@ Manual 445 - G&O Bioreactor

G&O Bioreactor
Service Manual
TMS AVR-3
BR74000-V-BS / Plant 445
Gertsen & Olufsen A/S

Savsvinget 4
DK 2970 Hrsholm
Denmark
Tel: +45 4576 3600
Fax: +45 4576 1773
info@g-o.dk
www.g-o.dk
G&O Bioreactor
Service Manual
Projekt TMS AVR-3

Anlg 74000-V-BS
No. 445
G&O Bioreactor
Service Manual
Projekt TMS AVR-3

Anlg 74000-V-BS
No. 445
G&O Bioreactor
Service Manual
Projekt TMS AVR-3

Anlg 74000-V-BS
No. 445
G&O Bioreactor
Service Manual
Projekt TMS AVR-3

Anlg 74000-V-BS
No. 445
G&O Bioreactor
Service Manual
Projekt TMS AVR-3

Anlg 74000-V-BS
No. 445
G&O Bioreactor
Service Manual
Projekt TMS AVR-3

Anlg 74000-V-BS
No. 445
G&O Bioreactor
Service Manual
Projekt TMS AVR-3

Anlg 74000-V-BS
No. 445
G&O Microbac Bioreactor

Manual
TMS AVR-3

Savsvinget 4
DK 2970 Hrsholm
Denmark
Tel: +45 4576 3600
Fax: +45 4576 1773
info@g-o.dk
www.g-o.dk
G&O Microbac Bioreactor

Manual
TMS AVR-3

Savsvinget 4
DK 2970 Hrsholm
Denmark
Tel: +45 4576 3600
Fax: +45 4576 1773
info@g-o.dk
www.g-o.dk
OPERATION & MAINTENANCE MANUAL

REVISION R01
CERTIFICATION DATA BOOK

G&O SEWAGE TREATMENT PLANT TYPE 74000-V-BS
PLANT NO.: 445
FOR
AVR-3
CHAPTER 01
GENERAL DESCRIPTION
CHAPTER 02
INSTALLATION
CHAPTER 03
OPERATION/MAINTENANCE
CHAPTER 04
COMPONENT DESCRIPTION
CHAPTER 05
TROUBLE SHOOTING
CHAPTER 06
RECOMMENDED SPARE PARTS
CHAPTER 07
DRAWINGS
CHAPTER 08
CERTIFICATES
CHAPTER 09
VACUUM UNIT
GERTSEN & OLUFSEN A.S.

SAVSVINGET 4
DK-2979 HRSHOLM
DENMARK
TEL.: +45-45763600
FAX: +45-45761773
E-mail address: info@gertsen-olufsen.dk
01
01.1
01.1.1
01.2
GENERAL DESCRIPTION
VESSEL PARTICULARS......................................................2
PARTICULARS SEWAGE TREATMENT PLANT..........2
DESCRIPTION OF THE SYSTEM.......................................3
01.2.1 GENERAL..............................................................................3
01.2.2 SYSTEM..................................................................................3
01.3
SYSTEM BUILD UP..............................................................4
01.3.1 TANK SYSTEM......................................................................4

01.3.2 AIR SUPPLY...........................................................................4
01.3.3 DISCHARGE PUMPS............................................................5
01.3.4 MACERATING PUMP...........................................................5
01.3.5 UV-STERILIZER...................................................................6
01.3.6 SLUDGE RETURN AIRLIFT SYSTEM................................6
01.3.7 CONTROL CABINET............................................................6
01.3.8 VACUUM UNIT......................................................................6
01.1 VESSEL PARTICULARS

Hull number:
445
Yard / Owner:
TMS ARV-3
Delivery Date of Plant:
02-07-2012
01.1.1
PARTICULARS SEWAGE TREATMENT PLANT
Designed Hydraulic Load:
74 m3/day
Designed Organic Load:
30,0 kg BOD5/day
Compressor (optional):
Becker DT 3.140
Discharge Pump:
Orpu Orcut ES 130
Macerating Pump:
Orpu Orcut 135/4
UV-Sterilizer:
W8
Level Switches:
Pepperl+Fuchs LFL2
Solenoid valve:
Danfoss EV 220B 6B
Dry weight:
5800 kgs approx.
Operation weight:
38700 kgs approx.
Plant Dimensions
See Chapter 07 Drawings
Vacuum unit (optional):
See chapter 9
01.2 DESCRIPTION OF THE SYSTEM

01.2.1 GENERAL
The G&O Sewage Treatment Plant(STP) is a biological sewage treatment plant working on the fixed
bed principle, constructed to meet the rules and regulations described in Marpol 73/78 and approved
according to IMO MEPC 159(55).
The G&O STP is a continuation of the well-proven Microbac Bioreactor, which has been on the market
for more than 15 years and has been constantly improved.
The G&O STP is an aerated submerged fixed film unit with a unique proprietary aeration system that
provides major advantages to the operator. There are no moving parts inside the bioreactor and the
self-cleaning aeration system provides the required amount of dissolved oxygen for the biomass to feed
on and degrade the waste.
For sewage treatment, the bioreactor needs no nutrient addition or pH-correction, and chemicals are not
needed, hence there is no added costs or environmental problems associated with the use of chemicals.
The bioreactor will accept all wastewaters produced in the accommodation, including combination of
black, gray and galley water. Depending of the quality of the galley water, a grease trap is normally
needed. Waste from food grinder is not accepted as waste water.
01.2.2 SYSTEM
The installed plant is built up as follows;
Inlet mixing tank (optional see below)
Bioreactor with matrix
Settling tank with matrix
Clean water tank
The inlet mixing tank is optional supply from G&O if case the ship can accommodate this tank within
the ship.
Please see General arrangement drawing in Chapter 07 for further details.
With the following components see chapter 07 or chapter 01.1.1 for details:
Compressor
Discharge pump
Macerating pump
Sludge return pump
UV-Steriliser
Aerators in the bioreactor
Level switches in clean water tank
Level switch in inlet mixing tank
Depending of customer request further component can be fitted/omitted:
- Standby pumps as to customers specification.
- Compressor in case the customer dont want to supply the unit via the ship air system.

Black water and grey water will be let into the inlet mixing tank. The wastewater will be macerated by
circulation through the macerator pump. The macerating pump will start/work according to the settings
of the timer if the liquid level is higher than the installed low level switch.
The macerator pump is controlled by the timer in order to ensure a even flow to the bioreactor which
contains a Polypropylene cross fluted structured matrix as its media, on which the degrading bacterial
biomass adheres and rapidly grows. This matrix is manufactured so that constant intermixing of the
wastewater occurs in each vertical column of the media, ensuring maximum contact between the
effluent and on the surfaces on which biomass is fixed. The wastewater is driven upwards in the
adjacent column. In this way, the effluent moves in a serpentine fashion through the whole of the
bioreactor to ensure the maximum contact time and optimum biological treatment.
Treated waste water from the bioreactor is directed to the settling tank where treated water is led in
below the installed matrix in order to ensure separation of water and solids(if any) and flow, by gravity,
through the installed UV-Steriliser to the clean water tank.
Connected to the settling tank is the sludge return system, which periodically transfers the settled
sludge back to the influent tank.
The installed level switches control the water level in the clean water tank. The discharge pump will
start when water reaches high and stop when water level reaches low. In addition to the high and
low level switches, a High-High level switch is installed. Should water level reach this switch, a
common alarm signal is set in order to alert the crew for further action.
01.3 SYSTEM BUILD UP

The G&O STP is connected to the vessels piping and electrical systems. Description of fitted
components to the plant is described in Chapter 04 Component description.
01.3.1 TANK SYSTEM

The tanks(Bioreactor/Settling/Clean water inlet mixing tank is optional) are built together to one
compact unit, interconnected with necessary piping/overflows for flow of wastewater under
maceration, treatment, settling of sludge, flow of treated water, air transport and venting.
01.3.2 AIR SUPPLY

The air supply to the plant has the following functions;
-
to supply necessary air to the air diffusers.
The plant will be supplied whit air from a compressor or external air supply.
In addition to/or as substitute for the compressor it is possible to use vessels air system, and a air
pressure regulator is fitted to ensure the right amount of air.
See Chapter 03 and 04 Component description for technical details and operation of the air
compressor.
01.3.3 DISCHARGE PUMPS

Normally one discharge pump are fitted on the pump manifold installed in front of the plant. Please
note that some customers specifies an additional discharge pump.
During normal operation the pump are discharging treated water from the clean water tank.
The installed level switches controls the pump functions;
-
High-level switch activated Discharge pump start

Low level switch activated Discharge pump stop
The discharge pump are also able, when operated in manual mode, to discharge water/sludge from the
following tanks;
-
Inlet mixing tank(optional).

Bioreactor tank.
Settling tank.
See Chapter 03 and 04 Component description for technical details and operation of the pump.
01.3.4 MACERATING PUMP

The macerating pump can be fitted in one of the following two ways:
- Fitted in front of the plant connected to the inlet mixing tank.
- Option, fitted inside the inlet mixing tank, special submerged pump.
The macerating pump mixes and macerates the incoming raw sewage, before it enters the Bioreactor
tank.
The pump can be operated in auto or manual mode.
In auto mode pump functions are controlled by a timer in the control cabinet and the installed level
switches in the inlet mixing tank. The low level switch protects the pump from dry running when the
pump is in auto mode.
-
Low level switch activated Macerating pump start by timer adjustment

High level switch Macerating pump start
Please note that when the pump is operated in manual mode the function of the level switches is bypassed.
Time settings for the macerator pump are preset and only intended as a guide to handle the expected
incoming hydraulic flow of sewage water, the time settings are to be adjusted after exsiting conditions
if necessary.
See Chapter 03 and 04 Component Description for technical details and operation of the pump.
01.3.5 UV-STERILIZER
The UV-Sterilizer is installed between the settling tank and the clean water tank and located on the left
side of the plant.
Water flows by gravity from the settling tank up through the UV-Sterilizer to the clean water tank.
See Chapter 03 and 04 Component description for technical details and operation of the
UV-Sterilizer.
01.3.6 SLUDGE RETURN SYSTEM

The sludge returns pipe is fitted to the bottom of the settling tank. Periodically, sludge will be
transferred back to the bioreactor tank for further treatment. A sludge return pump, controlled by a
timer in the control cabinet, operates the system.
The system can also be operated in manual mode, and here the timer function is by-passed.
See Chapter 03 and 04 - Component description for technical details for installed sludge return pump.
01.3.7 CONTROL CABINET

The control cabinet is installed on the front of the plant. The control cabinet operates automatically the
following;
-
functions in the G&O STP

function of the discharge system.
function of the macerating system
function of the sludge return system.
function of UV-unit
function of the high level alarm.
function of alarm for component failure.
function of pre alarm for UV-unit
function of vacuum pumps/alarm, only vacuum systems
See Chapter 07 - Drawings for component description for technical details and specification for the
installed control cabinet and electrical components.
01.3.8 VACUUM UNIT
For sewage system with vacuum unit see chapter 9, or enclosed documents for
additional Vacuum equipment.
02.
INSTALLATION
02.1
PREPARATION FOR INSTALLATION..............................2
02.2
LIFTING.................................................................................2
02.3
SPECIAL EQUIPMENT........................................................2
02.4
INSTALATION MATERIALS...............................................2
02.5
FOUNDATION.......................................................................2
02.6
EXTERNAL CONNECTIONS...............................................3
02.7
VALVE SYSTEMS.................................................................3
02.8
DISCHARGE PIPE LINE FROM PLANT............................3
02.9
VENTING PIPE LINE FROM PLANT.................................3
02.10 EMERGENCY OVERFLOW PIPE LINE.............................3

02.11 ELECTRICAL AND ALARM SYSTEM...............................4
02.12 GREASE TRAP (Optional)....................................................4

02.1 PREPARATION FOR INSTALLATION
Prior to installation of the Sewage Treatment Plant, all wrappings and other packing / sealing materials
must be fully removed.
A complete check of the plant integrity should be carried out prior to start of installation activities.
02.2 LIFTING
The Sewage Treatment Plant is designed for a 4 point lift in accordance with the document Slinging /
Lifting Arrangement; ref. Handling & Shipping Procedure.
02.3 SPECIAL EQUIPMENT

No special tooling or equipment is required for the installation of the Sewage Treatment Plant.
02.4 INSTALATION MATERIALS

Unless specifically agreed otherwise, G&O do not supply any materials required for installation.
02.5 FOUNDATION
It must be ensured that the supporting/underlying deck or platform structure will provide proper and
sufficient support for the sewage treatment plant.
For sewage treatment plants designed for bolting to the supporting structure, all intended bolts must be
fitted to ensure a sufficient mechanical strength of the attachment.
For sewage treatment plants to be welded to the supporting deck structure, the site welding must be
continuous and fully sealing the plant to the deck structure to prevent accumulation of water / other
liquids and substances underneath the plant.
IMPORTANT NOTE:
For sewage treatment plants manufactured in carbon steel and internally coated for corrosion
protection, no welding must be carried out on any part of the plant that may conduct excessive
heat to the tank internal coating. Failure to do so may permanently damage the internal
coating and will invalidate the manufacturers guarantee.
For welding of internally coated plants to the deck structure, it is advised to fill water in all
tanks to a level of approximately 0.5 m prior to any welding is initiated. During welding
extreme care must be exercised to control the heat conducted to the internal coating.

