Hamworthy Super Trident ST6A
生化污水处理装置，IMO MEPC.2(VI)
The Hamworthy Super Trident ST6A treats ship sewage by aerobic digestion before overboard discharge. The tank has three compartments: aeration (air from a rotary compressor through ceramic diffusers feeds the bacteria), settling (activated sludge settles and is returned by air-lifts, a skimmer removes scum) and chlorine contact (effluent flows through a tablet chlorinator and is discharged by a close-coupled pump controlled by float switches). Designed for 9.36 m³ per day and 6 kg BOD per day, approved to IMO MEPC.2(VI) and MED. The manual covers technical data, peak loading, installation and venting, commissioning, chlorine residual testing, desludging (overboard or to the incinerator), weekly to annual maintenance, diffuser replacement, troubleshooting and the discharge pump and blower spares.
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保养规程
Commissioning the unit
- Open all air line valves except the standby compressor delivery; start the duty compressor and check rotation by hand over the inlet (suction = correct). 第 50 页
- Close the compressor discharge to check the relief valve lifts and reseats; repeat on the standby compressor. 第 50 页
- Part fill with water to cover the diffusers and confirm air at each diffuser; select AUTO and No. 1 duty discharge pump. 第 50 页
- Close hatches and valves 1, 3, 4, 6; open 2 and 5 and fill with clean sea or fresh water until it flows over the skimmer and through the chlorinator. 第 50 页
- Set the sludge return air-lift as high as possible without the liquor turning clear; set the skimmer air-lift to the minimum reliable flow. 第 50 页
- Prime the discharge pumps, check rotation and float switch operation in AUTO, check no water is pumped from the syphon vent. 第 50 页
- Fill chlorinator tubes in restricted waters (about 2.5 kg per tube); check aeration tank air pressure is not over 15 mm H2O. 第 50 页
- Allow 14 days for the biology to condition before judging effluent quality. 第 56 页
Testing chlorine residual (DPD)
- Fill the middle and right-hand comparator chambers with effluent up to the line. 第 51 页
- Add a DPD No. 4 tablet to the right-hand chamber and crush it with the stirrer. 第 51 页
- Compare colours: aim for 4–6 ppm; above 6 ppm use one tablet tube only; consistently below 1 ppm check tablets and grey water load. 第 51 页
Monthly partial desludging
- Only outside controlled waters or to a shore facility: close raw sewage and waste water inlets and open the overboard by-pass. 第 57 页
- Set the discharge pump switch OFF, close valve 3, open valve 2 and run the duty pump in HAND. 第 57 页
- Discharge about 50 % of the aeration tank, then check the screen and remove scum from the settling tank. 第 57 页
- Refill with clean water, reset valves for normal running and switch the pumps back to AUTO. 第 57 页
Draining and cleaning the unit
- Never leave the tank full of sewage with the compressors stopped; never enter it unless cleaned, ventilated with all covers off, or with breathing apparatus. 第 58 页Toxic gas risk inside the tank
- Close inlets, pump switch OFF, close valves 1, 2, 5, open 3, 4, 6 and pump out the chlorine contact tank in HAND. 第 58 页
- Close 3, open 2 and empty the aeration compartment; then open 1 and empty the settling tank. 第 58 页
- Refill through valve 5 without over-pressurising; super-chlorinate and circulate if a recirculation line is fitted, then pump out. 第 58 页
- Recoat damaged areas with coal tar epoxy, renew cover joints and clean the filter. 第 58 页
Replacing air diffuser elements
- Replace yearly or when the air gauge rises 0.2 bar above commissioning pressure or the relief valve blows. 第 59 页
- With the tank empty, open the side manhole, undo the union and lift out the diffuser assembly. 第 59 页
- Remove wingnut and washer, fit the new ceramic element with rubber washers at both ends, do not overtighten. 第 59 页
- Refit with the spigot located in the bottom bracket and close the manhole. 第 59 页
Discharge pump: impeller shimming and seal
