 25 m3/hr
STC03-13 60 1.1 0.5 bar – 25 m3/hr
1.1.6 Sewage System Alarm

The sewage system general Volt Free alarm is rated at 500W normally closed.
1.1.7 Vent System Back Pressure

The allowable Vent System Back Pressure is limited to a maximum of 15mm w.g.
1.1.8 Temperature and Humidity Data
CAUTION
The Electrical Components on this Sewage Treatment Plant are designed to
work in ambient temperatures up to 55°C. Temperatures exceeding this limit
may cause irreparable damage to the equipment.
The Operating Ambient Temperature of the control panel can be up to a maximum of 55°C.
The Operating Relative Humidity of the control panel can be up to a maximum of 90%.
1.1.9 Requirement for Shipboard Cleaning Chemicals

NOTE
Toilet cleaning chemicals and de-scaling agents should be biodegradable, low
foaming, low toxicity or activated sludge process friendly.
The chemicals used on board that may have an impact on the operation of the sewage
treatment unit should be suitable for use with marine activated sludge sewage treatment
systems i.e. be biodegradable, low-foaming and have low toxicity. These chemicals include
toilet cleaners, de-scaling agents, etc.
1–2 PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 1. Technical Data
1.2 Record of Commissioning Data

NOTE
It is important that the table below is completed on initial commissioning to
provide a set of reference data against which the maintenance procedures can
be determined.
This sheet should be used to record parameter values at initial commissioning. Duplicates of
the sheet should be used to record values at subsequent intervals. The values are utilised
during Maintenance (See Section 5)
For Sewage Treatment Unit Number: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(Record Unit Number stamped on tank nameplate).
Status of Unit: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Record status: e.g. “Initial Commissioning”, “First Service”, etc.)
Table 1–4 Record of Commissioning Data
Date Parameter Value Units Section

Compressor No 1 Discharge Pressure bar 4.1.6
Compressor No 1 PRV Setting bar 4.1.3
Vent Pressure mm water 4.1.3
Dilution Water Flow Rate (if applicable) l/min 4.1.7
Chlorination Dosing Pump setting l/hr, minutes 4.1.4
e.g. 0.05 L/hr for 10 mins
De-chlorination Dosing Pump setting l/hr 4.1.5
PCH 1602 STC03-13 1P1C 1–3

1. Technical Data Installation, Commissioning, Operating and Maintenance
1–4 PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 2. Introduction
2. Introduction
2.1 General
2.1.1 STC Definition
An STC unit is defined by its code.
For example, for STC03-13:
ST C 03 -13
Year of Design Release

Super Trident
disinfection
Tank Size
Chemical
2.1.2 Nomenclature
ML – Mixed liquor, a term used to describe the liquid content within the Aeration Tank. It is a
mixture of bacteria and other particulate materials, also referred as biomass, or ‘sludge’ when
the surplus bacteria is wasted from the system.
DO - Dissolved oxygen, measured in mg/l of oxygen, represents the oxygen concentration in
the ML available for the aerobic bacteria to degrade the organic matter.
MLSS – Mixed liquor suspended solids, a measurement of solids content in the ML and
indicates the concentration of bacteria within the Aeration Tank.
RAS – Returned activated sludge or ‘Sludge Return’, refers to the stream of ML that is
returned from the Settlement Tank to the Aeration Tank via the RAS or ‘Sludge Return’ air lift
pipe.
pH – a measurement of the acidity of the treated effluent.
BOD – Biochemical oxygen demand, a measurement of the organic matter in oxygen
equivalent that would have been consumed by degrading the said amount of organic matter.
COD – Chemical oxygen demand, a measurement of the organic matter in oxygen equivalent
consumed by using strong chemical oxidants.
Faecal coliform – indicative bacteria which often find their origins in the faecal matter.
Chlorination – a process that uses chemicals such as sodium hypochlorite to kill bacteria
given sufficient contact time.
De-chlorination – a process that uses chemicals such as sodium bisulphite to remove residual
chlorine in the disinfected effluent.
2.2 General Description of STC Unit

The Wärtsilä Hamworthy Super Trident sewage treatment unit, certified in accordance with
IMO MEPC 227(64) guidelines, incorporates a number of new features to enhance the
treatment performance in comparison with the previous generation of Wärtsilä units.
The Super Trident STC unit is a self-contained system for treatment of sewage before it is
discharged overboard, thus preventing the pollution of harbour and coastal waters and inland
waterways. The system uses the activated sludge treatment technology, coupled with
chemical disinfection of the final effluent. It is generally accepted as the most compact,
efficient, flexible, and environmentally sustainable system for use on board ships.
PCH 1602 STC03-13 1P1C 2–1

2. Introduction Installation, Commissioning, Operating and Maintenance
The Wärtsilä Hamworthy Super Trident will operate satisfactorily on salt, fresh or brackish
flushing water.
The system is ideal for ship installation as, if necessary; a number of small units can be
arranged to suit accommodation requirements rather than one large installation requiring
considerable installation space and long lengths of piping.
The Wärtsilä Hamworthy Super Trident sewage treatment unit comprises a tank divided into
three water tight compartments – an Aeration Tank, a Settlement Tank, and a Chlorine
Contact Tank.
2.3 Detailed Description of STC Unit

2.3.1 General
Below is a typical 3D Cut-Away drawing of the sewage treatment plant.
Fig 2–1 Typical 3D Cut-Away drawing of the Sewage Treatment Plant (STCXX-
00036)
2–2 PCH 1602 STC03-13 1P1C

Below is a generic process diagram of the sewage treatment plant.
Fig 2–2 Generic process diagram of the sewage treatment plant (STCXX-00006)
2.3.2 Aeration Tank

The incoming sewage enters the Aeration Tank via a coarse mesh, where it is mixed with the
bacteria within the Aeration Tank to become the Mixed Liquor (ML). The organic materials in
the sewage are absorbed and bio-degraded by the aerobic bacteria which rely on the
constant supply of oxygen from the compressor. The aerobic bacteria convert the organic
materials into substances such as carbon dioxide and water, which are harmless to the
receiving waters. The same bacteria also convert the sulphide compounds, substances that
are generated by the anaerobic bacteria under septic or anaerobic conditions, into sulphate
compounds which are odourless and harmless.
The aerobic bacteria, feeding on organic materials as their ‘food’, will grow in their population.
This growth results in an increase of Mixed Liquor Suspended Solids (MLSS) concentration
in the Aeration Tank. It is therefore important to ‘de-sludge’ the unit to maintain a stable MLSS
and healthy bacteria in the system.
The ML, when sampled from the Aeration Tank should appear brown in colour, and with an
earthy smell that is not offensive. If the physical appearance looks grey or black, with a foul
smell, then the ML is suffering from a lack of aeration, or too much organic material to handle,
or toxicity in the wastewater.
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 diffusers generate very fine air bubbles from which the oxygen will diffuse
into the ML for use by bacteria. Therefore good diffuser condition is important to maintain
good aeration and complete mixing in the tank.
The ‘gas-off’ from the Aeration Tank contains carbon dioxide, nitrogen, un-used oxygen, and
water vapour and is emitted out through the vent system.
The Aeration Tank can be emptied using the Discharge Pump under manual control.
The ML gravitates into the Settlement Tank via an internal pipe.
PCH 1602 STC03-13 1P1C 2–3

2.3.3 Settlement Tank

The Settlement Tank and the Aeration Tank form the Activated Sludge treatment system.
From the Aeration Tank the ML flows into the Settlement Tank via an energy dissipation
device to minimise any turbulence. The aerobic bacteria flocs settle out within the middle
section of the Settlement Tank, and form increasingly concentrated layers towards the
bottom section of the Settlement Tank. The Settlement Tank is “hopper” shaped which
prevents the sludge from accumulating on the sides. Treated effluent is moved to the top
section of the Settlement Tank as a result of solids settlement, and gravitates into the Chlorine
Contact Tank (Chlorination).
From the bottom of the Settlement Tank, the concentrated ML is returned to the Aeration Tank
via the airlift tube, in a stream called Returned Activated Sludge (RAS) or ‘Sludge Return’. It
is important that the bacteria which enter the Settlement Tank are returned in sufficient
quantity to the Aeration Tank but in a more concentrated form. Otherwise, bacteria may build
up within the Settlement Tank and cause solids to escape into the effluent. To prevent this
from happening, the RAS or ‘Sludge Return’ flow needs to be maintained at the rated average
flow for the unit. The system allows easy calibration of RAS or ‘Sludge Return’ flow by means
of a fixed orifice plate on the air manifold on the side of the unit that ensures a constant air
flow.
The de-sludge operation, which aims to maintain a stable MLSS, is carried out by discharging
the entire content of the Settlement Tank as and when the MLSS settlement test indicates that
it is required. This operation also removes any possible accumulation of scum on the surface
of the Settlement Tank.
2.3.4 Chlorine Contact Tank (Chlorination)

The effluent from the Settlement Tank gravitates into the Contact Tank where sufficient
contact time is achieved, to kill off any remaining bacteria. The Chlorination Dosing Pump
doses Sodium Hypochlorite solution into the Contact Tank at a pre-set and adjustable dosing
rate under automatic control with a timer in the main control panel. The Discharge Pump
transfers the chlorinated effluent from the Contact Tank under automatic level control (see
Section 2.3.8 “Control Philosophy ” on page 2–5). At the suction of the Discharge Pump, the
de-chlorination chemical is dosed to remove residual chlorine content in the treated effluent
prior to discharge overboard or to shore connections.
A High-High level switch provides an alarm signal should the level within the Contact Tank
continue to rise above the normal “High” position and reach the High-High level. An
emergency overflow pipe connection is also provided through which only treated effluent can
pass.
It is important to prevent accumulation of particles within the Contact Tank in order to ensure
that chlorination is effective.
2.3.5 Chlorination and De-chlorination Dosing Units

1 The chlorination dosing unit comprises a bund sized to accommodate a 10 litre capacity
on the STC03-13 chemical container, a Chlorination Dosing Pump and controls to adjust
the dosing rate, as detailed in Section 4.1.4 “Setting up Chlorination Dosing Pump” on
page 4–4. The dosing pump is self priming and will alarm when the chemical reservoir
reaches low level. See also Section 8.1 “Chlorination Dosing Pump” on page 8–1.
2 The de-chlorination dosing unit comprises a bund sized to accommodate a 10 litre

capacity chemical container on the STC03-13, a Dechlorination Dosing Pump, and
controls to set up the dosing rate as detailed in Section 4.1.5 “Setting up De-
chlorination Dosing Pump” on page 4–5. The dosing pump is self priming and will alarm
when the chemical reservoir reaches low level.
2–4 PCH 1602 STC03-13 1P1C

2.3.6 Discharge Pump

The pump is a horizontal close-coupled centrifugal unit with a 2-bladed open impeller of the
non-clog type. The medium head pump is suitable for heads up to 18 metres. The high head
pump is suitable for heads up to 25 metres. A sampling point is fitted to the pump discharge
line for on-board analysis of residual chlorine and pH. See Section 6 “Discharge Pump
B50x50HC” on page 6–1 for the discharge pump operation and maintenance.
2.3.7 Compressor
One air compressor is fitted.
Table 2–1 Compressor Types and Manuals for each Sewage Plant Type
Sewage Plant Type Compressor Type Manual Section for Compressor Type
STC03-13 CYBW-25 Section 7 “Compressor (Type CYBW-25)”
2.3.8 Control Philosophy

2.3.8.1 General
The compressor is operated by a manual switch on the control panel and should be switched
on all the time the unit is in operation.
The Discharge Pump is controlled by a MANUAL/OFF/AUTO switch on the control panel.
When the Discharge Pump control switch is in the AUTO position, it is under the control of the
level switches situated in the Contact Tank. The typical sequence of operation is as follows:
• When the liquid reaches the “High” level float switch in the Contact Tank, the Discharge
Pump starts. The pump continues to run until the liquid drops to the Low-level switch and
the Discharge Pump stops. Activation of the High level switch also activates the De-
chlorination Dosing Pump, which stops when the Discharge Pump stops.
• When the Low-level switch is activated at the end of Contact Tank discharge cycle, the
Chlorination Dosing Pump starts. It doses the chlorine solution into the Contact Tank for
a pre-set period at a pre-set dosing rate which is controlled by a pre-set time in the control
panel to allow a pre-determined amount of chemical solution into the Contact Tank.
• Should the “High” level switch fail to operate for any reason, the liquid level will reach the
“High-High” level switch, and actuate the alarm circuit.
To empty the tank for cleaning or maintenance, move the control switch to the MANUAL
position. The Discharge Pump will run until the control switch is moved to OFF or Auto.
The level switches in the Contact Tank are of the magnetic reed type with three floats
mounted on a common stem and wired to the control panel. The two lower floats operate the
discharge pump, and the upper float operates the high-level alarm circuit should the level rise
above normal.
A control panel General Arrangement drawing including control switch layout is included in
Section 9.4 “Electrical Drawings” on page 9–42 together with circuit wiring diagrams.
2.3.8.2 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.
PCH 1602 STC03-13 1P1C 2–5

2.4 STC System Interface Configurations

STC units are designed to treat sewage flow from gravity and vacuum toilet systems. They
can also process grey water when the flow and concentrations are well defined (See
Section 3.2.4 “Grey Water Streams R62742” on page 3–18). The STC units can receive
wastewater from an integrated ejector system, vacuum collection unit, other dedicated
collection tanks, or a combination of these. When applicable, dilution water can also be
added to the feed system or to the STC Aeration Tank. However, it is important to ensure the
combined feed flow into an STC unit does not exceed the designed average and peak loading
conditions for the unit (refer to Section 3.2.3 “Peak Loading Considerations R63261” on
page 3–16).
Typical STC system configurations are illustrated in the P&I diagrams, located in Section 9.2
“General Arrangement and P&I Drawings” on page 9–29 and listed in detail in the Contents at
the beginning of the manual.
2–6 PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 3. Installation
3. Installation
3.1 General Data

DANGER
Death by crushing as a result of incorrect lifting applications and methods
causing equipment failure.
DANGER
Danger of death and equipment failure due to lifting the unit when full of water.
The Sewage Treatment Plant is to only be lifted when empty.
WARNING
Risk of limbs being crushed from lifting operations.
WARNING-ELECTRICITY
Danger or risk of personal injury due to electric shocks. Any electrical
connections or work on the control panel to be done by ships staff is to be
carried out by a suitably competent and qualified electrical installer.
NOTE
Any lifting operations should be planned and performed by competent
personnel. Use only the correct lifting equipment that is rated for the intended
use and ensure all lifting equipment is in serviceable condition.
3.1.1 Lifting Operations

The Weights and Centre of Gravity information for all lifting operations is shown at
Section 3.1.2 “Unit Weights and C of G” on page 3–3.
When lifting the sewage treatment plant the unit is to be lifted “only when empty” and any
lifting operations are to be planned and carried out by competent people. The preferred
method of lifting would be by spreader bars or spreader beams but should suitable spreader
bars/beams not be available then the unit can be lifted by the 4 point pyramid lift method
shown in Fig 3–1 on page 3–2. The unit is not designed to be lifted when full of water or by
utilising any less than 4 lifting lugs (See Fig 3–1 on page 3–2). The lifting diagram (See Fig 3–2
on page 3–3) demonstrates the minimum lifting apex height of the chains and Table 3–1
provides the minimum dimensions that must be maintained. Fig 3–2 also shows the inclusive
lifting angle on the shortest side of the unit that must be less than or equal to 60°. Fig 3–2
shows minimum chain ratings.
PCH 1602 STC03-13 1P1C 3–1

3. Installation Installation, Commissioning, Operating and Maintenance
Table 3–1 Minimum Apex Height for 4 Point Pyramid Lift
Unit Size Minimum Apex Height

STC03-13 1.350m
Table 3–2 Minimum Chain Leg Ratings
Unit Size Minimum Chain Ratings (each leg)

STC03-13 1500kg
Fig 3–1 Typical 4 Point Pyramid Lift Set Up
DANGER
Do not walk under a suspended load
3–2 PCH 1602 STC03-13 1P1C

Fig 3–2 Lifting Angle & Apex height Restrictions
3.1.2 Unit Weights and C of G

The individual sewage treatment plant weights and Centres of Gravity are shown in Table 3–3
on page 3–4. The datum for the C of G is shown in Fig 3–3 on page 3–3.
Fig 3–3 Centre of Gravity Datum
PCH 1602 STC03-13 1P1C 3–3

Table 3–3 Plant Weights and Centres of Gravity
Longitudinal Transverse Vertical Longitudinal Transverse Vertical

Unit Dry Wet
Pumps Compressors C of G (m) C of G (m) C of G (m) C of G (m) C of G (m) C of G (m)
Size Weight (kg) Weight (kg)
Dry Dry Dry Wet Wet Wet
STC03-13 1 1 1154 3959 0.652 0.578 0.690 0.829 0.611 0.720
3.1.3 Installation Position

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 22.5 degrees either side of the vertical.
CAUTION
Welding must not be carried out on the tank surfaces or the internal coating will
be destroyed.
To facilitate periodic maintenance and for use in an emergency, a direct overboard by-pass
of the unit must be provided. For details of the overboard by-pass refer to sheet 2 (P&I
Diagram) of the relevant unit general arrangement drawing in Section 9.2 “General
Arrangement and P&I Drawings” on page 9–29.
DANGER
If the unit is only supplied with a single compressor and the single compressor
failed, to avoid the loss of aeration and to prevent dangerous gases such as
Hydrogen Sulphide (H2S), Methane (CH4) or Ammonia (NH3) being generated
due to anaerobic sludge conditions, it is highly advisable to fit an emergency air
connection that originates from the ship’s air supply and connects into the
sewage treatment plant air manifold. For size details of the emergency air
connection, refer to connection CP7 on the general arrangement drawing in
Section 9.2 “General Arrangement and P&I Drawings” on page 9–29.
Galley grey water can be acceptable for treatment after it is pre-treated by a grease trap to
achieve fat, oil and grease (FOG) concentration to less than 300mg/l. No waste food or
cooking oil is allowed into the sewage plant. No piping connection to the STP shall be made
directly or indirectly from pulverisers, food presses or similar devices. Strainers with 6mm
holes or less shall be provided for shower cubicles, galley sinks, and all other grey water
connections that lead to the treatment plants.
The incoming electrical control terminals are clearly marked in the control panel and should
be connected to the ships supply.
WARNING-ELECTRICITY
See also the P&I diagrams, located in Section 9.2 “General Arrangement and P&I Drawings”
on page 9–29.
3–4 PCH 1602 STC03-13 1P1C

3.2 Further Installation Details

3.2.1 Typical Plant Installation Instructions T0406037A
29
22
15 11
20
6
5
9
23 21
12
24 10 26 27 28
FOUNDATION - SHIPYARD SUPPLY
FIGURE 1A
3 ART 20.11.14 NHS NHS N061605 SHT4 NOTE ADDED
02 NHS 12.12.13 ART TMD N061035 SHEET 6 AMENDED
01 NHS 14/01/2013 NHS TMD - ORIGINAL ISSUE

ISSUE DRAWN DATE CHK APP E.C.N. DESCRIPTION
ALL COPYRIGHT © AND DESIGN RIGHT SUBSISTING IN THIS DOCUMENT IS THE PROPERTY OF W‫ۯ‬RTSIL‫ ۯ‬WATER SYSTEMS LTD, AND MAY NOT BE REPRODUCED IN ANY
FORM OR BY ANY MEANS, IN PART OR WHOLE, WITHOUT W‫ۯ‬RTSIL‫ ۯ‬WATER SYSTEMS LTD CONSENT. THIS DOCUMENT AND THE INFORMATION WITHIN IT IS CONFIDENTIAL
TO W‫ۯ‬RTSIL‫ ۯ‬WATER SYSTEMS LTD AND MAY NOT BE DISCLOSED TO ANY THIRD PARTY WITHOUT THE PRIOR WRITTEN CONSENT OF W‫ۯ‬RTSIL‫ ۯ‬WATER SYSTEMS LTD.
CLIENT REF:
-
W‫ۯ‬RTSIL‫ ۯ‬REF: TOLERANCE UNLESS OTHERWISE STATED:
- T0103003/006
DIMS: SHT. SIZE SCALE DO NOT SCALE
mm A4 - IF IN DOUBT ASK FIRST ANGLE
Water Systems
TITLE:
INSTALLATION INSTRUCTIONS - 1 PUMP 1 DRG. No. SHT. No.
COMPRESSOR STC02-13 to STC06-13 T0406037-A 1 /9
PCH 1602 STC03-13 1P1C 3–5

FROM SHIP's WASTE DRAIN

18
ź
FIGURE 1B
19
BY-PASS OVER-BOARD
DISCHARGE LINE MUST BE
SEA
FITTED ON BLACK AND GREY
WATER LINES AS INDICATED
ź
TO SEWAGE
TREATMENT PLANT
14
FIGURE 1C 16A
7
25
13
3 16B
4B
17
30B
2
4A 30A
FOUNDATION - SHIPYARD SUPPLY
3 ART 20.11.14 NHS NHS N061605 SHT 4 NOTE ADDED

CLIENT REF:
-
- T0103003/006
Water Systems
TITLE:
3–6 PCH 1602 STC03-13 1P1C

Key to Typical Installation Diagram (Figures 1A-1C)

1). Isolating Valves - Air System
2). Chlorination pump (Sodium Hypochlorite)
3). De-chlorination pump (Sodium Bisulphite)
4). Dosing Skid chemical container bunds - Chlorination (4A-Black) & De-chlorination (4B-White)
5). Emergency overflow connection from the contact tank (effluent)
6). Level control switch for contact tank
7). Emergency air inlet connection
8). Rotary air blower
9). Control panel for sewage treatment tank
10). Seawater supply for initial filling and cleaning (use clean seawater or fresh water - not harbour water)
11). Discharge pump
12). Overboard discharge (installer to comply with appropriate legislation)
13). Orifice plate (for air lift supply to returned activated sludge system)
14). Returned activated sludge pipe (from settling tank to aeration tank)
15). Aeration tank sample point
16). Black/Grey water inlets - Raw sewage & urinal/Grey inlet (16A) & Hospital black/grey water (16B)
17). Vent connection to funnel or mast
18). Branch above maximum waterline (prevents system back-up) *
19). Storm valve *
20). Effluent discharge flow control valve
21). Final effluent sample point and pressure gauge
22). Chlorination (sodium hypochlorite) injection valve
23). De-chlorination (sodium bisulphite) injection valve
24). Contact tank sampling point
25). Access Hatch for cleaning screen filter
26). Isolation valve - Contact Tank
27). Isolation valve - Aeration Tank
28). Isolation valve - Settling Tank
29). Vent - Contact Tank
30). Dosing Chemical container - Chlorination ((30A = Grey-(STC02-13 & 03-13) Blue-(STC04-13 & 06-13)) &
De-chlorination (30B = White)
* All Items marked thus are not Wartsila supply

CLIENT REF:
-
- T0103003/006
Water Systems
TITLE:
PCH 1602 STC03-13 1P1C 3–7

GENERAL
The following should be read in conjunction with the appropriate general arrangement drawing and installation wiring diagram for the
contract and typical sectional arrangement shown in the installation, operation and maintenance manual.
The unit should be installed in a position where it is as level as possible when the vessel is in its normal trim state. The unit base flatness
is within the tolerance levels shown in BS EN ISO 13920 - 1997 (Table 3 tolerance class F) shown below - therefore, the requirement for
packers maybe necessary during the installation process.
It is expected that gaps of up to 4MM may be closed by the holding down bolts. For gaps greater than 4MM, the fitting of carbon steel shims at the
holding down bolt position should be considered once correctly fitted, the shims should be welded to the foundation structure.
Range of nominal sizes l in mm (relates to longer side of surface)
Over 30 up to 120 Over 120 up to 400 Over 400 up to 1000 Over 1000 up to 2000 Over 2000 up to 4000 Over 4000 up to 8000
Tolerance Class Tolerance t in mm Tolerance t in mm Tolerance t in mm Tolerance t in mm Tolerance t in mm Tolerance t in mm
E 0,5 1 1,5 2 3 4
F 1 1,5 3 4,5 6 8
G 1,5 3 5,5 9 11 16
H 2,5 5 9 14 18 26
Bolt holes are provided in the base plate of the unit for fixing. The holding down bolt dimensions are shown on the general arrangement
drawing. Alternatively the base angles may be welded to the support structure, but DO NOT weld to the tank sides or bottom as the
internal protective coating will be destroyed. It is NOT necessary to fully weld the complete exterior of the base angles to the support
structure. If the provided bolt holes are not going to be utilised, a weld pattern of a minimum 6mm fillet x 150mm long should be carried
out adjacent to each bolt hole location.
Supporting steelwork must span the base on the edges and the centre as shown in Figure 2 on page 9. It is recommended that the unit
is installed in a fore and aft direction to minimise the effects of vessel rolling. The maximum angle of roll at which the unit will continue to
function is 22 1 2 ° either side of the the vertical.
The incoming electrical control terminals are clearly marked in the control panel. All electrical work should be carried out by qualified
personnel.
Access to the following items must be arranged:-

a). Electrical control panel - switches are mounted on the outside of the door, the door opening dimension
is marked on the general arrangement drawing.
b). Chlorination and de-chlorination dosing tanks.
c). Valves that are regularly used for operation & maintenance etc.
d). Access covers in the top and sides of the unit. Refer to the specific unit general arrangement drawing for clearance
requirements in the operation/maintenance manual.

