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Technical Manual for

Installation Operation & Maintenance


Rev.00 04/12

SEWAGE WATER TREATMENT


PLANT FACET - STP-2

Serial N /
Order N /
Technical Manual for Installation, Operation & Maintenance

SEWAGE WATER TREATMENT


PLANT

FACET STP/VTP SERIES

75960000001 Sewage Water Treatment Plant STP.doc/Rev.01 05/11

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FACET Sewage Treatment Plant

1 SAFETY
These operating instructions contain basic requirements to be observed during the
installation, operation and maintenance of the Sewage Treatment Plant. Therefore, the
instructions must be read by the operator responsible of the unit prior to assembly and
commissioning, and kept available at the operating site of the Sewage Treatment Plant at
all times.
1.1 Risks that may be undergone during the operation of the Sewage Treatment Plant
The Sewage Treatment Plant has been fully tested and certified regarding safety, if it
were not properly set up or used, risks could arise and result in damage of:
The personnels life or their body.
the Sewage Treatment Plant and other installations on board.
the proper operation of the Sewage Treatment Plant.
The personnel responsible for the installation of the Sewage Treatment Plant and/or
its electrical and hydraulic systems must
be duly qualified to carry out their duties
strictly follow the instructions her explained
1.2 Labelling of Advice in the Operating Instructions
The following warnings are incorporated into these instructions:
In these operating instructions safety advice whose non-observance could lead to
danger for life or limb is labeled with the following text
Danger!!!
Safety instructions whose non-observance could jeopardize the machine and its
functions are labeled by the word:
Warning!!!
To indicate practical tips and other important information following text is used in this
manual:
Important
Always comply with instructions mounted directly on the unit, e.g.
rotational direction arrow
fluid connection indicators
and ensure that the information remains legible.

1.3 Personnel Qualifications and Training


Personnel charged with operation, maintenance, inspection and assembly must be in
possession of the appropriate qualifications for the tasks. The company operating the
machine must define exact areas of responsibility, accountabilities and personnel
supervision schemes. Personnel lacking the required skills and knowledge must
receive training and instruction. If necessary, the operating company may
commission the manufacturer/supplier to conduct these training courses.
Furthermore, the operating company must ensure that the personnel fully understand
the contents of the operating instructions.

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1.4 Security Precautions


The following precautions must be taken for the security of the personnel who
operate the Sewage Treatment Plant:
1. Precaution must be taken to keep the area around the Sewage Treatment Plant
clean to prevent accidents.
2. All product spills must be dried immediately with rags, and these removed to a
safe place.
3. Gloves must be used when parts are handled that have been in contact with the
fluids handled by the Sewage Treatment Plant.
4. Avoid unnecessary contact of the skin and clothes with the handled fluids.
5. After maintenance or working with the Sewage Treatment Plant, the hands and
parts that have been in contact with the fluids must be thoroughly washed.
6. Immediate medical attention must be lent to cuts in the skin, upset stomach, etc.,
due to possible contacts with the product or to the inhalation of gases.
Danger!!!
The equipment is normally fed voltages that can cause damage if contact with these
lines takes place. Precautions must be taken when opening the Control Panel, since
even if the general switch is open there will be tension in the input terminals of the
control panel. As a precaution the line that feeds the equipment should be
disconnected.
Important
Security and environmental protection are the responsibility of the user. Facet does
not assume any responsibility for the inadequate use of this Sewage Treatment Plant
or its use outside the parameters for which it was designed.

7. The Sewage Treatment Plant must be securely installed on a stable, horizontal


surface, following it to tip over would endanger life and limb.
1.5 Safety Instructions for equipments installed in explosive atmospheres
For skilled electricians and instructed personnel in accordance with national
regulation, including the relevant standard and, where applicable, in acc. with IEC
60079-17 on electrical apparatus for explosive atmospheres.
1. The apparatus must not be operated in Zones 0
2. The technical data indicated on the apparatus, in the technical documentation of
products, and in the present instructions are to be observed!
3. Changes of the design and modifications to the apparatus are not permitted!
4. The apparatus shall be operated as intended only in undamaged and perfect
conditions!
Danger!!!
Do not keep these operating instructions inside the enclosures during operation.