- Isolate the motor, close suction and delivery valves and remove the casing drain plug. 第 67 页
- Withdraw motor and pump, unlock the tab washer, remove impeller screw and pull the impeller with two jacking screws. 第 67 页
- With a new peel-off shim fitted, measure the clearance behind the impeller; remove laminations to get 0.457 ± 0.076 mm. 第 68 页
- Fit the mechanical seal using soft soap and water as lubricant, refit impeller and lock the screw with the tab washer within 15 minutes. 第 69 页
- Fit a new casing O-ring and bolt the inner cover to the casing. 第 69 页
保养周期
| 项目 | 周期 | 操作 | 说明书 |
|---|---|---|---|
| Chlorinator | Weekly (in controlled waters) | Refill tablet tubes, never below ¼ full; test chlorine residual | 第 57 页 |
| Sludge return and screen | Weekly | Check air pressure gauge and sludge return through the transparent pipe; clear the coarse screen | 第 57 页 |
| Air compressors | Monthly | Change over duty and standby compressor | 第 57 页 |
| Aeration compartment | Monthly | 30-minute settling test in a 100 ml cylinder; above 60 ml settled sludge, desludge about 50 % | 第 57 页 |
| Compressor filter cartridges | 6 months | Inspect and replace if dirty; check the air line non-return valve | 第 57 页 |
| Whole unit | Annually | Drain and clean all compartments, repair coating, inspect pumps and blowers, replace air diffuser elements | 第 57 页 |
| Discharge pump seals | Yearly / 8000 h inspect, 4 years / 20000 h replace | Inspect and replace O-rings and mechanical seal; inspect casing and impeller key | 第 70 页 |
故障及处理方法
Tank overflow / high level alarmDischarge pump failure, pipe blockage or excessive inflow (leaking WC flush valves)Bad smell from the unitAnaerobic tank: compressor, air-lifts or diffusers not working, or too much sludgePoor effluent qualityLack of oxygen, killed bacteria by disinfectant cleaners, sludge not returning, too much flushing waterScum on the settling tankSkimmer or air-lifts not workingFoaming in the aeration tank and ventToo much cleaning agentDischarge pump gives no flowClosed valves, blocked suction, air leaks or loops in suction pipeReduced or irregular pump dischargeChoked impeller, valve or non-return valve partly closedAir gauge 0.2 bar above normal / relief valve blowingClogged diffuser elements or dirty filters
技术参数
| Design hydraulic load | 9.36 m³/day | 第 10 页 |
|---|---|---|
| Design organic load | 6.0 kg BOD/day | 第 10 页 |
| Power supply | 440 V, 3 phase, 60 Hz; control 220 V AC | 第 30 页 |
| Discharge pump | B50x50 close-coupled, high head, 8 m³/h at 25 m, 5.7 kW, 3480 rpm (60 Hz) | 第 30 页 |
| Aeration compressor | Rietschle DLT 40 rotary, 0.5 bar, 41 m³/h, 1.50/1.80 kW (50/60 Hz) | 第 30 页 |
| Vent system back pressure | 15 mm w.g. maximum | 第 30 页 |
| Max roll or pitch | 15° either side | 第 38 页 |
| Ambient conditions | 0–45 °C, up to 95 % RH | 第 30 页 |
| Chlorine residual target | 4–6 ppm (below 1 ppm: not enough disinfection) | 第 51 页 |
| Chlorine tablet use | about 2 g per person per day; 2.5 kg fills one tube | 第 51 页 |
| Daily desludge to incinerator | 135 l (ST6A) | 第 52 页 |
| Pump impeller clearance | 0.457 ± 0.076 mm (shim laminations 0.076 mm) | 第 68 页 |
| Pump tightening torques | impeller screw 3.0 kg·m, stud and nut 5.0 kg·m, bolt and nut 3.0 kg·m | 第 62 页 |
备件与目录号
| 零件 | 编号 | 数量 | 说明书 |
|---|---|---|---|
| Blower spares kit (Rietschle DLT 40) | 49950559 | 1 | 第 22 页 |
| Blower carbon blade | 6 | 第 22 页 | |
| Blower filter cartridge, paper | 1 | 第 22 页 | |
| Blower filter cartridge, metal | 1 | 第 22 页 | |
| Discharge pump spares kit | 73478448 | 1 | 第 27 页 |
| Pump motor spares kit (bearings 6307 2Z / 6206 2Z) | 73478042 | 1 | 第 25 页 |
| Mechanical seal (rotating + stationary) | 42619072 | 1 | 第 27 页 |
| Impeller screw, tab washer, peel-off shim, O-rings | 1 set | 第 26 页 | |
| DPD No. 4 test tablets | T9201005 | 50 | 第 51 页 |
| Control panel spares: contactor, auxiliary contact, lamp, 5 A and 2 A fuses | 1 set | 第 28 页 |
来源：制造商说明书《Sewage treatment plant manual》，共 99 页。页码以原文为准。作业前请核对船上的说明书。
本页为自动翻译。零件号、代码和页码与原文一致。