CLIENT REF:
-
- T0103003/006
Water Systems
TITLE:
3–8 PCH 1602 STC03-13 1P1C

PIPE CONNECTIONS REQUIRED

1. BLACK/GREY WATER INLETS
These are for handling the waste from toilets, urinals and hospital waste water as required by health codes.
Consult Wartsila if hospital waste is expected to be an exceptionally large volume or any other waste is to be
designated as "black".
Ensure that peak flows and periods do not exceed the peak handling capability of the sewage treatment plant.
To facilitate maintenance on a ship fitted with a gravity toilet system an overboard bypass line must be fitted.
This is not possible on a vacuum system and the units must be temporarily shut down for maintenance.
Ensure that all facilities connected directly or indirectly to the sewage treatment plant inlet have adequate
water traps fitted or other means to prevent any venting back flow from the system into living areas.
Wartsila can supply a transfer station if the final soil pipe position is below the sewage treatment plant.
On gravity collection systems a macerator is recommended where larger material is likely to be present,
particularly on passenger vessels and ferries.
If it is required to combine the grey water waste mains and the soil main, Wartsila must be advised at an early
stage as the size of the unit will be affected.
2. BLACK WATER GRAVITY PIPELINE FALLS (SLOPE)
This should be a minimum of 10mm per 300mm run in the direction of flow after allowing for the worst trim
conditions.
Non return valves or valves that could cause a flow restriction should not be fitted.
For Wartsila vacuum systems please consult Wartsila for the relevant documentation, for other manufacturer's
systems please refer to suppliers instructions.

CLIENT REF:
-
- T0103003/006
Water Systems
TITLE:
PCH 1602 STC03-13 1P1C 3–9

3. GREY WATER WASTE DRAINS
This can be discharged directly overboard unless restricted by local regulations.
If it is required to treat grey water waste in the sewage treatment plant then Wartsila must be consulted as the size of the unit will be
affected.
It is best practise that any grey water entering the sewage treatment plant must be subject to chemical control to ensure that only
biologically friendly and low foaming chemicals are used. Consideration should also be given to installing anti-foam dosing equipment.
This can be supplied by Wartsilla.
Grey Water waste must be piped seperately from the black water soil main.
To facilitate maintenance an overboard bypass line must be fitted.
Ensure that all facilities connected directly or indirectly to the sewage treatment plant inlets have adequate water traps fitted or other
means to prevent any venting back flow from the system into living areas.
4. GALLEY WASTE WATER
Galley waste water can normally be fed directly overboard in accordance with IMO MARPOL Annex V Regulation 4 requirements, which
states that the ship must be a minimum of 3 nautical miles from the nearest land mass when NOT in special areas and outside 12
nautical miles from the nearest land mass when IN special areas, the waste must have been passed through a comminuter or grinder.
Such comminuted or ground waste shall be capable of passing through a screen with openings no larger than 25mm.
If it is intended to connect galley waste water directly into the sewage treatment plant, Wartsila must be consulted as the size of the unit
will be affected and an effective grease trap must be fitted, the following also applies for galley waste water being fed directly to the STP:
Galley grey water can be acceptable for treatment after it is pre-treated by a grease trap to achieve fat, oil and grease (FOG)
concentration to less than 300mg/l. No 'WASTE FOOD' or 'COOKING OIL' is allowed into the sewage plant. No piping
connection to the STP shall be made directly or indirectly, from pulverisers, food presses or similar devices. Strainers with
6mm holes or less shall be provided for shower cubicles, galley sinks and all other grey water connections that feed to the
treatment plants.
5. LAUNDRY WASTE
Laundry waste may be treated in an STP designed for this purpose. Consult Wartsila.

CLIENT REF:
-
- T0103003/006
Water Systems
TITLE:
3–10 PCH 1602 STC03-13 1P1C

6. VENT
Do not connect other system vents to the sewage treatment plant 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 that is not used in the stabilisation process.
It is important that no liquid pockets can form in the vent to restrict the free run of the gases. If liquid pockets are
unavoidable then an automatic drain connection must be fitted and included in the maintenance schedule.
Ensure that the water traps on all facilities on any drains connected to the sewage treatment plant inlets are of an
adequate depth to isolate the living areas from any vent gases. Consideration must be given to worst trim and vent
pressure conditions. This is especially important should any hazardous gases be generated from an incorrectly
maintained or operated system.
Although best avoided, a suitably specified vent fan can be used for difficult pipe arrangements that would give more
than 15mm water gauge back pressure.
Flame traps or spark arresters are not necessary, however if required by local regulations they must be generously
sized to meet the vent requirements between maintenance periods.
A seperate guide for vent pipes can be found in the operation manual or is available from Wartsila.
7. EMERGENCY OVERFLOW FROM CONTACT TANK
If this is piped directly overboard then the connection must be at least 1.5m above the maximum sea water level to
ensure that the discharge storm 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 the emergency overflow connection is below the maximum water level, then it should be connected to a customer
specified interface (eg bilge or existing sewage holding tank) via a minimum water trap of 300mm to prevent venting
into the compartment. The overflow connection 'SHOULD NOT' be blanked off.

CLIENT REF:
-
- T0103003/006
Water Systems
TITLE:
PCH 1602 STC03-13 1P1C 3–11

8. DISCHARGE OVERBOARD - SIPHON PREVENTION

If the top of the sewage treatment tank is above the minimum sea water level then the pump discharge pipeline
must be looped above the top of the 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.
9. DISCHARGE OVERBOARD - BACK FLOW PREVENTION
If the sewage treatment tank is below the maximum sea water level then appropriate ship building regulations
must be complied with. This may involve the fitting of suitable ship side valves and/or the running of a siphon
prevention loop (similar to that described in item 8) above the maximum sea water level.
INSTALLATION OPTIONS
10. ASIATIC TYPE CONSTANT FLUSH TOILETS
These will affect the size of the unit and Wartsila should be consulted.
11. LOW FLUSH SEWAGE DELIVERY SYSTEM (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 or fresh water, but it may be possible to use grey water for this providing that
the plant has been initially sized on this basis. Dilution water should be fed to the aeration tank at a constant
rate for 24 hours/day to prevent shock loading. Consult Wartsila for the recommended flow rate of water to be
added.

CLIENT REF:
-
- T0103003/006
Water Systems
TITLE:
3–12 PCH 1602 STC03-13 1P1C

12. EMERGENCY AIR SUPPLY

Please refer to the sewage treatment plant manual technical data section or contract specific data for
maximum and minimum air flow required for any particular model of sewage treatment plant. The unit will
require a regulated supply of no greater than 0.6 Bar.
To avoid contamination of the process and clogging of the air diffuser elements the air supply must be free of
oil, condensate and particles.
13. COMPARTMENT VENTILATION
The sewage plant blowers require a minimum amount of air to supply the necessary oxygen to the biomass
and sludge return air lift. When positioning the STP in a compartment on the ship, consideration must be given
to the minimum ventilation requirements for the blower and associated motors. For minimum ventilation flow
rates refer to the operation/maintenance manual.
FIGURE 2:- FOUNDATION
Note:-
The holding down feet may be
welded to the support structure
but DO NOT weld to the tank
sides or bottom as the internal
protective coating will be
destroyed. Packers are to be
used as required.
3 LONGITUDINAL FOUNDATION SUPPORTS MUST

BE FITTED AND ARE OF SHIPYARD SUPPLY

CLIENT REF:
-
- T0103003/006
Water Systems
TITLE:
PCH 1602 STC03-13 1P1C 3–13

3.2.2 Vent System Design Recommendations R63262
Vent System Design

Recommendations R63262
for use with Wärtsilä Hamworthy SHEET 1 SHEETS 2
Sewage Treatment Plant
WARTSILA WATER SYSTEMS LTD - © COPYRIGHT & ALL OTHER RIGHTS RESERVED
Good vent design and vent routing will ensure system backpressure is kept to a minimum and reduces the
chance of condensation problems and gas or odours escaping into the accommodation or machinery spaces.
A good design will eliminate or reduce the need for additional equipment, which could increase maintenance
times to ensure the required backpressure is achieved.
(i.e. Reduce the need for flame traps, filters, fans etc)
General rules can be applied to the vent design for a Wartsila Hamworthy Sewage Treatment plant as follows:
1. The total system backpressure should typically not be above 15mm water gauge. (See table 1 for expected
air flow rates for typical sewage treatment plants)
2. Coupling into other vent systems is discouraged. When coupling into any other vent pipe-work cannot be
avoided or when fitting a vacuum sewage collection system to the sewage treatment plant, its effect must be
taken into account on the overall vent pressure drop.
(Allow for potential peak flushing rates by increasing the air flow rate from the sewage treatment plant
according to the number of vacuum producing units venting into the sewage treatment plant & their air
pumping capacity. The typical surge from a toilet flush will induce approximately 60 litres of air in 3-4
seconds.)
3. Ensure that the vent pipe continuously rises from the Sewage Treatment Plant to the vent discharge point so
that condensate can drain back to the sewage treatment plant. Also ensure that the ships motions are taken
into account in the vent design. As part of the type approval the system is designed to operate at an
inclination up to 22.5° and be able to operate under conditions of heel of up to 22.5°.
4. Facilities to enable draining of the vent pipe should be added where unavoidable water traps could occur in
the vent line, this can be achieved with the addition of a U trap drain at the lowest point in the pipework.
5. The vent pipe run should be to the point of discharge using the minimum number of bends. Bends should be
long radius type, where possible.
6. On the larger STP units ( STC08-14 to STC60-14 ), where a smaller separate balancing vent pipe proves to
be required for the settling & disinfecting compartments, this should ideally be run separately from the larger
aeration vent pipe all the way to the vent point. Where this is not practicable, connect to a point in the larger
vent as far above the Sewage Treatment Plant as possible (minimum 2 metres). Make the connection so as
to avoid liquid transfer from the large vent to the small vent.
7. All waste water inlets, Water Closets (W.C.), urinals, etc connected to the Sewage Treatment Plant or its
feed pipe-work must have a device fitted to prevent venting from the plant into compartments e.g. water seal
of at least 30mm greater depth than the vent back pressure. Ensure that the ships motions (inclination up to
22.5° and conditions of heel of up to 22.5°) are taken into account in the vent design. The sewage treatment
plant overflow and any other connection to the system terminating within the vessel should be fitted with a
similar device.
8. This is particularly the case with vacuum sewage collection systems, which will increase the air flow rate from
the sewage treatment plant, also creating surges as each W. C. flush will induce approximately 60 litres of air
in 3-4 seconds. (Allow for potential peak flushing rates by increasing the air flow rate from the sewage
treatment plant according to the number of vacuum producing units venting into the sewage treatment plant
& their air pumping capacity.)
ISSUE No. 1
ECN -
DATE 25/09/14
INITIALS WJD
CHECKED ART
APPROVED & DATE NHS 25/09/2014
3–14 PCH 1602 STC03-13 1P1C

Vent System Design

Recommendations R63262
for use with Wärtsilä Hamworthy SHEET 2 SHEETS 2
Sewage Treatment Plant
9. The following air flows can be considered when calculating the required vent diameter:
UNIT SIZE MAXIMUM TYPICAL VENT DESIGN VENT FLANGE MINIMUM VENT(A) DIAMETER (mm)
3
NUMBER AIR FLOW (m /h) CONNECTION
OF NOMINAL
STC RTC VACUUM DIRECT VACUUM DIAMETER SEPARATE VACUUM VACUUM
EJECTORS GRAVITY SYSTEM (mm) COLLECTION TANK OR COLLECT
FITTED FEED FITTED DIRECT GRAVITY FEED ION ON
TANK
STC01-13 1 9 29 80 50 80
STC02-13 RTC20-14 2 20 60 80 50 80
STC03-13 2 32 72 80 50 80
STC04-13 RTC40-14 2 32 72 80 50 80
STC06-13 RTC60-14 2 50 90 80 50 80
RTC80-14 2 50 90 100 80 100
STC08-14 2 58 98 100 80 100
STC10-14 2 68 108 100 80 100
STC13-14 2 89 129 100 80 100
STC15-14 2 125 165 100 80 100
STC20-14 3 190 250 125 100 125
STC25-14 3 190 250 150 100 150
STC30-14 3 300 360 150 100 150
STC40-14 3 300 360 150 150 150
STC50-14 3 500 560 250 225 250
STC60-14 3 500 560 250 225 250
(A) The vent diameter should be sized to allow a maximum pressure drop of 15mm wg with the typical air
flows quoted against gravity and vacuum systems.
10 Flame traps are not normally required (check specified rules) in or at the end of the vent, but if fitted, should
be sized so as not to increase the overall pressure drop above the required limit when dirty and should be
regularly maintained.
11. Where choice of vent discharge location is restricted to sensitive areas it may be a requirement to fit odour
extraction filters. If fitted they should be sized to not increase the overall pressure drop above the required
limit when dirty and should be regularly maintained. A suitably sized vent fan may also be required as a result
of fitting additional odour filtration; this fan is to be sized to ensure the maximum pressure drop in the system
is kept below 15mm wg.
12. In the last resort, where system back-pressures cannot meet the required limits, a suitably sized vent fan can
be fitted but needs to be sized to ensure the maximum pressure drop in the system is kept below 15mm wg.
WARNING – During a prolonged STP power failure, shut down or loss of aeration for a period greater
than 6 hours there is a potential for build up of Hydrogen Sulphide (H2S), Methane (CH4) or Ammonia
(NH3) gas in the vent system. Care is to be taken when dismantling the vent pipework for maintenance or
refurbishment in case these gases are present. Ensure the inside of the STP, all pipework and the
compartment within which the STP is housed, is certified gas free prior to commencement of works or
entry into the compartment. Ensure correct PPE is worn, safe working practices are followed and a risk
assessment carried out by ships staff before commencement of any maintenance procedures on the vent
system.
ISSUE No. 1
ECN -
DATE 25/09/14
INITIALS WJD
CHECKED ART
APPROVED & DATE NHS 25/09/2014
PCH 1602 STC03-13 1P1C 3–15

3.2.3 Peak Loading Considerations R63261
PEAK LOADING R63261

CONSIDERATIONS FOR SHEET 1 SHEETS 2
SEWAGE TREATMENT
PLANTS
The Reason for Peak Load Limitations
The STC sewage treatment unit is designed to be able to treat a specified sewage flowrate and biological
sewage loading. This design flowrate allows the liquid to have a specific retention time in the Aeration,
Settling and Disinfection tank. This enables the sewage to be treated and discharged, complying with the
IMO MEPC 227(64) resolution.
However, at certain peak times, these flowrates may be exceeded which will affect the operation of the
unit. Limits must be applied to ensure that the retention times calculated for the unit are not compromised
to such an extent that the treatment process is adversely affected.
A biological peak loading can also be considered which is limited by the aeration capability of the unit.
Allowable Peak Loads

Allowable peak flows into the STP are detailed in Table 1.
This allowable peak flowrate is based on a 1-hour duration. There must be a 3-hour recovery period after
any peak loading to allow the hydraulic retention and settling process to recover.
Collection / Buffer Tank

In order to mitigate the problems of peak flows, a buffer tank can be used to collect the sewage and feed it,
via a dedicated feed pump into the STP at controlled flowrates. This allows the peak flows to be buffered.
The selection of the pump is critical and must be sized to ensure the correct flow to the unit is achieved
and excessive starting of the pump does not occur.
The feed pump can be controlled in various ways, depending on the feed pump chosen:
The pump can be controlled with a low level switch, allowing sewage to be pumped into the STP at an
allowable rate, when available. The volume above the low level switch provides buffering capability.
Alternatively, if a larger pump capacity is chosen, a timer along with the low level switch can be used to
allow the pump to run for set periods, still ensuring the peak flow load is not exceeded.
Low and high level switches can be used to batch appropriate flows into the STP, again ensuring the
flowrate is within the allowable limits. Alternative control using pressure transducers can also be utilised.
In each case, the pump must be protected from blockages by a suitable macerating device.
The size of this buffer tank must consider the expected sewage production peaks from all sources, and the
allowable flow in the STP to avoid overflows from the system.
(Buffer Tank, pump, level switches, macerator etc are not WWS Default Supply)
ISSUE 1
ECN -
DATE 25/09/14
INITIALS WJD
CHECKED ART
APPROVED/DATE NHS 25/09/2014
Form: T0104103
3–16 PCH 1602 STC03-13 1P1C

PEAK LOADING R63261

CONSIDERATIONS FOR SHEET 2 SHEETS 2
SEWAGE TREATMENT
PLANTS
Model Max. 1hr Max. Instant Max. 1hr Model Max. 1hr Max. Max. 1hr
Peak Feed Peak Peak Instant Peak
note 2& 3
Hydraulic Vol. Biological Hydraulic Feed Biological
note 2 note 2 note 2 note 2& note 2
Flow (litres) Load Flow Vol. Load
3
(litres/min. (kg/hr) (litres/min.) (litres) (kg/hr)
)
STC08-14 12.95 66 1.070

STC01-13 1.65 See note 1 0.124 STC10-14 14.67 103 1.159
STC02-13 3.42 6 0.253 STC13-14 22.07 140 1.549
STC03-13 5.10 10 0.383 STC15-14 22.30 150 1.078
STC04-13 6.47 15 0.485 STC20-14 27.62 200 1.747
STC06-13 11.00 35 0.825 STC25-14 39.70 190 2.135
RTC20-14 3.42 6 0.383 STC30-14 48.90 220 2.547
RTC40-14 6.47 15 0.485 STC40-14 63.28 300 2.547
RTC60-14 11.00 35 0.825 STC50-14 103.57 380 5.617
RTC80-14 12.95 66 1.070 STC60-14 105.00 400 5.617
Notes:
Table 1 Peak Loading Limits for STC & RTC

1. Not suitable.
2. All flows added directly to the aeration tank must be considered when assessing maximum feeding conditions.
3. Max 1 hr & average flow conditions still apply.
NB the Max Instant feed value listed is only applicable where all flow to aeration compartment is included in the batch.
Where other flows go direct to the aeration compartment the ‘Max Instant Feed’ batch size must be reduced proportionally.
ISSUE 1
ECN -
DATE 25/09/14
INITIALS WJD
CHECKED ART
APPROVED/DATE NHS 25/09/2014
Form: T0104103
PCH 1602 STC03-13 1P1C 3–17

3.2.4 Grey Water Streams R62742
Grey Water Streams Suitable for R62742

ST-C Sewage Treatment Plants SHEET 1 OF 1
WARTSILA WATER SYSTEMS LIMITED

POOLE, DORSET BH17 0JT UK
The document serves as an operational guidance and a design basis for grey water treatment in ST-C units.
1. Grey water need not be treated according to IMO MARPOL Annex IV.
2. Grey water streams, once mixed with black water, treated or untreated, have to be managed as black
water according to IMO MARPOL Annex IV.
3. Grey water flow rate is typically many times the black water flow. Grey water treatment cannot be
accomplished via a sewage treatment plant that is not correctly selected for that purpose. Treating only
black water reduces the capital and operational costs and simplifies the managerial procedures.
4. Grey (& black) water characteristics vary greatly due to the system configurations, equipment
specifications and conditions and the managerial and operational practices on board. Wartsila designs
the grey water treatment capacity against the specifications provided by our clients. In the absence of
such information the following assumptions apply:
Grey water Unit Commercial Peak

ships* Factor
Accommodation L/person/day 100 1.58
Galley L/person/day 15 1.58
Laundry-note 5.2 L/person/day 20 1.58
It should be noted that these assumptions are in accordance with Lloyds Register Environmental
Protection (EP) Notation 2011.
*For passenger, offshore and military applications in the absence of specifications provided by our
clients, advice must be obtained from Poole Sales/Engineering for flow rates to be used in the sizing
selection.
5. In addition, the following qualifications apply:
5.1. Galley grey water can be acceptable for treatment after it is pre-treated by a grease trap to achieve
fat, oil and grease (FOG) concentration to less than 300mg/l. No waste food or cooking oil is
allowed into the sewage plant. No piping connection to ST-C shall be made directly or indirectly
from pulverisers, food presses or similar devices. Strainers with 6mm holes or less shall be
provided for shower cubicles, galley sinks, and all other grey water connections that lead to the
treatment plants.
5.2. Low foaming and biodegradable cleaning products should be used on board.
5.3. Grey water can be used in place of dilution water to condition the black water.
5.4. It is preferable to mix the black and grey water in a collection tank to balance out the flow and
concentration fluctuations.
5.5. The mixed black and grey water feed into the ST-C units shall have the following characteristics:
- temperature < 40 degC

- Average BOD < 600 mg/l; and Average COD < 1,500 mg/l.
- FOG shall not exceed 100 mg/l.
- Total available chlorine < 1 mg/l.
ECN/ISSUE -/1 2 N060155/3 N060309/4 N060382 6/N060482 7/N060941

DATE 13/08/08 23/03/2009 24/8/11 5/12/11 15/2/12 12/6/12 17/10/13
INITIALS KWC KWC ART ART TMD TMD NHS
CHECKED ART WC ART ART ART ART ART
APPROVED/DATE TMD 13/08/08
3–18 PCH 1602 STC03-13 1P1C

3.3 Fitting Instructions for Items Packed Separately for

Safe Transit
WARNING
Manual Handling Warning possible crushed limb or serious injury from tripping
over — the discharge pump assembly weighs 62kg. Care must be taken when
attempting to manoeuvre the pump into position. Ships staff to perform a risk
assessment and produce a method statement prior to commencement of any
installation work. Correct PPE to be worn.
WARNING-ELECTRICITY
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 Discharge Pump General Arrangement
drawing is included in Section 6 “Discharge Pump B50x50HC” on page 6–1.
3.4 Compartment Ventilation

CAUTION
Ensure the compartment which contains the Sewage Treatment Plant has an
unrestricted supply of clean air for the compressors to operate correctly.
Minimum flow rates are shown under the heading ‘Compressor Duties’ in
Table 1–3 of Section 1.1.5 on page 1–2
Ensure that the compartment containing the Sewage Treatment plant has an unrestricted
supply of clean air (For flow rates see Section 1.1.5 “Compressor Electrical Ratings and
Duties” on page 1–2). Ventilation should be directed in the vicinity of the compressor
themselves, to provide ample cooling.
3.5 Space for Maintenance

A minimum space must be provided around the plant for diffuser, air lift and float switch
withdrawal. Refer to the relevant general arrangement drawing of each unit type for the
minimum space requirements.
PCH 1602 STC03-13 1P1C 3–19

3–20 PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 4. Commissioning and Operation
4. Commissioning and Operation
4.1 Start Up Procedures

4.1.1 General
This procedure covers the setting to work of the STP tank only. It does not cover the setting
to work of any vacuum collection, feed or sludge holding system.
4.1.2 Health and Safety Information

NOTE
Do not attempt to operate the Sewage Treatment Plant until the instruction book
has been read and understood.
WARNING
For all tasks carried out in relation to the operation of the unit ensure correct PPE
is worn.
WARNING-ELECTRICITY
WARNING
over. The Sodium Hypochlorite chemical tank weighs 25kg. Care must be taken
when attempting to manoeuvre the tanks into position. Ships staff to perform a
risk assessment and produce a method statement prior to installing the chemical
tanks. Correct PPE to be worn.
WARNING
over. The Sodium Bisulphite chemical tank weighs 25kg. Care must be taken
when attempting to manoeuvre the tanks into position. Ships staff to perform a
risk assessment and produce a method statement prior to installing the chemical
tanks. Correct PPE to be worn.
WARNING
Warning possible injury from pressurized equipment/manifolds causing leakage
of effluent, chemicals or compressed air. Correct PPE to be worn.
PCH 1602 STC03-13 1P1C 4–1

4. Commissioning and Operation Installation, Commissioning, Operating and Maintenance
WARNING
Warning, during normal operation and when the discharge pump is running, the
noise levels around the STP can exceed 80dBa. Wear ear protection.
WARNING
Care must be taken when working with raw sewage to prevent risk of raw
sewage related illnesses and diseases (by Ingestion, Skin contact or Inhalation).
For all tasks carried out in relation to the handling or working with raw sewage
ensure correct PPE is worn and that all personnel are adequately vaccinated.
Further guidance is available by following the two links below:
http://www.hse.gov.uk/pubns/indg197.pdf
http://www.dft.gov.uk/mca/mgn0033.pdf
NOTE
In the unlikely event of Methane Gas (CH4) being generated by the Sewage
Treatment Plant and the unlikely possibility of the gas causing a fire/explosion it
is advisable to fit gas detection equipment inside the compartment in which the
STP is housed to provide an early warning system.
Before commencement of commissioning, the handbook should be read and understood. All
chemical handling should be carried out in accordance with the Materials Safety Data Sheets
under Section 9.1 “Health and Safety” on page 9–1.
4.1.3 Preparation of Unit for Initial Operation