5. The tasks of inspections in explosive atmospheres have to be done by qualified


personnel in accordance with the Electrotechnical Low Voltage Regulations. It is
recommended follow the instructions indicated in IEC 60079-17.

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6. A qualified electrician may only carry out repairs the effects of explosion
protection, and subsequently will have to be checked by an expert
7. Improper operations can invalidate the guarantee!
8. The national safety rules and regulations for prevention of accidents and the
following safety instructions described in theses operating instructions, will have
to be observed
9. The respective national regulations as well as the general rules of engineering
which apply to the installation and operation of explosive atmospheres protected
apparatus will have to be observed
Danger!!!
The opening of enclosures always shall be without voltage!

10. Mounting the selected cable entries (cableglands or seals according needs) in
accordance with the type and dimensions of the cable, following their
manufacturer instructions.
Danger!!!
The flameproof enclosures are well closed when all of their screws closing the flange
joint are perfectly tighten and their gaps are 0.2mm

11. The selected cable entries have to be a minimum protection mode EExd IIB.
12. Unused cable entries have to be closed by a correspondent certified blanking
plug with a minimum protection mode EExd IIB.
13. Connect the apparatus in accordance with their technical product documentation
of the supplied apparatus.
14. The flameproof joints have to be cleaned, undamaged, without corrosion and
perfect greased.
15. Exd enclosures damaged or with corrosion can minimize their mechanical
resistance.
16. The flameproof joints of these apparatus have to be greased permanently in
order to ensure its protection against corrosion, water intake and size up
problems. Clean rest of grease and corrosion with no sharp metallic devices that
can damage the surface of the joints and grease the joints using appropriate
thermally and chemically stable grease with a drop point > 200C.
17. If necessary change the supplied screws closing the enclosure (cover to body)
pay attention to use a screw with identical dimensions an resistance > 65
kg/mm2.
18. The cable glands must be well tightened and without corrosion.
19. The cables must be well tightened to their cable glands which must be of
adequate size.
20. When seals are installed the internal sealing shall be in perfect conditions to
ensure the sealing of the cables.
21. The repair tasks shall be carried out according the standard IEC 60079-19 and in
compliance with respective national regulations.

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2 INTRODUCTION
2.1 Description.
This Manual gives instructions for the installation, operation and
maintenance of the Sewage Water Treatment Plant Facet
STP/VTP
2.2 Purpose.
To give the user the necessary instructions for its continuous and trouble-free
operation, and the procedures and tests to detect failures and correct them in the
less possible time.
This manual is valid for all the Facet STP/VTP Systems.

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3 GENERAL INSTRUCTIONS
3.1 Purpose of the Equipment.
To treat the black sewage waters from ships, according to international criteria and
recommendations (U.S.C.G., IMO, RINA, etc.).
3.2 Recommendations
The efficiency of the Unit is mainly determined by the periodic performance of
the tests and maintenance operations described in Table 6 Periodic
Maintenance page 20. An adequate maintenance of the Unit will avoid failures
and unpleasant smells.
In case of detecting an unpleasant smell it is recommended to check the
aeration system of the unit. See Paragraphs 7.3 page 16 and 0 page 20.
Regulations require treatment of black waters only. Therefore gray waters may
be discharged directly without passing through the unit, obtaining a considerable
reduction on its size.
Warning!!!
When equipment has been handled and you have been in contact with the
waters to be treated, it is important to wash hands thoroughly and apply a
disinfectant. Avoid at all times splashing on eyes and prolonged vapor
inhalation.
Beware to disconnect the unit before any operation on it or in any of its electrical
components.

Facet Ibrica, S.A. recommends the installation of a by-pass in the unit, by


means of manual valves, that may allow for isolation in case of failure or
revision. The Unit can only be by-passed if the ship is in international waters,
following the closing procedure described in Paragraph 11.1 page 26.
Vertical motion of the vessel can result in extremely high local high-loading, due
to the mass of the contained liquid. For this reason, adequate support must be
provided for the Unit, preventing permanent deformation and/or fracture. See
Paragraph 0
Installation page 15.