02.6 EXTERNAL CONNECTIONS
See component list in chapter 07.
02.7 VALVE SYSTEMS

The following valves are Yard supply:
Valve
Inlet valve (Black water)
Inlet valve(Grey water)
Water inlet valve
No return Valve, discharge pump
Sampling valve(Treated water)
Valves for Grease trap(if fitted)
02.8 DISCHARGE PIPE LINE FROM PLANT.

If the Sewage Treatment Plant discharge level is above outside discharge level, install a water trap in
the discharge pipe, water trap highest point should be over the High Alarm level switch in clean water
tank.
For system mounted with two discharge pumps it is recommended to install non-return valves in the
discharge pipe line for both pumps.
02.9 VENTING PIPE LINE FROM PLANT

To ensure the proper function of the venting line, it is very important that it is routed into free air as
directly as possible as a continuously rising pipe. As such negative elevation and water traps must be
avoided and the use of 90 pipe bends should be kept to an absolute minimum. Drain valves must be
installed in critical locations.
02.10 EMERGENCY OVERFLOW PIPE LINE

In case a dedicated overflow line is to be installed and this is not routed to a closed tank or into a
closed piping system or similar, a water trap must be fitted to eliminate foul smelling. The water trap
must be equipped with a water supply suitable for filling of the water trap.

02.11 ELECTRICAL AND ALARM SYSTEM
The main components on the Sewage Treatment Plant have the following power consumption:
Electric equipment
Air compressor
Discharge pump
Macerating pump
Sludge return pump
UV sterilizer
Power consumption at rated voltage

KDT3.60 3,0 kW; KDT3.80 3,5 kW; KDT3.100 6,4 kW; KDT3.140 9,3 kW
2,60 kW
2,60 kW
0,66 kW
W5 0,23 kW; W8 0,365 kW
Vacuum system:
Vacuumarator
MBA 25 3,45 kW; MBA 65 6,3 kW
Rated Voltage:
380-480 V 50/60 Hz voltage to be defined upon order.

Optional 690 V 50 Hz / 690 V 60 Hz
Please see electric drawing for further details in Chapter 07 Drawings.

Visual indications for electrical components failure, high level and pre alarm for UV-unit, alarms on
front on Control Panel.
Vacuum systems are additional equipped with vacuum alarm.
Control Panel Interface connections:
-
Common alarm.
Vacuum alarm (vacuum system)
Emergency Shut Down
Power supply to the control panel
02.12 GREASE TRAP (Optional)

The grease trap must be installed horizontally in the galley water drain line. Make sure that a pipe of
approx. one meter is installed horizontally on the inlet side to ensure stabilization of flow; grease trap
is to be installed above level of Sewage treatment plant to ensure natural flow by gravity through
grease trap. The grease trap must be installed as close as possible to the galley area. In another case the
grease can block the galley water drain line. Make sure space for opening the grease trap and remove
the collected grease, is available at location of installation. Shut off valves must be installed on inlet
and outlet side of the grease trap. We recommend also installation of a by pass valve, to be operated
during cleaning of grease trap. A shut off valve must be installed in the drain line from the grease trap.
Drain line to be connected to the caisson. The venting from the grease trap must go to free air to avoid
smell from the drain line. If grease trap is mounted with water connection for filling/spray nozzle
cleaning, it is recommended to install a quick coupling for dismantling the water connection when
maintenance of the grease trap/spray nozzle is needed.
.
For installation also see Installation diagram and P & ID drawing.
03
OPERATION/MAINTENANCE
03.1
GENERAL NOTICE ...................................................................................... 2
03.2
PREPARATION FOR FIRST START UP .................................................. 3
03.3
START UP BIOREACTOR ....................................................................... 4
03.4
START UP GREASE TRAP (optional)..................................................... 4
03.5
ROUTINE OPERATION/MAINTENANCE .............................................. 5
03.6
SLUDGE REMOVAL .................................................................................... 6
03.7
BIOREACTOR SEEDING AND START UP ............................................. 7
03.8
BIOREACTOR SHUT DOWN FOR STAND BY. ..................................... 8
03.9
SUBMERGED FIXED FILM UNITS .......................................................... 8
Appendix 1:
INSPECTION OF COMPRESSOR ................................................. 9
Appendix 2:
UV-UNIT........................................................................................... 12
Appendix 3:
DISASSEMBLING OF PUMPS ..................................................... 21
Appendix 4: ASSEMBLING OF PUMPS............................................................ 27

Exploded drawing for pumps
Appendix 5:
SLUDGE RETURN PUMP (optional)............................................. 34

03.1
GENERAL NOTICE
Sewage Treatment Plant is designed for treatment of grey waste water from wash basins / floor drains and black waste
water from toilets and must be operated in strict accordance with the design specifications.
Proper earthing connection of the Sewage Treatment Plant skid must be ensured prior to connection to electrical power
supply.
Electrical panel doors must be properly secured / locked after start-up to avoid un-authorised / un-intentional access to
the panel internals.
A detailed local procedure must be established to secure cut-off of electrical power supply to the Sewage Treatment
Plant prior to commencement of service activities involving opening of the local electrical panel and/or entry to
electrical components on the plant.
Similarly, detailed local procedures must be established for other relevant maintenance / service activities.
No alterations of the mechanical design and/or electrical and instrument components and connections on Sewage
Treatment Plant should be carried out without the prior written consent of the manufacturer.
Any such alterations will immediately invalidate all the manufacturers warranty obligations and the product liability.
Operational Precautions
Use of re-circulated toilet paper should not be used, as this may contain plastic materials that are not degradable in the
biological process in the Sewage Treatment Plant
The following cleaning agents and substances should not be directed to the Sewage Treatment Plant:
Organic solvents
Strong acids and alkalis
Biocides
Medicine
Paint
Oil
Petrol
Toxic substances
Salt
Large quantities of detergents
Large quantities of ammonia
Large quantities of sulphate
Use of above materials will seriously deteriorate the performance of the biological process in the Sewage Treatment
Plant.
For cleaning of toilets and bathroom areas it is recommended only to use products compatible with the biological
cleaning process in the Sewage Treatment Plant.
Safety instructions
When working at or in the sewage treatment plant be aware that bacteria and viruses are present. According to the work
done on the plant use protective glasses, clothes, gloves and rubber boots where necessary.
Good personal hygiene and proper precaution minimize health risk.
If entering the tank area take precautions for working in close areas. Ventilate the tanks, measure and secure the
oxygen concentration and supply. It is recommended to carry detectors for CO an H2S gasses, and have a safty person
outside the tanks if help needed.

03.2
PREPARATION FOR FIRST START UP
Fill up of the G&O STP (Sewage Treatment Plant) by carry out the following steps
Turn main switch to Off.

Turn switches for compressor, discharge pump, sludge return and macerating pump to Off
Close all discharge pump suction valves
Turn switch for UV-sterilizer to Off
Open the valve for UV-Sterilizer
Connect the flush water line to flushing water inlet (Please note that it is also possible to fill the STP via the
inspection hatch on top of the Bioreactor tank)
Check/Adjust timer settings for the Sludge return system, T2 set to 5 minutes (tr) per 30 minutes (ta).
Check/adjust timer settings for the macerating pump, T3 and T1 is set to the values according to the table.
BR27750
BR37000
BR46250
BR55500
BR64750
BR74000
T3 6 min. T1 3 min(tr). each 30 min(ta).

All time settings for the macerator pump are preset and only intended as a guide to handle the expected
incoming hydraulic flow of sewage water, the time settings to be adjusted after exsiting conditions if
necessary.
Check that all delivery valves after the discharge pump are opened!
Turn main switch to On

Start filling the sewage plant with water by opening the discharges valves for the inlet tank and the Bioreactor
The settling and the clean water tanks will be filled via internal connections
When high level alarm (clean water tank) appears on the control panel, switch off the water filling.
Close the discharge suction valve for the Bioreactor and the inlet tanks.
DURING RUNNING OF THE PUMPS, CHECK FOR RIGHT ROTATION DIRECTION OF PUMP MOTORS
BEFORE SWITCHING ON PUMPS AFTER A LONG STAND-STILL THEN ALL PUMPS MUST BE
CHECKED FOR FREE ROTATION BY ROTATING THE MOTOR SHAFT BY HAND.
-
Open air inlet aeration valves

Connect air supply, open for external air or turn switch for compressor to On.
ENSURE THAT THE COMPRESSOR ROTATES IN RIGHT DIRECTION BY BUILD UP THE PRESSURE
QUICKLY AS IT CAN, IF OPERATED IN WRONG DIRECTION CAN CREATE A VACUUM AND END UP
WATER FILLED WITH WATER FROM THE BIOREACTOR TANK AND CAUSE BREAK DOWN OF THE
COMPRESSOR.
For sewage system with vacuum unit see chapter 9
THE VACUUM PUMPS MUST NEVER BE STARTED OR OPERATED WITHOUT SUFFICIENT

PRE-FILING OG WATER IN SUCTION CHAMBER
-
Close air supply or turn switch for compressor to off, make sure to close air inlet aeration valves to prevent
water standing in air supply pipe line.
Turn main switch to off.
Close all inlet valves.

03.3
START UP BIOREACTOR
When the G&O STP is filled with clean water then begin start up of the bioreactor tank by carry out the following steps:
-
Check the control panel. (The main switch positioned in Off)

Check air supply, open valve for external air supply or set the switch for compressor in position On
Check that switch for sludge return is in position Auto
Check that discharge pump is in position Auto. (Remember to check all suction and discharge valves for the
pump are open)
Check that macerating pump is in position Auto. (Remember to check all suction and discharge valves for
the pump are open)
For vacuum systems: Check that vacuum pumps are in position Auto. (Remember to check all suction and
discharge valves for the pumps are open and suction chamber is pre-filled with water)
Ensure that discharge valves from bioreactor tank and settling tank are closed.
Ensure that discharge valve from clean water tank and UV-sterilizer is open.
Keep the UV-sterilizer switch in position Off
Turn main switch to On
Check of UV-sterilizer:
o Check that no water leaks are observed on the UV-Sterilizer.
o Turn UV-sterilizer switch to ON.
o Control LED Lamp on on UV-sterilizer panel is lit.
o On some models it is possible to visual confirm that the lamp is lit via the optical ring at the end of
the lamp connectors.
After check of UV-sterilizer, turn switch to Off.
Check correct flow rate for macerating pump.
For vacuum systems: Check vacuum in suction line.
Add Biotal MDS-PAK
After sewage water is fed to the STP the turn UV-steriliser switch to On.
The Bioreactor is now operating in automatic mode.
03.4
START UP GREASE TRAP (optional)
The Grease trap is optional equipment and if fitted positioned in the Grey water line from the Galley or other room
where grease are a component in the waste water. Waste from food grinders in galley are NOT recommended to be let
to the bioreactor.
The ideal temperature for separation is 30-35 C.
For grease trap equipped with heating element the temperature range is 3085 C.
Thermal safety release set to 110 C, reset by removing the lid of the socket and press the reset button in the upper part
of the thermostat.
Please refer to P&ID drawing for position and the drawing of grease trap connections in chapter 7 Drawings.
-
Inlet and outlet valves to be opened.(normally not a part of G&O supply)

By-pass and drain valve to be closed.(normally not a part of G&O supply)
Check that the Grease trap is ventilated.
Fill the grease trap with fresh water.