For Valve number positions see the P&I diagram in Section 9.2 “General Arrangement and P&I
Drawings” on page 9–29
1 Ensure that all valves in the air supply lines are open (that includes V8 & V9). Close
control panel isolator. Switch on the duty compressor (C1) and check for correct
rotation by placing a hand over the inlet. Suction effect indicates correct rotation. If
incorrect rotation is found then reverse two of the phase wires in the compressor motor
terminal box.
CAUTION
Check correct rotation of the compressor. Damage to equipment may occur if
the compressor is run in the wrong direction for more than 3 seconds.
WARNING-ELECTRICITY
Check operation of Pressure Regulator/Relief valve (V13) by throttling compressor discharge

valves (V8 & V9).
4–2 PCH 1602 STC03-13 1P1C

WARNING
Warning; possible injury due to exhausting compressed air. Use appropriate eye
protection and ear defenders.
Record the Pressure relief valve (V13) set point registered on G2 (Refer to Section 1.2 “Record
of Commissioning Data” on page 1–3). Open compressor discharge valves to check that relief
valve reseats.
WARNING
Hot air pipework surfaces and equipment; during normal operation the outlet of
the compressor, its associated pipework and the air distribution manifold on the
side of the STP will be hot and can cause burns. Ensure the correct PPE is used
when touching any of the air pipework.
Temporarily remove the “aeration tank inspection and maintenance hatches” from both sides
of the unit, this will allow you to check filling in the aeration compartment.
2 With compressor running, partially fill unit with water to cover diffusers. Adjust valve V9
to diffusers and visually inspect air to each diffuser via the local inspection cover.
NOTE
Remember to replace the “aeration tank inspection hatches” before filling the
tank fully for operation.
3 On “Pump” switch select auto on control panel.
4 Close all side and top hatches on tank, close valves V1, V3 and V6. Open valves V2 and
V5 and fill unit with clean sea water or fresh water until water flows into Contact Tank.
Check for leaks at covers. Close valves V2 and V5, open V3 and black water inlet valves
V0 and V6 of Discharge Pump.
5 Partially fill Contact Tank and prime Discharge Pump P1. Check pump rotation is in
accordance with the direction arrow on the pump casing. If incorrect rotation is found
then reverse two of the phase wires in the pump motor terminal box.
CAUTION
Check correct rotation of the discharge pump. Damage to equipment may occur
if the discharge pump is run in the wrong direction for more than 3 seconds.
WARNING-ELECTRICITY
Check pump discharges correctly with no sign of cavitation.
6 Check operation of pumps from float switch when in “AUTO”. (High level switch
activation starts discharge pump, low level emergence stops pump.)
PCH 1602 STC03-13 1P1C 4–3

7 Check operation of “High High Level” alarm switch.
8 Check that the Contact Tank level holds when the Discharge Pump is stopped, to
ensure that no syphoning occurs.
9 Check air pressure above liquid in Aeration Tank with manometer. Not to be more than
15mm (H20 “Water Gauge”) with compressor running. Record data on Commissioning
Sheet.
10 Commission the chlorination & de-chlorination dosing pumps IAW 4.1.4 and 4.1.5 then
turn ON ‘Dosing’ Switch on control panel.
4.1.4 Setting up Chlorination Dosing Pump

WARNING
Chemical Warning; possible injury from chemical contact or ingestion, ensure
the safety data sheet for the Sodium Hypochlorite chemical is read and followed.
Care must be taken when attempting to manoeuvre the tanks into position. Refer
to the relevant Safety Data Sheet in Section 9.1.2 “Sodium Bisulphite
(De-chlorination): Document SDS S011” on page 9–2. Correct PPE to be worn.
Note that chlorination and de-chlorination are only required in restricted waters.
A certain amount of Sodium Hypochlorite solution (14%) should be pumped by the
Chlorination Dosing Pump into the Contact Tank over a 10 minute period after the discharge
pump has stopped. The quantity and flow rate are shown in the following table. The timer in
the control panel (TR605) should be set to 10 minutes and be set to Mode ‘B’ for ‘One Shot’.
See also Section 8.1 “Chlorination Dosing Pump” on page 8–1.
If an alternative solution of Sodium Hypochlorite is available, different dosing rates should be
used. Figures based on a 10% solution of Sodium Hypochlorite have also been included for
information.
Table 4–1 Chlorination Dosing Requirement (Over 10 Minute Period)
Sodium Hypochlorite Approximate Daily

Contact Sodium Hypochlorite Flow Rate over 10 Chemical
Tank Dose Per Pump Out minute period Consumption
Working (10% Sol) (14% Sol) (10% Sol) (14% Sol) (10% Sol) (14% Sol)
Sewage Volume
Plant Type (m³) (ml) (ml) (lit/hr) (lit/hr) (lit) (lit)
STC03-13 0.230 160 115 0.960 0.690 3.3 2.3
Table 4–2 Chlorination Dosing Pump Settings
Dosing Pump Frequency ‘Switch 3’ Stroke Length (%) set with

(%) Setting ‘Switch 1’
(Shown in Diagram 4.1 below) (Shown in Diagram 4.1 below)
Sewage
Plant Type (10% Sol) (14% Sol) (10% Sol) (14% Sol)
STC03-13 Set to 75% Set to 75% 85% 62%
4–4 PCH 1602 STC03-13 1P1C

Fig 4–1 Chlorination Dosing Pump Control
Once the chemical dosing drum has been filled with Sodium Hypochlorite the Chlorination
Dosing Pump stroke rate frequency and stroke length should be set in accordance with
Table 4–2 and Fig 4–1 above. Once set, the dosing rate can be checked by dosing into a
measuring cylinder. The dosing pump settings in Table 4–2 are a guide and are dependent on
pressure in the tubing, therefore if the required dosing rates are not achieved then increase
or decrease the pump stroke length ‘s’ by adjusting Switch 1 on the pump to achieve the
desired output. If the unit has been commissioned on water, the residual chlorine in the
Contact Tank, taken from Sample Point V11 shortly before pump out should be 8 PPM or
greater.
When the unit has an established biomass, the residual chlorine in the tank just before pump
out will need to be measured by the operator and should be between 6 and 8 PPM. If this is
not the case then the dose should be adjusted accordingly. (See Section 4.5.2.3 “Analysis of
Residual Chlorine Content” on page 4–14 for analysis method.)
If the sodium hypochlorite solution is available, check it is within its shelf life.
After the chlorine dosing unit has been powered down due to an interruption in the main
power supply to the STP, it will automatically re-start once the power is returned to the panel
and dosing is called for by the panel. Please note the rest of the STC will restart automatically
after a power interruption.
4.1.5 Setting up De-chlorination Dosing Pump

WARNING
Chemical Warning: possible injury from chemical contact or ingestion, ensure
the safety data sheet for the Sodium Bisulphite chemical is read and followed.
Care must be taken when attempting to manoeuvre the tanks into position. Refer
to the relevant Safety Data Sheet in Section 9.1.3 “Sodium Hypochlorite
(Chlorination): Document SDS S024” on page 9–12. Eye Wash stations are
recommended and correct PPE to be worn.
Note that chlorination and de-chlorination are only required in restricted waters.
PCH 1602 STC03-13 1P1C 4–5

A certain amount of Sodium Bisulphite (12%) solution should be added to each litre of
disinfected effluent discharged from the Contact Tank during the pump out process, as
shown in the following table.
Table 4–3 De-chlorination Dosing Requirement
Sodium Bisulphite Approximate Daily

Contact Sodium Bisulphite Flow Rate required at Chemical
Tank Dose Per Pump Out pump Duty point Consumption
Working (12% Sol) (12% Sol) (12% Sol)
Sewage Volume
Plant Type (m³) (ml) (lit/hr)
STC03-13 0.230 87 3.02 1.8
Table 4–4 De-chlorination Dosing Pump Settings
Dosing Pump Frequency Stroke Length (%) set with

‘Switch 1’ Setting ‘Switch 2’
(Shown in Fig 4–2) (Shown in Fig 4–2)
Sewage Control
Plant Type (12% Sol) (12% Sol) Type
STC03-13 Set to III (100%) 56% 0
Fig 4–2 De-chlorination Dosing Pump Control
Once the chemical dosing drum has been filled with Sodium Bisulphite the above dosing
requirement must be achieved within the pump out period of the Contact Tank This time
period is affected by the pump capacity and the discharge head.
4–6 PCH 1602 STC03-13 1P1C

4.1.6 Setting up Discharge Pump Outlet Gauge Pressure
NOTE
Use of a Stroke length less than 30% will result in significant reduction in
metering accuracy.
In order to achieve the correct de-chlorination dosage, the discharge pressure on the
Pressure Gauge G1 should be set to 1.8 barg for a medium head pump, and 2.6 barg for a
high head pump by adjustment of the Diaphragm Valve V6. This will equate to a discharge
flowrate of 8m3/hr. (1 barg on the gauge equates to 10m head). With the discharge pressure
set as above, the Dechlorination Dosing Pump stroke rate & stroke length should be set as
shown in Table 4–4 on page 4–6 to provide a flow rate of 3.02 l/hr.
If the discharge pump (P1) has to be set at a different delivery pressure for any reason, the
de-chlorination dosing rate should be adjusted dependent on the value of the delivery
pressure in accordance with the graph shown in Section 8.3 “De-chlorination Dosing Rate
Against Discharge Pump Pressure” on page 8–56. This graph is based on Sodium Bisulphite
12% solution. Once the revised dosing rate is obtained from the graph then Table 4–5 on
page 4–7 provides a guide for the revised dosing pump settings required to achieve the
correct de-chlorination chemical flow for the medium and high head pump options or refer to
the manufacturers curve shown in Fig 4–3 on page 4–8 for a more accurate flow rate.
Delivery Pressures – Medium Head Pump
Dosing Pump Stroke Dosing Pump

Dosing Pump Flowrate Length ‘Switch 2’ Frequency ‘Switch 1’
(litres/hour) Setting (%) Setting (I/II/III)
Discharge Pump
Pressure (barg) (12% Sol) (12% Sol) (12% Sol)
1.63 5.3 99% III (100%)
1.70 4.4 82% III (100%)
1.80 3.0 56% III (100%)
1.90 2.2 85% II (50%)
1.95 1.9 70% II (50%)
Delivery Pressures – High Head Pump
Dosing Pump Stroke

Discharge Pump Dosing Pump Flowrate Length ‘Switch 2’ Dosing Pump Frequency
Pressure (barg) (litres/hour) Setting (%) ‘Switch 1’ Setting (I/II/III)
(12% Sol) (12% Sol) (12% Sol)

2.40 5.3 99% III (100%)
2.50 4.1 77% III (100%)
2.60 3.0 56% III (100%)
2.70 2.3 87% II (50%)
2.78 1.9 70% II (50%)
PCH 1602 STC03-13 1P1C 4–7

180 Strokes/min = Setting III (100%)

90 Strokes/min = Setting II (50%)
45 Strokes/min = Setting I (25%)
Fig 4–3 De-chlorination Dosing Pump Alternate Settings for Different Discharge
Pressures
If the unit has been commissioned on water, the residual chlorine in the effluent, taken from
Sample Point V12 during pump out, should be 0.5 PPM or less. (See Section 4.5.2 “STC unit
Routine Analysis ” on page 4–14 for analysis method). If this is not the case then the dosing
rate should be adjusted accordingly using Switch 2 in Fig 4–2 on page 4–6.
See also Section 8.1 “Chlorination Dosing Pump” on page 8–1
When the unit has an established biomass, the residual chlorine measured by operator in the
effluent taken from sample point V12 during pump out should be between 0 and 0.2 PPM. If
this is not the case then the dose should be adjusted accordingly. (See Section 4.5.2 “STC
unit Routine Analysis ” on page 4–14 for analysis method.)
4.1.7 Dilution Water Requirement for Vacuum Collected

Sewage
Vacuum collected sewage is highly concentrated due to the reduced flushing water volume.
If the sewage entering the STC has been collected via a vacuum collection method and to
allow the bacteria to aerobically digest the waste, it must be diluted.
The dilution water, clean sea or fresh water should be continuously dosed at the rate of
approximately 55 litres/person/day.
4–8 PCH 1602 STC03-13 1P1C

Care should be taken to ensure that the combined dilution water and raw sewage flow does
not exceed the designed daily hydraulic loading of the sewage treatment plant.
NOTE
Dilution water should be done with clean sea or fresh water, but it may be
possible to use grey water for this providing that the plant has been initially sized
on this basis. Dilution water should be fed to the aeration tank at a constant rate
for 24 hours/day to prevent shock loading. Consult Wärtsilä for the
recommended flow rate of water to be added. Dilution water combined with the
black water flow should never exceed the designed hydraulic flow of the unit.
This typically equates to the maximum dosing rates quoted in the following table:
Table 4–7 Maximum Dilution Water Dosing Rates
Sewage Plant Type Dosing Rate (l/min)

STC03-13 2.0
NOTE
If the sewage plant has been sized to treat black and grey water, dilution water is
not required.
For installations on board passenger vessels or if there is any doubt regarding the correct
dosing rate for a particular application Wärtsilä should be consulted.
4.2 Process start up Procedures

Process start-up may take a period of 7~10 days. During this period, the unit is operated
under automatic control, receiving the sewage feed. Bacteria will grow their population during
this period. Section 4.3 “Schedule of Routine Procedures” on page 4–10 is applicable during
this period.
NOTE
The activated sludge sewage treatment process relies on naturally occurring
bacteria found in raw sewage to break down and consume the organic material.
Due to this natural process it can take 7-10 days for the biomass to fully
establish itself. Therefore early effluent quality results may be affected during this
early period.
PCH 1602 STC03-13 1P1C 4–9

4.3 Schedule of Routine Procedures
WARNING
Handling raw sewage, use correct PPE.
4.3.1 Daily
1 Walk around to observe any abnormal equipment conditions.
Confirm the chlorination & de-chlorination pumps are operating automatically. If it is not
operating automatically refer to advice at end of Section 4.1.4 “Setting up Chlorination
Dosing Pump” on page 4–4.
2 Observation of ML physical conditions
3 Open & Close the gas ‘bleeder valve’ on the dosing pumps (Item 5 in the dosing pump
manual) to allow any trapped chlorine gas to be expelled.
4 Complete Daily Operational Log (See Section 4.3.6 “Daily Log Sheet” on page 4–11)
4.3.2 Every Three Days

1 Perform a ML (mixed liquor) settlement test in accordance with Section 4.5.2.2 “Mixed
Liquor (ML) Settlement test” on page 4–14 using the 500ml measuring cylinder
provided, and if the sludge level is more than 300ml (or 60% of the volume of the
measuring device used) then perform a de-sludge operation in accordance with
Section 4.4.1 “De-sludge Operation ” on page 4–12.
4.3.3 Weekly
1 Inspect compressor inlet filter
4.3.4 Monthly
1 Clean compressor inlet filter
Note if air pressure rises above 0.2 Bar (31bF/in2) above original commissioning pressure at
any time, check filters and aerators and replace as necessary. A blocked inlet air filter can
restrict the compressor output which will contribute to early blockage of diffusers. A blocked
inlet filter may also hide the fact that the diffusers are blocking, because the compressor
discharge pressure will reduce as the airflow reduces.
4.3.5 Every 3 months

1 Calibrate Chlorination Dosing Pump (see Section 4.1.4 “Setting up Chlorination Dosing
Pump” on page 4–4)
2 Calibrate De-chlorination Dosing Pump (See Section 4.1.5 “Setting up De-chlorination

Dosing Pump” on page 4–5)
3 Fill In Commissioning Log Sheet and assess changes (See Section 1.2 “Record of
Commissioning Data” on page 1–3)
4–10 PCH 1602 STC03-13 1P1C

4.3.6 Daily Log Sheet
R62741
ST-C Daily Log Sheet
SHEET 1 OF 1
WARTSILA WATER SYSTEMS LIMITED

POOLE, DORSET BH17 0JT UK
Date Compressor Settling Biomass Biomass De-sludge
Time Pressure ML Colour Smell Comments
DD/MM/YY (Bar) (%) (1,2,3) (1,2,3) (Yes/No)
Colour Colour Smell Settling Decision

Description
- Mixed liquor (ML) -1 Mixed liquor (ML)
-1 <30% Good
light-brown earthy smell
. ML dark-brown
.2 ML slight sulphide
-2 >30-<60% OK
smell.
/ ML grey,
/3 ML foul smell. /3 >60% De-sludge
dark-grey or black
ECN/ISSUE 1 2/N060942
DATE 13/08/08 17/10/13
INITIALS KWC NHS
CHECKED ART ART
APPROVED/DATE TMD 17/08/08
PCH 1602 STC03-13 1P1C 4–11

4.4 Methods for Routine Procedures

4.4.1 De-sludge Operation
See the General Arrangement Drawing & P&I diagram in Section 9.2 “General Arrangement
and P&I Drawings” on page 9–29 for the valve references.
The sludge can be discharged overboard, if outside controlled waters, or to a specific sludge
holding tank or shore facility.
NOTE
When de-sludging overboard. You must ensure you are outside controlled
waters. If inside controlled waters then discharge must be to a sludge holding
tank or dedicated shore facility.
These de-sludge operations will have to be carried out as and when the Mixed Liquor (ML)
settlement tests at 4.5.2.2 indicate that it requires it:
1 Close valve V3 and open Valve V1.
2 Turn the dosing switch to ‘OFF’.
3 Valves in the discharge line must be positioned to divert flow either to an onboard
holding tank or overboard, if outside controlled waters. (Note: Check suitable capacity
is available in the sludge tank for storage of the sludge or ensure correct interlocks exist
to avoid overfilling holding tank – See Table 4–8 on page 4–13 for necessary de-sludge
volumes).
NOTE
Before de-sludging commences and if inside controlled waters, make sure there
is sufficient capacity in the sludge holding tank or the correct interlocks exist to
avoid overfilling of the holding tank.
4 Operate the Discharge Pump (P1) in manual ‘MAN’ until the Settlement Tank is emptied
completely.
Note: An amount of fluid will gravitate from the Aeration Tank at this time. This will allow
the settling tank to be flushed through to a certain degree.
5 After the pressure is seen to fall on the discharge pressure gauge, switch the Discharge
Pump ‘OFF’.
6 Close Valve V1 and open Valve V3.
7 Turn the dosing switch to ‘ON’.
8 Turn the discharge pump back to ‘Auto’ on the panel.
9 If the sludge is being stored in the holding tank, it should be aerated to avoid anaerobic
conditions.
10 The contents of the sludge tank should be discharged at the soonest opportunity.
4–12 PCH 1602 STC03-13 1P1C

Table 4–8 Estimated De-sludge Volume from Each De-sludge Operation
Sewage Plant Type Total Volume Wasted during De-sludge (m³)

STC03-13 0.6
NOTE
The volumes shown in Table 4–8 above are required for each de-sludge
operation. If the vessel is unable to de-sludge overboard for a significant length
of time, it will be necessary to retain multiple de-sludges onboard.
PCH 1602 STC03-13 1P1C 4–13

4.5 Sampling and Analysis

4.5.1 STC unit Sampling Points
The STC sampling points are illustrated in the General Arrangement Drawing & P&I diagram
in Section 9.2 “General Arrangement and P&I Drawings” on page 9–29.
WARNING
Handling raw sewage, use correct PPE.
Sampling Point (V11) is fitted to the Contact Tank for official sampling purpose and laboratory
analysis of the following:
Total Suspended Solids
BOD
COD
Faecal Coilforms
Sampling Point (V12), downstream of the Discharge Pump is used for official sampling
purposes and laboratory analysis of the following:
Residual Chlorine, and pH
4.5.2 STC unit Routine Analysis

4.5.2.1 Requirement
Routine testing of the biology is necessary to ensure the unit is operating correctly.
4.5.2.2 Mixed Liquor (ML) Settlement test

The ML sample is taken from the Aeration Tank sample point V10. The sample should be run
through to ensure a representative sample is taken. The liquid should be placed in the 500ml
cylinder (supplied) and allowed to settle for 30 minutes.
If the level of the settled sludge is more than 300ml (or 60% of the cylinder volume if using a
different measuring cylinder) then carry out the De-sludge Operation as detailed in
Section 4.4.1 “De-sludge Operation ” on page 4–12.
4.5.2.3 Analysis of Residual Chlorine Content

The Residual Chlorine tests can be carried out using the chlorine test kit Wärtsilä part number
R63058 supplied with the unit.
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) Wärtsilä Part Number T9201005
1 Cleaning Brush
1 Stirrer
WARNING
DPD No. 4 Tablets for checking PH and residual chlorine levels are of low toxicity
and present a minimal hazard but observe correct use of PPE when handling the
tablets. Ensure the safety data sheet for the DPD No.4 tablet is read and
followed. Refer to the relevant Safety Data Sheet in Section 9.1.1 “DPD No. 4
Tablets” on page 9–1.
4–14 PCH 1602 STC03-13 1P1C

Ensure chambers are clean then:
1 Fill the middle chamber with sample up to the line.
2 Dependent on the expected chlorine level, fill either the left or the right hand chamber
up to the line.
3 Add D.P.D. tablets to left or right hand chamber and crush with stirrer. (Replacement
tablets Wärtsilä Part Number T9201005).
4 Make comparison to the colour chart on the test kit.
4.6 Unit Shut Down Procedure

4.6.1 General
The STC unit needs to be shut down in situations such as:
• Total loss of aeration capacity (loss of compressor capacity and the ship’s back-up air
supply).
• Prolonged period of no feed (such as a dry dock period).
• Maintenance work that requires the unit to be emptied and cleaned.
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.
4.6.2 Unit shut down for a short period without emptying (Up to
6 Hours)
The wastewater feed shall be stopped immediately if the air supply is lost. The unit can remain
shut down and without aeration for up to 6 hours. During this period, there is no need to empty
the unit.
The unit must be emptied if it remains without aeration for a longer period.
4.6.3 Unit shut down for a long period

DANGER
pipework and the compartment within which the STP is housed is certified gas
carried out by ships staff before commencement of any maintenance
If the unit is to be shut down for up to a week, and there is a suitably aerated Sludge Holding
Tank, the biomass within the STC Aeration Tank can be transferred to this Sludge Holding
Tank as a seeding material. The remaining sludge can be discharged. This biomass from the
PCH 1602 STC03-13 1P1C 4–15

Sludge Holding Tank can be returned to the STC unit at restart to reduce the process start up
time. If there is no aerated Sludge Holding Tank or the unit will be shut down for longer than
one week, the following procedure should be followed.
For Valve number positions see the P&I diagram in Section 9.2 “General Arrangement and P&I
Drawings” on page 9–29.
1 Close the valves V0 on the raw sewage and waste water inlet lines, or alternatively,
ensure that the connected appliances are not used.
2 Select the ‘Pump’ control panel switch to OFF and set the Control Panel ‘Dosing’ switch
to OFF, this will switch off the discharge pump and both the Chlorination &
De-chlorination Dosing Pumps.
3 Close valves V1, V3 and V5.
4 Open valve V2.
5 Select ‘MAN’ (manual pump operation) on the control panel switch to operate the
Discharge Pump to empty the Aeration Tank.
6 When empty, close valve V2 and open valve V1.
Discharge Pump to empty the Settlement Tank.
8 Close V1 and open V3.
Discharge Pump to empty the Contact Tank.
10 Flush all tanks with a suitable hose, and empty content by repeating above steps.
11 Isolate Vent connection when applicable.
12 Inspect the internal coating and recoat as necessary.
13 Examine the inspection cover joints for serviceability and renew if necessary. Refit the
joints and covers.
4–16 PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 5. Maintenance and Trouble Shooting
5. Maintenance and Trouble Shooting
WARNING
For all tasks carried out in relation to the maintenance of the unit ensure correct
PPE is worn.
WARNING
Care must be taken when working with raw sewage to prevent risk of raw
sewage related illnesses and diseases. For all tasks carried out in relation to the
handling or working with raw sewage ensure correct PPE is worn and that all
personnel are adequately vaccinated. Further guidance is available by following
the two links below.
http://www.hse.gov.uk/pubns/indg197.pdf
http://www.dft.gov.uk/mca/mgn0033.pdf
WARNING-ELECTRICITY
Danger of risk of personal injury due to electric shocks. During any routine or
failure maintenance the correct control panel lock-off procedures are to be
carried out by a suitably qualified and competent electrical installer before any
work is carried out on any electrical items. All electrical components are to be
checked with a proprietary voltage tester prior to commencement of work and
confirmed as electrically dead.
WARNING-ELECTRICITY
Danger of risk of personal injury due to electric shocks. During any routine or
failure maintenance ensure all earth cables and earth bonding is reconnected
prior to re-starting the equipment or making the control panel live.
WARNING
Warning: possible cut injury from sharp edges when removing the pipe clamps
from the air distribution pipework. Use appropriate PPE.
WARNING
Care must be taken when handling discarded spare parts or broken components
that are contaminated with raw sewage. Segregate the discarded parts by
correctly cleaning or bagging them to prevent base staff and ship's crew
becoming ill as a result of raw sewage related illnesses and diseases (by
Ingestion, Skin contact or Inhalation). For all tasks carried out in relation to the
handling of the components contaminated with raw sewage ensure correct PPE
is worn and that all personnel are adequately vaccinated.
PCH 1602 STC03-13 1P1C 5–1

