Installation, Operation and Maintenance Manual Sewage Treatment System WWT LC 1.

print run

Installation, Operation and Maintenance Manual

Sewage Treatment System WWT LC

Ac c . I MO R es ol u ti o n M E PC .1 5 9( 5 5)

RWO GmbH ● Marine Water Technology ● Bremen ● Germany issue 10.08.2010

Installation, Operation and Maintenance Manual Sewage Treatment System WWT LC 1. print run page 2
Copyright

Co p yr ig h t

© Copyright 2010 by RWO GmbH, Bremen, Germany

All rights reserved.
The contents of this manual are copyrighted.
Without a written approval by RWO GmbH it is strictly forbidden to misuse the manual and
the, either partly or fully, duplication, publishing, saving, releasing or for the purpose of
competition inform trespassers or third parties.
This manual and all of its contents are property of RWO GmbH and have to be returned on
demand at all times.

RWO GmbH ● Marine Water Technology ● Bremen ● Germany issue 10.08.2010

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Table of Contents

T abl e of Co n te nts
1 General ................................................................................................................... 6
1.1 Design of the Documentation 6
1.2 Depository of the Manual 6
1.3 Use of these Documents 6
1.4 Guarantee 6
1.5 Contact Information 6
2 General Safety Notes.............................................................................................. 8
2.1 Care of the Operator 8
2.2 Specific Safety Notes and used Symbols 9
2.3 Safety measures at the installation site 9
2.4 Principle Safety Measures during Normal Operation 9
2.5 Principle safety Measures during Maintenance 10
2.6 Principle Personal Protection Equipment (PPE) 10
2.7 Observe Environmental Regulations 11
2.8 Risk Potential of the Sewage Treatment System for Ships 11
2.9 Sources of Danger 12
3 Design and Function ............................................................................................. 13
3.1 Common Function and Use According the Specification 13
3.2 Proper Use 13
3.3 Component Overview 14
3.4 Identification of Type 15
3.5 Type Tests 15
3.6 Technical data 16
3.6.1 Capacity, Dimensions and Weights 16
3.6.2 Electrical Data 16
3.6.3 Pipe Connections 17
3.7 Environmental Requirements 18
3.7.1 Voltage 18
3.7.2 Feed Water 18
3.7.3 Connections 18
3.7.4 Cleaning Facilities 18
3.7.5 Surplus Sludge Discharge 19
3.7.6 Protection 19
3.7.7 Humidity 19
3.7.8 Temperature 19
3.8 Noise Level 19
3.9 Vibrations 19
3.10 Storage 20
4 Important Terms and Definitions for Waste Water Treatment Plants.................... 21
4.1 Test and Certificate of Unit 21
4.2 Waste Water Character 21
4.3 Black Water 21
4.4 Grey Water 21
4.5 Activated Sludge Process 21
4.6 Biochemical Oxygen Demand (BODn) 21
4.7 Chemical Oxygen Demand COD 22
4.8 DPD – Test Kit (Diathyl-Phenylendiamin) 22
4.9 Coliform Bacteria 22
4.10 Escherichia Coli (E. Coli) 22
4.11 Disinfection 22
4.12 pH – Value 22

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Table of Contents

4.13 Sludge Volume 22

4.14 Floating Sludge 22
4.15 Suspended Solids 22
4.16 Dry Substance 22
4.17 Mohlmann Index 23
4.18 Surplus Sludge 23
5 Preparation for Operation...................................................................................... 24
5.1 Transport and Storage 24
5.2 Unpacking 24
5.3 Dispose of Packing 24
5.4 Safety Aspects Before Use 24
5.5 Installation 24
5.6 Conditions when Unit Out of Service 25
5.7 Location of Manual 25
6 Operation .............................................................................................................. 26
6.1 Description of realised process 26
6.2 Mechanical Pre – Treatment 27
6.3 Biological Purification Stage (biologic chamber - tank 1) 28
6.4 Sedimentation Stage (secondary sedimentation chamber – tank 2) 29
6.5 Disinfection (disinfection chamber – tank 3 30
6.6 Neutralisation (injection into the discharge line) 31
7 Preparation for Commissioning of System............................................................ 32
7.1 Control box 32
7.1.1 Unit with PCB Control 32
7.1.2 Unit with Relay Control 33
7.2 Valves 33
7.3 Metering Pumps for Chemical Dosing 36
7.4 Discharge Pump 38
7.5 Blower 39
7.6 Checking the Overboard Discharge Line 39
7.7 Checking the Feed Lines 40
7.8 First Filling the Unit 40
8 Starting the System............................................................................................... 41
8.1 Adjusting the Metering Pumps 41
8.1.1 Chlorination 41
8.1.2 Dechlorination 42
8.2 Air Supply Adjustment 42
8.2.1 Air Supply to Biology 42
8.2.2 Air for Disinfection Turbulence 43
8.2.3 Air Supply to Mammut Pump for Floated Sludge Return 43
9 Operation of the System ....................................................................................... 44
9.1 Operation log (OL) 44
9.2 Daily Routines 44
9.2.1 Cleaning the Pre-Treatment Screen 44
9.2.2 Entire Sewage Treatment System 44
9.2.3 Blower 44
9.2.4 Discharge Pump 45
9.2.5 Disinfectant and Neutralisation Agent 45
9.2.6 Sludge Volume Inside of Biologic Tank 1 45
9.2.7 Removal of Surplus Sludge 45
9.2.8 Check of Effluent Quality 46
9.2.9 Floating Sludge Return 47
9.2.10 Cleaning the Bevelled Cover Zone of Tank 2 48
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Table of Contents

9.3 Weekly Routines 48

9.3.1 Metering Pumps 48
9.4 9.4 Monthly routines 48
9.4.1 9.4.1 Inspection of tanks 2, and 3 48
10 Maintenance ......................................................................................................... 50
10.1 Danger Warnings 50
10.2 Blower 51
10.3 Discharge Pump 51
10.4 Metering Pumps for Chlorination and Dechlorination/Neutralizing 52
10.5 Membrane Diffuser 52
10.5.1 WWT LC 01 52
10.5.2 WWT LC 02 or Higher 53
10.6 New Start of Unit after Brake down of Treating Function 54
11 Troubleshooting .................................................................................................... 55

List of Tables
Tab. 1 Contact Information .................................................................................................. 7
Tab. 2 Component Overview .............................................................................................14
Tab. 3 Additional National Certificates...............................................................................15
Tab. 4 Capacity, Dimension and Weights..........................................................................16
Tab. 5 Electrical Data ........................................................................................................ 16
Tab. 6 Pipe Connection ..................................................................................................... 17
Tab. 7 Pipe Dimensions..................................................................................................... 18
Tab. 8 Overview of the procedural phases in biological sewage water treatment .............26
Tab. 9 Carbon balance of aerobe degradation .................................................................. 28
Tab. 10 PCB Control..........................................................................................................32
Tab. 11 Relay Control........................................................................................................ 33
Tab. 12 Metering pump for chlorination .............................................................................36
Tab. 13 Metering pump for de - chlorination...................................................................... 37
Tab. 14 Diffuser WWT LC 01.............................................................................................52
Tab. 15 Diffuser WWT LC 02 or higher..............................................................................53

Table of Figures
Fig. 1Component Overview ...............................................................................................14
Fig. 2 Pipe Connections..................................................................................................... 17
Fig. 3 Lifting Eyes ..............................................................................................................20
Fig. 4 Overview of the procedural phases in biological sewage water treatment...............26
Fig. 5 Carbon balance of aerobe degradation ................................................................... 28
Fig. 6 PCB Control.............................................................................................................32
Fig. 7 Relay Control...........................................................................................................33
Fig. 8 Arrengement of the ball valves A – D ...................................................................... 34
Fig. 9 Feed sampling valve E ............................................................................................34
Fig. 10 Arrengement of needle valves at the blower..........................................................35
Fig. 11 Metering pump for chlorination ..............................................................................36
Fig. 12 Metering pump for de – chlorination ...................................................................... 37
Fig. 13 Valve I at the bevelled cover zone of secondary sedimentation chamber (tank 2) 48
Fig. 14 Diffuser WWT LC 01..............................................................................................52
Fig. 15 Diffuser WWT LC 02 or higher...............................................................................53

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1 – General

1 General
1.1 Design of the Documentation
This document includes all important information for the
user of the described plant / unit:
 Safety Notes
 Instructions for Commissioning, Handling and
Maintenance
 Technical Data
Should you require further information or should problems
occur, which are not treated in these operation instructions
in detail, please contact directly RWO GmbH. (1.5
Contact Information)
1.2 Depository of the Manual
A copy of the manual must be kept in the centre region of
the operating and supervising staff.
1.3 Use of these Documents
 Descriptions are held in a running text
 Enumerations are marked with (●).
 Steps are marked with (1), 2), 3)…).
 Notes are marked with ().
 Highlights in the running text indicate to security
advices
1.4 Guarantee
 The warranties, in terms of our sales and delivery
conditions as well as RWO’s confirmation of order are
only granted if:
 The plant / unit is used corresponding to the designs
of these operation instructions,
 The operating log has been completely updated daily,
 The plant / unit is not used improperly in any other
kind,
 Repairs are carried out by authorised specialised
personnel only, (Such training can be booked through
the service department (1.5 Contact Information)).
 Only original or spare parts and chemicals approved
by RWO GmbH are used for repair,
 No unauthorised alterations are carried out on the
whole plant.
Excluded from the guarantee are typical wear and tear
parts, like e. g.
 All rotating parts, packings, membranes, filter etc.