03.5
ROUTINE OPERATION/MAINTENANCE
When operating in AUTO MODE:

Check daily
Reset alarms, no light in common alarms.
Check air supply
Check tanks, piping and pumps for leakages.
Check UV-sterilizer for operation, faint purple/blue light is visible through the
optical ring on the end of the lamp
WARNING
NEVER LOOK AT DIRECTLY AN UV-LAMP WITHOUT USING
PROTECTION GOGGLES!
Check weekly
Check full air flow through air membranes by closing one of the inlet valves and
letting the full flow through one membrane for approx. 30 sec. and vice versa. Do
this twice.
Add bacteria as described in Bioreactor seeding and start up
Check every 2 weeks
De sludge the bioreactor tank and settling tank using the discharge pump.
(See 03.6 Sludge removal on following pages).
Check monthly
Check function of all alarms.
Control running hour for UV-sterilizer on UV- lamp display
Inspection of UV Quartz sleeve
(See Appendix 2)
STP with compressor G&O delivery.
Check filter in air compressor and replace/clean if necessary
(See Appendix 1 and spare part list in chapter 6)
Empty and clean grease trap, fill with fresh water.
(See 03.6 Sludge removal on following pages).
Check every 3 months
STP with compressor G&O delivery.
Check measurement of compressor vanes, fill out Vanes measurement log, and
replace vanes if necessary.
Check every 12 months
Shut down air supply
De sludge Bioreactor, inlet- and settling tanks, remove hatches and flush the filling
material with clean water, inspect fixed film units (see 3.9) fill plant with clean
water.
Remove inspection hatch clean water tank, clean if necessary.
Open grease trap for complete cleaning, fill with fresh water.
STP with compressor G&O delivery
Check vanes and filters, replace if necessary.
(See Appendix 1and spare part list in chapter 6)
Clean all piping in sludge return system, flush with clean water by activate sludge
return in manual mode.
Check/clean restrictor in pipeline from macerator pump.
Start air supply and check aeration system.
Check function of the solenoid valve.
Disassembly UV-sterilizer and replace UV lamp and O-ring if needed
recommended after 9000 hours, clean/replace quarts sleeve.
Add bacteria as described in Bioreactor seeding and start up
Close inspection hatch
For new upstart follow start up procedure
5

03.6
SLUDGE REMOVAL
In the first two months manual sludge removal is not necessary.

After two months then following manual sludge removal is recommended every two weeks:
(The frequency of sludge removal is determined by the sludge accumulation depending of the quality and the load of the
sewage water.)
Bioreactor:
- Close discharge valve from clean water tank.
- Open discharge valve from bioreactor tank.
- Switch off air supply, remove inspection hatch, discharge sludge/water from the Bioreactor to 10-15 cm under
top of filling material by turning discharge pump switch to position Man.
- Turn discharge pump switch to Off
- Close discharge valve from bioreactor tank.
- Inspection off Bioreactor, see below.
- Replace inspection hatch.
- Start air supply.
- Open discharge valve from settling tank.
- Turn discharge pump switch to Man
- Discharge sludge/water from settling tank, empty the tank make sure the discharge pump is not dry running
as this could make serious damage to the pump.
- Open inspection hatch and wash down the filling material, discharge water as above.
(Washing down settle tank should be done every week or more frequently if large accumulations of sludge.)
- Turn discharge pump switch to Off
- Close discharge valve from settling tank.
- Open discharge valve from clean water tank.
- Turn discharge pump switch toAuto and make sure the discharge pump is bled.
IMPORTANT!
DISCHARGE OF SLUDGE FROM THE PLANT MUST NOT TAKE PLACE WHEN THE VESSEL IS
WITHIN 12 NAUTICAL MILES FROM THE NEAREST LAND.
Inspection of Bioreactor
In connexion with the two weeks sludge removal, a visual check of the inside of the Bioreactor could be carried out.
The Biofilm in the filling material should be sensed as a thin mucous/greasy layer in the aerated zones.
Start air supply, to be observed - bubbles in surface in aerated zones, seen as a boiling surface.
Sludge removal from Grease Trap(optional)
In general the grease trap requires only minimal maintenance.
We recommend and removing grease and solids at least ones a month depending on how much load the Grease trap is
subjected to.
Manual cleaning:
Grease is to be removed manually by opening of the top cover (see drawing in chapter 7) at the outlet side of
the grease trap.
Solids are to be removed by drainage using the drain valve (see drawing in chapter 7).
After drainage clean the grease trap, flush with hot water and drain.
Spray nozzle cleaning:
Open drain valve (see drawing in chapter 7) start spray nozzle cleaning, hot water to be preferred.
When cleaning by spray nozzle, it is recommended to inspect grease trap at least 4 times a year, including
inspection and cleaning of spray nozzle.
IF THE GREASE TRAP IS SUBJECTED TO POOR OR LACK OF MAINTENANCE THE GREASE WILL
THEN END UP IN THE STP AND CAUSE LOSS OF CAPACITY.
IN WORSE CASE THE STP WILL STOP FUNCTIONING AND NEEDS TO BE TOTALLY CLEANED AND
STARTED AGAIN.

03.7
BIOREACTOR SEEDING AND START UP

BIOREACTOR SEEDING AND START UP
Biotal MDS-PAK
PRODUCT DESCRIPTION
MDS-PAK organic water treatment is designed to keep marine sanitation devices, holding tanks and sanitary systems
operating at peak efficiency.
MDS-PAK is formulated with a synergistic blend of Bacillus strains to digest sewage, grease, fats, starch and other
organic compounds. The degradation of paper, protein and waste product residuals is greatly increased, and the odours
that these produce, are reduced.
The bacteria in MDS-PAK create a bio film inside the pipe work/tank system and degrade the waste, cleaning the
system and preventing the build up of sludge and deposits. The biological activity in the marine sewage treatment plant
is greatly increased, so the plant can thus handle more waste. The Malodour in toilet areas and scruppers, normally
associated with overload or blocked systems, are reduced .
Note!
Re-circulated toilet paper should be avoided, as this type contains plastic, which will not be broken down in the
biological process.
APPLICATION
Biotal MDS-PAK 3000 organic waste treatment is available in 10 kg. (22 lb.) Kegs each containing 88 water soluble
small bags.
DOSING INSTRUCTIONS
Direct dosing to the sewage treatment plant or via the nearest toilet will greatly enhance the biological activity and keep
the plant operating efficiency.
START UP or REACTIVATION
Ineffective sewage treatment can be reactivated by dosing 4-8 bags of MDS-PAK into the sewage tank via the nearest
toilet. The MDS-PAK bags should be dissolved in 4-8 litters of warm water and allowed to stand for 10-15 minutes
before being flushed down the toilet to reach the tank.
MAINTENANCE
The MDS-PAK contain enzymes which are naturally present in the sewage water, these enzymes in the sewage water
are not self producing and the present of the enzymes will depend of the quality of the incoming sewage water, to obtain
the best performance for the degradation of the waste products we recommend to add MDS-PAK waste water treatment,
to keep a optimum quantity of enzymes.
For a vessel with a crew of up to 50 people, 1 bag should be dosed weekly via the nearest toilet.
Place the bag in the toilet, leave for 10-15 minutes then flush the toilet.

03.8
BIOREACTOR SHUT DOWN FOR STAND BY.
The sewage treatment plant is capable to stay on stand by for one week if aeration is retained, after one week it is
strongly recommended to shot down and clean the plant for new start up.
For shut down of sewage treatment plant, all equipment are to be turned to Off position. Emptying all the tanks by
manual running of discharge pump. Flush the tanks, pipes and pumps with clean water for removing of sludge.
Fill the tanks with water for conservation. It is important to keep the filling material under water.
Turn off the main switch.
Close all inlet valves
The plant is now ready to start up, follow the start up procedure.
03.9
SUBMERGED FIXED FILM UNITS
The submerged fixed film units condition depends of the quality of the incoming sewage water, which could cause
blockage, create scaling or attach the plastic media etc and weather and sea influence. A visual inspection of the fixed
film units are recommended once a year in connection with the 12 month cleaning of the sewage plant. The fixed film
unit shall appear with no damage or blockage in the channels.
Wash down the fixed film units and ensure that no blockage occurs in the units, damaged units to be replaced.
Expected life time for submerge fixed film units is 8 to 10 years depending of load and quality of sewage water and see
condition.

Appendix1:
INSPECTIONOFCOMPRESSOR
To achieve proper and secure operation of the compressor, it is very important to inspect the length of the vanes every
3000 operational hours.
The vanes are subject to wear due to abrasion from the walls of the enclosure.
Running the compressor with vanes below the minimum length can cause serious damage to the compressor. Please
read below for minimum vane length for each compressor type..
In Order to gain access to the compressor vanes then please look below
For type KDT 3.60, 3.80, 3.100 and 3.140:

Minimum vane length:
Type
DT 3.60
DT 3.80
DT 3.100
DT 3.140
Minimum length (mm)

21
26
26
31
We commend to log the vane length at least at every 3000 operating hours as to the recommendations from the
compressor manufacturer.
However if the compressor is working under high temperatures and/or in dirty air which clogs up the filters frequently
then the vanes has to be inspected at shorter intervals than 3000 hours.
Please look at next page for an example on a vane measurement log sheet which can be copied and used by the crew
onboard.
10
Measurement log for compressor vanes:

Vane
Signature and date
Please enclosure copy of compressor vane measurement log if contact is made to G & O regarding questions concerning
compressor problems or maintenance.
11

Appendix 2:
UV-UNIT
Controls
On/Off Switch
Display
Menu buttons
: This will switch the UV unit on or off.

: Shows actual status of UV unit.
: Step through the menu with three buttons.
Display
Menu buttons
On/Off switch
Display messages:
Lamp defect.
Hours pre alarm; 730 operation hours to go before lamp life time is over.
Hours main alarm; lamp life expired.
Flush active (optional); if the temperature rises above 35C the dump valve will be activated for 10 seconds
(flush time). After 60 seconds waiting time the dump valve is activated again. This sequence will stop as
soon as the temperature drops below 35C.
Lamp off, temp too high (optional); if the temperature rises above 35C (lamp off type) or 50C (flush valve
type) the lamp will be switched off automatically. If the temperature drops below 50C the lamp will be
switched on automatically.
UV pre alarm (optional); if the UV intensity drops below 70% a UV pre-alarm is generated. Quartz sleeve
cleaning or lamp replacement is required soon.
UV low (optional); if the UV intensity drops below 50% a UV low alarm is generated. Quartz sleeve
cleaning or lamp replacement is required. Effective disinfection is not guaranteed.
12

MenuControls

Increment value
Change option
Decrement value
Change option
Enter menu
Enter change mode
Accept changed parameter
Enter menu:
Press button
Next menu item:
Press button
Previous menu item:
Press button
Change value / enter change mode:
Press button
Increment value / change option:
Press button
Decrement value / change option:
Press button
General:
At value changes keep button pressed for faster changes.

All changes and setups are stored when leaving the menu. If you stop pressing any of the control buttons for
longer than 5 seconds, the menu will revert back to the default screen automatically.
Menu structure
Operation screen:
Remaining lamp hours, warnings and errors, UV intensity (optional)
Menu items:
1. Starts - Number of lamp starts.
2. Sysstarts - Number of system starts.
3. SystemHrs - Number of system hours.
4. Language:
Press button for entering change mode.
Choose language (change with and button). Provisional only English available.
Press button to confirm.
5. Lamp power & Software version.
6. UV calibration (optional):
Press button to enter the calibration mode.
Change the calibration value with or button (default 110%)
Press button to activate the calibration.
Are you sure? Press button for YES, press button for NO.
Press button to activate above choice.
7. Alarm settings (Password protected: 8131):
Press button to enter the alarm settings menu.
Press the button and button to enter the password. Confirm each number with
the button.
Max lamp life - Lamp life time in hours:
Change the value with or button (default 9000hrs for standard lamps, 16000 hrs for long life
lamps).
Hours pre alarm - Lamp hours left when the pre alarm is activated:
Change the value with or button (default 730hrs).
Hours main alarm - Lamp hours left when the main alarm is activated:
Change the value with or button (default 0hrs).
13

Temp pre alarm
- Lamp out type: too high temperature pre-alarm, lamp ON.
Flush valve type: Temperature too high, flush valve activated.
Change the value with or button (default: lamp out type 30C, flush valve type 35C).
Temp main alarm - Lamp out type: too high temperature main alarm, lamp turns
OFF
Flush valve type: Temperature too high, flush valve de-activated, lamp turns OFF
Change the value with or button (default: lamp out type 35C, flush valve type 50C).
Flush time:
Change the value with or button (default 10s).
Waiting time i.e. the time before the controller re-check the temperature again:
Change the value with or button (default 60s).
UV pre alarm:
Change the value with or button (default 70%).
UV main alarm:
Change the value with or button (default 50%).
Exit:
Press button to exit the alarm settings menu.
Reset - Reset the lamp hours left and lamp starts:
Temperature
option
UV option
Alarm conditions:
The UV unit can activate 2 different alarms: a pre alarm and a main alarm.
Pre alarm:
A beep every 30 sec.