5. Maintenance and Trouble Shooting Installation, Commissioning, Operating and Maintenance
CAUTION
If connecting a new piece of electrical equipment to the sewage treatment plant
electrical system, check that the supply voltage is in accordance with the motor
nameplate before connecting to the supply.
5.1 Maintenance Schedule

5.1.1 Monthly
Coarse screen filter to be inspected and any plastic bags or other debris etc. to be removed.
Access to screen is obtained through the circular inspection cover on top of the sewage
treatment plant.
DANGER
Working at Height: danger of falling. Ensure Ship’s staff produce the necessary
risk assessment and method statement for safe access to the top of the sewage
treatment plant.
5.1.2 3 Monthly
Examine filter cartridges fitted to the air compressor and replace if dirty. (These may be
cleaned by blowing air from the inside of the cartridge outwards in an emergency).
WARNING
Hot air pipework surfaces and equipment; during normal operation the outlet of
the compressor, its associated pipework, filter and the air distribution manifold
on the side of the STP will be hot and can cause burns. Ensure the correct PPE
is used when touching any of the air system components
WARNING
Danger of injury when using compressed air. When attempting to clean the filter
with compressed air, solid particles may be carried along or powder dust
swirling around may cause injuries to the eyes. Use correct PPE to protect
personnel.
Check the functioning of the non-return valve fitted to the air line.
5.1.3 Annually
Drain and clean all compartments of the unit and inspect and repair any damaged coating.
(See Section 4.6.3 “Unit shut down for a long period ” on page 4–15)
For instructions on how to repair the damaged coating, contact the technical service
department listed in the front of this manual. See Spare Parts and Service on page xi.
WARNING
Access to confined spaces. Ship’s staff to produce a risk assessment and
method statement for working in confined spaces prior to carrying out any
internal maintenance on the Sewage Treatment Plant.
5–2 PCH 1602 STC03-13 1P1C

DANGER
pipework and the compartment within which the STP is housed, is certified gas
carried out by ship’s staff before commencement of any maintenance
WARNING
Inhalation of toxic fumes; when carrying out any paintwork repair to the internal
or external surfaces, the area in which the operation is being carried out is to be
kept well ventilated. Refer to the specific safety data sheet for the paint being
applied. Use appropriate PPE for the task.
Inspect the Discharge Pump and Air Compressor for wear. (Refer to Section 6 “Discharge
Pump B50x50HC” on page 6–1 and Section 7 “Compressor (Type CYBW-25)” on page 7–1)
for information about how to repair the pump and compressor.
Replace aerator air diffuser ceramic elements. See Section 5.3.2 “Air Diffuser Assemblies
Replacement Procedures” on page 5–5.
NOTE
If the air pressure reading on the pressure gauge (G2) rises 0.2 Bar (3 lbf/in2)
above the original commissioned working pressure (recorded at Section 1.2
“Record of Commissioning Data” on page 1–3) at any time, check both filter
cartridges and aerators and replace as necessary.
PCH 1602 STC03-13 1P1C 5–3

5.2 Trouble Shooting

Table 5–1 STC Trouble Shooting Guide
Problem Cause Remedy

Tank overflow. Pump failure. Check electrical circuit.
Blockage. Check for discharge pipe blockage.
High-level alarm.
Excessive input. Check feed regime.
Check for leaking flush valves on
w.c.s.
Noxious odour emissions. Anaerobic condition caused by a Check compressor pressure.
lack of aeration or overloading Check compressor inlet filters.
within the Aeration Tank. Check air diffusers for blockage.
High sludge level in Settlement Carry out Settlement Test as per
Tank. 4.5.2.2 and de-sludge if necessary.
Poor Biomass conditions. Check compressor, diffusers, filters
and valve positions.
Check toilet cleaning chemical is
bio-degradable with low toxicity.
Check abnormal use of toilet
cleaning chemicals.
Turbid effluent with fine particles. Eliminate toxic cleaners.
Poor effluent quality. Turbid effluent with large particles. Check de-sludge frequency.
(Note: Allow 7-10 days Check feed regime.
process start-up period No RAS flow. Check compressor, diffusers, filters
before raising concerns and valve positions.
over effluent quality). Remove orifice plate and check for
blockages
Excessive hydraulic throughput. Check for leaking flush valves on
w.c.s and urinals.
Check feed regime.
Check dilution water if applicable.
Scum build up on Settlement Tank Carry out De-sludge operation.
surface. Check RAS flow.
Rising bubbles in Settlement Tank Check de-sludge frequency.
due to De-nitrification. Check RAS flow.
High Faecal Coliform Count Under dosing of Chlorine Check Chemical Tank level.
chemical. Check / Calibrate dosing pump rate.
Low chlorine levels in Under dosing of Chlorine Check Chemical Tank level.
Contact Tank (Sample chemical. Check / Calibrate dosing rate.
Point V11) Check shelf life of Chemical.
High chlorine levels in Under dosing of De-chlorinating Check Chemical Tank level.
Effluent. (Sample Point chemical. Check / Calibrate dosing rate.
V12/V12A) Check overdose of Chlorine
chemical.
Foaming in aeration tank. Excessive use of cleaning agents. Use low foam cleaners and prevent
emptying of cleaners’ buckets down
w.c.s.
Check de-sludge frequency.
Compressor pressure Fouling Diffusers Inspect / replace diffusers
Increase by >0.2 Bar from Orifice Plate blocked Remove and check for blockages
commissioning data.
Vent Blockage Check vent pressure.
Compressor pressure Problem with down pipe/diffuser Inspect / replace diffusers
decrease by >0.1 Bar from
commissioning data.
5–4 PCH 1602 STC03-13 1P1C

5.3 Specific Maintenance Procedures

5.3.1 Cleaning the Dosing Pump Injectors
The sodium hypochlorite & sodium bisulphite dosing injectors must be cleaned periodically,
at intervals determined by the characteristics of the chemical used.
WARNING
Chemical Warning possible injury from chemical contact or ingestion, ensure the
safety data sheet for the Sodium Hypochlorite & Sodium Bisulphite chemical is
read and followed. Care must be taken when attempting to clean the dosing
injectors. Refer to the relevant Safety Data Sheets in Section 9.1.2 and 9.1.3.
Eye wash stations are recommended & correct PPE to be worn.
5.3.2 Air Diffuser Assemblies Replacement Procedures

5.3.2.1 General
NOTE
All maintenance to the diffuser assemblies should be possible without having to
gain access to the inside of the tank.
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 reading rises by 0.2 Bar (3lbf/in2) above the original commissioning
pressure, or if the air pressure relief valve is blowing. Ensure that the air filter cartridges are
clean and that the airlift valves are adjusted to give the required flow.
NOTE
If the air pressure reading on the pressure gauge (G2) rises 0.2 Bar (3 lbf/in2)
above the original commissioned working pressure (recorded at Section 1.2
“Record of Commissioning Data” on page 1–3) at any time, check both filter
cartridges and aerators and replace as necessary.
5.3.2.2 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.
WARNING
Manual Handling, removing access hatch from side of aeration compartment
and danger of crushed limbs. The access hatch weighs approximately 20kg;
care must be taken when removing the hatch. Correct PPE to be worn.
Remove wing nut and washer and withdraw ceramic element.

Fit a new element taking care that the stainless steel washers are in place at either end.
Replace the wing nut taking care not to over tighten.
Replace diffuser assembly in the tank taking care to locate spigot in the bracket in the bottom
of the tank. Replace manhole cover.
PCH 1602 STC03-13 1P1C 5–5

WARNING
Beware of the potential for head injury when leaning into the tank compartment.
Wear appropriate PPE.
5.3.3 Discharge Pump Maintenance Procedures

Refer to Section 6 “Discharge Pump B50x50HC” on page 6–1 for details of discharge pump
maintenance.
5.3.4 Compressor Maintenance Procedures

Refer to Section 7 “Compressor (Type CYBW-25)” on page 7–1 for details of compressor
maintenance.
5.3.5 Removing Dosing Skid

When following this procedure for removing the dosing skid refer to Sheet 8 of 8 of the
sectional arrangement STC02-06-103 found in Section 9.3 “Sectional Arrangements” on
page 9–33.
1 Isolate/disconnect the 110/220V & 24V supplies to the junction box (Item LDF031) and
make the loose cables electrically safe.
WARNING-ELECTRICITY
Danger or risk of personal injury due to electric shock. Any electrical connections
or work on the control panel to be done by ship’s staff is to be carried out by a
suitably competent and qualified electrical installer.
2 If the sodium hypochlorite & sodium bisulphite chemical tanks are full then disconnect
the suction lance and remove these from the bunds separately to reduce the overall
weight of the dosing skid remembering to replace the cap on the chemical tank to avoid
spills.
WARNING
Manual Handling Warning: possible crushed limb or serious injury from tripping
over - The Sodium Hypochlorite and Bisulphite chemical tanks weigh 25kg.
Correct PPE to be worn and manual handling assessment to be done.
3 Disconnect the chemical supply hose (Item LDF026 & LDF027) from the outlet of both
dosing pumps.
WARNING
Chemical Warning: possible injury from chemical contact or ingestion, ensure
the safety data sheet for the Sodium Hypochlorite & Sodium Bisulphite chemical
is read and followed. Refer to the relevant Safety Data Sheets in Section 9.1.2
“Sodium Bisulphite (De-chlorination): Document SDS S011” on page 9–2 and
Section 9.1.3 “Sodium Hypochlorite (Chlorination): Document SDS S024” on
page 9–12. Eye wash stations are recommended and correct PPE to be worn.
5–6 PCH 1602 STC03-13 1P1C

4 Remove the nuts and washers items (LDF003, LDF004 & LDF005) from the studs holding
the skid to the tank.
CAUTION
The skid may fall of the studs as the nuts and washers are removed. Apply
pressure to the top of the skid to prevent damage to the equipment.
5 With 2 personnel, lift the skid of the tank and place it on a firm level surface.
WARNING
Manual Handling Warning; possible crushed limb or serious injury from tripping
over - the dosing skid weighs 33kg. Correct PPE to be worn and manual
handling assessment to be done.
6 To replace the skid, reverse steps 1 to 5 above and re-connect the junction box in
accordance with sheet 5 of the relevant circuit diagram in Section 9.4 “Electrical
Drawings” on page 9–42.
5.3.6 Removing Control Panel

1 Isolate the incoming ships supply and make the panel electrically safe.
WARNING-ELECTRICITY
Danger of risk of personal injury due to electric shock. When removing the
control panel the correct lock-off procedures are to be carried out by a suitably
qualified and competent electrical installer before attempting to remove the
control panel. All electrical components are to be checked with a proprietary
voltage tester prior to commencement of work and confirmed as electrically
dead.
2 Disconnect all incoming cables for the compressor, discharge pump, controls, dosing
pumps, level switch and any other ships control wires that are connected to the control
panel.
3 Remove the lock nuts and washers (Item EMB025 & EMB030 shown on sectional
arrangement drawing STC02-06-103 Sheet 1 of 8).
CAUTION
The control panel may fall off the studs as the nuts and washers are removed.
Apply pressure to the top of the control panel to prevent damage to the
equipment
4 Using a sling and hoist where possible and remove the control panel and place on a flat
sturdy surface.
WARNING
Manual Handling Warning; possible crushed limb - The control panel weighs
approximately 63kg. Correct PPE to be worn and lifting assessment to be
carried out by ship’s staff prior to removal of the control panel.
PCH 1602 STC03-13 1P1C 5–7

5 To replace the control panel reverse steps 1 to 4 above and re-wire the control panel in
accordance with the relevant circuit & installation wiring diagrams in Section 9.4
“Electrical Drawings” on page 9–42.
5.3.7 Removing Ruptured Chemical Tank

In the event that either the sodium hypochlorite or the sodium bisulphite chemical tanks
rupture and spill their contents into the chemical bunds in the dosing skid, the following
procedure should be followed. Refer to sectional arrangement STC02-06-103 Sheet 8 on
page 9–41 for the item numbers referenced below.
1 Switch ‘OFF’ the dosing switch on the control panel.
2 Using a separate chemical container that is free from damage, pump the contents of the
bund into the separate container using a hand pump. This will make removal of the bund
easier and provide a safe means of disposal of the spilt chemicals.
WARNING
Chemical Warning; possible injury from chemical contact or ingestion, ensure
the safety data sheet for the Sodium Hypochlorite & Sodium Bisulphite chemical
is read and followed. Refer to the relevant Safety Data Sheets in Section 9.1.2
“Sodium Bisulphite (De-chlorination): Document SDS S011” on page 9–2 and
Section 9.1.3 “Sodium Hypochlorite (Chlorination): Document SDS S024” on
page 9–12. Eye wash stations are recommended and correct PPE to be worn
3 Once the majority of the spilt chemical has been removed from the bund remove the
lashing strap (Item LDF014) & disconnect/remove the suction lance from the dosing
tank.
4 Remove the chemical tank from the bund and place on suitably absorbent material to
prevent further contamination.
5 Lift the bund out of the frame and pour the residual spilt chemical into the disposal
container.
NOTE
The bund in the dosing skid is there to retain spilt chemicals and shouldn't be
used to transport the spilt chemical for disposal. Do not attempt to lift the bund
out of the frame when full of chemicals.
6 Clean the bund with suitable cleaning materials (refer to the relevant safety data sheet
in section 9.1.2 & 9.1.3 for information about how to clean up the chemical). Then
replace the bund back into the frame.
7 Fit new chemical container into the bund and replace/refit the suction lance, replace the
lashing strap and tighten.
8 Turn the dosing switch ‘ON’ on the control panel.
9 Dispose of spilt chemical and clean up surrounding area to make safe.
5–8 PCH 1602 STC03-13 1P1C

5.3.8 Dosing Pump Head Exploded View for Spares Items

In the event that either the sodium hypochlorite or the sodium bisulphite pump head fittings
break in service, identify the broken component from the illustrations below and include the
item number & description in the request for replacement spare parts.
100 Dos.h.ass. 70x12.5-2 hc50 PVT 130 Union nut M20x1.5x25, white PVDF
MFV
101 Disch.valve cpl. 4.7-2 PVT 133 union nut d6-G1/8 PVDF
102 Suct.valve cpl. 4.7-2 PVT 135 Valve ball 4.7 mm Al2 O3
103 Vent valve cpl. -2 PVDF/PTFE 136 Valve spring d0.3/DA 3.9 0.1bar 1.4571
104 Connect. set 6x 4 PVT 138 valve face 3.0x10.5 (d4.7) PVDF
110 Dosing head 70x12,5-2 hc 50 PVDF 139 Flat gasket 17.8x 6.5x1 PTFE
112 Discharge conn. M20x1.5 (d4.7) PVDF 141 O_ring 14.00 - 2.00 PTFE
113 Suction conn. M20x1.5 (4.7) PVDF 143 gasket D14xd6x0,5 PTFE
115 Knob for vent valve dosh. FLOW.CON. 150 Flat gasket 17.8x 6.5x1 PTFE
122 Valve insert 4.7 -2 bypass PVDF 200 Diaphragm 30.0x 7.5 -M5 PTFE
123 Valve insert 4.7-2 PVDF 201 Back plate 70x12,5-E hc50 PPE
RAL7016
128 Tube nozzle 6 x 4 PVDF MFV 202 Cyl.screw DIN 912 M 5x 45
129 Clamp ring d 6 PVDF MFV 204 Washer
Fig 5–1 Chlorination Dosing Pump Liquid End Spares – CNPb1602PVT (STC03-13)
PCH 1602 STC03-13 1P1C 5–9

1 Valve insert for vent valve; PP 13 Tube nozzle 8x5; PP
2 Dosing head for CONC0806; PP 14 Clamp ring D8; PPE
3 Back plate for CONC08 RAL 5003; PPE 15 Union nut M20 x 1.5x25; PP
4 Discharge connection M20x1.5-2; PP 16 Tube nozzle for vent valve; PP
5 Suction connection M20x1.5-2; PP 17 Moulding gasket 14x1.5; FPM-B
6 Knob for vent valve; ABS 18 Valve Ball 9.2mm MFV; AL203
7 Valve insert under 9.2-2; PP 19 Diaphragm 46.0 x 21.5-M5; PTFE
8 Valve insert tops 9.2-2; PP 20 O Ring/m 14.00 – 2.00; FPM-B
9 Valve lid 9.2-2; PP 21 O Ring 7.65 – 1.78; FKM
10 Cap head Screw DIN 912 M5 x 45; A4 22 O Ring 3.68 – 1.78; FKM
11 Washer DIN 9021 5.3 / 15; A2 23 O Ring/m 9.00 – 2.50 BPV; FPM-B
12 Disc d 13 / d 9.5 x 1 MFV; PP
Fig 5–2 De-chlorination Dosing Pump Liquid End Spares – CONC0806PP2
5–10 PCH 1602 STC03-13 1P1C

5.4 Recommended Spares List

Items within the STC unit are illustrated, numbered, and described in Section 9.3 “Sectional
Arrangements” on page 9–33
When ordering spare parts, or in any correspondence, please include the following data:
• The STC unit serial number (this is stamped on the unit nameplate and begins with “GO…”)
• For each spare part: the relevant Sectional Arrangement Drawing Number, and the Item
Number and Item Description as listed on the Sectional Arrangement Drawing in
Section 9.3 “Sectional Arrangements” on page 9–33.
NOTE
When ordering spare parts, remember to always provide the type and serial
WARNING
Care must be taken when handling discarded spare parts or broken components
that are contaminated with raw sewage. Segregate the discarded parts by
correctly cleaning or bagging them to prevent base staff and ship's crew
becoming ill as a result of raw sewage related illnesses and diseases (by
Ingestion, Skin contact or Inhalation). For all tasks carried out in relation to the
handling of the components contaminated with raw sewage ensure correct PPE
is worn and that all personnel are adequately vaccinated.
PCH 1602 STC03-13 1P1C 5–11

Table 5–2 Recommended List of Spares
Wärtsilä
1 2 3 5 Part
Equipment Description Qty Year Year Year Year Number
Impeller Screw 1 X X X X 32521502
Peel off Shim 1 Pump Set X X X X 31511546
Tab Washer 1 X X X X 31512585
O ring - Impeller 1 X X X X 42010082
O Ring - Casing 1 X X X X 42030445
Discharge Pump Liquid Thrower 1 X X X 36712131
Mechanical Seal 1 X X X 42619072
Impeller - Medium Head 18m 50Hz & High
3446401100
Head 26m Pump 60Hz (Ø130) Select 1 by
X X X
Impeller - Medium Head 18m Pump @ 60Hz Pump Type
3446401101
(Ø116)
Carbon Blades 1 Compressor STCXX-
Compressor X X X X
Filter Element Set 9550002
Contactor - 110V Control Circuit X X X X 98100058
Control Panel - 110V
Auxiliary Contact
Control Circuit
Relay Select 1 by
Contactor - 220V Control Circuit control voltage X X X X 98100059
Control Panel - 220V
Auxiliary Contact
Control Circuit
Relay
Test Kit c/w Lovibond DPD No.4 Tablets x 50 1 Kit X X X X R49727
Sampling Kit
Measuring Cylinder 1 X X X X 49440019
RTCXX-
Chlorination Chemical Drum 10 Litre Drum - Grey 1
4900005
De-Chlorination Chemical RTCXX-
10 Litre Drum - White 1
Drum 4900006
25 Litres of Sodium Hypochlorite Chemical
Chlorination Chemical 1 B18013
(14% concentration)
25 Litres of Sodium Bisulphite Chemical (12%
De-Chlorination Chemical 1 B18014
concentration)
Metering Diaphragm
Intake Valve Complete
Chlorination Dosing Pump
Discharge Valve Complete 1 Set X X X X 8511200336
Kit Comprising
Kit of Seals
Ball Valves x 2
Metering Diaphragm
Intake Valve Complete
De-Chlorination Dosing
Discharge Valve Complete 1 Set X X X X 8511200269
Pump Kit Comprising
Kit of Seals
Connection Kit
Chlorination Dosing Pump - Suction Lance c/w screw cap and signal STCXX-
1 X X
Suction Line cable 4900059
De-Chlorination Dosing Suction Lance c/w screw cap and signal STCXX-
1 X X
Pump - Suction Line cable 00060
Tank Set of Diffusers Seal washer 24 X X X X 36212272
Comprising Ceramic Diffuser Element 12 X X X X 49550023
Tank Internals Filter Screen 1 X X 33547944
Contact Tank Level Switch 1 X T2801080
Float switch - Round 2 X X X X 36234474
Hatch Cover Joints
Hatch - Large 4 X X X X 36154243
5–12 PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 6. Discharge Pump B50x50HC
6. Discharge Pump B50x50HC
NOTE
Wärtsilä reserve the right to update the technical data in Section 6 of this
instruction manual at our sole discretion. Thus, such information may be
changed or updated without prior notice.
PCH 1602 STC03-13 1P1C 6–1

6. Discharge Pump B50x50HC Installation, Commissioning, Operating and Maintenance
6.1 Technical Data

6.1.1 Standard Discharge Pump Performance
Table 6–1 Standard Discharge Pump Performance
Pump type Capacity Head

B50 x 50HC Medium Head Up to 35 m3 /hr Up to 18 Metres
B50 x 50HC High Head Up to 42 m3 /hr Up to 25 Metres
6.1.2 Recommended Tightening Torque — Discharge Pump

Table 6–2 Recommended Tightening Torque — Discharge Pump
Component Torque Setting

Impeller Screw (Item 8) 3.0 kg m
Stud and Nut (Item 22 and 23) 5.0 kg m
Bolt and Nut (Item 19 and 20) 3.0 kg m
6.1.3 Discharge Pump Motor Speed

Table 6–3 Discharge Pump Motor Speed
Frequency Speed
50 Hz (2 pole) 2925 rev/min.