1.5 Contact Information

Department Telephone Fax eMail

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1 – General

Service and
+49 421 53705 0 +49 421 53705 440 [email protected]
repair
Spare part
+49 421 53705 228 +49 421 53705 442 [email protected]
service
Sales +49 421 53705 213 +49 421 53705 442 [email protected]
Internet www.rwo.de
Postal address RWO GmbH
Marine Water Technology
Thalenhorststrasse 15A
28307 Bremen
Germany

When ordering spare parts, please provide us with the serial number of
the plant / unit (see cover page of these operation instructions or name
plate of the plant / unit).
IMPORTANT
Tab. 1 Contact Information

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2 – General Safety Notes

2 General Safety Notes

2.1 Care of the Operator
The plant / unit has been constructed and manufactured
considering the applicable resolutions, standards and
technical specifications. It corresponds to the state of the
art of technology and guarantees highest possible safety
during all operation states.
The safety of the plant / unit operation can only be
guaranteed, if all the required measures are fulfilled. The
operator of the plant has to plan these measures
according to the instructions.
Especially, the operator must make sure that:
 The plant / unit is used as specified only. (3.2
Proper Use)
 The plant / unit is operated in perfect, functional
condition only. The safety devices should checked
regularly to ensure correct function.
 Required personal protection equipment (PPE) is
available and used when required.
 The operation instructions are always complete
readable and available at site for use on the plant /
unit.
 The operating log must be updated daily in full.
 Only qualified and authorised personnel are permitted
to operate, maintain and repair the plant / unit (Such
training can be booked through the service
department (1.5 Contact Information)).
 That personnel are instructed regarding all questions
of working safety and environmental protection, and
knows the contents of the operation instructions and
contained safety notes.
 All safety and warning notes assembled at the plant /
unit are visible, readable and are not removed.
 Modifications only, are to be carried out by authorised
specialised personnel and in coordination with
contractor.

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2 – General Safety Notes

2.2 Specific Safety Notes and used Symbols

Specific safety notes are given in the following operation
instructions.
These are to avoid dangers to:
 Persons
 Product and plant / unit
 Environment
The symbols used in the operation instructions shall draw
the attention to the following!
Denotes an immediate danger. Non-observance of
the instruction can result in most severe or fatal
injuries
DANGER
Denotes a potentially dangerous situation. Non-
observance of the instruction can cause health
damages, injuries and/or damages to the plant / unit
CAUTION
Denotes important information and steps, non-
observance of which can cause damages and/or
functional faults at the plant / unit

IMPORTANT

Denotes application help, tips and other useful

information about the respective topic

Note

2.3 Safety measures at the installation site

The plant / unit must be placed onto even and solid
ground and also be fixed or welded onto the ship
fundament with the particular marked points.
To overthrow the plant / unit means mortal danger!

DANGER
WWTLC 01 – 02 should be welded to the foundation by
connecting the base plate with the provided foundation
WWTLC 03 – 06 have to be screwed to the ship's
foundation using the provided spots on its base plate.
2.4 Principle Safety Measures during Normal Operation
The plant / unit must be operated by specially trained and
authorised persons only, who know the operation
instructions (Such training can be booked through the
service department (1.5 Contact Information)).

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2 – General Safety Notes

Check and make sure before starting the plant / unit that:
 Only authorised persons are allowed to stay in the
working area of the plant / unit.
 Nobody can be injured when plant / unit is started!
Check plant / unit for visible damage before starting and
make sure that it is operated in perfect condition only! Any
damage to the plant / unit must be reported!
2.5 Principle safety Measures during Maintenance
Ensure the intervals and activities for inspection and
maintenance are observed, where stated in the operating
instructions!
Observe maintenance and repair instructions regarding
the single components in the appendix!
Before starting maintenance or repair works close the
access to the plant / unit by unauthorised persons! Provide
signs mentioning that maintenance or repair works are
carried out!
Depressurise the system, interrupt the feed to the plant /
unit and protect against restart!
Switch-off main switch of power supply before starting
maintenance and repair works!
When exchanging heavy plant / unit parts, use suitable
and perfect lifting devices only!
Make sure before starting maintenance and repair works
that all parts are at room temperature.
2.6 Principle Personal Protection Equipment (PPE)
For any kind of work or maintenance at the unit
change your closes before.
Use:
 Disposable single-use boiler suite
 Rubber boots
 Rubber coated textile gloves
 Eye protection
After work dispose the one time useful matters
properly and clean the other parts with fresh water
before storage.

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2 – General Safety Notes

2.7 Observe Environmental Regulations

Legal regulations for e. g. avoiding wastes have to be
taken in consideration during all works carried out at the
plant / unit
Especially during installation, repair and maintenance
works water endangering materials such as:
 Lubricants and oils
 Hydraulic oils
 Cooling media
 Acids and lyes
 Cleaning fluids
Are not to be discharged into the soil or the drain!
These substances must be collected in suitable tanks,
transported and disposed of and must be disposed
according to valid regulations!
2.8 Risk Potential of the Sewage Treatment System for Ships
The sewage treatment system has been subject to a
safety inspection and acceptance test. Faulty operation or
misuse may result in severe health risks for the user.
Additionally, the sewage treatment system and other
assets of the ship can suffer permanent damages.
All persons involved in the installation (electrical and
hydraulically) of the sewage treatment system and its
operation must be qualified accordingly (Such training can
be booked through the service department (1.5 Contact
Information)) and must pay close attention to these
installation and operating instructions.
Your safety is concerned!

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2 – General Safety Notes

2.9 Sources of Danger

Electrical voltages > 42 V. Direct contact with live
parts may cause serious injury or death. Before
working on electric equipment, interrupt the voltage
supply externally and switch (PCB Q1, Relay Q0 7.1
DANGER Control box) to 0. Any wiring at the unit only be
trained staff!
The sewage treatment system operates with a
sewage block pump. Do not touch the area of the
rotating shaft! Danger of most severe finger injuries
DANGER
The sewage treatment system operates with a blower
in nearly permanent operation. Do no touch the
housing of the cooling ribs of the motor! Danger of
burns in first or second degree
DANGER
During operation of unit if you could come in contact
with any fluid or waste use gloves and change your
clothing after. Disinfect your hands when finished
your work. Danger for your health.
DANGER

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3 – Design and Function

3 Design and Function

3.1 Common Function and Use According the Specification
The unit is designed for treatment of waste water on board
ships acc. to the IMO given specification for waste water
regarding flow and pollution load. That means it can be
used for black and grey water. Even laundry water can be
part of feed. For galley water a grease trap becomes
necessary prior the system. In order to achieve optimum
and reliable operation of the system, it must be installed
and operated according to these instructions. We do not
assume any liability for damages due to failure to comply
with these installation instructions and/ or due to improper
use.
3.2 Proper Use
The sewage treatment system for ships must only be used
for treatment of the wastewater generated aboard ship
(black and grey water).
MARPOL 73/78, Annex IV, Regulation 1 Par. 3 and the
Helsinki Convention HELCOM, Annex IV, Regulation 7, A,
No. 3 define the terms "black water" and "grey water"
(4.2 Waste Water Character).
Other wastewater than types listed above may not be
discharged into the sewage treatment system, they require
special treatment and a proper disposal ashore.
Solids such as sanitary pads, condoms, textiles, cloths,
paper, and poisonous liquids such as acid, lye, grease,
ink, lacquer, mineral oil, solvents, disinfectants etc. may
also not be discharged into the system.
Sewage water from galley has to pass a pre-treatment
with an appropriately dimensioned grease trap or
separator before discharging into the sewage treatment
system!
Never dispose of liquid waste through toilets or sinks
as these are directly connected to the sewage
treatment system. Non-observance can cause
operational or functional faults. In addition, the
installation technology (container walls, pumps) can
IMPORTANT
be damaged.

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3 – Design and Function

3.3 Component Overview

Fig. 1Component Overview

Pos. Description
7 Dosing tanks
8 Dosing pump chlorination
9 Dosing pump de-chlorination
10 Control cabinet
13 Cover – Biologic chamber – tank 1
14 Discharge pump
15 Blower
18 Screen
20 Cover – Sec. sedimentation chamber – tank2
21 Cover – Disinfection chamber – tank 3
22 Injector
23 Aeration sludge disposal
24 Name plate
Tab. 2 Component Overview

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3 – Design and Function

3.4 Identification of Type

Each unit gets an engraved name plate with following
data:
 Type
 Hydraulic load
 Serial no.
 RWO order no.
 Year of construction
 SBG approval no.
 SBG approval date
 Class (optional)
 Wheel mark
 No. of notified body
3.5 Type Tests
The unit has been type-examination tested by the
Transport Accident Prevention and Insurance
Association – Ship Safety Division (BG Verkehr –
Dienststelle Schiffssicherheit) of the Federal Republic of
Germany on 13.11.2009.
The type-test certificates according to IMO - Resolution
MEPC.159(55) and Helsinki Convention has been issued
by the BG Verkehr on 01.05.2010, EC conformity
according to the Marine Equipment Directive MED
(module B + module D) has been confirmed.
Additional National Certificates
Country Organisation
Canada Transport Canada, Marine Safety
China China Classification Society
Russia Russian Maritime Register of Shipping
Tab. 3 Additional National Certificates

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3 – Design and Function

3.6 Technical data

3.6.1 Capacity, Dimensions and Weights
Type Pers. Hydraulic Load1 Dimensions Net wght. Wet wght.
(m³/d) W x D x H (mm) (kg) (kg)
WWT LC 01 8 1,44 1290 x 1690 x 1810 718 2146
WWT LC 02 12 2,16 1450 x 1790 x 1790 788 2672
WWT LC 03 20 3,60 1550 x 2150 x 2100 1037 4387
WWT LC 04 30 5,40 1800 x 2430 x 2100 1274 6186
WWT LC 05 45 8,10 2200 x 3000 x 1950 1603 8875
WWT LC 06 60 10,80 2500 x 3100 x 2290 1846 11423
Tab. 4 Capacity, Dimension and Weights
For defining your size pls. use our experience and contact
RWO (1.5 Contact Information).