Pre alarm relay contacts activated.
Will be generated for any of the following reasons:
730 lamp hours are left.
UV intensity is lower than 70% (if UV sensor is fitted).
Main alarm:
A beep every 5 sec.

Pre alarm relay contacts activated.
Main alarm relay contacts activated.
Will be generated for any of the following reasons:
UV lamp life expired, the level of UV-C being emitted by the lamps is insufficient to ensure correct
disinfection and the lamp must be replaced.
Lamp defect.
Temperature is equal or above 35C/50C(if temperature sensor is fitted).
UV intensity is lower than 50% (if UV sensor is fitted).
14

Maintenance
General
In general the UV unit requires only minimal maintenance. A regular visual check of the operation of the UV
lamp is generally all that is required. If the UV unit is equipped with an external alarm a visual check is maybe
less important.
In case of a failure of the UV unit, alternative means of water disinfection should be used until the UV unit is
operational again.
Do not use alternative makes of UV lamp. Effective disinfection is not guaranteed and it may cause damage to
electrical components and cause a safety hazard.
Maintenance should only be performed once the unit has been electrically and hydraulically isolated.
Wear suitable personal protective equipment during maintenance.
Replacing the UV lamp
UV lamp replacement must take place with a maximum interval of 8000 hours (or 16000 hours in case of a
long life lamp). After this period the level of UV-C being emitted by the lamps is insufficient to ensure correct
disinfection and the lamps must be replaced.
Never touch the UV lamp with bare hands. Remove any finger marks with a soft cloth and industrial alcohol
(or similar). Wear gloves or use protective materials when handling UV lamps to prevent contamination of the
lamp surface. UV lamps are fragile, support the UV lamp always with two hands. Take care when handling
them to avoid breakage. Breakage of the UV lamp or the quartz sleeve is not covered by the warranty.
It is recommended to remove, check and clean the quartz sleeve during the replacement of the UV lamp. The
quartz sleeve o-ring seal should also be replaced.
Lamp change procedure
To gain access to the lamp, loosen the locking (outer) section of the cable gland on top of the locking plug (1)
before the locking plug (2) is unscrewed. Prevent unscrewing of the reactor plug (5).
Installation of the UV lamp:
Before the installation of the UV lamp, the lamp should be checked for surface contamination (dirt or other
marks). These should be removed using a soft cloth and industrial alcohol (or similar).
Insert the lamp support spring(10) into the quartz sleeve (if not already present).
Insert the UV lamp nearly all the way into the chamber. Do not drop the lamp into the quartz sleeve as this
may cause breakage of the UV lamp and/or quartz sleeve.
Connect the lamp to the 4 pin connector.
Re-fit the locking plug, hand tight is sufficient. Feed the UV lamp as far as possible into the quartz sleeve
by using the lamp cable. Re-tighten the cable gland.
Removal of the UV lamp is a reversal of the above procedure.
Whenever a new lamp is placed, reset the hour counter. (see Menu structure).
End of useful life/Disposal
UV lamps are to be disposed of as special waste in the same manner as fluorescent lamps. This should be
carried out in accordance with the local environmental regulations or by an authorised disposal company. If in
doubt, contact your supplier for advice.
15

Removal of the UV lamp
Step 1.
Release the cable gland by
turning it anti-clockwise.
If the cable can be moved

easily, the cable gland is
loose enough.
Step 2.
Release the locking plug
by turning it anti clockwise.
Check that the lamp cable

is not twisting!!
Important:
Prevent unscrewing of the
reactor plug!
Step 3.
Take out the UV lamp
carefully.
Do not touch lamp with

bare hands, ware gloves
Take care, the UV lamp
can still be hot!
Do not drop the UV lamp

into the sleeve!
Step 4.
Disconnect the connector
from the UV lamp.
16

Installing the UV lamp
Step 1.
Check if the spring is inside
the quartz sleeve, and
insert the lamp carefully.
Do not touch the UV lamp

with bare hands, ware
gloves.
Step 2.
Place the connector on the
UV lamp end.
Do not drop the UV lamp

into the quartz sleeve!
Step 3.
Hand tighten the locking
plug. (clockwise)
Step 4.
Tighten the cable gland.
(clockwise)
Do not over tighten!!
Quartz sleeve cleaning

If there is hardness in the water a scale deposit may be formed on the quartz sleeve. This obstructs the UVC radiation and subsequently adversely affects disinfection. If a light covering of scale is present on the
quartz sleeve, carefully clean the quartz sleeve with a proprietary descaler or industrial acid e.g. citric acid.
Ensure that the correct safety measures are taken and the correct personal protective equipment is used
during this operation.
See: Quartz change procedure.
17

Quartzchangeprocedure
Installing new quartz sleeves
Before use, the quartz sleeve should be cleaned using a clean cloth and industrial alcohol (or similar).
Slide the sealing o-ring(7) down from the open end by about 5 cm.
Gently insert the quartz sleeve into the chamber with the closed end first. Gently slide the quartz sleeve
through the hole in the flow management plate until it meets the bottom support pin.
Press the locking sleeve (6) onto the o-ring (ensure that the chamfer is facing the o-ring).
Hand tighten the reactor plug (5) (clockwise).
Fill the chamber with water and slowly increase the water pressure.
Check for leakage and retighten the reactor plug, if required.
Insert the lamp support spring(10).
Carefully insert the UV lamp (see procedure for changing UV-lamps).
Removal of the quartz sleeve is a reversal of the above procedure.
Removal and cleaning of the quartz sleeve
Step 1.
Remove the UV lamp as described in the installing UV
lamp section
Step 2.
Release the reactor plug by
turning it anti-clockwise.
Step 3.
Remove the locking sleeve
and o-ring.
Step 4.
Carefully remove the
quartz sleeve care fully.
Do not touch the quartz

sleeve with bare hands,
ware gloves.
Step 5.
Clean the quartz sleeve
with clean piece of cloth
and proprietary descaler or
similar.
Do not use an aggressive

cleaning method. This will
damage the sleeve.
18

Installing the quartz sleeve
Step 1.
Carefully insert the quartz
sleeve in the UV chamber.
Take care to prevent

breakage!
Step 2.
Ensure that the sleeve is in
the correct position through
the flow plate.
Step 3.
Fit a new o-ring and
replace the locking sleeve
(with the internal chamfer
side towards the o-ring).
Step 4.
Re-fit the reactor plug by
turning it clockwise and
hand tighten. Re-pressurise
the chamber and check for
leaks.
Never touch the quartz

sleeve with bare hands,
ware gloves
Step 5.
Install the de UV-lamp as described in the
Installing UV lamp section.
Use the gloves provided.
19

Logbook
UV unit serial number: .

Installation date
Options:
Temperature Sensor Dump
(with solenoid controlled dump valve)
Temperature Sensor Safety

(Lamp-Off type)
UV Sensor
Wiper System
Date
Quartz Sleeve
System
Hour
counter
Lamp
Hour
counter *
Action
9000 or
16000
Installed
*Depending of type of lamp
20
Carried
out by

Appendix 3:
DISASSEMBLING OF PUMPS
Disassembly of ORPU pump.

Tools to be used:
Combination wrench size 13 and 17 mm
Allan key/box wrench size 4, 5 and 14 mm
Screw driver or crowbar
Mallet
Special tool: rotor disk puller including
mandrel.
1
Hex. nuts (pos. no. 28) and spring lock
washer (pos no. 30) is loosened and
removed. Intake (pos. no. 27) is then
removed.
NOTE: Remember to mark the intake in
order to fit it back in the right position.
Intake pos. no. 27.
5 pcs. hex. nut pos.

no. 28
+ 5 pcs. spring lock
washer pos. no. 30
2
Hex. socket screws (pos. no. 35) and spring
lock washer (pos. no. 36) is loosened and
removed. The knife (pos. no. 32) is then
lifted via the grub screws (pos. no. 34)
Knife pos.
no. 32
4 pcs. Hex. socket

screw pos. no. 35 + 4
pcs. spring lock
washer pos. no. 36
Grub screw
pos. no. 34
21

3
Hex. nut (pos. no. 22) is loosened and
removed.
5 pcs. hex.
nut pos. no.
22
Housing
cover pos.
no. 20
4
Housing cover (pos. no. 20) is removed and
grub screw (pos. no. 21) is loosened and
removed.
5 pcs. grub
screw pos.
no. 21
22

5
The cutter (pos. no. 33) is loosened by
means of an Allan key and a screw driver
(or similar) in order to hold the rotor disk
(pos. no. 18) while loosening the cutter.
NOTE: It is very important that the screw
driver (or similar) is able to enter the rotor
disk, all the way to the shaft in order to
keep the rotor disk in same position.
Cutter pos.
no. 33
6
Hex. nut (pos. no. 25) is loosened and
removed together with rotor disk holding
disk (pos. no. 26)
Use a box wrench or a stiff Allan key, the
screw is secured with loctite.
23

7
Fit the mandrel for the rotor disk puller
(special tool)
Mandrel
Rotor disk
pos. no. 18
8
Fit the rotor disk puller (special tool) into the
rotor disk (pos. no. 18) and pull it off the
shaft (pos. no. 3) with an Allan key and
spanner.
Rotor disk
puller
(special
tool)
24

9
Feather key (pos. no. 14) is loosened and
removed from shaft (pos. no. 3)
10
The rotating part of the end-face seal (pos
no. 23) is loosened and removed by means
of two screw drivers or similar tool.
NOTE: It is very important that the shaft
surface is smooth and without any sharp
edges before removing the stationary part
of the end-face seal as this can cut the oring inside the end-face seal.
If rotating part of end face seal is stuck, go
to no. 11 and remove the seal by gently lift
the pump housing e.g. use a tree leg puller.
Rotating part of the

end-face seal pos.
no. 23
25

11
Hex. screws (pos. no. 15) and spring lock
washers (pos. no. 16) is loosened and
removed. Pump housing (pos. no. 19) is
then removed together with the stationary
part for the end-face seal (pos. no. 23)
Pump
housing
pos. no. 19
4 pcs. Hex. screws

pos. no. 15 + 4 pcs.
spring lock washers
pos no. 16
The stationary part

for the end-face seal
(pos. no. 23)
26

Appendix 4:
ASSEMBLING OF PUMPS
Assembly of ORPU pump.