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4 GENERAL DESCRIPTION
4.1 Description
The Facet STP / VTP Unit is a treatment system comprised of a tank divided by
bulkheads in several deposits interconnected by pipes, and with an air supply system
for the liquid recirculation and reactivation of aerobic biological reactions. It also
includes a chlorine injection system as disinfection in the last stage. The description
and function of each of the components is given in the following paragraphs.
4.1.1. Tank
Made of mild steel plate including all baffles, pipes and bulkheads, whose
water-tightness is verified by hydrostatic pressure tests. The surfaces are
protected by Epoxy paints according to a special treatment. Can be supplied
in modules adaptable on board.
It is internally divided into three compartments. According to their order of
process sequence they are:
A. Aeration Chamber
B. Clarifier Chamber
C. Disinfection / discharge Chamber
Covers and hatches have been provided for cleaning and checking
operations.
Figure 1 Elements

Air from
Ship Client
Chlorine
Blower Supply
Tank
Tanque Soplante
Metering
de cloro
Pump
Optional Y1 Aeration
Chamber Control
Cmara Panel Sewage
Aireacin Inlet
Clarification
Entrada
chamber
Aguas
Cmara
Dosing Negras
Decantaci
Valve n
Disinfection
Chamber
Chamber
Cmara de
Desinfeccin Biofilm

Discharge
Pump Sewage treatment unit Facet STP / VTP
Bomba
Descarga Planta de Tratamiento de Aguas
Client Fecales Facet STP / VTP
Gravity Supply
Discharge
Descarga
Por Gravedad
Overboard
Al mar To IMO Flange
A Brida IMO

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4.1.2. Biofilm
The Biofilm Media Cassettes are a patented fixed film system which are
submerged in the aeration chamber, and provide a large surface area for
entrapment and holding of waste water digesting microbes.
4.1.3. Aeration System
1. The Aeration System is comprised of the necessary pipes, valves and
interconnections for the distribution and control of the air flow supplied to
the diffusers and to the sludge return line. The air is used to obtain
agitation in the Aeration Chamber, activating the oxygen transfer for the
biological reduction and to generate flow for the transfer recycling of
activated sludge.
2. Facet offers two possible configurations for the air supply:
Use the compressed air system of the ship. In this case a regulation
valve will be provided to reduce the air pressure as well as a protection
filter.
The unit may be equipped with a/two blower/s. It is recommended to
provide a connection with the air of the ship in case there is a failure in
the blower. In this case the pressure is automatically regulated.
The air flow is regulated manually by valves in the distribution pipe.
Figure 2 Elements (continuation)

Sludge return
valve
Vlvula retorno de
lodos Aeration
Chamber
Cmara de
Blower aireacin
Soplante

Clarifier
Chamber
Control
Cmara de
Panel
Decantacin
Panel de
control

Disinfection Discharge
Chamber Pump
Cmara de Bomba de
Desinfeccin Descarga

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4.1.4. Chlorination System


The Chlorination System is designed to attain the destruction of the coliform
bacteria on the influent coming from the Clarifier Chamber. It is comprised of
a storage tank fabricated in polyethylene containing the Hypochlorite solution.
The disinfectant discharge system may be supplied in two ways:
With variable flow chlorine dosing pump to obtain the Hypochlorite
solution required on the effluent.
Dosing by gravity regulated by a dosing valve.
The complete equipment is externally located to allow for ease of access in
case of repair or inspection.
4.1.5. Discharge System
It may be made in three different ways depending on the location of the Unit
on board.
Discharge by gravity.
Discharge by one (or two) centrifugal pumps that directly suction from the
Chlorine Contact Chamber.
Installation of a pumping station with one (or two) submersible pumps.
The Unit will discharge by gravity to this tank.
The two last systems are provided with level detectors for the automatic
operation of the pumps.
4.1.6. Control Panel
Includes the required components for the energy control and supply
necessary for the operation of the elements installed in the Unit (motors,
valves, sensors, etc.), including the required protections and securities. It
may be directly installed over the Unit or in any other place as convenient.