3.6.2 Electrical Data

Type Electrical Consumption Cable Cable Gland (pos. 11)2 Fuse
(440V) Input 4x max. outside ø
P (kW) I50 (A) I60 (A) (mm²) (mm) (A)

1
Pollution acc. to IMO Resolution

2
 Fig. 2 Pipe Connections
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3 – Design and Function

WWT LC 01 2.1 4.7 4.5 1.5 18 10

WWT LC 02 2.1 4.7 4.5 1.5 18 10
WWT LC 03 2.1 4.7 4.5 1.5 18 10
WWT LC 04 2.1 4.7 4.5 1.5 18 10
WWT LC 05 2.1 4.7 4.5 1.5 18 10
WWT LC 06 2.1 4.7 4.5 1.5 18 10
Tab. 5 Electrical Data
Other voltage values are possible. Comply with the
connection voltage as clearly indicated inside the given
wiring diagram and as it is stated on the label at the
control cabinet. The unit comes ready internally wired as
package. All external connections have to be arranged
acc. to the wiring diagram.

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3 – Design and Function

3.6.3 Pipe Connections

Fig. 2 Pipe Connections

Pos. Description
1.1 Sewage inlet
1.2 Hospital water inlet
2 Ventilation
3 Ventilation
4 Ventilation
5 Overboard discharge
6 Overflow
11 Electrical connections
12 Flushing water inlet – sample cock
16 Sample cock
17 Flushing water inlet – sample cock
19 Vacuum inlet
Tab. 6 Pipe Connection

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3 – Design and Function

Type

WWT LC 01

WWT LC 02

WWT LC 03

WWT LC 04

WWT LC 05

WWT LC 06
Pos.
1.1 (DN) 100 100 100 125 125 125
1.2 (DN) 80 80 80 100 100 100
2 (DN) 65 65 65 65 65 65
3 (DN) 25 25 25 25 25 25
4 (DN) 25 25 25 25 25 25
5 (DN) 25 25 25 25 25 25
6 (DN) 65 65 65 65 65 65
12 (inch) ½“ ½“ ½“ ½“ ½“ ½“
16 (inch) ½“ ½“ ½“ ½“ ½“ ½“
17 (inch) ¾“ ¾“ ¾“ ¾“ ¾“ ¾“
19 (DN) 50 50 50 50 50 50
Tab. 7 Pipe Dimensions
Carry out all pipe connections acc. to the given dimension.
Fit the piping stress less and tight to the unit.
3.7 Environmental Requirements
3.7.1 Voltage
Comply with the connection voltage as clearly indicated
inside the given wiring and as it is stated on the label at
the control cabinet. The unit comes ready internally wired
as package. All external connections have to be arranged
acc. to the wiring. The power consumption depends on
size of unit and is given inside of wiring too.
3.7.2 Feed Water
Feed water has to have the character acc. to the IMO
definition. Do not use any biocides or chemicals for
cleaning on board which aren’t biodegradable as long as
this product finally reaches the plant.
3.7.3 Connections
Carry out all pipe connections acc. to the given P&ID in
right dimension. Fit the piping stress less and tight to the
unit.
3.7.4 Cleaning Facilities
Provide a fresh water trap beside the unit and some space
for doing easy investigations of biologic status of unit

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3 – Design and Function

3.7.5 Surplus Sludge Discharge

Due to the used process biologic growth of a sludge
culture takes place inside the system. This occurs a
defined level of dry substance inside the fluid phase inside
the biologic chamber. The level has to be kept inside a
given range. So timely a part of grown sludge has to be
removed from the process by discharge. This procedure
must be done manually in accurate intervals depending on
regularly system checks.
3.7.6 Protection
The electrical protection is arranged acc. to it’s use on
board as IP 54
3.7.7 Humidity
The conditions inside the engine room on board
(tropically) will be tolerated by our unit acc. to the IMO
requirements
3.7.8 Temperature
45°C inside the engine room will be tolerated. The unit can
be operated in deck areas to as long as the system will be
kept frozen free. The feed temperature as given normally
on board is useful. If the place of installation is subject to
frost, the sewage treatment system must be completely
discharged after each operation, or the installation location
of the sewage treatment system must be permanently
heated. Prior to commissioning, the feed and discharge
lines of the sewage treatment system must be cleaned,
the residue (incl. flushing water) must be disposed of and
treated separately.
3.8 Noise Level
The unit is equipped with a blower. This aggregate is the
relevant noise emitting part of unit. So the noise pressure
level is defined as below 80 dB(A)
3.9 Vibrations
The unit is made and tested for the acceleration/vibration
load which can be expected on board acc. to the IMO
requirements.

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3 – Design and Function

3.10 Storage
Depending on unit’s size it comes in adequate packing.
Keep the unit inside as long as possible for protection. So
use a dry store and provide a horizontal area were it can
be located on a flat grounding. For lifting only use the
available lifting eyes (X). Store it horizontal in dry and
frozen free environment.

Fig. 3 Lifting Eyes

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4 – Important Terms and Definitions for Waste Water Treatment Plants

4 Important Terms and Definitions for Waste Water Treatment

Plants
4.1 Test and Certificate of Unit
Test and certification acc. to regulation by German
BG Verkehr – Dienststelle Schiffssicherheit based on IMO
MEPC.159(55)
4.2 Waste Water Character
Water characterised by MARPOL 73/78, Annex IV,
Regulation 1 Par. 3 and the Helsinki Convention
HELCOM, Annex IV, Regulation 7, A, No. 3 define the
terms "black water" and "grey water".
4.3 Black Water
Acc. to MARPOL 73/78, Annex IV, Regulation 1, Par. 3
and Helsinki - Convention, Annex IV, Regulation 7, A,
No. 3
1) Effluent and other waste of any kind from toilets,
urinals and toilet scuppers
2) Effluent of the healthcare areas (pharmacy, hospital
etc.) through the sinks, baths and scuppers situated in
that area
3) Effluent of rooms in which livestock in located
4) Other wastewater if mixed with the effluent as defined
in 1) to 3) above.
4.4 Grey Water
Acc. to MARPOL 73/78, Annex IV, Regulation 1, Par. 3
and Helsinki - Convention, Annex IV, Regulation 7, A,
No. 3
Waste water from kitchens, pantries, laundries, galleys,
baths, and showers.
4.5 Activated Sludge Process
Procedure for biological wastewater treatment in which
biomass (activated sludge) is mixed with wastewater, then
separated by sedimentation and (mostly) returned to the
process as recycled sludge. In the sewage treatment
system WWT LC, suspended foam rubber cubes in a
separated area are serving as culture holding media for
the biomass in order to stabilise and optimise the process.
4.6 Biochemical Oxygen Demand (BODn)
Volume-related mass of oxygen used up for the aerobe
biological degradation of the biochemical oxidising
contents in one litre sampling water within n days by the
metabolism of a corresponding microbiocenosis at 20°C.
E.g. n = 5 (BOD5) - oxygen consumption in 5 days in mg/l

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4 – Important Terms and Definitions for Waste Water Treatment Plants

4.7 Chemical Oxygen Demand COD

Mass of oxygen used up for the chemical oxidation of the
organic water contents with a strong oxidising agent. The
COD is given in mg/l. The COD includes the BOD.
4.8 DPD – Test Kit (Diathyl-Phenylendiamin)
Test Kit to check the residual chlorine content inside of
overboard discharge. Item No.:60BF102233
4.9 Coliform Bacteria
Enterobacteria (arising from the intestines), which are
naturally present in all mammals. Coliform bacteria are
indicators for faecal pollution of water due to any kind of
mammals (and also birds)
4.10 Escherichia Coli (E. Coli)
Bacteria type of the family of enterobacteria (faecal
bacteria), indicator for a faecal pollution of the water due
to human faeces.
4.11 Disinfection
Process to destroy pathogenic micro organisms by heat,
radiation or chemical oxidation, e.g. chlorination, UV
sterilisation.
4.12 pH – Value
The negative decade logarithm of the hydrogen ion
activities in aqueous solutions.
4.13 Sludge Volume
Volume of the sludge deposited after 30 min in relation to
1 litre wastewater, determined as sludge volume share in
ml/l. The measurement is done in a cylinder with a volume
of 1 litre and a diameter of 6 to 7 cm (refer to detailed
instruction for investigation!)
4.14 Floating Sludge
Floating sludge in the settling tank. This sludge rises due
to biological side effects which are undesired but mainly
normal. Preventing the side effects would need another
realisation of process.
4.15 Suspended Solids
Concentration of the sinking, floating and suspended
matter not dissolved in the water which can under certain
conditions be filtered and are weighed after a specified
drying process.
4.16 Dry Substance
Content of DSC (solids content, sludge content, sludge dry
matter) in the water phase of biologic chamber
characterising the available treatment potential. The dry
matter contained in a volume is given as kg/m³, g/l, mg/l.