Tools to be used:
Combination wrench size 13 and 17 mm
Allan key size 4 and 5 mm
Screw driver or crowbar
Rubber (plastic) mallet
Special tool: Sleeve for end-face seal,
Fitting tool for end-face seal, Fitting tool for
rotor disk and a piece of paper.
1
Apply lubricant on sealing surface on pump
skirt (pos. no. 4) Fit pump housing (pos. no.
19) with the discharge flange facing away
from the motor feet.
Pump skirt
pos. no. 4
2
Fit spring lock washers (pos. no. 16) and
tighten hex. nuts (pos. no. 15)
27

3
Fit the stationary part for the end-face seal
(pos. no. 23) by pressing it into the pump
housing.
NOTE: It is very important to protect the
sealing surface and to press it into correct
position using fitting tool for end-face seal.
Washer for the

end-face seal
(pos. no. 23)
Stationary part
for the endface seal (pos.
no. 23)
Rotating part
for the endface seal (pos.
no. 23)
4
Fit the sleeve for end-face seal onto shaft
before fitting the end-face seal.
28

5
Fit the rotating part of end-face seal
(remember to fit the two sealing faces
towards each other) and press it down
using the fitting tool for end-face seal in
order to ensure that it is positioned correct.
6
Sleeve for end-face seal is removed from
shaft and washer for end-face seal is fitted
and apply grease or similar in order to keep
it in position during pump assembly.
7
Fit feather key (pos. no. 14).
Feather key
(pos. no. 14)
29

8
Grease or lubricating pasta is applied onto
shaft in order to avoid the rotor disk to
seize up on the shaft.
9
Rotor disk is fitted using the fitting tool for
rotor disk in order to ensure that the rotor
disk is pressed all the way down and
hereby into correct position.
Fitting tool for
rotor disk
30

10
Rotor disk holding disk (pos. no. 26) and
Hexagon screw (pos. no. 25) add a little
loctite, is fitted and tightened.
11
Grease or lubricating pasta is applied onto
thread of the cutter (pos. no. 33). The
cutter is tightened using an Allan key and
rotor disk is kept in position using a screw
driver (or similar).
NOTE: It is very important that the screw
driver (or similar) is able to enter the rotor
disk, all the way to the shaft, in order to
keep the rotor disk in same position.
12
The O-ring (pos. no. 24) is fitted into
groove using a small amount of grease or
lubricating pasta. Also the sealing surfaces
are well greased.
31

13
The knife (pos. no. 32) is fitted onto the
housing cover (pos. no. 20). A plastic or
rubber mallet can be used.
NOTE: It is very important that both parts
are cleaned and all sealing surfaces are
well greased with grease or lubricating
pasta before assembly.
14
The housing cover with knife is fitted onto
pump housing (pos. no. 19).
32

15
4 pieces of Hexagon socket screws (pos.
no. 35) and spring lock washers (pos. no.
36) are fitted along with 4 pieces of grub
screws (pos. no. 34) but not tightened.
Also the 5 pieces of grub screws (pos. no.
21) are fitted and tightened.
Hexagon nuts (pos. no. 22) are fitted but
not tightened.
Grub screw
pos. no. 21
+ Hex. nuts
pos. no. 22.
Grub screw
pos. no. 34
4 pcs. Hex. socket

screw pos. no. 35 + 4
pcs. spring lock
washer pos. no. 36
16
Adjustment of cutter system:
Step 1:
Hexagon nuts (pos. no. 22) are slightly
tightened.
Step 2:
Hexagon socket screws (pos. no. 35) are
slightly tightened.
Step 3:
Grub screws (pos. no. 34) are adjusted so
they just touch the housing cover (pos. no.
20)
Step 4:
loosened again.
Step 5:
Grub screws (pos. no. 34) are
tightened/turned 20 to 25 minutes (equals
120 to 150 degrees)
Step 6:
tightened properly.
Step 7:
A pieces of paper (1/10 mm) is used as
feeler gauge in order to center the cutter
system why it has to fit in between the knife
and cutter all the way round.
If any adjustment is needed then use a
rubber or plastic mallet on the housing
cover.
Repeat this until the cutter system is
centered.
Step 8:
When cutter system is centered the
hexagon nuts (pos. no. 22) are tightened
properly.
Allan key is used to

turn cutter in order to
check the clearance
with a piece of paper
If the paper doesnt

fit, the mallet is used
in the opposite side in
order to adjust the
clearance.
33
Spare part set BR.2000

Mechanical seal
Angular ball bearing
O-ring 24x6
O-ring 80x3
O-ring 185x3
O-ring 185x3
Item No. 23
Item No. 6
Item No. 7
Item No. 37
Item No. 24
Item No. 31
04.
04.1
COMPONENT DESCRIPTION
AIR COMPRESSOR ...................................................................2
04.2 DISCHARGE PUMP ...................................................................2

04.3
MACERATOR PUMP .................................................................2
04.4
UV -STERILIZER .......................................................................3
04.5
LEVEL SWITCHES ....................................................................3
04.6
SLUDGE RETURN PUMP .........................................................3
04.7
VACUUM UNIT ...........................................................................3

04.1 AIR COMPRESSOR
One of the following air compressors is installed on the sewage treatment plant
according to chapter 01.1.1:
Maker:
Type:
Insulation class:
Protection class:
Motor voltage:
Speed:
kW:
Weight:
Becker
KDT3.60
F
IP55
Becker
KDT3.80
F
IP55
Becker
KDT3.100
F
IP55
Becker
KDT3.140
F
IP55
190-255/330-440 50Hz
190-290/330-500 60Hz
190-255/330-440 50Hz
190-290/330-500 60Hz
340-430/588-745 50Hz
340-500/588-866 60Hz
340-430/588-745 50Hz
340-500/588-866 60Hz
1465-1780
3,0
80
1465-1780
3,5
85
1465-1780
6,4
129
1465-1780
9,3
140
04.2 DISCHARGE PUMP

The following discharge pump are installed on the sewage treatment plant:
Maker:
Type:
Insulation class:
Protection class:
Flow:
Delivery head:
Motor voltage:
Rotation speed:
Normal power consumption:
Pump housing/impeller:
Weight:
Orpu
Orcut 130
F
IP55
0-16 m3/h
28-0 m
400/690-480 V 50/60 Hz
3460 rpm
2.60 kW
GG 25
46 kg
04.3 MACERATOR PUMP

The following macerator pump is installed on the sewage treatment plant:
Maker:
Type:
Insulation class:
Protection class:
Flow:
Delivery head:
Motor voltage:
Rotation speed:
Normal power consumption:
Pump housing/impeller:
Weight:
ORPU
Orcut 130
F
IP55
0-16 m3/h
28-0 m
400/690-480 V 50/60 Hz
3460 rpm
2,6 kW
GG 25
46 kg

04.4 UV -STERILIZER
One of the following UV sterilizer is installed on the sewage treatment plant

according to chapter 01.1.1:
Maker:
Type:
Power supply:
Protection class:
Lamp consumption:
Flow 60% transmission
Expected life time of
lamp:
Van Remmen
W5
230Vac 50/60Hz
IP55
0,23 kW
6,2 m3
16000
Van Remmen
W8
230Vac 50/60Hz
IP55
0,365 kW
9,2 m3
16000
04.5 LEVEL SWITCHES

The following level switches are installed on the sewage treatment plant:
Pepperl+Fuchs
LFL2
250 V
Maker:
Type:
Max voltage:
04.6 SLUDGE RETURN PUMP

The following sludge return pump is installed on the sewage treatment plant
Maker:
Type:
Insulation class:
Protection class:
Flow:
Delivery head:
Motor voltage:
Rotation speed:
Motor consumption:
Pump casing:
housing/impeller:
Weight:
Noise Level:
Herborner Unipump
0,75/K25-1-100-V-W1
F
IP55
0,6 m3/h
3.0/4,4 m
400/440 V 50/60 Hz
1500/1800 rpm
0,66 kW
GG 25
GG 25
26 kg
04.7 VACUUM UNIT
05
05.1
TROUBLE SHOOTING
TROUBLE SHOOTING..............................................................2

05.1 TROUBLE SHOOTING
Discharge pump does not start / Common Alarm to ECR / High Level Alarm:
1.
2.
3.
Reset alarm by pressing reset alarm on control panel.

Start discharge pump in manual mode and empty clean water tank.
If the pump is running check the high level switch replace if needed.
If the pump is not running,
Check power supply to motor.
Check for clogged pump.
Check Contactor and thermal protection replace if needed.
Check insulation on motor winding replace if needed.
WARNING
THINK SAFETY WHEN WORKING WITH ELECTRICAL COMPONENTS.
Discharge pump does not stop:

1.
2.
Immediately switch to OFF.

Check low level switch replace if needed.
Discharge pump is running but not pumping:

1.
2.
3.
4.
5.
Pump rotates in wrong direction(initial start) stop immediately - change

one of the phases on power cable(remember to check the other
pumps/Compressor also)
Check all inlet/outled valves.
Check water level in the tank.
Bleed the pump.
Check impeller replace if needed
Macerating pump does not start / Common Alarm to ECR / High Level Alarm:
1.
2.
3.
4.
Check timer settings adjust/replace timer if needed.

Start macerator pump in manual mode.
If the pump is running,
Check the high level switch replace if needed.
Check the low level switch replace if needed.
WARNING
Macerating pump does not stop:

1.
2.

Check high level switch in inlet tank.

Macerating pump is running but not pumping:
1.
5.

Bleed the pump.
1.
2.
3.
4.
Check that the discharge valve on clean water tank is open.

Check function of level switches.
Check if discharge/macerator pump is in auto mode.
Check discharge/macerator pump as mention above.
2.
3.
4.
Overflow in STP:
Air Compressor does not work:

1.
2.
3.
Check power supply to compressor.

Check air filter on compressor replace if needed
Check vanes in compressor replace if needed
WARNING
Air Compressor running, but insufficient capacity:

1.
2.
3.
Compressor rotates in wrong direction(initial start) stop immediately as

water can enter the compressor - change one of the phases on power
cable(remember to check the pumps also)
Check filters on compressor replace if needed.
Check vanes in compressor replace if needed.
Sludge pump does not start:

1.
2.
3.
4.

Start sludge return pump in manual mode.
If the pump is running,
Check timer replace if needed.
WARNING
Sludge return pump does not stop:

3.

Sludge return pump is running but not pumping:
1.
2.
3.
4.
5.

Bleed the pump.
UV-sterilizer does not work:

1.
2.
3.
Check power supply to UV sterilizer.

If power supply is ok and lamp is not lit then check
Lamp starter.
If unit is overheated.
Loose lamp connection/wire.
Internal fuse.
Replace lamp (9000 operating hours)

Foam in the STP:
1.
2.
Unbalance between biofilm and sewage water, normally when the plant is
started up.
To much use of soap/cleaning devices, choose detergents with low foaming
properties for cleaning and/or do not empty used cleaning water in dains
lead to sewage treatment plant.
Foul smelling from Bioreactor:

1.
2.
Air supply to bioreactor missing.

Bacteria killed.
(Brown sludge: Indicate normal Bacteria life)
(Black sludge: Bacteria killed,- check chemicals used for general cleaning)
CONTACT GERTSEN & OLUFSEN A/S. FOR FURTHER ACTION.
06
RECOMMENDED SPARE PARTS
06.1
SPARE PARTS FOR COMPRESSOR .....................................2
06.2
SPARE PARTS FOR DISCHARGE/MACERATOR PUMP..2
06.3
SPARE PARTS FOR SLUDGE RETURN SYSTEM ..............2
06.4 SPARE PARTS FOR UV STERILIZER ...................................3

06.5
SPARE PARTS FOR LEVEL SWITCH ...................................3
06.6
VACUUM UNIT (OPTIONAL) ..................................................3

06.1 SPARE PARTS FOR COMPRESSOR
See component list chapter 07 or chapter 01.1.1 for the installed equiptment.
KDT 3.60- KDT 3.80
Article number Quantity
BR.3012
2 pcs
BR.3028
1 sets
BR.3014
1 set
Description
Filter
Filter
Vanes
Remarks
Pos 68
Pos 91
1 set consist of 4 vanes
DT 3.100 KDT 3.140

BR.3012
2 pcs
BR.3029
1 pcs
BR.3027
1 sets
Description
Filter
Filter
Vanes
Remarks
Pos 68
Pos 91
1 set consists of 4 vanes
06.2 SPARE PARTS FOR DISCHARGE/MACERATOR PUMP

Discharge and Macerator pump ES 130
Description
BR.2000
1
Wearing part set
Article number
BR. 2020
Quantity
1 pcs.
Remarks
1 Mechanical seal
1 Angular ball bearing
1 O-ring 24x6
1 O-ring 80x3
1 O-ring 185x3
1 O-ring 185x3
Description
Special pump tool for
disassembling and
assembling
Remarks
Rotor disk puller incl. mandrel
Sleeve for end face seal
Fitting tool for end face sleeve
Fitting tool for rotor disk
06.3 SPARE PARTS FOR SLUDGE RETURN SYSTEM

0,75/K25-1-100-F-V-W1
BR.2039
1 pcs
BR.2040
1 pcs
BR.2041
1 pcs
BR.2042
1 pcs
BR.2043
1 pcs
BR.2044
1 pcs
Description
Mechanical seal
Bearing non drive side
Bearing drive side
Impeller nut
Labyrinth ring
Gasket
Remarks
Pos. 433
Pos. 320.1
Pos. 320.2
Pos. 920
Pos. 423
Pos. 433

06.4 SPARE PARTS FOR UV STERILIZER
W5
Article number
BR.7150
BR.7151
BR.7152
Quantity
1 pcs.
1 pcs.
1 pcs.
Description
UV-lamp
Quartz sleeve
Coupling complete 25mm
BR.7153
1 pcs
Lamp support spring
W8
Article number
BR.7157
BR.7159
BR.7152
Quantit
y
1 pcs.
1 pcs.
1 pcs.
Description
UV-lamp
Quartz sleeve
Coupling complete 28mm
BR.7153
1 pcs
Lamp support spring
Remarks
1 Locking sleeve
1 Reactor plug
1Transparent sleeve
1 O-ring 28x3,5
1 O-ring 41x1,78
Remarks
1 Locking sleeve
1 Reactor plug
1Transparent sleeve
1 O-ring 28x3,5
1 O-ring 41x1,78
06.5 SPARE PARTS FOR LEVEL SWITCH