60 Hz (2 pole) 3525 rev/min.
6.1.4 General Dimensions

Refer to the General Arrangement drawing in Section 6.6 on page 6–18 or that supplied with
the contract documents for maximum equipment weight, dimensions and the minimum
clearance needed for dismantling.
6.1.5 Rotation
The direction of rotation is clockwise when looking at the non-drive end of the pump.
CAUTION
6.1.6 Bearing Lubrication

The motor bearings must be lubricated as detailed in the motor manufacturer’s handbook.
6–2 PCH 1602 STC03-13 1P1C

6.1.7 Discharge Pump Weight
Table 6–4 Discharge Pump Weight
Discharge Pump Weight

Discharge Pump Nett Weight 62kg
WARNING
over - the discharge pump assembly weighs 62kg. Care must be taken when
attempting to manoeuvre the pump into position. Ship’s staff to perform a risk
installation work. correct PPE to be worn.
PCH 1602 STC03-13 1P1C 6–3

6.2 Description
6.2.1 General
These pumps are horizontal close coupled centrifugal units with a 2-bladed open impeller of
the non-clog type. They are designed for capacities up to 40 m3/h and operate at 2-pole
motor speeds.
The medium head pump is suitable for heads up to 18 metres. The high head pump is suitable
for heads up to 25 metres.
The pumps are particularly suited for effluent discharge, sump drainage and handling dirty
water containing solids up to 25mm. diameter.
6.2.2 Pump Inner Cover

The inner cover is bolted onto the electric motor and houses the mechanical seal.
6.2.3 Pump Casing

The pump casing is bolted to the inner cover and incorporates the suction branch which is in-
line with the motor shaft, and the discharge branch which is arranged at right angles to the
suction branch.
6.2.4 Mechanical Seal

The mechanical seal arrangement comprises two basic parts, a stationary seal ring, located
in the pump cover, and a rotating seal ring, carried on the impeller hub. A spring maintains
pressure between the seal faces, and lubrication is by the pumped fluid. Circulation passages
are arranged to maintain flow rate and prevent the accumulation of sediment.
6.2.5 Impeller
The impeller is keyed to the motor shaft and retained by a screw and lockwasher. A shim is
fitted at the bottom of the impeller hub to permit the running clearance to be correctly set
between the impeller and inner cover.
6–4 PCH 1602 STC03-13 1P1C

6.3 Installation
6.3.1 Storage
Pumps must be stored in dry places, free of dust, vibrations, gases, and corrosive smokes,
under constant temperature and in normal position free from other objects.
The storage temperature must remain between 5°C to 60°C, with relative humidity not
exceeding 50%.
CAUTION
When storing the discharge pump, the storage temperature must remain
between 5°C to 60°C, with relative humidity not exceeding 50%. Irreparable
damage to the critical components inside the pump may occur if these
conditions are not maintained.
In case the pumps are stored for more than two years, the bearings must be replaced.
CAUTION
The discharge pump bearings must be replaced if the pump is kept in storage for
more than 2 years.
Measure the insulation resistance before operating the motor and/or when there is any sign
of humidity in the winding. If the insulation resistance is less than 2 mega-ohms, the winding
must be dried according to the following:
CAUTION
Do not start the motor if the insulation resistance test shows a reading less than
2 Mega-ohms, it is likely that moisture is present in the motor windings. The
motor must be properly dried out before use.
• Warm it up inside an oven at a minimum temperature of 80°C increasing in increments of

5°C every hour until a maximum temperature of 105°C is reached, leave at 105°C for at
least one hour.
• Check that the stator insulation resistance remains constant within the accepted levels, if
not, stator must be re-impregnated.
6.3.2 Installation Data – Pump Weight And Dimensions

The maximum weight of the pump is shown in Section 6.1, the overall dimensions, and the
minimum clearances for removal of parts are shown on the General Arrangement Drawing in
Section 6.6 on page 6–18 or that supplied with the contract documents.
For dimensional data on any particular installation, reference must always be made to the
General Arrangement drawing in Section 6.6 on page 6–18 or that supplied with the contract
documents.
6.3.3 Installation Procedure

6.3.3.1 General
It is of the utmost importance that sufficient space is provided around the pump to allow
personnel access, and to facilitate removal and installation of components during normal
maintenance routines. It is advisable to leave adequate headroom above the unit for crane
hoists or lifting tackle. Minimum required clearance dimensions for components removal are
PCH 1602 STC03-13 1P1C 6–5

shown in the General Arrangement drawing in Section 6.6 on page 6–18 or as supplied with
the contract documents.
6.3.3.2 Pipework
All pipework should be constructed so that pipe strains are eliminated and the unit protected
against frost.
Pipe fittings must fit easily without strain, and suction and discharge pipes must be supported
independently near the pump so that no strain is transmitted to the pump casing. The bore of
the suction line must NOT be less than the pump suction flange nominal bore.
Suction piping must be absolutely air tight and as short as possible, avoiding bends and
elbows. Also, it should be between one and two sizes larger than the suction opening of the
pump if the suction line exceeds 15m (50ft) in length. Care should be exercised in routing the
pipework to eliminate loops which create air pockets. If possible, hydro-test the pipework to
check for leaks.
CAUTION
If the discharge pump is mounted remotely and the length of suction pipework
connected to the discharge pump has to exceed 15m in length (horizontally),
then the size of suction pipework should be one to two sizes larger than the
suction opening of the pump.
6.3.3.3 Electrical Installation

Voltage and connection are indicated on the nameplate. The acceptable voltage variation is
+/-10%; the acceptable frequency variation is +/-5% and the total acceptable variation is +/
-10%.
CAUTION
When connecting the discharge pump to the sewage treatment plant electrical
system, check that the supply voltage on the motor nameplate is the same as
the supply voltage in the control panel.
WARNING-ELECTRICITY
Danger of risk of personal injury due to electric shocks. Any electrical work
carried out on the discharge pump is to be done by a competent electrical
installer.
Each installation must be wired in accordance with recognised standards of practice. Earth
continuity must be provided for all exposed metalwork of electrical apparatus, cable sheaths
and armour, cable glands, conduits, ducts, trunking, etc. Flexible conductors must be
provided to earth resiliently mounted equipment.
Ensure that overload relays are set to the correct current rating of the motor(s) they are
protecting.
6–6 PCH 1602 STC03-13 1P1C

6.3.3.4 Direction of Rotation

On initially starting the pump, ensure that it is running in the direction indicated by the arrow
on the pump body. If the direction is incorrect, the wiring connections at the motor terminal
box must be reversed. The correct rotation is clockwise when viewed on the NON-drive end.
CAUTION
WARNING-ELECTRICITY
installer.
CAUTION
The discharge pump motor cooling air inlet cowl must be kept clear of debris
and cleaned regularly. Avoid recirculation of cooling air. The clear space between
the air inlet and the wall or a solid obstruction must be at least ¼ of the inlet cowl
opening diameter.
PCH 1602 STC03-13 1P1C 6–7

6.4 Operation
NOTE
Health and safety act compliance; before operating the equipment, ship’s staff
WARNING
For all tasks carried out in relation to the operation of the unit, ensure correct
PPE is worn.
NOTE
Do not attempt to operate the pump in relation to the sewage treatment plant
until the instruction book has been read and understood.
WARNING
Do not attempt to make adjustments to the pump, its connections or fittings
whilst the machine is running.
WARNING
Make sure the pump shaft guard is in place and secure before operating the
pump.
6–8 PCH 1602 STC03-13 1P1C

6.4.1 Checks Before Running For The First Time

Before running the machine for the first time after installation or maintenance, proceed as
follows:
1 After initial installation, fill the pump with the liquid to be pumped (see Section 6.4.2).
2 Rotate the pump manually through at least one revolution to ensure that the pump is
free to rotate. (It may be necessary to remove the motor fan shroud to achieve this).
CAUTION
Prior to turning the pump ON after maintenance or initial start-up check that the
pump rotates freely. (It may be necessary to remove the fan shroud to achieve
this).
3 Check that the motor bearings are lubricated as detailed in the motor manufacturer’s
handbook.
4 Ensure that the suction and discharge line stop valves are in the “Open” position.
5 On initially starting the pump, ensure that it is rotating in a clockwise direction when
viewed from the NON-drive end of the shaft. If rotation is incorrect, reverse any two
wiring connections at the terminal.
CAUTION
WARNING-ELECTRICITY
installer.
6.4.2 Priming
The pump can be primed by filling with the liquid to be pumped. The installation of a tee in the
discharge line just above the pump will provide a means of filling. Remove the priming plug
and pour liquid through the open branch of the tee until the pump and suction line are
completely filled, then replace the priming plug and start the pump.
6.4.3 Starting The Pump

1 Prime the pump in accordance with instructions under ‘Priming’.
2 Make sure the discharge valve (V6) is open.
3 Start motor (quickly select ‘MAN’ then ‘OFF’ on the pump selector switch if checking
rotation, once correct running achieved put pump selector switch into ‘AUTO’).
PCH 1602 STC03-13 1P1C 6–9

6.4.4 Regulating Flow From Pump – Pumped Media Without

Solids
CAUTION
Do not operate the discharge pump with a closed discharge valve for longer than
5 seconds. Failure of the equipment may occur.
The quantity of fluid delivered by the pump is regulated by opening or closing the discharge
valve (V6) to give the required rate of flow. Care must be taken not to overload the motor or
reduce the rate of flow to such a small capacity that over-heating of the pump will occur.
CAUTION
When the pumping media contains solids, the discharge rate must not be
regulated by the discharge valve (V6). During a de-sludge cycle the discharge
valve (V6) shown on the P&I diagram should be fully open. Once the de-sludge is
complete the discharge valve (V6) should be set in accordance with
Section 4.1.5 “Setting up De-chlorination Dosing Pump” on page 4–5.
6.4.5 Stopping The Pump

To stop the pump, turn the control panel selector switch to the ‘OFF’ position.
6–10 PCH 1602 STC03-13 1P1C

6.5 Maintenance
WARNING
Before proceeding with maintenance of the pump, it must be stopped and
isolated electrically and mechanically and visible warning notices displayed.
Some units may be on automatic standby duties. Isolators may be remote from
the pump. In these cases extra care is necessary to be absolutely sure that
isolation of the unit is complete.
NOTE
Health and safety act compliance; before operating the equipment, ships staff
CAUTION
Do not attempt to repair or overhaul the discharge pump unless you are suitably
competent to do so.
NOTE
Do not attempt to repair or overhaul the discharge pump until this instruction
book has been studied.
NOTE
Prior to carrying out any routine maintenance, check the spares are available for
the task to be carried out before taking the equipment out of service.
WARNING
Before attempting to dismantle the pump ensure that the pump suction and
delivery valves are closed and that the casing drain plug is removed.
WARNING
over - The discharge pump assembly weighs 62kg. Care must be taken when
attempting to manoeuvre the pump into position. Ship’s staff to perform a risk
installation work. Correct PPE to be worn.
PCH 1602 STC03-13 1P1C 6–11

WARNING
Manual handling warning, when carrying out maintenance on the discharge
pump it may be necessary to remove the discharge spool piece and diaphragm
valve. This assembly weighs approximately 16kg. Ships staff to produce a
manual handling assessment prior to commencement of any maintenance work.
Correct PPE to be worn.
6.5.1 General
The item numbers in the text refer to the item numbers called up on D8103 Sectional
Arrangement on page 6–19.
NOTE
When ordering spare parts, remember to always provide the type and serial
When ordering spare parts or in any correspondence relating to the pump, 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.
A complete pump and motor are readily available as standard spares so that should trouble
be experienced with either of these relatively small items it can be quickly remedied without
interfering with the normal duties of the unit.
A maintenance schedule is given in Table 6–5 on page 6–16, and a fault finding chart in
Table 6–6 on page 6–17
6.5.2 Lubrication
The pump requires no lubrication.
The motor bearings are ‘sealed for life’ type bearings and therefore require no lubrication.
6.5.3 Preparation For Dismantling The Pump

1 Ensure that the electrical power supply to the motor is switched off or disconnected.
WARNING
Before proceeding with maintenance of the pump, it must be stopped and
isolated electrically and mechanically and visible warning notices displayed.
Some units may be on automatic standby duties. Isolators may be remote from
the pump. In these cases extra care is necessary to be absolutely sure that
isolation of the unit is complete.
2 Shut the delivery valve (V6) in the system pipelines.
3 Remove the drain plug (Item 27) and joint washer (Item 28) from the pump casing.
WARNING
Warning; possible injury due to pressurized fluid in the discharge pipework and
pump casing. Use appropriate eye protection.
6–12 PCH 1602 STC03-13 1P1C

6.5.4 DISMANTLING PUMP

Refer To Sectional Arrangement Drawing D8103 on page 6–19.
WARNING
For all tasks carried out in relation to the maintenance of the discharge pump
ensure correct PPE is worn.
WARNING
When dismantling the discharge pump shortly after taking it out of service the
components inside the pump may still be hot and can cause burns. Ensure the
correct PPE is used when touching any of the internal pump components.
1 Remove the bolts securing the electric motor to its seating and the nuts (Item 20),
washers (Item 34) and bolts (Item 19) that secure the inner cover to the casing.
2 Withdraw the motor and pump from the casing and remove the ‘O’-ring seal (Item 15)
3 Bend back the locking tab washer (Item 17) and remove the impeller screw (Item 8), tab
washer and ‘O’-ring (Item 14).
4 Turn the impeller (Item 5) so that the jacking screw holes are horizontal, as shown on
the Sectional Arrangement drawing, and screw in the two jacking screws to withdraw
the impeller.
5 Withdraw the stationary part of the mechanical seal (Item 16) from the inner cover (Item
2) and the rotating part from the impeller.
6 Remove the nuts (Item 23) and spring washers (Item 25) and remove the inner cover
from the electric motor.
7 Remove the peel-off shim (Item 11) and the liquid thrower (Item 10).
6.5.5 Inspection
Thoroughly clean and examine all components for corrosion, cracks, wear or any other
damage and renew any parts found defective. If the mechanical seal faces are damaged, the
complete seal assembly must be renewed. The ‘O’-ring seals (Items 14 & 15) and tab washer
(Item 17) must be replaced with new ones.
NOTE
Always replace the O Ring seals and tab washer if these items are removed
during maintenance.
PCH 1602 STC03-13 1P1C 6–13

6.5.6 Assembling Pump

1 Position the liquid thrower on the motor shaft and the inner cover on the motor. Fit the
spring washers (Item 25) and nuts (Item 23).
2 Impeller Shimming:
To determine the amount of shimming required between the impeller and motor shaft:
a Position a new peel-off shim (Item 11) in the bore of the impeller (Item 5) (do not fit
mechanical seal at this stage).
NOTE
Do NOT fit the mechanical seal at this stage.
b Line up the keyway in the impeller with the key in the motor shaft and push the
impeller onto the shaft.
c Place the tab washer (Item 17) on the impeller screw (Item 8) and fit the screw into
the tapped hole in the end of the motor shaft. Fully tighten the screw but do not lock
it at this stage.
d With the aid of feeler gauges, measure the clearance between the rudimentary vanes
at the back of the impeller and the inner cover (see Fig 6–1 on page 6–15). This
dimension should be 0.457mm  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
which needs to be removed from the peel-off shim.
e.g.
Clearance measured 0.991 mm (0.039 in)
Deduct required clearance 0.610 mm (0.024 in)
Total to be removed from shim 0.381 mm (0.015 in)
Note: Each lamination of shim is 0.076 mm (0.003 in)

Therefore, the amount of laminations to be removed from the shim is 0.381 mm (0.015 in) or
five laminations. A new peel-off shim is 20 laminations or 1.524 mm (0.060 in) thick.
6–14 PCH 1602 STC03-13 1P1C

Fig 6–1 Discharge Pump Impeller Shimming
e Ensure that the end of the motor shaft key does not protrude beyond the end of the
motor shaft or the peel-off shim pack will be fouled.
f Remove the impeller screw and tab washer and withdraw the impeller from the
motor shaft.
g Remove the peel-off shim from the bore of the impeller and remove the number of
laminations determined in (d) above.
3 Smear the inside of the impeller bore with grease.
4 Fit the mechanical seal as follows:
a Ensure the ceramic seat is fully inserted into the cup rubber. Lubricate the outside
diameter of the cup rubber and also the bore of the recess in the inner cover, which
locates the stationary seat, with soft hand soap and water.
b Feed the cup rubber and ceramic seat into the recess and press into position
ensuring an even pressure over the whole of the ceramic seat face. Make sure that
the cup rubber and seat are pressed fully home.
CAUTION
Take care not to damage the ceramic and carbon sealing faces of the
mechanical seal. Damage will result in leaking through the motor shaft.
PCH 1602 STC03-13 1P1C 6–15

c Stand the pump, less casing and impeller, vertically with the impeller end of the shaft
uppermost.
d Lubricate the bore of the bellows with soft hand soap and water.
e Apply soft hand soap and water to the outside diameter of the impeller hub, and pass
the bellows of the mechanical seal carefully over the taper on the hub (rubber end
first) until the bellows contacts the hub shoulder.
f Ensure that the impeller adjusting peel-off shim (Item 11) is in position on the shaft
end.
g Line up the keyway in the impeller hub with the shaft key, locate the bore of the hub
with the shaft end and push the impeller fully onto the shaft.
5 Carefully position the liquid thrower on the impeller hub.
6 Secure the impeller with the impeller screw (Item 8) and tab washer (Item 17). Lock the
screw with the tab washer.
7 Place a new ‘O’-ring seal (Item 15) on the inner cover (Item 2) and position the motor and
pump assembly on its mounting and secure the inner cover to the casing with bolts
(Item 19), washers (Item 34), and nuts (Item 20).
8 Fit the bolts and washers securing the motor to its mounting.
Table 6–5 Discharge Pump Maintenance Schedule
Every 4 Years or
Item Action Every Year or 8,000 hrs 20,000 hrs
Inspect X
‘O’-Ring Seals
Replace X
Inspect X
Mechanical Seals
Replace X
Pump Casing Inspect X
Impeller Key Inspect X
NOTE
Where running hours and time are quoted, the shorter period is the criterion if
the component is a dynamic part.
NOTE
All clearances and parts should be checked as routine if the unit is dismantled
for any reason
NOTE
The table is for guidance only and indicates the minimum recommended
schedule. This may be varied where for specific conditions; operating
experience indicates that a different schedule would be beneficial.
6–16 PCH 1602 STC03-13 1P1C

Table 6–6 Discharge Pump Fault Finding Chart
Fault Cause Remedy

Delivery valve closed. Open valve.
Suction valve closed. Open suction valve.
No Discharge Blocked suction pipework Clean suction pipework
Water level beyond maximum lift Change the set up to improve
of pump. suction head.
Attend to joints and glands in
Air leaks or upturned loops in
Reduced and/or Irregular suction system and check run of
suction pipework.
Discharge pipe for loops.
Choked impeller. Dismantle and clean.
Valve or non-return valve Attend to valve or non-return
partially closed. valve.
Reduced Output and High
Temperature Consult our Technical
Actual total head exceeds max.
Department giving full
generated by pump.
particulars.
Pump Absorbing Excessive
Worn motor bearing. Renew bearing.
Power
PCH 1602 STC03-13 1P1C 6–17

6.6 Drawings
6.6.1 List Of Drawings — Discharge Pump Drawing List
Table 6–7 List Of Drawings — Discharge Pump
Drawing Number Drawing Title

D8103 Sectional Arrangement, B50x50HC 2-Pole Sewage Pump
A21980/ A21981 General Arrangement, B50x50HC 2-Pole Sewage Pump
6–18 PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C 6–19

Table 6–8 Items List for B50x50HC 2-Pole Sewage Pump Drawing D8103, Issue 1
SHEET No. DESCRIPTION G.O.

3a Standard Bronze Pump Standard
3b Standard Cast Iron Pump Standard
Item Description Material Qty.

1 Pump Casing B.S.1400 LG2 1
2 Inner Cover B.S.1400 LG2 1
5 Impeller B.S.1400 AB1 1
8 Impeller Screw B.S.970 431s29 1
10 Liquid Thrower Oil Resisting Rubber 1
11 Peel-off Shim Brass 1
14 ‘O’-ring (impeller) Nitrile Synthetic Rubber 1
15 ‘O’-ring (casing) Nitrile Synthetic Rubber 1
16 Mechanical Seal Carbon/Ceramic/Nitrile/316ss 1
17 Tab Washer Monel 1
19 Bolt H.T.S. Grade 8.8 6
20 Nut H.T.S. Grade 8.8 6
22 Stud Mild Steel Grade 4.8 4
23 Nut Mild Steel Grade 4.8 4
25 Spring Washer Spring Steel 4
26 Nameplate Aluminium 1
27 Plug Brass 3
28 Joint Copper 3
31 Key Key Steel 1
34 Washer Mild Steel 6
39 Jacking Screw Mild Steel 2
50 Motor 1
6–20 PCH 1602 STC03-13 1P1C

Item Description Material Qty.

1 Pump Casing B.S.1452 Grade 250 1
2 Inner Cover B.S.1452 Grade 250 1
5 Impeller B.S.1400 AB1 1
8 Impeller Screw B.S.970 431s29 1
10 Liquid Thrower Oil Resisting Rubber 1
11 Peel-off Shim Brass 1
14 ‘O’-ring (impeller) Nitrile Synthetic Rubber 1
15 ‘O’-ring (casing) Nitrile Synthetic Rubber 1
16 Mechanical Seal Carbon/Ceramic/Nitrile/316ss 1
17 Tab Washer Monel 1
19 Bolt H.T.S. Grade 8.8 6
20 Nut H.T.S. Grade 8.8 6
25 Spring Washer Spring Steel 4
26 Nameplate Aluminium 1
27 Plug Brass 3
28 Joint Copper 3
31 Key Key Steel 1
34 Washer Mild Steel 6
39 Jacking Screw Mild Steel 2
50 Motor 1
PCH 1602 STC03-13 1P1C 6–21

6–22 PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C 6–23

6–24 PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 7. Compressor (Type CYBW-25)
7. Compressor (Type CYBW-25)
7.1 General
CYBW series marine air compressor are oil-free self lubricating sliding-vane type air
compressors, which are a small compact size, light weight, energy-saving and discharges
clean exhausted air with no oil pollutants. It meets the requirements for marine use.
NOTE
Health and safety act compliance: before operating the equipment, ships staff
7.1.1 Applications
The CYBW series marine air compressor is designed specially as the auxiliary equipment for
marine sanitary sewage treatment plants.
7.1.2 Model Number Description

Example:
C Y B W -25
Air flow (m³/h)

Oil-free self-lubricating
Sliding-vane
Air compressor
Marine
7.2 Main performance index

7.2.1 Table of Main Compressor Performance Parameters
(Table 7–1 on page 7–5)
7.2.2 Performance Curve (Fig 7–1 on page 7–6)
PCH 1602 STC03-13 1P1C 7–1

7. Compressor (Type CYBW-25) Installation, Commissioning, Operating and Maintenance
7.3 General Introduction (With General Arrangement

Drawing Enclosed)
The compressor parts of this unit in the form of the motor, rotor and the output shaft of the
motor are connected directly, this makes the motor compact & reliable. The compressor body
skirt is fitted with radiating fins and a cooling fan is fitted on the main shaft of the CYBW-25
model, it provides excellent heat radiation. At the air outlet of the compressor there is a
regulating value installed to adjust the exhaust pressure and an air filter is installed on the air
inlet.
7.3.1 Assembling and Disassembling of Compressor Model

CYBW-25
WARNING
For all tasks carried out in relation to the assembly and dis-assembly of the
compressor ensure correct PPE is worn.
WARNING
over - the compressor weighs between 16-38kg dependant on size of STP. Care
must be taken when attempting to manoeuvre the compressor. Ship’s staff to
produce a manual handling assessment. Correct PPE to be worn.
WARNING
Warning; danger of scalding from hot compressor surfaces and components if
working on a compressor that has just been taken out of service and that has
not had time to cool down. Ensure the correct PPE is used when touching any of
the hot components.
7.3.1.1 Disassembling
1 Remove the three fastening screws on the fan casing at the front of the compressor and
remove the fan casing.
2 Remove the central lock bolt that holds the fan impeller in place, use two M8 bolts to
jack the fan impeller of the key and shaft.
3 Remove the air inlet cover.
4 Remove the four fastening bolts on the front sealing cover and use that bolt to push out
the front sealing cover. Take out the sliding vanes and replace them as necessary.
5 Tap the compressor body with a wooden hammer to loosen the compressor body from
the positioning pin on the back sealing cover, then remove the compressor body.
6 Insert an M10 bolt into the central screw hole of rotor shaft to jack the rotor from the
shaft and remove the flat key.
7 Remove the three fastening screws on the back sealing cover, pull out the back sealing
cover then you can clean the motor bearing and replace the grease.
7–2 PCH 1602 STC03-13 1P1C

7.3.1.2 Assembling
Reassemble the compressor by reversing the procedure for dis-assembling; make sure the
rotor is rotating freely at intervals during the assembly process.
CAUTION
Check frequently throughout the assembly process that the rotor continues to
turn freely to avoid the chance of equipment damage.
7.3.1.3 Cautions in dis-assembling

1 When dis-assembling, take care not to damage the compressor body or its machined
surfaces. Before assembling make sure you’re the internal surfaces are scrubbed clean
with a dry cloth and the inner cavity of the compressor shall is free of oil and dirt.
CAUTION
Take care not to damage the machined surfaces inside the working parts of the
compressor.
2 When dis-assembling the front sealing cover, take note of the six tuning screws on the
bearing seat of the front sealing cover, these are for adjusting the clearance between
the rotor end face and the front/back sealing covers, (the clearance should be
0.06~0.08mm), this should have been pre-adjusted in the factory.
3 When taking off or replacing the sliding vanes be careful not to drop or damage them,
do not damage the edges and corners of the sliding vane.When replacing the sliding
vane, the bevel edge of the sliding vane shall be in flush with the circular area of the
rotor outside diameter. If the bevel edge of the sliding vane is too small or the sliding
vane is too long, you may sand it with fine emery paper.
CAUTION
Take care not to damage the sliding vanes as this will prevent the equipment
from working.
PCH 1602 STC03-13 1P1C 7–3

7.4 Installation and start-up
NOTE
Do not attempt to operate the compressor in relation to the sewage treatment
plant until the instruction book has been read and understood.
1 The compressor shall be installed in a clean, dry and well ventilated room with ambient
temperatures that do not exceed 55°C. It shall be located such that there is plenty of
free space for ventilation around the unit and the base of the air compressor is fixed to
the STP with bolts.
CAUTION
Ensure the compartment which contains the Sewage Treatment Plant has an
unrestricted supply of clean air for the compressors to operate correctly.
Minimum flow rates are shown under the heading ‘Compressor Duties’ in
Table 1–3 of Section 1.1.5 on page 1–2.
2 When connecting the wires for the motor, make sure that the supply voltage is in
accordance with the motor data plate and that the direction of rotation of the
compressor is as indicated by the label on the unit. Incorrect rotation of the compressor
that causes reverse rotation or back suction is not allowed and the polarity of the motor
should be altered by swapping two of the wires in the terminal box.
CAUTION
WARNING-ELECTRICITY
carried out on the compressor is to be done by a competent electrical installer.
CAUTION
Check that the supply voltage is in accordance with the motor nameplate when
connecting the supply to the terminal box.
3 During the initial start-up of the compressor be careful that the compressor is not
making any abnormal noises. If it is then the compressor must be stopped immediately
and should not be started again until the problem has been checked and fixed.
7–4 PCH 1602 STC03-13 1P1C