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4 – Important Terms and Definitions for Waste Water Treatment Plants

4.17 Mohlmann Index

Given as ml/g the relation of sludge volume to dry
substance. It characterises the internal condition of sludge
culture regarding it’s sedimentation speed (which is
required as high as possible)
4.18 Surplus Sludge
Due to the biological degradation processes in the
activated sludge tank, the biomass multiplies (micro
organisms) – surplus sludge is the result. The surplus
sludge must continuously be removed.

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5 – Preparation for Operation

5 Preparation for Operation

5.1 Transport and Storage
Depending on unit’s size it comes in adequate packing.
Keep the unit inside as long as possible for protection.
Store it horizontal in dry and frozen free environment.
5.2 Unpacking
Open the transport case by removing the top side first.
After that remove the side walls. Have attention to added
parts inside the case and keep them beside the unit. For
lifting use the available lifting eyes. When necessary use a
beam for the ropes to prevent any damage of fitted
equipment.
5.3 Dispose of Packing
The material is treated with heat (56°C) for 30 min acc. to
ISPM 15 rules so it can be disposed regularly acc. to the
procedures at site
5.4 Safety Aspects Before Use
The unit has to be fasten well to the foundation. All piping
acc. to the P&ID must be arranged properly in the given
dimension and material. Fix all pipe work free of tension.
The electric connections have to be carried out acc. to the
given wiring.
5.5 Installation
The unit needs a flat area acc. to its bottom size which
shall be supported in well manner. You can weld on the
unit using the available zones for or fixing the system by
bolts acc. to the available fastening holes. The piping
should be arranged in steel (galvanised or well coated) PN
10 (16). We strongly recommend a canopy surround the
unit equipped with a drain. Further a freshwater tap near
the unit is necessary (for connection of hose in case of
cleaning). 2 sides of unit need working space of min. 800
mm width. Above the unit working space of min 500 (we
recommend 800) must be kept. Ensure good lightning and
fresh air at site. Further take care that at (or near to) the
unit easy analysis can be made.
Electric installation acc. to the wiring has to be carried out
in proper workmanship reflecting VDE by trained staff
only.
Please consider that different units are possible – so also
the wiring may change according to the made order.
Following units are possible:
Standard version – to which additional equipment may be
added:
Second discharge pump, and/or second blower, and/or
vacuum system as installation beside the unit consisting

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5 – Preparation for Operation

out of one or two vacuum pumps controlled by one/two

pressure switches.
In case a vacuum system is available it’s controlling is
integrated into the available control panel. For detailed
information regarding pump and pressure switch look into
the special chapter.
5.6 Conditions when Unit Out of Service
In case the unit is stopped for longer because of failure or
other reason dry it first. Uses the discharge pump to drain
in areas were this is allowed. After that switch of the
system and open the covers of biologic, sedimentation
and disinfection chamber. Clean the chambers with fresh
water and drain the rest water at least. Try to dry the
system by keeping it open for longer before closing the
covers again. Close all external valves (prevent any feed
into the unit) and disconnect the power line.
5.7 Location of Manual
Keep the manual beside the unit for easy access.
Fastening of important parts in foiled condition as short
booklet is recommended. Ensure that the safety data
sheets of used chemicals are directly available.

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6 – Operation

6 Operation
6.1 Description of realised process
RWO sewage treatment system for ships of the series
WWT LC operate with a mechanical pre-treatment screen,
an aerobe biological purification stage basing on the
"Moving-Bed-Bio film Reactor Technology“ (MBBR)
followed by an upward passed sedimentation (secondary
sedimentation) and a disinfectant phase. The biological
purification stage and the sedimentation are directly
connected and work as one procedural unit. The
disinfecting chamber is constantly filled according the feed
flow. Here disinfectant which is injected will kill the
relevant bacteria. The chamber is discharged in batches.
During this discharge, the remaining active chlorine in the
treated water is neutralised as well as the pH-value. The
total concept is illustrated in below:

Fig. 4 Overview of the procedural phases in biological sewage water treatment

Pos. Description
A Mechanic pre – treatment
B Biologic purification stage (biologic chamber –
tank 1)
C Sedimentation stage (sec. sedimentation
chamber – tank 2)
D Disinfection an neutralisation (disinfection
chamber – tank 3)
1 Feed of raw waste water
2 Discharge of purified waste water
3 Disinfectant
4 Neutraliser
Tab. 8 Overview of the procedural phases in biological sewage water treatment

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6 – Operation

6.2 Mechanical Pre – Treatment

The first step of a proper sewage water treatment system
is a mechanical pre-treatment by a screen. In this step, all
rough solid matters (mainly comprising of paper and
faeces) are removed from the sewage system. This solid
matter are not or only partially degraded in the system and
deteriorate the quality of the cleaned water significantly.
As they can also damage the system technology,
especially due to a tendency to clog the pumps and lines,
it is of utmost importance to remove them from the system
as early as possible. Further they would disturb the
substance exchange between the installed fest bed with
it’s bio sludge culture and the water phase. If the ship
system is equipped with a wastewater collection tank
including a chipping device (macerator / grinder pump),
make sure that the solids content per litre supplied
wastewater does not exceed 500 mg/l.
The operator of the system (crew) is responsible for
cleaning the screen. If the cleaning frequency is too
low, the risk of malfunction of system increases
(9.2.1 Cleaning the Pre-Treatment Screen). For
cleaning wear protection gloves and useful clothing.
IMPORTANT The solids can be disposed to dry waste or given to
an incinerator (if available).

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6 – Operation

6.3 Biological Purification Stage (biologic chamber - tank 1)

Wastewater on board normally contains (as municipal
ones) a multitude of different dissolved organic and
inorganic carbon compounds. These carbons are to be
considered as pollutants which must be limited and thus
removed. There are several procedures to achieve this
aim chemically (using strong oxidants) or biologically
(using micro organisms). Many micro organisms can use
this carbon dissolved in water as resource for their own
metabolism. The final product herein is mainly carbon
dioxide (CO2) and water (H2O) and new biomass
according to the carbon balance in the following (Fig. 5
Carbon balance of aerobe degradation). For this product
conversion (chem.: oxidation, combustion), the micro
organisms need oxygen which is supplied to the system
by air compressors. The venting also ensures a level of
turbulence inside of fluid phase that guaranties roughly the
same concentration of micro organisms inside the entire
reactor volume; allowing for carbon removal or conversion
in every part of the system. This process in the available
wastewater ecosystem is called biological sewage
purification.
B

A D

C
Fig. 5 Carbon balance of aerobe degradation
(acc. to Röske, 2005, modified)

A – Organic Carbon 100%

B – CO2 Production approx. 55%
C – Biomass production approx 40%
D – Residual content of the waste water approx 5%
Tab. 9 Carbon balance of aerobe degradation

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6 – Operation

To achieve the best possible and optimum cleaning

results, the micro organisms require not only a preferably
high number of organisms but also an environment in
which they can live, grow and multiply. These
environmental factors include:
 Substrate in sufficient quantities as food source, in the
form of wastewater
 Water temperature of approx. 5-35°C
 Sufficient amount of water-dissolved oxygen (0.5-2.0
mg/l), added artificially to the system by installed
blowers/compressors.
 pH-values in the range of 6 to 8.5, depending on the
wastewater quality
The micro organisms themselves are suspended or
sessile in the bioreactor. A system with both types of
organisms has some operational advantage as explained
in chapter 9.2.7. The sessile organisms are called bio film;
the suspended organisms "activated sludge". The
separation of this "sludge" from the purified wastewater
also contained therein is achieved in the secondary
sedimentation.
The procedure to clean wastewater has been copied
from nature and transferred to a technical scale.
Every water body contains this form of biomass in a
low concentration due to the limited environmental
Note conditions (low polluted load, little oxygen, low
temperatures).
6.4 Sedimentation Stage (secondary sedimentation chamber – tank 2)
In the calm flow zone of the secondary sedimentation the
biomass is separated from the purified wastewater. Due to
low flow speed and very little turbulence, the biomass
starts building up punctiform concentrations. This physical-
biological process is called flocculation – the bacteria build
clusters which have a higher density than the surrounding
water and therefore sink. Sedimentation of biomass in
opposite direction of the flow is possible if the rising speed
of the water (due to the volume of the secondary
sedimentation and the real flow volume) is lower than the
sedimentation speed of the "organism clusters". These
values can be calculated and have been taken into
account in the planning stage of the secondary
sedimentation system.

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6 – Operation

6.5 Disinfection (disinfection chamber – tank 3

The purified wastewater contains, apart from the residual
content of carbon, nitrogen and phosphor compounds,
some bacteria that are classified harmful or potentially
harmful. The indicator bacterium is called Escherichia Coli
(E.Coli); it is one of many bacteria that occurs in large
amounts in human intestines and thus gets into the
wastewater together with the faeces. Contact with water
containing these bacteria can cause severe illnesses for
mammals, in particular humans (e.g. cholera). Therefore
these bacteria must be removed from the purified
wastewater. Particularly proven for this purpose is chlorine
(can be obtained from RWO as CLF 35 liquid), which
eradicates the bacteria almost completely, in a low
concentration when sufficient contact time and proper mix
is given. Purified wastewater with a E.Coli content reduced
to a minimum (threshold) can be classified as hygienically
harmless and is even used for other purposes in
agriculture where no drink water quality is required (e.g.
irrigation of planted areas). In the disinfection chamber of
the WWT-LC, low amounts of chlorine are metered and
completely mixed due to the low air entrainment. By
effective inactivation, these bacteria are almost completely
eradicated, which can be proven by the number of E.Coli.