Article number
BR.6001
Quantity
1 pcs.
Description
Level switch complete
Remarks
LF2-CK-U
06.6 VACUUM UNIT (OPTIONAL)

25 MB-A
Article number
BR.10009
Quantity
1 set
Description
Spare part kit
Remarks
Shaft seal, sealing ring, rubber flap, split sleeve
and O-rings.
65 MB-A
Article number
BR.10010
Quantity
1 set
Description
Spare part kit
Remarks
Shaft seal, sealing ring, rubber flap, V-ring, split
sleeve and O-rings.
07
DRAWINGS
Description
P&I DIAGRAM
GENERAL ARRANGEMENT
COMPONENT LIST
ELECTRICAL DRAWING
INSTALLATION DIAGRAM
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
GERTSEN & OLUFSEN
08
CERTIFICATES
DECLARATION OF CONFORMITY
EC TYPE-EXAMINATION CERTIFICATE FOR G&O
BIOREACTOR, ISSUED BY DET NORSKE VERITAS
G&O LEAKAGE TEST CERTIFICATE
PAINT SPECIFICATION ( OPTIONAL )
Painting Specification - Protective Coatings

Customer:
NVG.
Date: Januar 2012.
Project:
Schmidt Marine- El aps. Tanks outside.
Area:
Black steel.
Pretreatment:
Oil and grease is removed by emulsifier, followed by highpressure freshwater hosing to remove salts and other impurities. The surface is blasted to Sa 2 according to ISO 8501-1. Clean the
surface for impurities.
Product no. and name

7802 SigmaFast 205
7524 SigmaDur 520
Prepared by: Johnny Yssing
Shade
Vol. Sol.
%
Div Ral / NCS

Div Ral / NCS
70
57
Filmthickness
Dryfilm
Wetfilm
80
60
140
114
105
219
Re-coating Intverval
at 20C
Min.
Max.
4 hrs
6 hrs
6 mth.
none
Thinner
91-92
21-06
Remark:
1.
2.
3.
4.
31
17
0
37
Above mentioned system applies according to demands in ISO 12944-5 corrossionscategori C3 Medium.
Stripecoating is carried out on weldingseams, holes as well as areas difficult to reach.
For runnig maintance and/or repair of evt. montage damage refur to repair maintance guide.
It is highly recommended to consult relevant technical- and safety datasheets before the job is begun.
Sigma Coatings and Amercoat are brands of PPG Industries
All relations with third parties shall be governed by PPG Coatings SPRL/BVBAs general Conditions of sale. Third party conditions are excluded. The conditions contain a jurisdiction whereas the country court in Charleroi shall be the competent court of
jurisdiction (Court District of Charleroi, Avenue General Michel, 6000 Charleroi, Belgium). Please refer to the PPG Coatings SPRL/BVBAs terms and conditions of sale.
PPG Coatings SPRL/BVBA hereby draws the attention to, that PPG Coatings SPRL/BVBA in connection with inspection and technical advice, does not take over the full responsibility of the surface treatment. PPG Coatings SPRL/BVBAs guarantee for the
quality of our products, and that specification, datasheets and advice, are given in accordance to the best of our knowledge and know-how.
SQP PC UK.xls
PPG Coatings SPRL/BVBA.Tweemontstraat 104BE-2100 Deurne-Antwerpen
05-01-2012
Painting Specification - Protective Coatings

Customer:
NVG.
Date: Januar 2012.
Project:
Schmidt Marine- El aps. Tanks inside.
Area:
Black steel.
Pretreatment:
Oil and grease is removed by emulsifier, followed by HPFW hosing to remove salts and impurities. The surface is sandblasted to Sa 2 according to ISO 8501-1, with a roughness corresponding to
50-100 my. Clean the surface.
Product no. and name

7409 Sigma Phenguard 930 (Primer)
7448 Sigmaguard 790 (HS)
7448 Sigmaguard 790 (HS)
Prepared by: Johnny Yssing
Shade
Vol. Sol.
%
Filmthickness
Dryfilm
Wetfilm
Re-coating Intverval
at 20C
Min.
Max.
Thinner
Offwhite
66
100
152
36 hrs
21 days
91-92
Greenish grey
Greenish grey
86
86
100
100
300
116
116
384
16 hrs
16 hrs
5 days
5 days
91-92
91-92
Remark:
1.
2.
3.
4.
31
17
0
37
Stripecoating is carried out on weldingseams, holes as well as areas difficult to reach.

For runnig maintance and/or repair of evt. montage damage refur to repair maintance guide.
It is highly recommended to consult relevant technical- and safety datasheets before the job is begun.
Sigma Coatings and Amercoat are brands of PPG Industries
All relations with third parties shall be governed by PPG Coatings SPRL/BVBAs general Conditions of sale. Third party conditions are excluded. The conditions contain a jurisdiction whereas the country court in Charleroi shall be the competent court of
jurisdiction (Court District of Charleroi, Avenue General Michel, 6000 Charleroi, Belgium). Please refer to the PPG Coatings SPRL/BVBAs terms and conditions of sale.
PPG Coatings SPRL/BVBA hereby draws the attention to, that PPG Coatings SPRL/BVBA in connection with inspection and technical advice, does not take over the full responsibility of the surface treatment. PPG Coatings SPRL/BVBAs guarantee for the
quality of our products, and that specification, datasheets and advice, are given in accordance to the best of our knowledge and know-how.
SQP PC UK.xls
PPG Coatings SPRL/BVBA.Tweemontstraat 104BE-2100 Deurne-Antwerpen
05-01-2012
09
VACUUM UNIT OPERATION & MAINTENANCE

INSTALLATION
SANITARY SYSTEM
MODE OF OPERATION VACUUMARATOR
DATA SHEET VACUUMARATOR
DATA SHEET EL MOTOR

OPERATION - VACUUM UNIT
TROUBLESHOOTING & REPAIR
DISASSEMBLY & ASSEMBLY INSTRUCTION
DRAWINGS
INSTRUCTION FOR VACUUM SWITCHES
Installation Jets Vacuumarator pump

DATA SHEET NO. 2108 - 01.01.2009 Page 1 af 1
Vacuum unit
Sewage treatment plant
When designing the installation of the vacuum unit, it

is important to provide sufficient space for inspection
and maintenance. Install shut-off valves (included in
Jets supply) according to piping diagram. Each
pump is supplied with vibration dampers. Flexible
joints (included in Jets supply) must be used when
connecting the pump's suction and pressure side.
If connected to a sewage treatment plant, the

discharge pipe(s) from lhe pump(s) IS connected to
the plant. See SewageTreatment Plant Instruction
Manual.
The pump must be located to avoid head loss on

outlet pipe. Height of outlet pipe should be kept at
a minimum, preferably less than 2 meters, because
increased height of outlet pipe will reduce vacuum
capacity of pump.
If increased height is needed, please contact Jets
Vacuum Technical Oepartment.
Connected to an integrated holding tank, connections

for pumps must be made according to Technical
Manual.
Level switches for controlof discharge pump(s)
must be instalied according to drawing in Technical
Manual.
Please natice:
For pump Jets15M/15MB and Jets15MB-0:
To keep sufficient priming of the pump, outlet pipe
should be at least 1 m long in vertical direction.
Fresh water supply
Rotation ot the Jets

Vacuumarator pump
The correct rotation is indicated with an arrow on the
pump housing. The rotation of the pump is always
clockwise seen from the motor fan end.
Prior to checking the rotation, make sure that the
pump is filled with liquid.
Starting up the pumps without liquid will damage the
shatt seals.
Integrated holding tank
Fresh water supply may be connected to the suction

chamber on each pump to flush and clean when
neccessary and to fill the pump with water atter
service.
How to fill water into the pump:
Unscrew plug* on side of suction chamber**, one
of the plugs. Fill fresh water through the plug hole
up to piug hole level. Level may be control led by
looking through the suction chamber cover ***. Refit
plug.
Owg**
Plug No*
Cover No***
Jets 15MB-0
31739-029
020202900
029150310
Jets 25MBA
31781-023
020202900
023280000
Jets 65MBA
32020-02A 020202900
023280050
33126-020
020220010
Jets
Vacuumarator
020202900
A Jets Vacuumarator pump must never be started

or operated without sufficient pre-filling of water
in Suction Chamber
Note: Changes without prior notice
The Jets Sanitary Systems

DATA SHEET NO. 2104 - 28.02.2008 Page 1 of 1
Principle
Jets Vacuum System uses differential air pressure (vacuum) for the transport of sewage from the toilets
to the vacuum generating unit (Jets pump).
From the pump the sewage is pumped either to a holding tank or to a sewage vacuum treatment plant
(STP).
A NR-valve (Non-Return Valve) mounted on the vacuum side of the pump, separates the vacuum side from
the atmospheric side of the system.
Start and stop is controlled by a pressure switch or vacuum transmitter, starting the pump at appr. 40%
vacuum and stopping at appr. 55 % vacuum.
Function
Each toilet is connected to the discharge pipes via the Jets interface valve. The valve is open only during
the discharge cycle.
One or more pumps keep the discharge pipes under vacuum. Start and stop of the pump is controlled by a
pressure switch or vacuum transmitter.
A non- return valve incorporated in the pump doses off the connection to the mains when the pump comes
to a stop.
When a toilet is operated, the Jets interface valve is activated.
Sewage, waste water and air are sucked into the vacuum mains and transported to the pump.
The macerator integrated in the Jets Vacuumarator pump finally pulps the sewage while pumping it to a
holding tank or a sewage treatment plant (STP).
Operation & Maintenance
Jets Vacuumarator
Principle &
Function
Mode of Operation
The Jets Vacuumarator's main function is to create
vacuum in the piping system.The Vacuumarator
is a screw pump with a built-on macerator. The
principle of operation is a helical rotor running in
a cylindrical housing, which together with two end
plates forms the pump body.
When the Vacuumarator is in operation, a liquid
ring is created round the rotor. The depth of the
liquid ring is governed by the size of the opening
in the end plate on the pressure side. This opening
is arranged so that the created liquid ring will be
touching the rotor hub on one side and the rotor
tips on the other. This arrangement creates a
series of progressive crescent shaped cavities
travelling from suction to pressure side. Air,
sewage and water is pulled into those cavities and
transported through the vacuumarator.
The sewage is macerated by the built-on
macerator before it enters the pump body.
The macerator consists of one rotating knife xed

to the shaft and one stationary knife xed to the
suction chamber.
In order to provide sufcient liquid level at the
time when the Vacuumarator is starting, and thus
securing the initial priming of the screw pump, a
vacuumaratortank is mounted on the outlet pipe
of the Vacuumarator. This is done for all types of
Vacuumarator except for the Vacuumarator Jets
10N Tand 15MB/15MB-D, where the 50mm pipe
on the outlet pipe functions as a tank to ensure
return water.
How to ll water into the vacuumarator prior to
start or after service:
Unscrew plug on side of suction chamber, one of
the plugs. Fill fresh water through the plug hole
up to plug hole level. Level may be controlled by
looking through the suction chamber cover. Ret
plug.
Discharge (Outlet)/ Return water

Suction
(Inlet)
Pump Housing
Macerator
Liquid ring
Rotor
www.jets.no
Myrane
Myrane Industriomrde,
Industriomrde, N-6060
N-6060 Hareid,
Hareid, Norway.
Norway.Tel.
Tel. ++ 47
47 70
70 03
03 91
91 00.
00. Fax
Fax ++ 47
47 70
70 03
03 91
91 01.
01. E-mail:
E-mail: post@jets.no
post@jets.no
35
Vacuumarator Jets 65MBA
Vacuumarator
The patented Jets Vacuumarator