7.5 Operation and maintenance

1 During operation, the air outlet pressure can be adjusted with the regulating valve
installed at the air outlet if the valves on the STP aren’t sufficient (but the pressure
should not exceed the rated pressure).
2 The sliding vanes of the compressor are made of self-lubricating materials. It is

prohibited to allow liquids such as water or oil to enter into the compressor chambers.
CAUTION
Do not allow water or oil to enter the compressor chamber
3 The air inlet filter should always be kept clean and it should be removed and cleaned
once every 1~2 months.
4 In normal operation the compressor should be taken apart for checks and maintenance
every 6 months for cleaning the bearings and refilling the composite calcium-based
grease.
NOTE
It is recommended that calcium based grease is used in the compressors.
5 If the sliding vane is worn and affects the working performance or breaks into pieces
you should stop the compressor immediately and replace the sliding vanes. The dis-
assembly procedure is described in Section 7.3.1.1.
6 If the compressor is stopped for longer than three months or has just been overhauled,
you should run the compressor without load for 30 minutes then fully load for 30
minutes. If it is observed with no abnormal conditions then you can operate the
compressor continuously as normal.
7.6 Storage and handling

During periods of long term storage measures should be taken to prevent rust and damp, it
should be stored in a dry warehouse. When moving the compressor it should be handled with
care, do not drop or damage the compressor.
Table 7–1 Table of Main Compressor Performance Parameters
Exhaust Motor Motor Outside

Type Flow pressure Power Speed Takeover weight Dimension
Size m³/h KPa KW r/min mm Kg L×W×H

CYBW-25 25 60 1.1 1400 27 34 445×270×270
PCH 1602 STC03-13 1P1C 7–5

Fig 7–1 Compressor Performance Curve — CYBW-25
7–6 PCH 1602 STC03-13 1P1C

7.7 Operating Instructions for the Compressor Motor

7.7.1 General
The motor fitted to this compressor is a totally enclosed, fan cooled cage type marine three
phase asynchronous type. The motor is suitable for marine use.
7.7.2 Preparations Before Installing the Compressor Motor

1 Carefully check that all the data on the nameplate including the rated power, voltage,
frequency & speed are correct for their intended use and to check that they conform to
the actual application requirements.
CAUTION
Check that the supply voltage is in accordance with the motor nameplate when
connecting the supply to the terminal box.
2 Carefully check that each part is in good condition, check all fasteners are tight and turn
the rotor by hand to be sure there is no fowling or rubbing and the rotor is free to rotate.
3 Measure the insulation resistance between the winding phases and the winding to
ground insulation resistance with 500V megameter, the resistance measured under
normal temperature before operation shall not be lower than 30M, if the reading is
lower than stated the motor will need to be dried out.
CAUTION
Do not start the motor if the insulation resistance test shows a reading (less than
30M), it is likely that moisture is present in the motor windings. The motor must
be properly dried out before use. Refer to Section 7.7.6 “Drying the Compressor
Motor” on page 7–9 for the drying out process.
7.7.3 Compressor Motor Installation

1 The orientation of the cable gland stuffing box inside the junction box can be changed
to suit 4 different positions. To enable the cable gland stuffing box to be rotated to an
alternate orientation you should remove the four screws in the junction box and rotate
it to provide an alternate cable gland stuffing box position then replace the 4 screws.
2 Drill a hole in the rubber ring inside of the cable gland stuffing box and connect the
wires, tighten the glands to ensure a water tight seal is achieved and to prevent the
cable becoming loose due to vibration.
3 After the changing of the wiring connection of the motor is completed check all the
fasteners and connections are tight.
7.7.4 Test Run of the Compressor Motor

1 This series motor has six wiring terminals which are marked with U1, V1, W1, U2, V2 &
W2. The connection of the outgoing wires should be done in accordance with the
diagram in the cover of the junction box.
2 After the wires have been connected test run the compressor without load. During the
test run if the direction of rotation of the motor does not comply with the requirements
PCH 1602 STC03-13 1P1C 7–7

of the label on the air compressor the unit should be stopped immediately, switch over
any two of the power wires and the problem will be fixed.
CAUTION
In the first test run, when the rotating speed of the motor reaches the rated value, the motor
shall be stopped for inspection. Check if there are any loose items and if any of the
mechanical components are rubbing or touching. If any issues are found then make the
necessary adjustments and repairs and continue to run the motor without load for 2-3 hours.
Check again for abnormal conditions or sound during the operation. After the 2-3 hours of no
load operation, you should also check if the bearing has overheated or leaking oil. If the motor
is running normally without load then put compressor on load and onto normal operation with
load.
3 During normal operation with the compressor on load continue to observe its start-up
conditions to check it is running normally and if the full load (running) current exceeds
the rated value on the nameplate.
CAUTION
Measure the current of the compressor motor when the compressor is running
on full load. Check the current doesn’t exceed the values stated in the table on
sheet 9 of the relevant circuit diagram in Section 9.4 on page 9–42.
After running for 30-60 minutes stop the motor to check if there is any loose mechanical
connection or components on the motor or check if the bearing is overheated or leaking oil or
if there is rubbing between the stator and rotor. If the compressor & motor are running
normally put the motor into normal full load running operation with the STP.
7.7.5 Maintenance, Overhaul and Storage

1 The motor shall be operated according to the rated values indicated on the nameplate,
do not overload the motor. Pay attention to the daily checks and cleaning requirements
so as to prevent moisture or foreign particles entering the motor.
2 During the operation of the motor make regular records of the readings on
corresponding instruments and thermometers and take notes of the maintenance
conditions. At the same time any faults found should be recorded for maintenance and
overhaul tasks.
3 Make sure that the air duct of the motor is free from obstacles and no heat source is
located close to the motor.
CAUTION
Do not locate heat sources close to the cooling fan of the motor or obscure the
motor cowl. Air should be allowed to flow freely around the vent cowl.
4 To prevent motor faults and increase reliability the motor should be serviced regularly,
normal servicing should take place on a monthly to three monthly period with a major
overhaul annually. Regular services include cleaning the accumulated dust and dirt
from the outside of the motor, keeping the terminal plate clean to avoid power leakage
due to dust and moisture accumulation & checking the insulation resistance connection
7–8 PCH 1602 STC03-13 1P1C

and the grounding wire of the motor winding. Also check the mechanical fasteners/
components are tight and haven’t worked loose during operation. During an annual
major overhaul you should first disassemble the motor to check the windings are
complete and in good condition. If the Binding at the end of the winding has been
damaged, clean the inside and outside of the motor body, and check the wearing
condition of the motor bearing. Also check the components normally covered by the
monthly and 3 monthly services.
7.7.6 Drying the Compressor Motor

1 If excessive moisture is found inside the electrical parts of the motor it will need to be
dried.
2 If the motor shows signs of erosion by seawater, it needs to firstly be cleaned

thoroughly with fresh water to remove any of the salt residues and then dried.
3 When drying in an oven or other heating device, the temperature of the oven must not
exceed 100°C. The motor needs to be held at temperature for approximately four hours
to dry it out properly.
CAUTION
Do not allow the temperature in the oven to exceed 100ºC when performing the
drying process on the motor.
7.7.7 Troubleshooting Compressor Motor Faults

Table 7–2 Troubleshooting Compressor Motor Faults
Item Fault Possible Reason Correcting Method
1 Motor start-up with noise or One phase not connected Find the open connection and
vibration but not running properly reconnect it
2 Motor start-up with noise or Short circuit of the winding Fix the winding
overheat
3 Low rotation speed after 1. Head end and tail end of 1. Check the head end and
motor start-up the phase winding were tail end of each phase,
connected wrong then re-connection as
2. Low voltage necessary
2. Check the main supply
voltage
4 Low insulation Dirty or damp windings Clean the motor and dry the
resistance winding
5 Excessive temperature-rise of Motor overload Dry the winding
the winding
6 Bearing overheat 1. Eccentric connection 1. Check the concentricity
between the motor and the 2. Replace bearing
compressor
2. Worn bearing
7 Bearing noise Worn bearing Replace bearing
8 Excessive vibration 1. Weak connection to the 1. Remount the motor

STP tank wall 2. Check concentricity
2. Motor shaft and the shaft
of the compressor are not
concentric
PCH 1602 STC03-13 1P1C 7–9

7–10
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Fig 7–2
7. Compressor (Type CYBW-25)
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PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 8. Key Components
8. Key Components
8.1 Chlorination Dosing Pump

Chlorination Pump Models
STC03-13 (110V – 50/60HZ) - TYPE: CNPb1602PVT
STC03-13 (220V – 50/60HZ) - TYPE: CNPb1602PVT
See following pages.
PCH 1602 STC03-13 1P1C 8–1

8. Key Components Installation, Commissioning, Operating and Maintenance
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De-chlorination Pump Models
STC03-13 (100V–230V – 50/60HZ) - TYPE: CONC0806PP
See following pages.
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8.3 De-chlorination Dosing Rate Against Discharge Pump

Pressure
Dechlorination Dosing
Rate against Discharge
R62745
Pump Pressure SHEET 1 OF 1
Fleets Bridge, Poole, Dorset, BH17 0JT, England
This graph gives the required Dechlorination Dosage of Sodium Bisulphite

(12% solution) vs Discharge Pump Pressure
Discharge Pressure Vs Dechlorination Dosing Rate

10
9
Dechloination Dosing Rate (l/hr)
8
7
6
High Head
5
Med Head
4
3
2
1
0
10 15 20 25 30
Discharge Pressure (m)
ISSUE 1 2
ECN N060951
DATE 01/10/08 22/10/13
INITIALS KWC NH
CHECKED ART ART
APPROVED/DATE WC 01/10//08
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8–58 PCH 1602 STC03-13 1P1C

Installation, Commissioning, Operating and Maintenance Manual 9. Documents and Drawings
9. Documents and Drawings
9.1 Health and Safety

9.1.1 DPD No. 4 Tablets
Table 9–1 Product DPD No.4 Tablets
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.
Handling Use only as instructed. Avoid handling whenever possible. Wash hands after
use. Not to be taken.
Transport Not regulated.
First Aid:
Skin/Eyes Wash with plenty of water.
Ingestion Give plenty of water to drink. OBTAIN MEDICAL ATTENTION
Spillage Sweep up and wash away with water.
Fire Water and all extinguishers may be used. Tablets are non-combustible
PCH 1602 STC03-13 1P1C 9–1

9. Documents and Drawings Installation, Commissioning, Operating and Maintenance
9.1.2 Sodium Bisulphite (De-chlorination): Document SDS S011
SAFETY DATA SHEET according to Regulation (EC) No. 1907/2006
SODIUM BISULPHITE <16% SO2 CONTENT (<25% SOLUTION)

Version 4.2 Print Date 2012/11/09
Revision date / valid from 2012/11/09 MSDS code: MSBS101
Section 1: Identification of the substance/mixture and of the company/undertaking

1.1. Product identifier
Trade name : SODIUM BISULPHITE <16% SO2 CONTENT (<25%

SOLUTION)
Substance name : sodium hydrogensulphite
CAS-No. : 7631-90-5
EC-No. : 231-548-0
1.2. Relevant identified uses of the substance or mixture and uses advised against
Use of the : At this time we do not yet have information on identified uses.
Substance/Mixture They will be included in this safety data sheet when available.
Uses advised against : At this moment we have not identified any uses advised
against
1.3. Details of the supplier of the safety data sheet
Company : Brenntag UK & Ireland

Albion House, Rawdon Park
GB LS19 7XX Leeds Yeadon
Telephone : +44 (0) 113 3879 200
Telefax : +44 (0) 113 3879 280
E-mail address : msds@brenntag.co.uk
1.4. Emergency telephone number
Emergency telephone : Emergency only telephone number (open 24 hours):

number +44 (0) 1865 407333 (N.C.E.C. Culham)
Section 2: Hazards identification
2.1. Classification of the substance or mixture
Classification according to Regulation (EC) No 1272/2008
The product is classified as dangerous in accordance with Regulation (EC) No. 1272/2008.
Classification according to EU Directives 67/548/EEC or 1999/45/EC
Directive 67/548/EEC or 1999/45/EC

Hazard symbol / Category of danger Risk phrases
R48213 1/10 EN
9–2 PCH 1602 STC03-13 1P1C

R31
For the full text of the R-phrases mentioned in this Section, see Section 16.
Most important adverse effects
Human Health : See section 11 for toxicological information.
Physical and chemical : See section 9 for physicochemical information.

hazards
Potential environmental : See section 12 for environmental information.
effects
2.2. Label elements
Labelling according to Regulation (EC) No 1272/2008
Additional Labelling:
EUH031 Contact with acids liberates toxic gas.
2.3. Other hazards
For Results of PBT and vPvB assessment see section 12.5.
Section 3: Composition/information on ingredients

3.1. Substances
Classification
(REGULATION (EC) No 1272/2008)
Classification
Hazardous components Amount [%] Hazard class / Hazard (67/548/EEC)
Hazard category statements
sodium hydrogensulphite
Index-No. : 016-064-00-8 Acute Tox.4 H302 Xn; R22
CAS-No. : 7631-90-5 R31
< 25
EC-No. : 231-548-0
C&L-No. : 02-2119752435-37-0000
For the full text of the H-Statements mentioned in this Section, see Section 16.
Section 4: First aid measures
4.1. Description of first aid measures
General advice : No special precautions required.
If inhaled : Remove to fresh air. If symptoms persist, call a physician.
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PCH 1602 STC03-13 1P1C 9–3

In case of skin contact : Wash off with soap and water.
In case of eye contact : Rinse thoroughly with plenty of water, also under the eyelids. If
symptoms persist, call a physician.
If swallowed : Clean mouth with water and drink afterwards plenty of water.
Never give anything by mouth to an unconscious person. If
symptoms persist, call a physician.
4.2. Most important symptoms and effects, both acute and delayed
Symptoms : See Section 11 for more detailed information on health effects

and symptoms.
Effects : See Section 11 for more detailed information on health effects

and symptoms.
4.3. Indication of any immediate medical attention and special treatment needed
Treatment : Treat symptomatically.

No further information available.
Section 5: Firefighting measures

5.1. Extinguishing media
Suitable extinguishing : Use water spray, alcohol-resistant foam, dry chemical or

media carbon dioxide.
Unsuitable extinguishing : High volume water jet
media
5.2. Special hazards arising from the substance or mixture
Specific hazards during : The vapour may be invisible, heavier than air and spread
firefighting along ground. Vapours may form explosive mixtures with air.
Flash back possible over considerable distance. In case of fire
hazardous decomposition products may be produced such as:
Carbon monoxide, Carbon dioxide (CO2)
5.3. Advice for firefighters
Special protective : In the event of fire, wear self-contained breathing

equipment for firefighters apparatus.Wear appropriate body protection (full protective
suit)
Further information : Cool closed containers exposed to fire with water
spray.Heating will cause a pressure rise - with risk of
bursting.Collect contaminated fire extinguishing water
separately. This must not be discharged into drains.
Section 6: Accidental release measures

6.1. Personal precautions, protective equipment and emergency procedures
Personal precautions : Use personal protective equipment. Provide adequate

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ventilation. Keep away from heat and sources of ignition.

Avoid contact with skin and eyes. For personal protection see
section 8.
6.2. Environmental precautions
Environmental : Do not flush into surface water or sanitary sewer system.

precautions
6.3. Methods and materials for containment and cleaning up
Methods and materials for : Contain spillage, and then collect with non-combustible
containment and cleaning absorbent material, (e.g. sand, earth, diatomaceous earth,
up vermiculite) and place in container for disposal according to
local / national regulations (see section 13).
Further information : Treat recovered material as described in the section "Disposal

considerations".
6.4. Reference to other sections
For personal protection see section 8.
Section 7: Handling and storage
7.1. Precautions for safe handling
Advice on safe handling : Keep container tightly closed. Handle in accordance with good
industrial hygiene and safety practice.
Hygiene measures : Keep away from food, drink and animal feedingstuffs. Smoking,
eating and drinking should be prohibited in the application area.
Wash hands before breaks and at the end of workday. Take off
all contaminated clothing immediately. Avoid contact with the
skin and the eyes. Do not breathe vapours or spray mist.
7.2. Conditions for safe storage, including any incompatibilities
Requirements for storage : Keep in an area equipped with solvent resistant flooring. Keep
areas and containers only in the original container.
Advice on protection : Keep away from sources of ignition - No smoking. The vapour
against fire and explosion may be invisible, heavier than air and spread along ground.
Vapours may form explosive mixtures with air. Take measures
to prevent the build up of electrostatic charge. Use only in an
area containing explosion proof equipment.
Further information on : Keep tightly closed in a dry and cool place. Keep away from
storage conditions direct sunlight. Keep away from heat. Keep in a well-ventilated
place.
Advice on common : Incompatible with oxidizing agents. Keep away from food,
storage drink and animal feedingstuffs.
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7.3. Specific end use(s)
Specific use(s) : No information available.
Section 8: Exposure controls/personal protection

8.1. Control parameters
Component: sodium hydrogensulphite CAS-No.

7631-90-5
Other Occupational Exposure Limit Values
EH40 WEL, Time Weighted Average (TWA):

5 mg/m3
ELV (IE), Time Weighted Average (TWA):

5 mg/m3
8.2. Exposure controls
Appropriate engineering controls

Refer to protective measures listed in sections 7 and 8.
Personal protective equipment

Respiratory protection
Advice : In case of insufficient ventilation, wear suitable respiratory

equipment.
Recommended Filter type:A
Hand protection
Advice : Wear suitable gloves.

The glove material has to be impermeable and resistant to the
product / the substance / the preparation.
As the product is a mixture of several substances, the durability of
the glove materials cannot be calculated in advance and has to be
tested before use.
Protective gloves should be replaced at first signs of wear.
The following materials are suitable:
PVC
Rubber gloves
Eye protection
Advice : Safety goggles
Skin and body protection
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Advice : Protective work clothing
Environmental exposure controls
General advice : Do not flush into surface water or sanitary sewer system.
Section 9: Physical and chemical properties

9.1. Information on basic physical and chemical properties
Form : Liquid
Colour : clear
pale
yellow
Odour : pungent
rotten-egg like
Odour Threshold : no data available
pH : 3.5 - 6
acidic
Crystallization point : < 10 °C
Boiling point : no data available
Flash point : no data available
Evaporation rate : no data available
Flammability (solid, gas) : no data available
Upper explosion limit : no data available
Lower explosion limit : no data available
Vapour pressure : 11.76 hPa (20 °C)
Relative vapor density : 2.26
Density : 1.12 - 1.33 g/cm3
Water solubility : completely soluble
Partition coefficient: n-octanol/water : log Kow -3.7
Auto-ignition temperature : no data available
Thermal decomposition : no data available
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Viscosity, dynamic : 4 - 5 mPa.s (20 °C)
Explosivity : Formation of explosive air/vapour mixtures is

possible.
Oxidizing properties : no data available
9.2. Other information
Section 10: Stability and reactivity

10.1. Reactivity
Advice : No information available.
10.2. Chemical stability
Advice : Stable
10.3. Possibility of hazardous reactions
Hazardous reactions : No information available.
10.4. Conditions to avoid
Conditions to avoid : Avoid high temperatures.
10.5. Incompatible materials
Materials to avoid : Strong oxidizing agents, Acids, nitrites
10.6. Hazardous decomposition products
Hazardous decomposition : Heating may cause toxic fumes, Sulphur oxides

products
Section 11: Toxicological information

11.1. Information on toxicological effects
Acute toxicity
Oral
LD50 : 1540 mg/kg (rat) (Calculation method)
Irritation
Sensitisation
Result : No sensitizing effect known.
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Further information
Other relevant : Handle in accordance with good industrial hygiene and safety
toxicity information practice.
Experience with : Health injuries are not known or expected under normal use.
human exposure
Section 12: Ecological information

12.1. Toxicity
Acute toxicity
Fish
LC50 : 150 - 220 mg/l (fish; 96 h) (Toxicity to fish)
Toxicity to daphnia and other aquatic invertebrates
EC50 : 89 mg/l (Daphnia; 48 h) (Toxicity to daphnia)
12.2. Persistence and degradability
12.3. Bioaccumulative potential
Bioaccumulation
Result : Bioaccumulation is not expected.

completely soluble
12.4. Mobility in soil
12.5. Results of PBT and vPvB assessment
12.6. Other adverse effects
Additional ecological information
Result : Do not flush into surface water or sanitary sewer system.

Avoid subsoil penetration.
Section 13: Disposal considerations

13.1. Waste treatment methods
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Product : Disposal together with normal waste is not allowed. Special

disposal required according to local regulations. Do not let
product enter drains. Contact waste disposal services.
Contaminated packaging : Empty contaminated packagings thoroughly. They can be

recycled after thorough and proper cleaning. Packagings that
cannot be cleaned are to be disposed of in the same manner
as the product. Do not burn, or use a cutting torch on, the
empty drum. Risk of explosion.
European Waste : No waste code according to the European Waste Catalogue

Catalogue Number can be assigned for this product, as the intended use dictates
the assignment. The waste code is established in consultation
with the regional waste disposer.
Section 14: Transport information
Not dangerous goods for ADR, RID, IMDG and IATA.
14.1. UN number
Not applicable.
14.2. UN proper shipping name
Not applicable.
14.3. Transport hazard class(es)
Not applicable.
14.4. Packaging group
Not applicable.
14.5. Environmental hazards
Not applicable.
14.6. Special precautions for user
Not applicable.
14.7. Transport in bulk according to Annex II of MARPOL 73/78 and the IBC Code
IMDG : Not applicable.
Section 15: Regulatory information

15.1. Safety, health and environmental regulations/legislation specific for the substance or
mixture
Other regulations : Occupational restrictions: Take note of Dir 92/85/EEC on the

safety and health of pregnant workers at work and of Dir
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94/33/EC on the protection of young people at work.
15.2. Chemical Safety Assessment
no data available
Section 16: Other information
Full text of R-phrases referred to under sections 2 and 3.
R22 Harmful if swallowed.

R31 Contact with acids liberates toxic gas.
Full text of H-Statements referred to under sections 2 and 3.
H302 Harmful if swallowed.
Further information
Other information : The information provided in this Safety Data Sheet is correct to
our knowledge at the date of its revision. The information given
only describes the products with regard to safety arrangements
and is not to be considered as a warranty or quality
specification and does not constitute a legal relationship.
The information contained in this Safety Data Sheet relates
only to the specific material designated and may not be valid
for such material used in combination with any other material
or in any process, unless specified in the text
|| Indicates updated section.
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9.1.3 Sodium Hypochlorite (Chlorination): Document SDS S024
SAFETY DATA SHEET according to Regulation (EC) No. 1907/2006
Sodium hypochlorite 10-15% (All grades)

Version 8.0 Print Date 2013/08/05
Revision date / valid from 2013/08/05 MSDS code: MSHY100
Section 1: Identification of the substance/mixture and of the company/undertaking

1.1. Product identifier
Trade name : Sodium hypochlorite 10-15% (All grades)

Substance name : sodium hypochlorite, solution 13% Cl active
Index-No. : 017-011-00-1
CAS-No. : 7681-52-9
EC-No. : 231-668-3
1.2. Relevant identified uses of the substance or mixture and uses advised against
Use of the : Identified use: See table in front of appendix for a complete
Substance/Mixture overview of identified uses.
Uses advised against : At this moment we have not identified any uses advised
against
1.3. Details of the supplier of the safety data sheet
Company : Brenntag UK & Ireland

Albion House, Rawdon Park
GB LS19 7XX Leeds Yeadon
Telephone : +44 (0) 113 3879 200
Telefax : +44 (0) 113 3879 280
E-mail address : msds@brenntag.co.uk
1.4. Emergency telephone number
Emergency telephone : Emergency only telephone number (open 24 hours):

number +44 (0) 1865 407333 (N.C.E.C. Culham)
Section 2: Hazards identification
2.1. Classification of the substance or mixture
Classification according to Regulation (EC) No 1272/2008
REGULATION (EC) No 1272/2008

Hazard
Hazard class Hazard category Target Organs
statements
Skin corrosion Category 1B --- H314
Acute aquatic toxicity Category 1 --- H400
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Classification according to EU Directives 67/548/EEC or 1999/45/EC
Directive 67/548/EEC or 1999/45/EC

Hazard symbol / Category of danger Risk phrases
Corrosive (C) R34
R31
Dangerous for the environment (N) R50
Most important adverse effects
Human Health : See section 11 for toxicological information.

Physical and chemical : See section 9 for physicochemical information., No further

hazards information available.
Potential environmental : See section 12 for environmental information.

effects No further information available.
2.2. Label elements
Labelling according to Regulation (EC) No 1272/2008
Hazard symbols :
Signal word : Danger
Hazard statements : H314 Causes severe skin burns and eye damage.
H400 Very toxic to aquatic life.
Precautionary
statements
Prevention : P260 Do not breathe vapours.