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6 – Operation

6.6 Neutralisation (injection into the discharge line)

As the injected chlorine liquid, due to the permanently
growing number of bacteria, must practically always be
present in a higher concentration than theoretically
required, excess chlorine can be washed out of the
system with the purified and hygienically harmless
wastewater. With adverse operation conditions, this
residual chlorine content can be so high that it can keep
reacting in the sea, thus damaging the marine ecosystem.
For this reason acc. to the IMO the residual chlorine
content must be reduced finally before leaving the
discharge line. This is achieved by feeding in a chemical
substance based on sodium hydrogen sulphide and soda
which is fed in precise doses into the discharge line of the
system during the water discharge. For well stirring the
discharge pump is used. The chemical substance has
been specifically designed for this purpose and can
exclusively be obtained from RWO as LC 35 liquid. A
chemical reaction bonds the excess chlorine which won’t
damage the marine biology anymore. In addition, the pH-
value of the purified wastewater is adjusted to a neutral
range (between 6 and 8.5).

According to the IMO regulations, the sewage

treatment system is only prescribed within the 12
miles limit. Do not put the system out of operation
outside of this zone. For growth of the bio sludge
culture a time of app. 3 weeks becomes necessary.
That means you can expect proper discharge quality
not before. It would take too much time to start this
process new when you are entering coastal waters.
Note That means, ensure that fresh wastewater feed flows
permanently into the unit. Otherwise the bacteria
content will decrease (down to 0) and the culture can
die from lack of nutrition. In that cases the function
of system isn’t available anymore
To minimise the chemical consumption it is possible
outside of restricted areas to stop the dosage of both
chemicals. When the dosing has to be started again
pls. consider that at first a disinfection of tank and
Note discharge line has to be done (see below)

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7 – Preparation for Commissioning of System

7 Preparation for Commissioning of System

7.1 Control box
In standard version, the control box is located directly at
the front side of the system. The front door of the control
box contains the following elements with these meanings:
7.1.1 Unit with PCB Control

Fig. 6 PCB Control

Pos. Description
H1 Blower operating
H2 Discharge pump operating
A2 HMI – Display / LED’s / control buttons
S3 Vacuum pump 1 hand/0/auto
S4 Vacuum pump 2 hand/0/auto
S1 Blower selection 1/2
S2 Discharge pump selection 1/2
S5 Unit hand/0/auto
Q1 Main Switch 0/1
Tab. 10 PCB Control
The display functions will be explained below in chapter
control. Pls. note that the switches for aggregates will be
available even when the option isn’t realised. In this case
both positions will activate the single aggregate which is
fitted. When the unit is ready installed and prepared for
operation switch on the power only (Q1). The display will
become active. Now choose the aggregates which shut be
duty. For operation switch S5 to auto. The unit will operate
accordingly to PCB control.

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7 – Preparation for Commissioning of System

7.1.2 Unit with Relay Control

Fig. 7 Relay Control

Pos. Description
H0 Power indication
H1 Discharge pump operating
H3 Motor failure indication
H2 Overflow indication
S1 Discharge pump hand/0/auto
Q0 Main Switch 0/1
Tab. 11 Relay Control
When the unit is ready installed and prepared for
operation switch on the power only (Q0). For operation
switch S1 to auto. The unit will operate accordingly to the
implemented relay control.

7.2 Valves
The system contains several of ball and needle valves at
the supply and discharge lines, at the bioreactor tank 1
and at the venting line of blower. In this operational
description of unit, the valves will be mentioned as labelled
in Fig. 8, Fig. 9 and Fig. 10

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7 – Preparation for Commissioning of System

Fig. 8 Arrengement of the ball valves A – D

Valve A is fitted between pump and disinfection chamber.

In normal operation this valve is open. Valve B is located
between bioreactor and pump. In normal operation, this
valve is closed. Valve C enables sample taking from the
bioreactor during normal operation. It can be used for
filling the chamber too. Valve D is the sampling valve for
the purified wastewater which is pumped overboard during
discharge phase. This water must meet the discharge
requirements of IMO MEPC.159(55). Valves C and D must
be closed during normal operation.
Valve E (Fig. 9) is foreseen for feed water sampling in
case of later analysis of feed water quality.

Fig. 9 Feed sampling valve E

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7 – Preparation for Commissioning of System

The needle valves (Fig. 10) serve for fine adjustments of

air which will be delivered to the membrane venting
elements inside of biologic tank 1 (valve F), the venting
element for the mixing of purified wastewater and chlorine
in disinfection tank 3 (valve G) and the Mammut pump for
sucking floating sludge from surface of sedimentation
chamber tank 2 (valve H). Before valve H a further air
supply line is fitted for the aeration of bubble injection
facility inside of sedimentation chamber. This valve I
(Fig. 13) has to be closed as well during normal
operation

Fig. 10 Arrangement of needle valves at the blower

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7 – Preparation for Commissioning of System

7.3 Metering Pumps for Chemical Dosing

The series WWT LC are equipped with two different
metering pumps fitted on operation front of unit. The pump
for chlorination is equipped with a calibration check facility
called P3 - in order to ensure a chlorine concentration as
precise and as low as possible for disinfection purposes.

Fig. 11 Metering pump for chlorination

Pos. Description
A Stroke length wheel
B Frequency wheel
Tab. 12 Metering pump for chlorination

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7 – Preparation for Commissioning of System

Fig. 12 Metering pump for de – chlorination

Pos. Description
A Stroke length wheel
B Frequency wheel
Tab. 13 Metering pump for de – chlorination

For handling and operation of dosing pumps refer for the

special chapter. The pumps will be activated by internal
control of unit (auto mode). Manual operation is possible
too. Pls. consider that the exact dosing volume have to be
checked weekly min. In case of manual operation the
dosed volume is not related to the process. Both pumps
are equipped with an alarm function in case the dosing
container becomes empty or an electronic failure is
available. This failure is connected to the common alarm
function of unit.
The necessary dosing rates were defined based on
our internal testing. This adjustment can be used as
start value. When the unit has developed a proper
working sludge culture (is in stable operation) this
has to be optimised. Correct the adjustment when
pump is operating only (otherwise you could damage
it). For optimising the discharge must be investigated
IMPORTANT
in a lab for Coliformes and the residual chlorine
content has to be checked (using a DPD test kit) at
site.
The dosing of chlorine takes place when the disinfection
tank is empty to ensure a sufficient contact time with
treated water during filling.

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7 – Preparation for Commissioning of System

Work involves the hazardous substance chlorine.

Personal protective equipment must be worn. At
least disposable gloves and eye protection. In case
of skin contact with chlorine, clean the spot
immediately with much water. In case of eye contact,
DANGER rinse eyes immediately with (portable) eye shower
and consult a physician!
Principally the stroke frequency of both pumps should be
adjusted to 100 % at first.
The stroke length of chlorine dosing (RWO chemical fluid
CLF35 with 12% active chlorine) should be fixed to 60%.
This adjustment should give you a dosing value 10 ml/10s
using the P3 facility. The dosing time (via relay or display)
should be fixed to:
tmin [min]=1.25 x (1/60) x V disinfection tank 3 [l]
So this means a concentration of 1.25ml chemical/l.
The dechlorination pump DMI 208-14-4 has to be
calibrated aboard ship. Pre-setting in the factory is made
as start value only. Pre-setting during commissioning also
means only a limited way because the dosing rate
depends on the dosing time and the real residual chlorine
concentration in the water (which may change during
operation). The dosing time is equal to running time of
discharge pump when it drains the disinfection tank to
overboard. This time depends mainly on the pipeline
lengths, pipe diameters and pipe layout - and these differ
from ship to ship. For dechlorination, only the product LC
35 by RWO may be used, which not only neutralises the
chlorine but in parallel also the pH-value.
Dechlorination + Neutralisation should be started with a
stroke length of 62% (RWO chemical fluid LC35 with
mixture of Sodiumbisulfite +Pentahydrate -
Na2S2O5+Na2Ca(CO3)25H2O).
This adjustment should give you a dosing value of 1.3 ml
chemical/l. Related to the available flow of discharge
pump (2.18l/s) this will mean a dosing volume of
170ml/min which is necessary. Pls. check regularly this
volume by disconnecting the discharge hose from the
injection point and dosing into a measuring cylinder.
During optimising unit’s operation later on you can try to
minimise the stroke length as long as the lab results will
give you proper values acc. to IMO regulation (100 Coli/l)
and residual chlorine (DPD) is below 0.5 mg/l. The pH
must be 6<pH<8.5
7.4 Discharge Pump
The pump is foreseen for discharge of treated wastewater
to overboard at least. For that it is connected to drain the
disinfection tank. The operation of pump is activated
automatically (auto mode) and can be operated manually
too (hand mode). Additionally this pump is used for