- creates vacuum
- macerates sewage
- pumps sewage
Designed for direct connection to any kind of sewage treatment plant.
Outlet can also be connected to gravity piping or holding tank.
Safe operation is secured by black water from the toilets.
Technical Data:
Capacity:.................................................................................................................................... 60rm3/hr
Flushing Capacity at 50 Hz:.............................................................................................. 520 flushes/hr
Flushing Capacity at 60 Hz:.............................................................................................. 600 flushes/hr
Outside Dimensions:.....................................................................................818x263x336 mm (LxWxH)
Electric Motor:......................................................................................................... MEZ 7BA 132 S0 2K
Pump Casing Material......................................................................................................Stainless steel
Rotor Housing Material:..................................................................................... Stainless steel AISI 316
Pump Rotor Material:...........................................................................................................Ni-Al Bronze
Pump Knives Material:....................................................................................... Stainless steel AISI 420
Pump Shaft Material:......................................................................................... Stainless steel AISI 316
Connection Inlet:..................................................................................................................DN65, PN10
Connection Outlet:...............................................................................................................DN50, PN10
Connection Return water:................................................................................. 1/2 BSP inside threads
Total Weight:................................................................................................................................... 97 kg
Part No. Jets 65MBA
Voltage/Frequency
230-380/50, 255-440/60
Part No.
02A065001
690/60
02A065002
690/50
02A065003
www.jets.no
Myravegen 1, N-6060 Hareid Norway Tel. + 47 70 03 91 00. Fax + 47 70 03 91 01. E-mail: post@jets.no
TM
Vacuumarator Jets 65MBA
Vacuumarator

1
Dimensions 65MBA
381,5
69,5
312
13,8
DN50
335
DN65
20,5
151,5
324
282
433,5
220
267
799
Operating Data:

820
70
Capacity 400V/50Hz 5,5kW AIR
60
50
D
50Hz
60Hz
Speed (nom.):............................................................ 2.895 RPM..........................................3.494 RPM

Power Connections (nom.):..............................3x400V / 3x230V................................................3x440V
Power Output (nom.):........................................................5,5kW.................................................6,3 kW
Current Consumption (230V):............................................ 18,7 A
Current Consumption (400V):............................................ 10,7 A
Current Consumption (440V):........................................................................................................ 11,2 A
For other voltages:.......................................................................................... See Data Sheet No, 3123
m/h
Part No. Jets 65MBA
Voltage/Frequency
02A065001
02A065002
kW
02A065003
230-380/50, 255-440/60
690/60
690/50
30
20
10
70
6,0
60
2,0
0
0
-0,1
-0,2
-0,3
-0,4
-0,5
-0,6
-0,7
-0,8
TM
20
-0,9
N-6069 HAREID
Tel. +47 70 03 91 00
Fax. +47 70 03 91 01
E.Mail post@jets.no
WWW.JETS.NO
10
-1
0,0
-0,1
-0,2
-0,3
-0,4
Capacity 400V/50Hz 5,5kW WATER
6
kW
2
0
2
1
Description
Dimension Drawing
3,0
Part no.:
Material:
See Table
-0,5
-0,6
-0,7
-0,8
-0,9
2,0
1,0
-1,0
10
10 11 12 13 14 15
kW
m/h
10
m/h
12
5,0
Title
Capacity 440V/60Hz 6,3kW WATER
14
10
m/h
6,0
65MBA Kurver Engelsk
10
m/h
Original Drawing
bar
12
bar
14
Revised drawing, title and table
Jets4,0
65MBA
kW
031226200
031226201
031226204
kW
30
1,0
Rev.
40 Part No. El-Motor

Part No. Vacuumarator
4,0 kW
m/h
02A100101
02A100101
3,0
02A100101
7,0
Capacity 440V/60Hz 6,3kW AIR

m/h
50
5,0
m/h
40
7,0
kW
6
4
2
0
2
0
mH2O
www.jets.no
Myravegen 1, N-6060 Hareid Norway Tel. + 47 70 03 91 00. Fax + 47 70 03 91 01. E-mail: post@jets.no
10 11 12 13 14 15
mH2O
TM
kW
Weight:
El.motor for Jets 65MBA
El.motor
Dimensions MEZ 7BA 132S02K
All dimensions in mm
Technical Data:
Type: ...................................................................................................................... MEZ 7BA 132 S0 2K

Outside Dimensions:.....................................................................................619x263x336mm (LxWxH)
Number of Poles: ..................................................................................................................................2
Mounting: .......................................................................... Special ange and foot mounting (IEC-72-1)
Frame Size: .................................................................................................................... 132 (IEC-72-1)
Enclosure: .............................................................................................................. IP 55 (DIN IEC 34-6)
Insulation Class: ...................................................................................................................................F
Material, Housing: .....................................................................................................................Cast iron
Material, fan Cover: ........................................................................................................................Steel
Material, Ventilator: .................................................................................................... Fibre-glass plastic
Terminal Box: ..............................................................................Top mounted, turnable in 900 intervals
Cable Conduit: ............................................................................................ Threaded holes for 2 x M32
Cooling: ........................................................................................................ Self ventilating /air cooling
Total Weight: .................................................................................................................................. 52 kg
Operating Data:
Voltage (V) ................... 230 ............. 400 ............. 415 ............. 440 ............. 660 .............690 .............690
Frequence (Hz).............. 50 ............... 50 ............... 50 ............... 60 ............... 50 ...............50 ...............60
Speed (Rpm) ............ 2.895 .......... 2.895 .......... 2.895 .......... 3.495 .......... 2.895 ..........2.895 ..........3.495
Power (kW) ................... 5,5 .............. 5,5 .............. 5,5 .............. 6,3 .............. 5,5 ..............5,5 ..............6,3
Main current (Amp) ..... 18,7 ............ 10,8 ............ 10,4 ............... 12 .............. 6,5 ..............6,3 ..............7,2
Efciency (%)................. 82 ............... 82 ............... 82 ............... 83 ............... 82 ...............82 ...............83
Duty ............................... S1 ...............S1 ...............S1 ...............S1 ...............S1 .............. S1 .............. S1
Cos ........................... 0,9 .............. 0,9 .............. 0,9 ............ 0,89 .............. 0,9 ..............0,9 ............0,89
Connection ......................D ................. Y .................Y .................Y .................Y .................Y ................ Y
Part. No. ............ 031226200 ... 031226200....031226202....031226200 ...031226203 ... 031226204... 031226201
www.jets.no
Myrane
Myrane Industriomrde,
Industriomrde, N-6060
N-6060 Hareid,
Hareid, Norway.
Norway.Tel.
Tel. ++ 47
47 70
70 03
03 91
91 00.
00. Fax
Fax ++ 47
47 70
70 03
03 91
91 01.
01. E-mail:
post@jets.no
- Vacuum Unit
Constant Vacuum System

Operating
Discharge Pump
A Jets vacuum system is commissioned according

to 501 Control Chart Start-up.
Some systems are supplied with a pump for

discharging the content from the holding tank. The
operating modes for the discharge pump is chosen
via a switch with folIowing functions.
The systems operating mode can be selected via

switches on control panel (see drawing).
On the control panel there is a separate switch for
each pump. The switch has folIowing positions:
o - OFF
1
2
- MANUAL
-AUTO
In normal operation the system is set with all pumps

in the AUTO mode. (switch in pos. 2 - AUTO). In this
mode, start and stop is controlled by the pressure
switch or vacuum transmitter and is normally set to
start at 42% vacuum and stop at 55%.
In a system with more than one pump:
A system with 2 pumps: No. 2 pressure switch to be
set to start at 40% vacuum.
A system with 3 pumps: No. 3 pressure switch to be
set to start at 38% vacuum.
See also instruction for pressure switches.
Setting the switch in pos. 1 - MANUAL, the pump
will be running until the switch is set in either pos.
0- OFF or in pos. 2 -AUTO.
- OFF
1
2
3
- LOCAL
- REMOTE
- INTERMIT. or AUTO
When operating in pos. 1 - LOCAL mode, start and

stop is manually operated from cabinet front. If not
stopped manual ly, it will be stopped by low level
switch.
When operating in pos.2: REMOTE, Same as
LOCAL.
When operating in pos. 3: INTERMIT., start of the
pump is controlled by a timer. Stop is controlled by
low level switch.
When operating in pos.3 AUTO, start is controlled by
high level switch and stop by low level switch.
Pump used as Discharge

Put the 3-way valve(s) and the other valves involved,
in discharge position (see pipeline drawing).
Put MODE SELECTOR in position
DISCHARGE.
Discharge will stop when the tank is empty.
Note: Part of the system may not be available during
discharge
Note! The lay-out and practical use of each unit

will decide the setting of pressure switch/vacuum
transmitter as opposed to normal setting
ww\,h".jets.no
Myrave~e;, 17N-60~0'Hareia. Norway. Ter:-. 47 70'03 91 00: Fax"'. 47700391: Ol. E-mai!: po;t@!Jets.no
40
Control Cabinet
DATA SHEET NO. 3105 - 05.11.2009 Page 1 ef 1
Note: Not applicable when Vacuum Unit is controlled by

Sewage Treatment Plant Control Cabinet
Control cabinet
If the control cabinet is fitted with a main switch
(inside cabinet), this must be switched on when in
operating mode.
Functions Jets
Vacuumarator pump
O.OFF
See enclosed drawing of front control cabinet for the

system in mention.
1. RUN
General functions
2. AUTO
Constant vacuum:
Pump will run independent of pressure switch.
Normal operation mode.

Pumps controlled by pressure switches.
When commissioning a system all functions are

preset.
Normaloperating mode of system is AUTO. In this
mode, start and stop of each pump is controlled
either by a pressure switch or vacuum transmitter.
Setting of Pressure Switches: See Data Sheet No.
3103.
Vacuum transmitter valves are preset in program.
an a system with more than one pump, the second
(and third) are normaily set to start at a slightly
lower vacuum than that of nO.1.
Alarm
For control cabinets equipped with alarm running
time: Running time should be preset to 10 minutes.
See enclosed data sheet for Timing Relays, and
El. Diagrams.
For control cabinets with alarm low vaccum, to be
adjusted according to Data Sheet 3103.
. ww*.jetSrn'o
Myravegen r!"N-6060'Aarei8. Norway. Tel. + 47 70 03 9i 00: Fax +'4770039101. E-mail: post@!jets.no
41
Operation &. Maintenance
atm
mbar
kPa
m~
1013
101,325
900
90
10,33
10
0,9
20
0,8
800
80
30
0,7
700
70
600
60
40
0,6
PSI
in Hg
mmHg
14,7
29,92
760
700
12
10
25
600
20
500
8
50
0,5
500
50
60
0,4
400
40
70
0,3
300
30
200
20
80
0,2
90
0,1
100
100
O
300
10
200
10
O
400
15
100
O
mercury
torr
CORR. MERCURY SCALE
Rev. Description of cho.nges
~IETS
N-6069 HAREID
Tel.: +47 70 03 91 00
Fnx: +47 70 03 9\ 0\
Appr.d
Titte:
Do.te
VACUUM COMPARISON
Dro.wn:
16.02.93
MB
130
Purt.no.:
www.jets.no
+
,
,
Myravegen 1. N-6060 Hareid Norway Te!. + '17 70 03 91 00. Fax + '17 70 03 91 01. E-mail: post@!jets:no
42
DATA SHEET NO.
2168
Troubleshooting & Repair
ISSUE C
Vacuumarator type Jets 65MBA

Maintenance
Job
Clean
connection pipe
for pressure
switches by
letting in air
Check function
pressure
switches
Reset pressure
switches*
(*if needed)
Replace
shaft seal
Vacuumarator
and El Motor
Change
bearings on
electric motors
Data Sheet
No
Drawing No
Part No
Piping Diagram
3103
Interval
Comments
Daily
032300100
Daily
3103
Piping Diagram
032300100
Monthly
2149
3123
2155
32020-02A
32026-031
038225700
037224200
2 years/
6000 hours or if
water leakages
should occur
during running.
3123
2155
32026-031
038226600 and
038223800
2 years/
6000 hours
See Data
Sheet 2155 for
disassembly
and
assembly of
Vacuumarator
Jets 65MBA
See Data
Sheet 2155 for
disassembly
and
assembly of
Vacuumarator
Jets 65MBA
DATA SHEET NO.
Troubleshooting & Repair
2168
ISSUE C
Vacuumarator type Jets 65MBA