P273 Avoid release to the environment.
P280 Wear protective gloves/ protective clothing/
eye protection/ face protection.
Response : P301 + P330 + P331 IF SWALLOWED: rinse mouth. Do

NOT induce vomiting.
P303 + P361 + P353 IF ON SKIN (or hair): Remove/ Take
off immediately all contaminated clothing.
Rinse skin with water/ shower.
P305 + P351 + P338 IF IN EYES: Rinse cautiously with
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PCH 1602 STC03-13 1P1C 9–13

water for several minutes. Remove contact

lenses, if present and easy to do. Continue
rinsing.
Additional Labelling:
EUH031 Contact with acids liberates toxic gas.
Hazardous components which must be listed on the label:
• sodium hypochlorite, solution
2.3. Other hazards
For Results of PBT and vPvB assessment see section 12.5.

No other information is available.
Section 3: Composition/information on ingredients

3.1. Substances
Chemical nature : sodium hypochlorite

Aqueous solution
Classification
(REGULATION (EC) No 1272/2008)
Classification
Hazardous components Amount [%] Hazard class / Hazard (67/548/EEC)
Hazard category statements
sodium hypochlorite, solution

Index-No. : 017-011-00-1 Met. Corr.1 H290 R31
CAS-No. : 7681-52-9 Skin Corr.1B H314 Corrosive; C; R34
EC-No. : 231-668-3 STOT SE3 H335 Dangerous for the
>= 10 - <= 15 Aquatic Acute1 H400 environment; N;
R50
sodium hydroxide
Index-No. : 011-002-00-6 Met. Corr.1 H290 Corrosive; C; R35
CAS-No. : 1310-73-2 >= 0 - < 5 Skin Corr.1A H314
EC-No. : 215-185-5
Section 4: First aid measures
4.1. Description of first aid measures
General advice : Take off all contaminated clothing immediately.
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If inhaled : In case of accident by inhalation: remove casualty to fresh air

and keep at rest. If breathing is irregular or stopped, administer
artificial respiration. Call a physician immediately.
In case of skin contact : Wash off immediately with soap and plenty of water. If irritation
appears or if the contamination is important, seek medical
advice.
In case of eye contact : Rinse immediately with plenty of water, also under the eyelids,
for at least 15 minutes. Consult an eye specialist immediately.
Go to an ophthalmic hospital if possible.
If swallowed : Clean mouth with water and drink afterwards plenty of water.
Never give anything by mouth to an unconscious person. If
swallowed, do not induce vomiting - seek medical advice. If a
person vomits when lying on his back, place him in the
recovery position.
4.2. Most important symptoms and effects, both acute and delayed
Symptoms : Inhalation may provoke the following symptoms: Cough,

Headache, Lung oedema
Effects : Risk of serious damage to the lungs (by aspiration).
4.3. Indication of any immediate medical attention and special treatment needed
Treatment : Treat symptomatically.Later control for pneumonia and lung

oedema.
Section 5: Firefighting measures

5.1. Extinguishing media
Suitable extinguishing : Use extinguishing measures that are appropriate to local

media circumstances and the surrounding environment. The product
itself does not burn.
Unsuitable extinguishing : Exempt
media
5.2. Special hazards arising from the substance or mixture
Specific hazards during : Fire may cause evolution of: Chlorine, Hydrogen chloride gas,
firefighting chlorine oxides
5.3. Advice for firefighters
Special protective : In the event of fire, wear self-contained breathing

equipment for firefighters apparatus.Wear appropriate body protection (full protective
suit)
Further information : Cool closed containers exposed to fire with water
spray.Heating will cause a pressure rise - with risk of
bursting.Collect contaminated fire extinguishing water
separately. This must not be discharged into drains.
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Section 6: Accidental release measures

6.1. Personal precautions, protective equipment and emergency procedures
Personal precautions : Use personal protective equipment. Wear respiratory

protection. Keep people away from and upwind of spill/leak.
Provide adequate ventilation. Danger of slipping if spilled
Avoid contact with skin and eyes. Do not breathe vapour.
6.2. Environmental precautions
Environmental : Do not flush into surface water or sanitary sewer system.

precautions Avoid subsoil penetration. If the product contaminates rivers
and lakes or drains inform respective authorities. If material
reaches soil inform authorities responsible for such cases.
6.3. Methods and materials for containment and cleaning up
Methods and materials for : Absorb with liquid-binding material (sand, diatomite, acid
containment and cleaning binders, universal binders). Keep in suitable, closed
up containers for disposal. Do not keep the container sealed.
Further information : Treat recovered material as described in the section "Disposal

considerations".
6.4. Reference to other sections
For personal protection see section 8.
Section 7: Handling and storage
7.1. Precautions for safe handling
Advice on safe handling : Do not keep the container sealed. Handle and open container
with care. Ensure adequate ventilation. Use personal protective
equipment. Avoid contact with the skin and the eyes. Do not
breathe vapours or spray mist. Use respirator with appropriate
filter if vapours or aerosol are released. Emergency eye wash
fountains and emergency showers should be available in the
immediate vicinity.
Hygiene measures : Keep away from food, drink and animal feedingstuffs. Smoking,
eating and drinking should be prohibited in the application area.
Wash hands before breaks and at the end of workday. Take off
all contaminated clothing immediately.
7.2. Conditions for safe storage, including any incompatibilities
Requirements for storage : Keep in an area equipped with alkali resistant flooring. Keep
areas and containers only in the original container. Store in a receptacle equipped
with a vent.
Advice on protection : The product is not flammable. Normal measures for preventive
against fire and explosion fire protection.
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Further information on : Keep in a well-ventilated place. Protect against light. Store in

storage conditions cool place. Do not keep the container sealed.
Advice on common : Keep away from food, drink and animal feedingstuffs. Do not
storage store together with acids and ammonium salts.
German storage class : 8B: Non-combustible substances, corrosive
7.3. Specific end use(s)
Specific use(s) : No information available.
Section 8: Exposure controls/personal protection

8.1. Control parameters
Component: sodium hydroxide CAS-No.

1310-73-2
EH40 WEL, Short Term Exposure Limit (STEL):

2 mg/m3
ELV (IE), Short Term Exposure Limit (STEL):

2 mg/m3
Component: chlorine CAS-No.

7782-50-5
EU ELV, Short Term Exposure Limit (STEL):

0.5 ppm, 1.5 mg/m3
Indicative
EH40 WEL, Short Term Exposure Limit (STEL):

0.5 ppm, 1.5 mg/m3
ELV (IE), Short Term Exposure Limit (STEL):

0.5 ppm, 1.5 mg/m3
Indicative OELV
8.2. Exposure controls
Appropriate engineering controls

Refer to protective measures listed in sections 7 and 8.
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Personal protective equipment

Respiratory protection
Advice : Use respirator with appropriate filter if vapours or aerosol are

released.
Recommended Filter type:
Combination filter:B-P2
Combination filter:B-P3
For low vapor concentrations: EN 136. For higher concentrations:
EN 137
Hand protection
Advice : Protective gloves complying with EN 374.

The glove material has to be impermeable and resistant to the
product / the substance / the preparation.
Take note of the information given by the producer concerning
permeability and break through times, and of special workplace
conditions (mechanical strain, duration of contact).
Protective gloves should be replaced at first signs of wear.
Material : butyl-rubber
Break through time : 8h
Glove thickness : 0.5 mm
Material : Polyvinylchloride
Material : polychloroprene
Eye protection
Advice : Safety glasses with side-shields conforming to EN166

Tightly fitting safety goggles
Skin and body protection
Advice : alkali resistant protective clothing

(EN 340)
Environmental exposure controls
General advice : Do not flush into surface water or sanitary sewer system.
Avoid subsoil penetration.
If the product contaminates rivers and lakes or drains inform
respective authorities.
If material reaches soil inform authorities responsible for such
cases.
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Section 9: Physical and chemical properties

9.1. Information on basic physical and chemical properties
Form : liquid
Colour : yellowish green
Odour : slight chlorine
Odour Threshold : Currently we do not have any information from our

supplier about this.
pH : > 11
Melting point/range : -17 °C
Boiling point/boiling range : 110 °C
Flash point : not applicable
Evaporation rate : Currently we do not have any information from our

Flammability (solid, gas) : does not ignite
Upper explosion limit : not applicable
Lower explosion limit : not applicable
Vapour pressure : Currently we do not have any information from our

Relative vapour density : > 1.0

(Air = 1.0)
Density : 1.2 - 1.3 g/cm3
Water solubility : completely soluble
Partition coefficient: n-octanol/water : Currently we do not have any information from our
Auto-ignition temperature : not applicable
Thermal decomposition : To avoid thermal decomposition, do not overheat.
Viscosity, dynamic : 3.45 mPa.s (20 °C)

(Aqueous, solution, 15 %)
Explosive properties : EU legislation: Not explosive
Oxidizing properties : Currently we do not have any information from our
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9.2. Other information
Section 10: Stability and reactivity

10.1. Reactivity
Advice : This product is a very reactive substance that can react with
many inorganic and organic compounds.
10.2. Chemical stability
Advice : Decomposes on heating.

Decomposes on exposure to light.
10.3. Possibility of hazardous reactions
Hazardous reactions : May develop chlorine if mixed with acidic solutions.
10.4. Conditions to avoid
Conditions to avoid : Heat.

Thermal decomposition : To avoid thermal decomposition, do not overheat.
10.5. Incompatible materials
Materials to avoid : Acids, ammonium compounds, Acetic anhydride, Organic

materials, Hydrogen peroxide, metal salts, Copper, Nickel, Iron
10.6. Hazardous decomposition products
Hazardous decomposition : Hydrogen chloride gas, Chlorine, chlorine oxides

products
Section 11: Toxicological information

11.1. Information on toxicological effects
Acute toxicity
Oral
LD50 : 2900 - 3400 mg/kg (mouse)

Cause serious burns with severe pains, vomiting, pains in the
stomach, possibly chock and damaged kidneys. The burn may
occur even if only small amounts have been swallowed.
Dermal
LD50 : > 2000 mg/kg (rabbit)
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Irritation
Skin
Result : Severe skin irritation (rabbit) (OECD Test Guideline 404)
corrosive effects (human)
Eyes
Result : corrosive effects (rabbit)

Risk of serious damage to eyes.
Sensitisation
Result : not sensitizing (guinea pig)
Further information
Other relevant : If ingested, severe burns of the mouth and throat, as well as a
toxicity information danger of perforation of the oesophagus and the stomach.
Section 12: Ecological information

12.1. Toxicity
12.2. Persistence and degradability
Persistence and degradability

Persistence
Result : no data available
Biodegradability
Result : The methods for determining the biological degradability are not
applicable to inorganic substances.
12.3. Bioaccumulative potential
Bioaccumulation
Result : Bioaccumulation is not expected.
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12.4. Mobility in soil
Mobility
Result : The product is mobile in water enviroment.
12.5. Results of PBT and vPvB assessment
Results of PBT and vPvB assessment
Result : no data available
12.6. Other adverse effects
Additional ecological information
Result : Do not flush into surface water or sanitary sewer system.

Very toxic to aquatic organisms.
Section 13: Disposal considerations

13.1. Waste treatment methods
Product : Disposal together with normal waste is not allowed. Special

disposal required according to local regulations. Do not let
product enter drains. Contact waste disposal services.
Contaminated packaging : Empty contaminated packagings thoroughly. They can be

recycled after thorough and proper cleaning. Packagings that
cannot be cleaned are to be disposed of in the same manner
as the product.
European Waste : No waste code according to the European Waste Catalogue

Catalogue Number can be assigned for this product, as the intended use dictates
the assignment. The waste code is established in consultation
with the regional waste disposer.
Section 14: Transport information
14.1. UN number
1791
14.2. UN proper shipping name
ADR : HYPOCHLORITE SOLUTION

RID : HYPOCHLORITE SOLUTION
IMDG : HYPOCHLORITE SOLUTION
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14.3. Transport hazard class(es)
ADR-Class : 8
(Labels; Classification Code; Hazard 8; C9; 80; (E)
identification No; Tunnel restriction code)
RID-Class : 8
(Labels; Classification Code; Hazard 8; C9; 80
identification No)
IMDG-Class : 8
(Labels; EmS) 8; F-A, S-B
14.4. Packaging group
ADR : III
RID : III
IMDG : III
14.5. Environmental hazards
Labeling according to 5.2.1.8 ADR : Fish and tree

Labeling according to 5.2.1.8 RID : Fish and tree
Labeling according to 5.2.1.6.3 IMDG : Fish and tree
Classification as environmentally : yes
hazardous according to 2.9.3 IMDG
14.6. Special precautions for user
Note : not applicable
14.7. Transport in bulk according to Annex II of MARPOL 73/78 and the IBC Code
IMDG : Not applicable.
Section 15: Regulatory information

15.1. Safety, health and environmental regulations/legislation specific for the substance or
mixture
Other regulations : Occupational restrictions: Take note of Dir 92/85/EEC on the

safety and health of pregnant workers at work and of Dir
94/33/EC on the protection of young people at work.
15.2. Chemical Safety Assessment
A Chemical Safety Assessment has been carried out for this substance.
Section 16: Other information
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PCH 1602 STC03-13 1P1C 9–23

Full text of R-phrases referred to under sections 2 and 3.
R31 Contact with acids liberates toxic gas.

R34 Causes burns.
R35 Causes severe burns.
R50 Very toxic to aquatic organisms.
Full text of H-Statements referred to under sections 2 and 3.
H290 May be corrosive to metals.

H314 Causes severe skin burns and eye damage.
H335 May cause respiratory irritation.
H400 Very toxic to aquatic life.
Further information
Other information : Restricted to professional users. Attention - Avoid exposure -

obtain special instructions before use.The information provided
in this Safety Data Sheet is correct to our knowledge at the
date of its revision. The information given only describes the
products with regard to safety arrangements and is not to be
considered as a warranty or quality specification and does not
constitute a legal relationship.
The information contained in this Safety Data Sheet relates
only to the specific material designated and may not be valid
for such material used in combination with any other material
or in any process, unless specified in the text
|| Indicates updated section.
R47984 / Version 8.0 13/41 EN
9–24 PCH 1602 STC03-13 1P1C


Environm
Main
Sector Product Process ental Article
User
No. Short title of Use Category Category Release Category Specified
Group
(SU) (PC) (PROC) Category (AC)
(SU)
(ERC)
Manufacture of 1, 2, 3, 4,
1 3 8 NA 1 NA ES447
substance 8a, 8b, 9
1, 2, 3, 4,
2 Use as an intermediate 3 8, 9 19 6a NA ES9182
8a, 8b, 9
Formulation &
1, 2, 3, 4,
(re)packing of
3 3 10 NA 5, 8a, 8b, 2 NA ES9179
substances and
9, 14, 15
mixtures
Use in Cleaning 5, 7, 8a,
4 3 4 35 6b NA ES9191
Agents 9, 10, 13
Use in Cleaning 5, 9, 10, 8a, 8b,
5 22 NA 35 NA ES538
Agents 11, 13, 15 8d, 8e
1, 2, 3, 4,
Use in sewage water
6 3 23 20, 37 5, 8a, 8b, 6b NA ES9187
treatment
9
1, 2, 3, 4,
7 Use in textile industry 3 5 34 5, 8a, 8b, 6b NA ES9185
9, 13
1, 2, 3, 4,
8 Use in paper industry 3 6b 26 5, 8a, 8b, 6b NA ES9189
9
34, 35, 8a, 8b,
9 Consumer use 21 NA NA NA ES653
37 8d, 8e
R47984 / Version 8.0 14/41 EN
PCH 1602 STC03-13 1P1C 9–25

1. Short title of Exposure Scenario 6: Use in sewage water treatment

SU 3: Industrial uses: Uses of substances as such or in preparations at industrial
Main User Groups
sites
Sectors of end-use SU23: Electricity, steam, gas water supply and sewage treatment
PC20: Products such as ph-regulators, flocculants, precipitants, neutralization
Chemical product category agents
PC37: Water treatment chemicals
PROC1: Use in closed process, no likelihood of exposure
PROC2: Use in closed, continuous process with occasional controlled exposure
PROC3: Use in closed batch process (synthesis or formulation)
PROC4: Use in batch and other process (synthesis) where opportunity for
exposure arises
PROC5: Mixing or blending in batch processes for formulation of preparations
Process categories and articles (multistage and/or significant contact)
PROC8a: Transfer of substance or preparation (charging/discharging) from/to
vessels/large containers at non-dedicated facilities
PROC8b: Transfer of substance or preparation (charging/discharging) from/to
vessels/large containers at dedicated facilities
PROC9: Transfer of substance or preparation into small containers (dedicated
filling line, including weighing)
Environmental Release ERC6b: Industrial use of reactive processing aids
Categories
2.1 Contributing scenario controlling environmental exposure for: ERC6b
Concentration of the Covers percentage substance in the product up to
Product characteristics Substance in 25 %.
Mixture/Article
Amounts used in the EU 999.999 ton(s)/year
Amount used
(tonnes/year)
Frequency and duration of use Continuous exposure 360 days/year
Flow rate of receiving
18,000 m3/d
surface water
Environment factors not
Dilution Factor (River) 10
influenced by risk management
Dilution Factor (Coastal
100
Areas)
Technical conditions and Air Substance release to air can be excluded
measures at process level Risk from environmental exposure is driven by
(source) to prevent release freshwater., Do not release wastewater directly into
Technical onsite conditions and Water environment., Onsite wastewater treatment
measures to reduce or limit required, No discharge of substance into waste
discharges, air emissions and water
releases to soil
Organizational measures to Soil Substance release to soil can be excluded
prevent/limit release from the site
Type of Sewage
Municipal sewage treatment plant
Conditions and measures related Treatment Plant
to sewage treatment plant Flow rate of sewage
2,000 m3/d
treatment plant effluent
Conditions and measures related External treatment and disposal of waste should
to external treatment of waste for Waste treatment comply with applicable local and/or national
disposal regulations.
2.2 Contributing scenario controlling worker exposure for: PROC1, PROC2, PROC3, PROC4,
PROC5, PROC8a, PROC8b, PROC9
Concentration of the Covers percentage substance in the product up to
Product characteristics
Substance in 25 %.
R47984 / Version 8.0 30/41 EN
9–26 PCH 1602 STC03-13 1P1C

Mixture/Article
Physical Form (at time of
Liquid, moderate fugacity
use)
Vapour pressure 25 hPa
Process Temperature 90 °C
Exposure duration per
8h
Frequency and duration of use day
Frequency of use 5 days/week
Body weight 70 kg
Human factors not influenced by Respiration volume under
10 m3/day
risk management conditions of use
Light activity
Indoor use.
Other operational conditions
affecting workers exposure Assumes activities are at ambient temperature., Outdoor location is covered by
the worst case inside location
Technical conditions and provide a good standard of general ventilation (not less than 3 to 5 air changes
measures to control dispersion per hour).
from source towards the worker Drain down system prior to equipment opening or maintenance.
Ensure that no inhalable aerosols are generated
Organisational measures to
Regular inspection and maintenance of equipment and machines.
prevent /limit releases, dispersion
Ensure that the task is not carried out overhead.
and exposure
Ensure containment of the emission source
Wear protective gloves/ protective clothing/ eye protection/ face protection.
Conditions and measures related
In case of odour, gas alarm or insufficient ventilation wear suitable respiratory
to personal protection, hygiene
protection
and health evaluation
In the case of hazardous fumes, wear self contained breathing apparatus.
Risk Management Measures are based on qualitative risk characterisation.
3. Exposure estimation and reference to its source
Environment
Qualitative approach used to conclude safe use.
Workers
Advanced REACH Tool (ART model)

Contributing Specific conditions Exposure routes Level of Exposure RCR
Scenario
Worker - inhalative, long-
PROC1 --- 0.02mg/m³ 0.01
term - local
PROC2, PROC3 --- 1.10mg/m³ 0.71
term - local
PROC4 --- 1.20mg/m³ 0.77
term - local
PROC5,
PROC8a, --- 1.25mg/m³ 0.81
term - local
PROC8b
PROC9 --- 0.91mg/m³ 0.59
term - local
The short-term exposure is covered by the assessment of long-term exposure. Qualitative assessment dermal.
Qualitative approach used to conclude safe use.
4. Guidance to Downstream User to evaluate whether he works inside the boundaries set by the
Exposure Scenario
R47984 / Version 8.0 31/41 EN
PCH 1602 STC03-13 1P1C 9–27

Guidance is based on assumed operating conditions which may not be applicable to all sites; thus, scaling may
be necessary to define appropriate site-specific risk management measures.
If scaling reveals a condition of unsafe use (i.e., RCRs > 1), additional RMMs or a site-specific chemical safety
assessment is required.
Additional good practice advice beyond the REACH Chemical Safety Assessment
Assumes a good basic standard of occupational hygiene is implemented.
Ensure that gas alarms are installed
Change gloves, if duration of activity exceeds breakthrough time
These measures involve good personal and housekeeping practices (i.e. regular cleaning), no eating and smoking at
the workplace, wearing of standard working clothes and shoes
R47984 / Version 8.0 32/41 EN
9–28 PCH 1602 STC03-13 1P1C

9.2 General Arrangement and P&I Drawings
Table 9–2 General Arrangement and P&I Drawings
Compressors Pumps Drawing Type Drawing Number

GA STC03-0A-865 Sheet 1 of 3
STC03-13 1 1 P&I STC03-0A-865 Sheet 2 of 3
P&I STC03-0A-865 Sheet 3 of 3
PCH 1602 STC03-13 1P1C 9–29

NOTES:-
Installation, Commissioning, Operating and Maintenance Manual 9. Drawings and Documents
9.3 Sectional Arrangements
Table 9–3 Sectional Arrangements
Drawing Content Drawing Number Number of Sheets in Drawing

STC02-13 to STC06-13 STC02-06-103 8
PCH 1602 STC03-13 1P1C 9–33

9. Drawings and Documents Installation, Commissioning, Operating and Maintenance
9–34 PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C 9–35

9–36 PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C 9–37

9–38 PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C 9–39

9–40 PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C 9–41

9.4 Electrical Drawings
Table 9–4 Circuit Diagram
Compressors Pumps Control Voltage Drawing No.

1 1 110/24 E19312 Sheets 3 to 11
1 1 220/24 E19313 Sheets 3 to 11
Table 9–5 Installation Wiring Diagram
Compressors Pumps Control Voltage Drawing No.

1 1 110/220 E19308 Sheets 3 & 4
9–42 PCH 1602 STC03-13 1P1C

CB1 CL1
A
A
A
MOTOR CIRCUIT
PCH 1602 STC03-13 1P1C

BREAKERS SET TO
F.L.C. OF INSTALLED
MOTORS
SELECT APPROPRIATE
VOLTAGE INPUT
TRANSFORMER
TEMPERATURE
480
460
440
415
400
380
COM
D TX1
RATING 55°C
4 BLK 82VA 20.5VA

24
110
COM
COM
1.5 BLK 1R
E
X2
LK1
1V
F 1R
X3
LK2
G
1V
380 - 480 VAC SUPPLY

H 50 - 60 Hz 3P+E 32 Amps
Drg. No.:- E19312

SEWAGE TREATMENT PLANT GO No.:- STC
WARTSILA Rev. No.:- 5.0
Water Systems 1 BLOWER - 1 DISCHARGE PUMP - 110 VAC CONTROL Project Date :- 15.10.15
Power Schematic ( 1 of 2 ) Page No. :- 3
Limited Total :- 11
WARTSILA WATER SYSTEMS LTD. Copyright and All Other Rights Reserved
9. Drawings and Documents
9–43
9–44
A
B
MOTOR CIRCUIT
BREAKERS SET TO
F.L.C. OF INSTALLED
MOTORS
1.5 BLK
Drg. No.:- E19312

Limited Total :- 11
PCH 1602 STC03-13 1P1C

A 1R
1R
PCH 1602 STC03-13 1P1C

C IF REMOTE E/STOP
REQUIRED WIRE TO
TERMINALS X2-1 & X2-2
REMOVE LINK 'A'
LINK 'A'
DOSING
JUNCTION
BOX
BROWN
BLUE
G/Y
BROWN
GREEN
BROWN
BLUE
G/Y
BROWN
GREEN
F
DU1 DU2
PULSE PULSE
CONT. CONT.
G
CR500 KM1 KM3
CR500. KM1. KM3. CHLORINATION UNIT DECHLORINATION UNIT
1R
CONTROL ON BLOWER No.1 DISCHARGE PUMP No.1

NO 7.C15 NO 3.D7,6.C5 NO .C8,4.D7
H NC NC NC
NO 7.C4,8.B7 NO .D17,7.C8,8.B9
NC NC
Drg. No.:- E19312

110 VAC Control Page No. :- 5
Limited Total :- 11
9–45
9–46
A
1V
1V
B
TIMER TO BE SET
TO MODE 'B'
ONE SHOT
G
A1
Y1
A2
NO FAULTS TANK LOW LEVEL CHLORINATION DECHLORINATION CHLORINE DOSING TIMER

1V
TANK HIGH LEVEL LOW LEVEL HEALTHY LOW LEVEL HEALTHY
H
Drg. No.:- E19312

24 VAC Control ( 1 of 2 ) Page No. :- 6
Limited Total :- 11
PCH 1602 STC03-13 1P1C

A
1V
1V
PCH 1602 STC03-13 1P1C

C
E
1V
BLOWER RUNNING PUMP RUNNING COMMON ALARM DOSING CHEMICAL LOW POWER AVAILABLE
1V
Drg. No.:- E19312

Limited Total :- 11
9–47
9–48
NOTES
A 1) TERMINALS X4-1 TO X4-11 ARE VOLTFREE CONTACTS
1O
FOR CUSTOMER MONITORING. THEY ARE RATED
FOR 5 A 250 Vac, 5 AMP 30 Vdc.
2) TERMINALS X4-1 to X4-3 ARE A HEALTHY SIGNAL,
(CONTACTS OPEN ON ALARM). IF THE HEALTHY
SIGNAL IS TO INDICATE A FAULT WHEN THE PLANT
B IS SWITCHED OFF, REMOVE LINK 'B'
3) TERMINALS X4-4 to X4-5 ARE CLOSED CIRCUIT WHILST
THE BLOWER No.1 IS RUNNING.
1O 1O 4) TERMINALS X4-6 to X4-7 ARE NOT USED.