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7 – Preparation for Commissioning of System

discharge of surplus sludge acc. to keep it’s concentration

in the proper range of 250 – 400 ml/l. For that valve A + B
have to be switched. The discharge must be made in
Hand mode starting the pump via panel or using H/0/A
switch of pump. For construction and maintenance of
discharge pump use the special chapter.
In case of extended standstill, the shaft (or the fan) of
the discharge pump must be turned several times
slowly by hand prior to commissioning. Non-
observance bears the danger of destroying the slide
IMPORTANT ring seal.
When the pump will be commissioned first ensure that
water on suction side is available and one ball valve is
open. Then start the pump for 5 s and check the rotational
direction of its fan. The fan must rotate clockwise as
indicated by the rotational arrow mentioned on pump.
If the rotational direction must be reversed, change two
phases on the inner side of power supply terminals inside
the control panel. Use the wiring! Consider that the
rotation direction of blower will change too. If this should
be wrong change 2 phases directly to the power supply
path of single aggregate.
7.5 Blower
The fitted blower is used for the necessary Oxygen supply
to our process. That means there is installed a distribution
to:
 Membrane aerators inside the biologic chamber tank1
 Mammut pump for floated sludge recirculation from
sedimentation tank 2 to tank 1
 Membrane aerator for turbulence creation inside of
disinfection chamber tank 3
 Valve I for destroying a compact floated sludge layer
on surface of tank 2
All different streams are adjustable using the static air
supply by the blower. The blower is fitted at the unit
including an air filter for noise damping and impeller
protection. The status of filter has to be checked regularly
(every month). In case of becoming blocked it has to be
exchanged. The air supply it’s discharge pressure is
chosen according to the available unit. Don’t install any
surroundings here to ensure that the case cooling can
take place. For construction and maintenance of blower
use the special chapter.
7.6 Checking the Overboard Discharge Line
Check the overboard line for proper connection. Make
sure that internal and all external valves are open to
discharge purified wastewater:
At the unit: open valve A and close B

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7 – Preparation for Commissioning of System

Externally: check the piping at ship side, track the entire

path of the discharge line - all valves must be in flow
position for operation.
If the discharge pump of the sewage treatment
system starts while a valve is closed, both motor and
pump can be damaged or destroyed.

IMPORTANT
7.7 Checking the Feed Lines
Ensure the wastewater feed flow into the system. Trace
the path of feed line, if possible. Open the valves at the
unit and externally according to the instructions given in
7.2 Valves.
7.8 First Filling the Unit
Fill the system completely with fresh water. For that
arrange a hose connection to valve C and/or E. Open the
valve and fill up the unit until you’ll see an increasing water
level inside the disinfection tank (transparent cover). Fill
up further until app. 50% filling level inside of tank 3 is
achieved. Stop the filling and disconnect the hose again.
Deaerate the discharge pump (the screw for it is located at
the pressure side of the pump)
Depending on the available fresh water pressure, the
line diameter and unit’s size (reactor vessel volume),
filling the system completely with freshwater can
Note take some hours.

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8 – Starting the System

8 Starting the System

As soon as the system is being filled with water or
wastewater, the unit should be switched into auto mode.
Observe the following steps:
1) Set power switch (PCB Q1, relay Q0) to 1
2) Set hand/auto selector (PCB S5; relay S1) to auto
Make sure that hand/auto selector (PCB pos. 8; relay
pos. 5) always is in position "A" during operation –
else the discharge pump will not start and the system
will overflow.
IMPORTANT

The running-in period of the system last about two to

four weeks under normal operation conditions.
Inoculation of the system with active biomass in form
Note of "activated sludge" reduces the running-in period
significantly even with small amounts. Activated
sludge can be obtained from municipal sewage
treatment system – in small amounts usually free of
charge.
8.1 Adjusting the Metering Pumps
Turn the frequency and stroke length wheels only
during operation of the respective metering pumps
because else there is danger of the pumps being
destroyed.
IMPORTANT

8.1.1 Chlorination
The dosing pump will operate automatically. So no further
activity is necessary when the ones mentioned in chapter
7 are finished. As the adjusted values can vary in either
direction in real operation the adjustment should be
controlled acc. to the appropriate working conditions. For
that the available P3 device should be used. Always
consider the special chapter of pump DMI 208-6.0,P3
when acting with or on the pump.
Check of proper dosing rate is only possible in connection
with a lab analysis. If this is available within 6 hours take a
100 ml sample at valve D into a sterilised glass bottle
(best from lab) and store it cool until investigation.
Depending on the result of lab you can keep (when the
values are properly = < 100 Coliformes/l) or change the
value for stroke length of pump. When this is desired, set
stroke length wheel to high/lower percentage while the
pump is dosing; keep the dosing frequency. Increase the
stoke length by 10% during operation of pump and repeat
the analysis by the lab as long as the value becomes
properly.

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8 – Starting the System

Consider that the content of active free chlorine

inside of CLF35 strongly depends on storage time,
light and temperature. Store the liquid cool and dark
as possible and try to use fresh ones only.
IMPORTANT

8.1.2 Dechlorination
The dosing pump will operate automatically. So no further
activity is necessary when the ones mentioned in chapter
7 are finished. As the adjusted values can vary in either
direction in real operation the adjustment should be
controlled acc. to the appropriate working conditions.
Always consider the special chapter of pump DMI 208-14-
4 when acting with or on the pump.
To readjust the dechlorination amount with LC 35 in
operation, proceed as follows:
Take a discharge sample through valve D and determine
the residual chlorine content by means of the DPD
procedure (see description of test kit).
If the residual chlorine content is <0.5 mg/l, keep the
settings
If the residual chlorine content is >= 0.5 mg/l, check if the
dechlorination pump operates properly during the whole
discharge process. When this is the case, set stroke
length wheel to high/lower percentage while the pump is
dosing; keep the dosing frequency. Increase the stoke
length by 10% during operation of pump and repeat the
measurement of the residual chlorine measurement. Once
a residual chlorine content of <0.5 mg/l has been reached,
keep the new adjustment, otherwise repeat changing +
check.
For check of pump’s proper dosing rate (because there
isn’t a device for check at the pump) act as follows:
Disconnect the discharge dosing hose from injection
point. During the next discharge process, fill the dosing
connection into a measuring cylinder with scale (volume at
least 300 ml) and measure total dose per 1 minute of
discharge. Compare the result with the needed 170ml/min.
Install the dosing hose connection again onto the injection
point.
8.2 Air Supply Adjustment
8.2.1 Air Supply to Biology
Open valve F fully for max. air supply. Later on when the
system is in stable operation you may check the oxygen
content inside of biologic chamber (a measurement would
be needed) and adjust it in a manner that a min content 1
mgO2/l is always available (even in feed phases!). If it
should be too high you should throttle valve F a bit.

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8 – Starting the System

8.2.2 Air for Disinfection Turbulence

Fully close needle valve G at first. When at the end of
unit’s filling the 50% level inside of disinfection is available
slowly start to open it until a slight movement on fluids
surface becomes visible through the transparent cover.
Try to minimise the air entry as much as possible but
ensure movement inside of fluid.
8.2.3 Air Supply to Mammut Pump for Floated Sludge Return
Fully open needle valve H at first. Later on, when the unit
is stable operating, open the cover of sedimentation
chamber tank2 and check the operation of fitted suction
device on chambers filling surface. You can reduce the
sucking by throttling at Valve H the air supply.

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9 – Operation of the System

9 Operation of the System

9.1 Operation log (OL)
For proper operation of the system WWT LC, an operation
log must be kept. Any routine works performed,
maintenance measures and operational results as well as
special occurrences and any changes have to be entered
in this log. This enables the operational staff and the
specialists to trace any system nonconformity.
Upon delivery of the sewage treatment system by the
manufacturer RWO GmbH, a first issue of the operation
log is handed over (see appendix).
A wastewater purification system is highly sensitive.
Even smallest nonconformities can impair the
cleaning functions of the system. Therefore it is of
utmost importance to enter any action and setting
into the OL. By means of these records – if entered
continuously - the service technicians of RWO GmbH
IMPORTANT
can react quickly and remedy the operational
problems of your system.
9.2 Daily Routines
The system must be checked and monitored daily for
proper function. The daily standard routine tasks are listed
and explained below:
9.2.1 Cleaning the Pre-Treatment Screen
Check the pre-treatment screen at least 2 x per day at first
(this number must be optimised depending on real solid
freight in your sewage). For that loose the 4 wing screws.
Pull out the screen carefully of the hopper and empty it
completely into a designated waste bin. For that lift up the
pulling side a bit (if not the take out is limited by a stopper
at least). If required, remove the available pollution from
the screen (by flushing with water if necessary). After
cleaning, insert the screen into the hopper again and
fasten it with the wing screws.
9.2.2 Entire Sewage Treatment System
Check that the unit is in proper operation and that power
supply is ensured (light/LED indication) ones a day. Check
that display at control panel works well and the related
process steps were carried out. Check that filling
indication of disinfection is properly.
9.2.3 Blower
Check that the blower works well and permanently ones a
day. Check the aggregate for any abnormal running
sounds and temperature in discharge area. If there should
be any fact, notice it in the OL.