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5 SPECIAL TOOLS AND TEST EQUIPMENT


5.1 General.
This section contains a list of those special items of equipment and supplies required
to operate and maintain the Unit. Standard items are not included in this section.
5.2 Special Tools.
No special tools are required. Maintenance of the equipment is limited to
inspection, fluid sampling, adjustment, cleaning; component replacement
or such minor repairs as can be effected using common tools.
The only special supply required is a dilute Sodium Hypochlorite solution
at 5,25%, or common bleach.
5.3 Test Equipment.
Comprises three phases:
o pH Test.
o Determination of dissolved oxygen.
o Determination of the chlorine amount.
These tests are made on the effluent according to Section 9.4 page 21.

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6 INSTALLATION
6.1 Preparation.
According to the Units General Dimensions drawings, the site location, inlet/outlet
connections, discharge and vents required will be determined, as well as clearances
required for hatch and cover removal.
A sewage by-pass to the Unit is recommended for the discharge of sewage waters
directly to the sea (only in areas where it is permitted by applicable regulations),
considering the position of the flotation line of the ship. (See drawing 3153730)
6.2 Installation.
After the site has been selected, a level mounting must be provided to assure proper
operation. The Unit must be fastened securely in place for a long, continuous trouble-
free operation.
Warning!!!
Vertical motion of the vessel can result in extremely high local loading due to the
mass of the contained liquid. For this reason, adequate support must be provided to
prevent permanent deformation and/or fracture..

1. A convenient support for the Chlorine Tank must be included with easy access
for filling and for washing down easily.
2. In the case of the Unit being fed by gravity, the installation of a trap at the inlet is
recommended to avoid air flow towards washbasins and toilets.

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7 START UP OF THE UNIT


7.1 Preparation.
Remove all hatches and visually check for foreign objects that may be present.
If necessary clean the Unit with water. Do not use cleaning agents other than
those recommended. Check all mechanical components assuring cleanliness
of the lines and proper lubrication of the blower, (oil and grease) chlorine
dosing mechanism (oil) and discharge pumps. Check all piping to detect
cracks or breaks incurred during shipping.
7.2 Fill
Make certain the inlet valve to the Unit is open and the by-pass is closed. Open the
Aeration Chamber Access Hatch and proceed as indicated below.
TABLE 2 POSITION OF VALVES TO FILL THE UNIT
Description of valves position Condition
Overboard Discharge Closed
Diffuser Air Valve Closed
Sludge Return Air Valve Closed
Equalizing Valve Open
Sampling Valve Open
Fill Unit, with the same water (salt or fresh) as used in the vessel's sanitary system,
until water flows freely from the Equalizing Valve of the Clarifier Chamber. Close this
valve and continue filling until the liquid flows through the Sampling Valve, close this
valve and shut-off water supply.
7.3 Air Supply
Air is supplied to the Unit by vessel air or by a unit blower air system (See Section 0
page 12). Whichever system is used, proceed as follows:
TABLE 3 ADJUSTMENT OF AIR SUPPLY VALVES
Condition
Description Vessel Air Unit Blower
Air
Diffuser Air Valve Open 75 Open 75
Sludge Return Air Valve Open 45 Open 45
Vessel's Air Stop Valve Open Closed
Pressure Regulator 5-7 PSI
2
Blower Oil Level 1
Blower Air Stop Valve 1 Closed Open
1
Blower Off On
1
On Units so equipped
2
See Appendix A