Additional Information on Maintenance and Repair
Problem
Causes
Action
Low vacuum
Lack of sealing
liquid to
Vacuumarators
Leaks in vacuum
pipes
Check that
Vacuumarator
has water during
operation
Check for leaks
and repair
Macerator clogged
Remove blockage
Clogged pipes
Remove blockage
Water leakage
from vacuumarator
Defective shaft
seals
Ckeck and replace

shaft seals
Frequent start
and stop of
Vacuumarator
Leakage in
vacuum pipes
Check for leakage

and repair
Piping Diagram
Leakage caused
by insufficient
closing of
Flap Valve
(Vacuumarator's
non-return valve)
Motor protection
relay tripped
Check flap valve

and clean surface
of valve
32020-02A/
037302100
Check causes
for overload and
repair
Check for leakages
in pipe system and
repair
El Diagram
Overload electrical
motor
Running time
alarm*
(*If installed)
Running time of
Vacuumarator
has extended
preadjusted time in
Time Relay
Data Sheet
Drawing/Part No.
2149,2106
Piping Diagram
and Vacuum
Piping Guide
32020-02A/
02A25512
Piping Diagram
and Vacuum
Piping Guide
32020-02A
32026-031
038225700
037224200
El Diagram
JETS VACUUM AS
P.O.Box 14
N-6069 Hareid, Norway
Tel.: +47 70 03 91 00
Fax: +47 70 03 91 01
DATA SHEET NO.
2155
Disassembly & Assembly Instruction

Vacuumarator 65MBA
S CHEDULED
MAINTENANCE
Replace the Shaft Seals every 24 th. month or after 6000

working hours whichever occurs first.
ISSUE A
2. Remove the suction chamber No. 023280040 by means

of a rubber mallet.
3. Unscrew the screw 13 mm in centre of the macerator,
by means of a socket wrench. Then remove the
macerator.
W ARNING
4. Unscrew and remove stay bolts No. 036202011.
Be sure the electricity supply has been switched off before

working on the Vacuumarator.
5. Remove end plate No. 02A265106.
Be aware of the nature of the liquid and take the necessary

precautions.
7. Remove macerator bushing No. 02A265104 and rotor

No. 02A265101.
Unscrew plug No.020202900 and empty the pump of liquid.
8. Remove pressure chamber No. 02A265109 by means

of a rubber mallet.
6. Remove rotor housing No. 02A265102.
A. DISASSEMBLY:
The references are located in drawing 32020-02A Vacuumarator Jets 65MBA Part Drawing.
All parts must be marked before disassembly to ensure
reassembled in the correct order and angle position.
The disassembly process shall always be carried out from
the suction side of the pump i.e. opposite the motor.
Dismount pump from bed plate. During disassembly/
assembly the Vacuumarator should be in upright position.
C. ASSEMBLY:
The assembly process takes place in the opposite order.
Ensure that all parts are perfectly clean, especially all
recesses where O-rings are used, before the assembly
process is carried out.
1. Use liquid soap when fitting the shaft seal
No. 038225700.
2. Always use new O-rings.
1. Unscrew 4 sylinder screws No. 036207621
JETS VACUUM AS
P.O. Box 14
N-6069 Hareid, Norway
Tel: +47 70 03 91 00
Fax: +47 70 03 91 01
Flange For Shaft Seal

02A265108
Flap Valve Body

023280061
O-Ring
037219270
Rubber Flap
037302100
Plate For Flap Valve
023280091
Flap Valve Complete

023280060
Nut M6 x 16
036232920
Macerator
02A265112
B
Nut for Flap valve

02A265100
Shaft Seal 40
038225701
Flange
02A265110
Pressure Chamber
02A265109
O-Ring
037219280
Plug 3/8"
021217000
Distance Sleeve
02A265105
O-Ring
037219261
Rotor Housing
02A265102
Key
02A265113
O-Ring
037219261
Suction Chamber
023280040
O-Ring
037219260
Suction Chamber Cover
023280050
D
Nut M6
036901200
Set screw
036202401
Stay Bolt
036202011
Plug 1/2"
020202900
O-Ring
037219220
Cylinder Screw
036207621
Updated part no
25.09.2007 MG
Removed Dripflange and V-ring
16.05.2007 Rhu
Revised part name V-ring
16.01.2007 RHU
ADD NEW PART "DRIPFLANGE"
06.04.2006 RoL
CHANGED SOME PART. NAME
01.12.2006 RoL
CHANGED P.NO. ON SCREWS ON SUCTION CHAMBER06.06.2005 TG
ADD PART NO. FOR "FLAP VALVE COMPLETE"
28.02.2005 RoL
ADD "THROW OFF RING"
10.09.2003 RoL
Original Drawing
22.08.2001 RoL
Date
Description
Rev.
Title
End Plate Suct. Chamber

02A265106
Maserator Bushing
N-6069 HAREID
Tel. +47 70 03 91 00
02A265104
Fax. +47 70 03 91 01
E.Mail post@jets.no
WWW.JETS.NO
Rotor
02A265115
Designed by
TM
VACUUMARATOR JETS 65MBA
22.08.2001 RoL
Scale
PART DRAWING
Part no.:
Material:
02A100101
5
Sign
Weight:
Drawing no
36 Kg
32020-02A.idw
6
Spacer Sleeve
031226900
A
Ball Bearing
038226000
Key
022222150
Shaft
02A265107
Terminal Box
031225700
Ball Bearing
038223800
Sealing Ring
037224200
B
B
Motor Flange
02A265103
Endshield
031225130
Hex Screw
M8x30 din933
036202200
Fan
031225120
Stator
See Table
Fan cover
031225110
Circlip
037227100
V-ring
038399550
Dripflange
02A265116
4 Pcs. Socket Head Screw
M8x50 Din912 12,9
036503410
Part No.
031226200
031226201
031226204
Part No. El.Motor Jets 65MBA

Voltage/ Frequency
Stator No.
031225103
380/50 / 440/60
031225104
690/60
031225105
690/50
Revised Title
11.06.2007 rhu
Added parts v-ring and dripflange
16.05.2007 Rhu
Added Table
17.11.2006 RHU
Added part No.
Added Part No.
24.09.2002 RL
Description for Hex. Screw
13.09.2001 RL
Original Drawing
30.08.2001 RL
13.12.02
Date
Description
Rev.
Title
Designed by
TM
Checked by
MOTOR 7BA132S02K
N-6069 HAREID
Tel. +47 70 03 91 00
Fax. +47 70 03 91 01
E.Mail post@jets.no
WWW.JETS.NO
30.08.01
Scale
%
Project no
PART DRAWING
Part no.
Material
See Table
Weight
Drawing no
32026-031.idw
6
RL
Sign
RoL
Operation & Maintenance
www.jets.no
Myrane Industriomrde, N-6060 Hareid Norway Tel. + 47 70 03 91 00. Fax + 47 70 03 91 01. E-mail: post@jets.no
57
Pressure switch
Installation
Technical data
Type: .......................................................................................................... Danfoss RT121 (-1 to 0 bar)

Ambient temperature: ........................................................................................................-40 to +70C.
Pressure connection temperature: ...................................................................................... max. 150C.
Enclosure: ................................................................................... IP 66 acc. to IEC 529 and DIN 40050.
Cable entry: ................................................. Two Pg 13,5 entries for cable diameters from 5 to 14 mm.
Pipe connection: ........................................................................................................................ 3/8" RG
Switch, Contact load, Alternating current:
AC1 (ohmic): ........................................................................................................................ 10 A, 380 V

AC3 (motor): .......................................................................................................................... 4 A, 380 V
AC11 (coils): .......................................................................................................................... 3 A, 380 V
Direct current: ..................................................................................................................... 12 W, 220 V
El. connection:
Start and stop: ............................................................................................................. Terminal 1 and 4

Alarm low vacuum: ...................................................................................................... Terminal 1 and 2
Setting
The pressure switches shall be adjusted to recommended setpoints, see table below.
See also: Data sheet no. 3105
1. Regulator
2. Differential setting disc
Setpoints:
Start of pump: - 40 kPa ( % vacuum)

Stop of pump: - 55 kPa ( % vacuum)
Alarm low vacuum:
- 25 kPa ( % vacuum)
ATTENTION:
Please note that the mentioned minus kPa in this

instruction is only related to the marked scale value
plate on the Danfoss RT121 Pressure Switch, and
not to kPa standard in general.
www.jets.no
Pressure switch
Installation
Adjustment
Pressure switch for start/stop
1. Remove front cover
2.
Adjust regulator (1) to - 40 kPa (scale value)
3.
Adjust rotating differential disc (2) to 2.5 (scale value)
4.
Start Vacuumarator and observe vacuum gauge.
5.
Set switch in AUTO position
6.
Drain air slowly into pipe system by opening ball valve on the pipe manifold. Close valve at - 40kPa
(% vacuum.)
7.
Adjust slowly regulator (1) till vacuumarator starts. Increase=Clockwise. Decrease=

Counterclockwise.
8.
Adjust rotating differential disc (2) so Vacuumarator stops at 0,55kPa. Increase=Clockwise.

Decrease=Counterclock-wise.
9.
Repeat 6 through 8 until recommended setpoints are achieved.
More than one Vacuumarator:

No. 1: Start 0,42 kPa, Stop 0,55kPa.
No. 2: Start 0,40 kPa, Stop 0,55kPa.
No. 3: Start 0,38kPa, Stop 0,55kPa.
Pressure switch for alarm

1.
Remove Front cover
2.
Adjust regulator (1) to - 25 kPa (scale value)
3.
Adjust rotating differential disc (2) to 1 (scale value)
4.
Start Vacuumarator and observe vacuum gauge.
5.
At appr.-25 kPa (% vacuum), stop the Vacuumarator.
6.
Drain air slowly into pipe system by opening ball valve on the pipe manifold.
7.
Check if the contact shifts at recommended setpoint.
8.
If necessary adjust regulator (1) Increase = Clockwise. Decrease=Counterclockwise.
9.
Repeat 4 through 8 until recommended setpoint is achieved.
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G&O Bioreactor

Gertsen & Olufsen A/S

Projekt TMS AVR-3

Projekt TMS AVR-3

Projekt TMS AVR-3

Projekt TMS AVR-3

Projekt TMS AVR-3

Projekt TMS AVR-3

Projekt TMS AVR-3

G&O Microbac Bioreactor

Gertsen & Olufsen A/S

G&O Microbac Bioreactor

Gertsen & Olufsen A/S

OPERATION & MAINTENANCE MANUAL

CERTIFICATION DATA BOOK

RECOMMENDED SPARE PARTS

GERTSEN & OLUFSEN A.S.

GERTSEN & OLUFSEN A.S.

SYSTEM BUILD UP..............................................................4

01.3.1 TANK SYSTEM......................................................................4

GERTSEN & OLUFSEN A.S.

01.1 VESSEL PARTICULARS

Delivery Date of Plant:

PARTICULARS SEWAGE TREATMENT PLANT

Designed Hydraulic Load:

Designed Organic Load:

Orpu Orcut ES 130

Orpu Orcut 135/4

5800 kgs approx.

38700 kgs approx.

See Chapter 07 Drawings

Vacuum unit (optional):

GERTSEN & OLUFSEN A.S.

01.2 DESCRIPTION OF THE SYSTEM

GERTSEN & OLUFSEN A.S.

01.3 SYSTEM BUILD UP

01.3.1 TANK SYSTEM

01.3.2 AIR SUPPLY

to supply necessary air to the air diffusers.

GERTSEN & OLUFSEN A.S.

01.3.3 DISCHARGE PUMPS

High-level switch activated Discharge pump start

Inlet mixing tank(optional).

01.3.4 MACERATING PUMP

Low level switch activated Macerating pump start by timer adjustment

GERTSEN & OLUFSEN A.S.

01.3.6 SLUDGE RETURN SYSTEM

01.3.7 CONTROL CABINET

functions in the G&O STP

function of vacuum pumps/alarm, only vacuum systems

01.3.8 VACUUM UNIT

GERTSEN & OLUFSEN A.S.

PREPARATION FOR INSTALLATION..............................2

DISCHARGE PIPE LINE FROM PLANT............................3

VENTING PIPE LINE FROM PLANT.................................3

02.10 EMERGENCY OVERFLOW PIPE LINE.............................3

GERTSEN & OLUFSEN A.S.

02.3 SPECIAL EQUIPMENT

02.4 INSTALATION MATERIALS

GERTSEN & OLUFSEN A.S.

02.7 VALVE SYSTEMS

02.8 DISCHARGE PIPE LINE FROM PLANT.

02.9 VENTING PIPE LINE FROM PLANT

02.10 EMERGENCY OVERFLOW PIPE LINE

@ Manual 445 - G&O Bioreactor

@ Manual 445 - G&O Bioreactor