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9 – Operation of the System

9.2.4 Discharge Pump

Check operation of discharge pump (in auto mode) when
process step will be proceeded ones a day. Consider that
the pump does not run continuously – for test and
maintenance purposes the pump can be checked in
manual mode + using the foreseen switch for the single
aggregate. Turn hand/auto selector (PCB S5, Relay S1) to
hand – pump has to operate as long as the disinfection
tank is filled. Check the proper discharge time of
disinfection tank to check pump’s function. Look for any
leakage and abnormally sound. Enter any matters into the
OL.
9.2.5 Disinfectant and Neutralisation Agent
Pay attention to the labels of the metering containers
and the refill tank of the chemicals. Fill the chemicals
only into the designated tanks. Never let the two
chemicals get in contact with each other - danger of
DANGER chemical burns
Check the filling level of the CLF35 - chlorination metering
tank and refill, if necessary.
Check the filling level of the LC 35 – dechlorination
metering tank and refill, if necessary.
Check the dosing rate of both pumps ones a day and keep
clean the pumps.
9.2.6 Sludge Volume Inside of Biologic Tank 1
Measure the sludge volume in tank 1 twice a day (for
information refer to the special instructions on sampling
and measurement). For that take a sample (at least 1 litre)
through valve C. Fill the sample into a measuring cylinder
– volume 1 litre. After 30 minutes read the sludge volume
on the scale of the cylinder. (e.g. 250 ml/l). Enter the value
in the OL.
9.2.7 Removal of Surplus Sludge
Surplus sludge has to be handled like untreated
wastewater. It may only be pumped overboard
outside of the 12-mile limit or if covered by other
legal regulations. Within the 12 miles limit, the
surplus sludge must be stored and/or disposed of
IMPORTANT ashore. Respect different rules acc. to any other local
regulations – special areas (Baltic Sea)
If the sludge volume ( 7.4 Discharge Pump) reaches a
value higher than 400 ml, the sludge must be removed
from the system because the settlement inside of
sedimentation tank 2 will be disturbed more and more. So
the risk of sludge being flushed out to the disinfection
tank3 together with the treated wastewater is increasing.
This will cause that the discharge quality deteriorates
significantly. That’s why act ones a day as follows:

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9 – Operation of the System

When you had notice high sludge content during

measuring the sludge volume in tank 1 close valve A and
open valve B.
1) Set hand/auto selector (PCB S1; Relay S5) to hand
(and hold it). The blower can be operated continuously
or stopped during this phase, but the regime should be
kept in same manner always (because the efficiency
of sludge reducing is different).
2) Pump sludge/water from biology for a defined time
(start with 2 minutes) overboard
3) Refill the unit with freshwater up to its construction
water line (when the disinfection tank filling starts).
Consider that this procedure may be carried out in
different manner using the opportunities of the HMI if
available.
After app. 5 minutes take another sample from the biology
and repeat the sludge volume measuring. Compare the
result with your primary one. So in short time you’ll get
experience how long you have to discharge the sludge for
a desired reducing of sludge content by verifying the
discharge time. We recommend to create a list with
different times for easy acting later.
Consider that the volume measurement gives proper
results only to a max. content of 250 ml sludge/l.
When it is higher you have to dilute the sample (start
with 50% freshwater – unit’s effluent is possible too).
After dilution mix the fluid/sludge shortly a carry out
the settlement. If the content still should be higher
IMPORTANT than 250 ml/l you have to take a new sample from the
biology and to dilute it further (100%). Repeat the
procedure ones again.

The surplus sludge removal can also be performed at

a sludge volume below 400 ml if required by
operational processes. Make sure, however, that the
Note system contains at least 200 ml sludge volume while
within the 12 miles limit - else it might not be
possible to adhere to the effluent values according to
IMO Resolution MEPC.159 (55).
When finished the sludge reducing set back the valve
positions to their normal operation positions and keep the
unit in its normal operation.
9.2.8 Check of Effluent Quality
There are only pure opportunities without any proper
analysis instruments. We recommend taking a sample
from valve D into a cleared white glass bottle ones a day.
Now:
1) Check the turbidity – it should be low, notice it inside
of OL
2) Check the colour – it should be colour less up to

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9 – Operation of the System

slightly yellow, notice it inside of OL

3) Check the smell – slightly acc. to humus is well, notice
it inside of OL
4) Check the pH-value of the purified wastewater by
means a pH using a mobile pH electrode
measurement (or litmus paper) – 6.5<pH<8 should be
the aim (if not readjust the dechlorination dosing
pump)l, notice the pH value in the OL.
5) Check the residual chlorine content using a DPD test
kit – free Chlorine content has to be < 0.5mg/l. (if not
readjust the chlorination dosing pump). Enter the
residual chlorine content in the OL.
The test kit isn’t part of standard scope of supply but can
be obtained from the RWO GmbH, Item No.: 60BF102233
For further investigations to check the IMO regulated
values, BOD/COD analysers, evaporation device
(suspended solids) and lab facilities (Coliformes) become
necessary (which aren’t on board normally). But when the
effluent characteristics above are well, you’ll have a high
probability to meet the IMO values.
The fest bed fixed in tank 1 for being occupied by bio
culture, consisting of foam rubber with depth-effect
and takes up sludge. After a complete discharge of
Note the tank for any reason, the cubes including the
sludge deposits remain inside the system. By filling
up with fresh water directly after, a large amount of
the sludge dissolves in the fresh water which causes
a rapid restart of the system. Flushing is not required
(and helpful) in this case.
9.2.9 Floating Sludge Return
For removing floating sludge from surface of
sedimentation tank 2 a drain funnel/skim facility is fitted
here. Check that it is working properly and free sucking by
looking into the chamber (through transparent cover) twice
a day. If necessary, open the cover and clean manually
the facility and readjust the air supply to Mammut pump
using needle valve H.
Beside needle valve H a solenoid is fitted. This
enables to interrupt the floated sludge return when
control panel is equipped with a display. Otherwise
Note the pump works continuously together with the
blower

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9 – Operation of the System

9.2.10 Cleaning the Bevelled Cover Zone of Tank 2

To remove floated sludge from this zone (were it will be
kept and grow below the cover plate open valve I twice a
day at the front side of unit for approx. 5 seconds (Fig.
13). The supplied air from blower flows into the bubble
tube located in the chamber – this drives floated sludge
sitting below the bevel towards the open surface were it
can be removed by the fitted floating sludge drain facility.

Fig. 13 Valve I at the bevelled cover zone of secondary sedimentation chamber (tank 2)

This facility contains out of a skimming gutter which is

connected to the Mammut pump. The gutter is fitted in a
defined height so that in horizontal position of unit no flow
will pass into. Only when the air initiated (open valve I)
wave comes up to the free zone of chamber an amount of
floated sludge will be flushed into the gutter. Don’t repeat
this procedure more often because it disturbs the
sedimentation (main function!) inside the chamber.
9.3 Weekly Routines
9.3.1 Metering Pumps
 Check the metering pumps for proper function and
adjustment
The metering pumps do not run continuously: The
chlorination dosing pump only runs after the
disinfectant tank 3 has been discharged; the
Note dechlorination dosing pump only operates during
treated water discharge to overboard.
9.4 9.4 Monthly routines
9.4.1 9.4.1 Inspection of tanks 2, and 3
Check the chambers 2, and 3 at least monthly, after
removing the surplus sludge and discharging the
disinfection, for residue, hair tresses, clogging, deposits,
etc., and remove those. During these inspections, no

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9 – Operation of the System

wastewater may enter the system. Therefore close the

entry valve A for time of acting.
Therefore remove the transparent covers of both tanks
and
1) check status of dived collecting pipe in the
sedimentation chamber (clean it if necessary)
2) when necessary clean the tank walls above water
surface
3) clean the walls of disinfection chamber tank 3 and the
inside fitted level sensor
Close again the covers and put back the unit into
operation.
 9.4.2 Measuring the wastewater quality parameters
If possible, a lab analysis of effluent discharge quality
should be made for the following parameters:
 CSB
 BSB-5
 Suspended solids
During the discharge process, take a sample of at least 1
litre through valve D into a clean bottle
Cool sample at 4 °C, analyse for Coliformes in a lab as
soon as possible
Enter the analysis results in the OL
The complete water analysis requires not only
knowledge and experience but also some laboratory
equipment which is very expensive and cannot be
Note used in a practical way aboard ships. It is more
feasible to commission a laboratory. Wastewater
analyses can be done very cost-efficiently in almost
any municipal sewage treatment plant.

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10 – Maintenance

10 Maintenance
For proper operation of the sewage treatment system
WWT LC, maintenance is of utmost importance.
General requirements for good and stable cleaning results
are:
 Proper installation of the system
 Regular checks of condition and functions by the
operating staff
 Optimising the unit’s operation if required by operating
staff or a specialised company
 Monitoring the system's operation by the operating
staff
10.1 Danger Warnings
Poison and explosion hazard!
The sewage treatment system operates using micro
organisms that degrade parts of the wastewater
under oxygen depletion into hydrogen (H2), nitrate
(NO3) and carbon dioxide (CO2) or transform them
into biomass. In oxygen-free (anaerobe) zones of the
sewage treatment system, the harmful gases
hydrogen sulphide (H2S), ammonia gas (NH3),
carbon dioxide (CO2) and methane (CH4) can be
DANGER produced. Smoking is forbidden near the system
during maintenance works!
Hydrogen sulphide is highly toxic and causes
vertigo, nausea, unconsciousness and apnoea.
During maintenance works at the sewage treatment
system, the valid regulations for the prevention of
accidents must be observed!
If the power supply is interrupted, by switching the
main switch (PCB Q1, Relay Q0) to 0 or by
interrupting the automatic operation of the sewage
Note treatment system, normal operation is not possible
any more. When the unit is kept full in this status
fouling will take place, which will occur that the
biologic culture dies within 4 hours and H2S
formation takes place
For all routine and maintenance works at the tanks 1-
3 the wastewater feed to the system must be cut off.
The wastewater accrued during the maintenance
Note works must be discharged overboard, to a take-over
station ashore or into a designated tank if possible
and feasible!