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When adjusting Diffuser Air Valve, note the liquid agitation state in the Aeration
Chamber. The correct agitation should be brisk, surface breaking without violent or
excessive splashing.
Adjust sludge return air valves so that liquid discharge from the return line fills
approximately 1/3 of the inside diameter of pipe outlet.
A solenoid valve is installed on all units to allow regulation of air supply to the sludge
return line. The operation of this valve is discontinuous, its working cycle is
determined by a timer in the control system. This timer may be adjusted to operate
the solenoid valve at the start up of the Unit, to regulate the air flow or when it is
necessary to check the sludge return flow. This periodical operation has as a
consequence a better and more effective sludge decanting with the result of less
turbulence and agitation in the Clarifier Chamber.
7.4 Chlorine System.
Fill the Chlorine Tank with a solution of: one (1) part 5.25% Sodium Hypochlorite and
ten (10) parts of fresh water. Set Injection Pump control indicator to the correct
position and operate as follows:
TABLE 4 ADJUSTMENT OF CHLORINE SYSTEM VALVES
Description Condition
Injection Pump Injection by gravity
Injection Pump On -
Heater System (If installed) Operative Operative
Injection Valve - Open
Discharge System Operative / Auto Operative / Auto
7.5 Final Preparation.
With the Sewage By-pass Valve still open flush all bowls and check for free flow out
of the overboard discharge port, then close the Sewage By-pass Valve and open
Sewage Inlet Valve. Unit is now ready for use.
7.6 Start-up Operation.
TABLE 5 START-UP OPERATION.
General Hatches and covers Closed
Chlorine tank Full
Air supply On
Valves Influent Inlet Open
By-pass Closed
Discharge system Open
Control Panel Electrical supply On
Discharge pumps Automatic
Injection pump On
Blower On
Sludge return Automatic

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8 OPERATION
8.1 Operation
1. Sewage waters are introduced into the Aeration Chamber. The biological
reduction process is initiated here.
2. The influent containing aerobic bacteria and the organic compounds that serve as
food for them, enter a turbulent environment, rich in oxygen. The air under
pressure is introduced through stainless steel diffusers located near the bottom of
the Aeration Chamber. Small bubbles of air are generated which create the
agitation necessary to mechanically reduce solids to small particles, increasing
the contact surface between the bacteria and the oxygen incorporated. This way
the bio-reduction of solids is produced, loosening carbon dioxide and other
simple compounds.

Sewage Water Treatment


Plant Facet STP / VTP

Aeration
Inlet Chamber Biofilm
Clarification
Chamber Chlorination
Chamber
Active Overboard
Clean Discharge
Sludge
Liquid

Inyection
Chlorine
Air
Supply Sludge
Return

Figure 3 Block Diagram

3. During this process, the bacteria form small loose colonies or flocs around small
particles of organic material in suspension and pass the Clarifier Chamber
through a baffled transfer port located between the two chambers.
4. The Clarifier Chamber is completely filled with liquid (having evacuated of all air
by the equalizing valve, during the filling operation) and operates under
hydrostatic pressure due to the level difference between the Aeration Chamber
and the Clarifier Chamber. This results in a more effective sludge decanting, rich
in bacteria concentration, referred to as activated sludge. The liquid in the top
part of the clarifier tank passes through a manifold to the Chlorine Contact
Chamber, as the last stage.
5. The activated sludge is periodically re-circulated to the Aeration Chamber,
according to the signal sent by the timer to the solenoid valve. The recirculation
velocity may be regulated by air valves depending on the variations in crew size.
The need for this regulation will be detected with the BDO analysis of the outlet.

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6. In the Aeration chamber are submerged the Biofilm Media Cassettes designed to
maximize treatment capacity. Its installation ensures maximum exposure of
activated sludge to the waste stream. The activated sludge adheres to the media
while digesting waste from plant production effluent streams.
The result is a resident population of biomass that removes BOD and COD from
the wastewater or in nutrient applications will nitrify ammonia or remove total
nitrogen.
7. The remaining clear liquid passes through the manifold towards the final
disinfection on the Chlorine Contact Chamber. This step also serves to control
the liquid level in the Aeration Chamber. The manifold should be wide enough to
avoid blockage or flow reductions.
8. The chlorine solution is added to the Chlorine Contact Chamber. The chlorine
injection must be a continuous operation.
9. After the chlorination stage the flow is sent to the sea by gravity or by pumps.
10. In total, the system is an assembly of pipes, baffles and deposits aimed to obtain
a biological reduction of solids, a physical separation and finally, disinfection.
8.2 Appearance of the Equipment operating correctly.
1. Aeration Chamber - air bubbles rising. Fluid color is brown with little or no foam.
Approximately 6.0 p.p.m. dissolved oxygen. (See paragraph 9.4 page 21).
2. Chlorine Contact Chamber. No solids. Approximately 2.0 p.p.m. dissolved oxygen
and 1.0 p.p.m. chlorine residue.

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