C THE DISCHARGE PUMP No.1 IS RUNNING.
LINK 'B' 6) TERMINALS X4-10 to X4-11 ARE NOT USED.
(SEE
NOTE 2)
1O
RUNNING
RUNNING
TERMINALS FOR VOLT FREE CONTACTS SHOULD HAVE
BLOWER No.1
D A CLEAR PLASTIC GUARD FITTED
THE GUARD SHOULD HAVE A LABEL THAT WARNS
' TERMINALS MAY REMAIN LIVE WITH PANEL ISOLATED '
DISCHARGE PUMP No.1

X4
X1 X3
24 VAC COMMON N4 LK2 N1 TX1:COM
E X2
110 VOLT COMMON N2 LK1 N1 TX1:COM
X1
F
X2 X3
X4
Label Jumper
Label Jumper
X1 Label Jumper
X2 Label Jumper
U1 X4
LK1 X3
V1 1
1 LK2
W1 2
LINK 'A' 1 LINK 'B'
2
G PE 3
3 2
U3 4
4 3
V3 5
5 4
W3 6
PE 5
PE 7
PE 6
X1 8
X2 7
9
8
10
PE
H 11
PE
ALL TERMINALS MUST BE LABLED BOTH SIDES PE
X3
PE
X4
Drg. No.:- E19312

Customer Interlocks & Terminals Page No. :- 8
Limited Total :- 11
PCH 1602 STC03-13 1P1C

RIETSCHLE BLOWERS TTS BLOWERS
STC02-13 to STC06-13 DISCHARGE PUMPS - 50 Hz MEDIUM HEAD (18 Metre) STC 02-13 BLOWERS STC 02-13 BLOWERS
PUMP TYPE 6757100100, 101, 106, 107 OR 146 BLOWER TYPE 49950649 (RIETSCHLE) BLOWER TYPE (TTS BLOWER)
380V-5OHz STCXX-8500009: 440V-60Hz STXX-8500010
SUPPLY POWER CURRENT MCB SUPPLY POWER CURRENT MCB
(KW) (MCB SETTING) RANGE (KW) (MCB SETTING) RANGE 415V-5OHz STCXX-8500016: 480V-60Hz STXX-8500018
SUPPLY
380 Vac 50 Hz 4.0 kW 8.0 AMPS 6 - 10 AMP 380 Vac 50 Hz 0.55 1.55 AMPS 1.0 - 1.6 AMP POWER CURRENT MCB
400 Vac 50 Hz 4.0 kW 7.7 AMPS 6 - 10 AMP 400 Vac 50 Hz 0.55 1.55 AMPS 1.0 - 1.6 AMP (KW) (MCB SETTING) RANGE
415 Vac 50 Hz 4.0 kW 7.5 AMPS 6 - 10 AMP 415 Vac 50 Hz 0.55 1.55 AMPS 1.0 - 1.6 AMP 380 VAC 50 Hz 0.55 1.55 AMPS 1.0 - 1.6 AMP
440 Vac 60 Hz 0.65 1.7 AMPS 1.6 - 2.5 AMP 400 VAC 50 Hz 0.55 1.48 AMPS 1.0 - 1.6 AMP
PCH 1602 STC03-13 1P1C

460 VAC 60 Hz 0.55 1.28 AMPS 1.0 - 1.6 AMP
480 VAC 60 Hz 0.55 1.23 AMPS 1.0 - 1.6 AMP
STC02-13 to STC06-13 DISCHARGE PUMPS - 60 Hz MEDIUM HEAD (18 Metre) STC 03-13 & STC 04-13 BLOWERS STC 03-13 & STC 04-13 BLOWERS
SUPPLY
460 VAC 60 Hz 1.1 2.3 AMPS 1.6 - 2.5 AMP

480 VAC 60 Hz 1.1 2.2 AMPS 1.6 - 2.5 AMP
STC02-13 to STC06-13 DISCHARGE PUMPS - 60 Hz HIGH HEAD (25 Metre) STC 06-13 BLOWERS STC 06-13 BLOWERS
SUPPLY
460 VAC 60 Hz 1.5 3.02 AMPS 2.5 - 4.0 AMP
480 VAC 60 Hz 1.5 2.9 AMPS 2.5 - 4.0 AMP
Drg. No.:- E19312

Power Selection Table 'A' Page No. :- 9
Limited Total :- 11
9–49
9–50
POWER
AVAILABLE
BLOWER PUMP COMMON DOSING

RUNNING RUNNING ALARM CHEMICAL LOW
BLOWER PUMP DOSING

OFF ON MAN OFF AUTO OFF ON
700
D ANGER
ISOLATE
ELSEWHERE
500 250
130
445
Drg. No.:- E19312

Panel Construction Page No. :- 10
Limited Total :- 11
PCH 1602 STC03-13 1P1C

BB1
KM1
KM1
CL1
CB1
CL1
CB1
X1
PCH 1602 STC03-13 1P1C

TX1
TX1
KM3
KM3
QM1
QM1
X2
QM3
QM3
1
Q
Q1
QM5
QM5
2
Q
Q2
CR600
CR601
X3
CR602
CR603
Q0
Q0
ISOL
X4
CR604
TR605
CR500
CR600 CR601 CR602 CR603 CR604 TR605

CR500
Drg. No.:- E19312

Backplate Layout Page No. :- 11
Limited Total :- 11
9–51
9–52
CB1 CL1
A
A
A
MOTOR CIRCUIT
BREAKERS SET TO
F.L.C. OF INSTALLED
MOTORS
SELECT APPROPRIATE
VOLTAGE INPUT
TRANSFORMER
TEMPERATURE
480
460
440
415
400
380
COM
D TX1
RATING 55°C
4 BLK 82VA 20.5VA24
220
COM
COM
1.5 BLK 1R
E
X2
LK1
1V
F 1R
X3
LK2
G
1V
380 - 480 VAC SUPPLY

H 50 - 60 Hz 3P+E 32 Amps
Drg. No.:- E19313

Limited Total :- 11
PCH 1602 STC03-13 1P1C

A
PCH 1602 STC03-13 1P1C

MOTOR CIRCUIT
BREAKERS SET TO
F.L.C. OF INSTALLED
MOTORS
1.5 BLK
E
Drg. No.:- E19313

Limited Total :- 11
9–53
9–54
A 1R
1R
B
C IF REMOTE E/STOP
REQUIRED WIRE TO
TERMINALS X2-1 & X2-2
REMOVE LINK 'A'
LINK 'A'
DOSING
JUNCTION
BOX
BROWN
BLUE
G/Y
BROWN
GREEN
BROWN
BLUE
G/Y
BROWN
GREEN
F
DU1 DU2
PULSE PULSE
CONT. CONT.
G
CR500 KM1 KM3
CR500. KM1. KM3. CHLORINATION UNIT DECHLORINATION UNIT
1R
CONTROL ON BLOWER No.1 DISCHARGE PUMP No.1

NO 7.C15 NO 3.D7,6.C5 NO .C8,4.D7
H NC NC NC
NO 7.C4,8.B7 NO .D17,7.C8,8.B9
NC NC
Drg. No.:- E19313

220 VAC Control Page No. :- 5
Limited Total :- 11
PCH 1602 STC03-13 1P1C

A
1V
1V
PCH 1602 STC03-13 1P1C

C
E
TIMER TO BE SET
TO MODE 'B'
ONE SHOT
G
A1
Y1
A2
NO FAULTS TANK LOW LEVEL CHLORINATION DECHLORINATION CHLORINE DOSING TIMER

1V
TANK HIGH LEVEL LOW LEVEL HEALTHY LOW LEVEL HEALTHY
H
Drg. No.:- E19313

Limited Total :- 11
9–55
9–56
A
1V
1V
B
1V
BLOWER RUNNING PUMP RUNNING COMMON ALARM DOSING CHEMICAL LOW POWER AVAILABLE
1V
Drg. No.:- E19313

Limited Total :- 11
PCH 1602 STC03-13 1P1C

NOTES
A 1) TERMINALS X4-1 TO X4-11 ARE VOLTFREE CONTACTS
1O
FOR CUSTOMER MONITORING. THEY ARE RATED
FOR 5 A 250 Vac, 5 AMP 30 Vdc.
2) TERMINALS X4-1 to X4-3 ARE A HEALTHY SIGNAL,
(CONTACTS OPEN ON ALARM). IF THE HEALTHY
SIGNAL IS TO INDICATE A FAULT WHEN THE PLANT
B IS SWITCHED OFF, REMOVE LINK 'B'
PCH 1602 STC03-13 1P1C

THE BLOWER No.1 IS RUNNING.
1O 1O 4) TERMINALS X4-6 to X4-7 ARE NOT USED.

C THE DISCHARGE PUMP No.1 IS RUNNING.
LINK 'B' 6) TERMINALS X4-10 to X4-11 ARE NOT USED.
(SEE
NOTE 2)
1O
RUNNING
RUNNING
TERMINALS FOR VOLT FREE CONTACTS SHOULD HAVE
BLOWER No.1
D A CLEAR PLASTIC GUARD FITTED
THE GUARD SHOULD HAVE A LABEL THAT WARNS
' TERMINALS MAY REMAIN LIVE WITH PANEL ISOLATED '
DISCHARGE PUMP No.1

X4
X1 X3
24 VAC COMMON N4 LK2 N1 TX1:COM
E X2
220 VOLT COMMON N2 LK1 N1 TX1:COM
X1
F
X2 X3
X4
Label Jumper
Label Jumper
X1 Label Jumper
X2 Label Jumper
U1 X4
LK1 X3
V1 1
1 LK2
W1 2
LINK 'A' 1 LINK 'B'
2
G PE 3
3 2
U3 4
4 3
V3 5
5 4
W3 6
PE 5
PE 7
PE 6
X1 8
X2 7
9
8
10
PE
H 11
PE
ALL TERMINALS MUST BE LABLED BOTH SIDES PE
X3
PE
X4
Drg. No.:- E19313

Customer Interlocks & Terminals Page No. :- 8
Limited Total :- 11
9–57
9–58
RIETSCHLE BLOWERS TTS BLOWERS
STC02-13 to STC06-13 DISCHARGE PUMPS - 50 Hz MEDIUM HEAD (18 Metre) STC 02-13 BLOWERS STC 02-13 BLOWERS
SUPPLY
460 VAC 60 Hz 0.55 1.28 AMPS 1.0 - 1.6 AMP
480 VAC 60 Hz 0.55 1.23 AMPS 1.0 - 1.6 AMP
STC02-13 to STC06-13 DISCHARGE PUMPS - 60 Hz MEDIUM HEAD (18 Metre) STC 03-13 & STC 04-13 BLOWERS STC 03-13 & STC 04-13 BLOWERS
SUPPLY
460 VAC 60 Hz 1.1 2.3 AMPS 1.6 - 2.5 AMP
480 VAC 60 Hz 1.1 2.2 AMPS 1.6 - 2.5 AMP
STC02-13 to STC06-13 DISCHARGE PUMPS - 60 Hz HIGH HEAD (25 Metre) STC 06-13 BLOWERS STC 06-13 BLOWERS
SUPPLY
460 VAC 60 Hz 1.5 3.02 AMPS 2.5 - 4.0 AMP
480 VAC 60 Hz 1.5 2.9 AMPS 2.5 - 4.0 AMP
Drg. No.:- E19313

Power Selection Table 'A' Page No. :- 9
Limited Total :- 11
PCH 1602 STC03-13 1P1C

POWER
AVAILABLE
BLOWER PUMP COMMON DOSING
PCH 1602 STC03-13 1P1C

RUNNING RUNNING ALARM CHEMICAL LOW
BLOWER PUMP DOSING

OFF ON MAN OFF AUTO OFF ON
700
D ANGER
ISOLATE
ELSEWHERE
500 250
130
445
Drg. No.:- E19313

Panel Construction Page No. :- 10
Limited Total :- 11
9–59
9–60
BB1
KM1
KM1
CL1
CB1
CL1
CB1
X1
TX1
TX1
KM3
KM3
QM1
QM1
X2
QM3
QM3
1
Q
Q1
QM5
QM5
2
Q
Q2
CR600
CR601
X3
CR602
CR603
Q0
Q0
ISOL
X4
CR604
TR605
CR500
CR600 CR601 CR602 CR603 CR604 TR605

CR500
Drg. No.:- E19313

Backplate Layout Page No. :- 11
Limited Total :- 11
PCH 1602 STC03-13 1P1C

SKID MOUNTED EQUIPMENT
ALL CABLES SHOWN DOTTED ARE CUSTOMER SUPPLY
STC PANEL
3 CORE + E
ISOLATOR
X1 2
U1 3 + E 1.5mm
U1 U1
V1 V1
( BLACK + GREEN/YELLOW ) W1 M1 BLOWER No.1
V1
W1 PE
W1
380 VOLTS 3 PHASE 50 Hz PLUS EARTH, OR PE
PE 2
400 VOLTS 3 PHASE 50 Hz PLUS EARTH, OR U3 3 + E 1.5mm
U3 U3
415 VOLTS 3 PHASE 50 Hz PLUS EARTH, OR V3 V3
( BLACK + GREEN/YELLOW ) M3 DISCHARGE PUMP No.1
PCH 1602 STC03-13 1P1C

V3 W3
440 VOLTS 3 PHASE 60 Hz PLUS EARTH, OR W3 PE
460 VOLTS 3 PHASE 60 Hz PLUS EARTH, OR W3
PE
480 VOLTS 3 PHASE 60 Hz PLUS EARTH PE
STC02-13 to STC06-13 : 42 kA MAX. FAULT LEVEL
UPSTREAM PROTECTIVE DEVICE ENERGY LET THOUGH TO BE LESS

THAN 736 x 10 ³ AMP ² SEC
DOSING JUNCTION BOX
X2 2
X1
522 3 + E 1.0mm 522 522
3 1
524 524 524 SUPPLIED WITH UNIT
4 ( RED + G/Y ) 2
N2 N2 N2
5 3
PE N2
PE 4
PE PE
PE
PE
PE
DU1 DU2
NOTES :-
1 - THE CABLE FOR THE DISCHARGE PUMP IS ONLY FITTED IF THE UNIT IS MOUNTED ON THE SEWAGE TREATMENT PLANT. IF IT IS NOT
PULSE PULSE
MOUNTED ON THE SEWAGE TREATMENT PLANT, THE CABLE IS SUPPLIED BY THE CUSTOMER. CONT. CONT.
2 - THE CABLES FOR THE CHLORINE DOSING PUMP CONTROLLER, BISULPHATE DOSING PUMP CONTROLLER AND THE LOW LEVEL
SWITCHES ARE ONLY TERMINATED IF THESE UNITS ARE MOUNTED ON THE SEWAGE TREATMENT PLANT. IF THEY ARE NOT MOUNTED ON CHLORINATION UNIT DECHLORINATION UNIT
THE SEWAGE TREATMENT PLANT, THESE CABLES ARE TERMINATED BY THE CUSTOMER
3 - TERMINALS X4-1 TO 11 ARE VOLT FREE CONTACTS FOR CUSTOMER MONITORING. THEY ARE RATED FOR 5 A 250 Vac, 5 AMP 30 Vdc.
4 - THE CUSTOMER MUST ENSURE SUITABLE OVERALL EARTHING OF THE SYSTEM
5 - THE CUSTOMER MUST ENSURE SUITABLE OVERALL OVERLOAD AND SHORTCIRCUIT PROTECTION OF THE SYSTEM
Drg. No.:- E19308

Water Systems 1 BLOWER 1 DISCHARGE PUMP Project Date :- 12.11.13
Power Page No. :- 3
Limited Total :- 4
9–61
9–62
SKID MOUNTED EQUIPMENT
ALL CABLES SHOWN DOTTED ARE CUSTOMER SUPPLY
STC PANEL
X3 2
608 5+E x 1.0mm
1 608 WH HIGH LEVEL ALARM
609 ( VIOLET ) 609 WH
2
L4
610 RD
3 HIGH LEVEL
610 L4 COM
5 611 BK LOW LEVEL
611
6
DOSING JUNCTION BOX
X3 2
X2
L4 3+E x 1.0mm L4 L4 SUPPLIED WITH UNIT
4 1 L4 1 FS1
612 ( VIOLET ) 612 CHLORINATION LIQUID LEVEL
L4 2
7 2
613 612 612
8 3
PE 613 613
PE 4
PE L4 FS2
PE 1
613 2 DECHLORINATION LIQUID LEVEL
REMOTE EMERGENCY STOP SIGNAL FROM THE SHIP
( VOLT FREE CONTACT TO BE ARRANGED TO OPEN ON EMERGENCY STOP )
IF USED REMOVE LINK 'A' X2
1
LINK 'A'
2
PE
HEALTHY SIGNAL FOR REMOTE MONITORING BY THE SHIP.

( VOLT FREE CONTACTS ARRANGED TO OPEN ON FAULT )
IF FAULT IS TO INCLUDE PANEL SWITCHED OFF REMOVE LINK 'B' X4
1
2
BLOWER No.1 RUNNING SIGNAL FOR REMOTE MONITORING BY THE LINK 'B'
3
SHIP. ( VOLT FREE CONTACTS ARRANGED TO CLOSE ON RUN )
4
DISCHARGE PUMP RUNNING No.1 SIGNAL FOR REMOTE MONITORING BY
5
THE SHIP. ( VOLT FREE CONTACTS ARRANGED TO CLOSE ON RUN )
8
9
PE
Drg. No.:- E19308

Water Systems 1 BLOWER 1 DISCHARGE PUMP Project Date :- 12.11.13
Control Page No. :- 4
Limited Total :- 4
PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C

ALL COPYRIGHT AND DESIGN RIGHT SUBSISTING IN THIS DOCUMENT IS THE PROPERTY OF HAMWORTHY WATER SYSTEMS LTD , AND MAY NOT BE REPRODUCED IN ANY FORM
OR BY ANY MEANS, IN PART OR WHOLE, WITHOUT HAMWORTHY WATER SYSTEMS LTD CONSENT. THIS DOCUMENT AND THE INFORMATION WITHIN IT IS CONFIDENTIAL TO
HAMWORTHY WATER SYSTEMS LTD AND MAY NOT BE DISCLOSED TO ANY THIRD PARTY WITHOUT THE PRIOR WRITTEN CONSENT OF HAMWORTHY WATER SYSTEMS LTD.'
CROSS REFERENCE ISS ALTERATIONS E CH NO. DATE SIGN. SCALE DATE

DATE HAMWORTHY WATER SYSTEMS LTD FIRST ANGLE PROJECTION
1:2 24/2/09
DRN.
DRN. CH. APP.
MLS ART SGCJ DN50 WAFER CHECK VALVE
G.O./L.O.P. GO096051 & PINCH VALVE ASSEMBLY PART NO.
R62693
ISS 1
ISS SHT.1
SHT.
PATT. NO. SHTS. 1
SECTION A-A MAT'L SPEC.
DIMENSIONS ARE MILLIMETRES UNLESS OTHERWISE STATED. REMOVE UNNECESSARY SHARP EDGES.
UNTOLERANCED DIMENSIONS TO T0103003/006. ABBREVIATIONS AND SYMBOLS TO BS 8888.
WELDING TERMS AND SYMBOLS TO BS 22553. WELD PREPARATIONS TO T0416000.
4
VISUAL INSPECTION OF FUSION WELDED JOINTS TO HKSES QP09 PT2.

1.6
14 8
5 6 3 2 3 1 9
9 Not Hamworthy supply WASHER M16 TABLE A MS ZINC PLATE 4

8 Not Hamworthy supply WASHER M16 SPRING SING-COIL-RECT 4
7 Not Hamworthy supply NUT FULL M16 GRADE 8 ZINC PLATE 4
A A 6
5
Not Hamworthy supply
Not Hamworthy supply
BOLT M16 X 80 GRADE 8.8 ZINC PLATE
DN50 SCH10 PIPE 316 x
4
1
4 Not Hamworthy supply 50NB slip on flange 316ss 1
57.2 3 42194068 JOINT GASKET DN50 2
2 B17826 50NB hinged wafer flap valve 1
76.7
1 4953500113 Saunders Valve DN50 1
ITEM STOCK NUMBER DESCRIPTION QTY
HAMWORTHY WATER SYSTEMS LTD
A4 0 10 20 30 40 50 Copyright and All Other Rights Reserved
Wärtsilä is the world´s leading manufacturer of marine sewage treatment plants. For over three
decades Wärtsilä Hamworthy sewage treatment plants have been widely regarded as standard
specification on all vessels.
See also www.wartsila.com
WÄRTSILÄ® is a registered trademark. © 2010 Wärtsilä Corporation.
Wartsila Water System Limited

Fleets Corner, Poole, Dorset, BH17 0JT, England
Telephone: +44 (0)1202 662600
Facsimile: +44 (0)1202 668793
Email: wastewater@wartsila.com
Find local offices at www.wartsila.com/addresses

9.sewage Treatment Plant

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HAMWORTHY WATER

HAMWORTHY WATER SYSTEMS LTD

98559 Final ISS1 04/6

SEWAGE TREATMENT PLANT Operating and Maintenance

Document ID PCH 1602 STC03-13 1P1C

STP Type STC03-13 with 1 Pump 1 Compressor

Issue No. Issue 4 September 2015

IMO Ref: Approved to MEPC 227 (64)

Issue No. ECN No. Description of Change

PCH 1602 STC03-13 1P1C

Safety and Warnings

Warning Instruction markings

PCH 1602 STC03-13 1P1C i

9 Before proceeding with maintenance on the unit, or making adjustments to its

10 Before commencing repair or overhaul a preliminary check of available spares must be

13 The equipment should not be installed in an explosive atmosphere.

15 Attention is drawn to the following publications:

a “Sewage systems on ships: associated hazards, installation and maintenance”,

ii PCH 1602 STC03-13 1P1C

Safety and Warnings..............................................................................................................................................i

1. Technical Data ..............................................................................................................................................1–1

4. Commissioning and Operation ....................................................................................................................4–1

PCH 1602 STC03-13 1P1C iii

5. Maintenance and Trouble Shooting ............................................................................................................5–1

6. Discharge Pump B50x50HC .........................................................................................................................6–1

iv PCH 1602 STC03-13 1P1C

6.3. Installation ................................................................................................................................................6–5

7. Compressor (Type CYBW-25) ......................................................................................................................7–1

9. Documents and Drawings............................................................................................................................9–1

PCH 1602 STC03-13 1P1C v

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vi PCH 1602 STC03-13 1P1C

Table 1–1 Sewage Loading Table ...................................................................................................................1–1

PCH 1602 STC03-13 1P1C vii

This page is intentionally blank

viii PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C ix

This page is intentionally blank

x PCH 1602 STC03-13 1P1C

Spare Parts and Service

Wartsila Water Systems Ltd. Telephone: +44 (0)1202 662600

Type and serial number of machine: Obtained from machine nameplate

Technical Service and Advice:

PCH 1602 STC03-13 1P1C xi

Wärtsilä Agents and Offices

Wärtsilä Netherlands B.V.

xii PCH 1602 STC03-13 1P1C

PCH 1602 STC03-13 1P1C xiii

Olio Resources Sdn. Bhd.

xiv PCH 1602 STC03-13 1P1C

Koastal Industries Pte . Ltd.

PCH 1602 STC03-13 1P1C xv

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xvi PCH 1602 STC03-13 1P1C

TECHNICAL DATA SHEET – SEWAGE TREATMENT PLANT

SEWAGE TREATMENT PLANT SELECTION / DATA

ELECTRICAL SUPPLY : 440 volts, 3 phase, 60 Hz.

CHLORINATION DOSING PUMP

DE-CHLORINATION DOSING PUMP

1.1 General Technical Data

Organic Loading Rate Hydraulic Loading Rate

1.1.2 Sewage Peak Loading Considerations

1.1.3 Electrical Power Supply

98559 Final ISS1 04/6