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10 – Maintenance

10.2 Blower
Electrical voltages > 42 V. Direct contact with live
parts may cause serious injury or death. Before
working on electric equipment, interrupt the voltage
supply (main switch off, or min. switch off the single
DANGER aggregate).
During maintenance works at the blower set the main
switch (PCB Q1, Relay Q0) to 0 - the blower stops and the
aggregate can be dismounted and disassembled for
maintenance.
For detailed information take note of the blower instruction
manual in the appendix.
When finished the maintenance set back the main switch
(PCB Q1, Relay Q0) to 1.
For replacing the air filter at the blower housing remove
the screws at the cap of connection on suction side of
blower. Replace the used filter cartridge by a new one and
remount the cap of connection.
10.3 Discharge Pump
Electrical voltages > 42 V. Direct contact with live
parts may cause serious injury or death. Before
working on electric equipment, interrupt the voltage
supply (power switch off, or min. switch off the single
DANGER aggregate).
For maintenance works at the discharge pump switch of
fuse F2. The discharge pump will not start now. The
blower remains in operation.
 Shut the wastewater feed off, close feed valves if
necessary.
 Close valve A and valve B completely
For detailed maintenance operation of pump take note of
discharge pump instruction manual in the appendix. When
finished the maintenance close fuse F2.
 Open valve A – valve B must remain closed in normal
operation
 Deaerate the discharge pump after concluding the
maintenance works. The screw for it is located at the
pressure socket of pump.

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10 – Maintenance

10.4 Metering Pumps for Chlorination and Dechlorination/Neutralizing

Electrical voltages > 42 V. Direct contact with live
parts may cause serious injury or death. Before
working on electric equipment, interrupt the voltage
supply (power switch off, or min. switch off the single
DANGER aggregate).

During maintenance works at the metering pumps,

the purified wastewater is neither disinfected nor
dechlorinated.
Note
 when works become necessary and the pumps
shouldn’t dose during this time set the main switch
(PCB Q1, Relay Q0) to 0 – no operation of whole unit
and remove the power supply connection inside of
control panel
 put back the main switch (PCB Q1, Relay Q0) to 1
 perform maintenance work according to special
chapter of dosing pumps
 remount and reconnect the pump to power supply –
test for proper function if necessary
10.5 Membrane Diffuser
10.5.1 WWT LC 01

Fig. 14 Diffuser WWT LC 01

Pos. Description
1 Support tube PP with air grove
2 Membrane
3 Clamp
4 Seal
5 Connector
6 Diffuser
7 Flood room
8 Connecting thread ¾” in drilled hole Ø45mm
Tab. 14 Diffuser WWT LC 01

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10 – Maintenance

Assembly: To assemble the membrane diffuser, assemble

a diffuser and a connector, insert them into the drilled hole
of the distributor line and fasten by screwing to the blind
plug. The tightening torque must be at least 45 Nm. Use
clamping tongs during the assembly. The assembly is
correct if the diffuser grooves point towards the tank floor
(on a clock scale = between 5°° and 7°° o'clock). If the
torque is achieved before reaching this position, keep
screwing until the correct position of the groove has been
reached. If the seal is squeezed irregularly, replace it and
repeat the tightening process. Do not apply lubricant onto
the sealing surfaces!
10.5.2 WWT LC 02 or Higher

Fig. 15 Diffuser WWT LC 02 or higher

Pos. Description
1 Support tube PP with air grove
2 Membrane
3 Flood room
4 Diffuser
5 Fastening latch
6 Air tube
Tab. 15 Diffuser WWT LC 02 or higher

Assembly: The membrane diffuser is swivelled into the

drilled hole with the fastening latch and tightened with a
torque of 27 Nm. The tightening torque of 27 Nm must be
observed! Assembly using a cordless screwdriver is only
possible if the maximum speed is at 60 rpm.

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10 – Maintenance

10.6 New Start of Unit after Brake down of Treating Function

When the unit’s function isn’t given anymore because the
discharge is very bad and you are not able to recover the
operation check the sludge for its colour, sedimentation
and smell. If this isn’t properly anymore best would be to
investigate it by microscopic view. But this needs special
equipment and knowledge. So mainly the other
characteristics have to be sufficient.
When you are in mind that the bio culture is damaged (for
any reason) you should act as follows:
Drain the whole unit using the discharge pump in Hand
mode and stop it.
Open all covers tank 1-3 and clean the system’s walls and
bottom using a freshwater hose. Only clean very slightly
the fitted fest bed inside. The residual culture inside will
fasten the re-establishment of a proper culture later on.
Drain the flushing water too.
Close all covers and refill the unit with freshwater up to its
construction water line.
Start the system again. Naturally it will take time to re-
establish its function, but it will go much faster than for the
first time.

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11 – Troubleshooting

11 Troubleshooting
Some malfunctions can occur during operation. The most common and best known
operational problems are listed in the table below

Malfunction Possible cause Remedy

No wastewater Feed line valve(s) closed Open the valve(s)

reaches the
Pre-treatment screen of unit is Clean the screen
system
clogged
Pre-treatment Fibres, hairs or grease inside of Remove the layer (using a high
screen clogged feed pressure device, if necessary)
Foam in tank 1 Tensides and cleaning agents Reduce use of cleaning agents
Biological malfunctions during the Wait until running-in phase is
running-in phase finished
Biological disturbances during Discharge tank 1 completely and
permanent operation fill up with fresh water
Putrid smell in blower out of operation / defective Start / check the blower
tank 1 Valve F closed Open valve F completely
Black sludge Discharge tank 1 and 2
completely and fill up with fresh
water
Floating sludge in Biological side reactions Remove surplus sludge more
tank 2 often
Clogging in the passage between Open tank 2 cover and flush the
tank 1 and tank 2 connection at the bottom to tank
1using a freshwater hose for a
short time
Display "Overflow Too much wastewater feed Only feed the max. amount of
Alarm" at the wastewater acc. to type plate
control cabinet
Level indication in tank 3 Check level indicator, recalibrate,
defective repair or replace it if necessary, at
the same time discharge and
clean disinfection tank 3
Maximum pumping head of the Check the pump and discharge
discharge pump exceeded or line
discharge line is clogged
Motor protection Motor burnt out Replace motor
switch of
Short circuit in supply line or Check motor and supply line
discharge pump
motor
triggers
Motor circuit breaker set too low Readjust motor protection
according to the motor value on
it’s type plate

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11 – Troubleshooting

Malfunction Possible cause Remedy

Motor protection Motor burnt out Replace motor

switch of blower
Shortcut in supply line or motor Check motor and supply line
triggers
Motor circuit breaker set too low Readjust motor protection
according to the motor value on
it’s type plate
Excessive heat due to insufficient Ensure sufficient venting, max.
venting at the installation location ambient temperature + 45°C
of the sewage treatment system (water temperature normally isn’t
a problem because of sufficient
mixture from many sources of
discharging tubes)
Blower failed Malfunction in the control cabinet Check the PCB inside of control
panel or the status of program
Mechanical defect Check the blower acc. to it’s
manual
Discharge pump Malfunction in the control cabinet Check the PCB inside of control
doesn’t work panel or the status of program
properly
Mechanical defect Check the pump acc. to it’s
manual
Discharge pump Level indicator inside the Repair or replace the level
doesn’t start/stop disinfection tank 3 is defective indication, at the same time clean
in automatic mode tank 3
Not enough air Air filter of blower soiled Clean air filter by blowing out or
escapes at the replace complete air filter
water surface on cartridge
tank 1 despite Shutoff device valve F closed Open valve F completely
blower is in
partially or completely
operation (only
visible when cover
tank1 was
removed)
Air escapes in big Defective membrane at the Replace the defective membrane
bubbles at the membrane diffusers or loosened diffuser
water surface in connection between diffuser and Retighten the connection
tank 1(only visible air tube of membrane aerator
when cover tank1
was removed)

RWO GmbH ● Marine Water Technology ● Bremen ● Germany issue 10.08.2010

Installation, Operation and Maintenance Manual Sewage Treatment System WWT LC 1. print run page 58
11 – Troubleshooting

Malfunction Possible cause Remedy

Visible solids in Too much wastewater is fed in Ensure the max. allowed feed to
the unit’s effluent and flushes the suspended solids the unit acc. to type plate
discharge into the discharge
Sludge volume in the tank 1 Remove surplus sludge
exceeds 400 ml/l
bad floating sludge return Open tank 2 check the function,
Mammut pump doesn’t work clean the sucking devise; readjust
air supply to Mammut pump or
clean the pump
Failure indication Dosing tank empty Refill the dosing tank
from dosing pump
Suction lance clogged Clean the lance
(at the pump/via
display) Pump’s check ball valves clogged Clean the check ball valves
(Notice the dosing pump
instruction manual in the
appendix)
Pump’s membrane broken Check/replace the membrane
(Notice the dosing pump
instruction manual in the
appendix)
Electronic failure Replace the pump

RWO GmbH ● Marine Water Technology ● Bremen ● Germany issue 10.08.2010