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12MXMP Custom Unit

Marine Sanitation DeviceOperation & Maintenance Manual

PETRONAS

Purchase Order No.: PO/023/06/07/SE/TRD

Serial No.: 07-12MXMP-D012602

STDN Part No.: A210533PKS264

Date: October 2007

1110 Indust rial Boulevard Sugar Land, Texas 77478Telephone: 281-240-6770 Fax: 281-240-6762

http://www.severntrentdenora.com/Revision 05.4 OMSTD/Current


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Preface

Preface

Construction of this Operations and Maintenance Manual

In an effort to provide a concise and informative equipment manual, Severn Trent De

Nora (STDN) has adopted the format of this particular Operations Manual based on its

past years of historical and field related experience in relation to the Omnipure Marine

Sanitation Device. Through a careful review of various customer maintenance

requirements and useful field service knowledge, this operations manual has become a

controlled standard per our ISO and Quality Assurance policies, and covers the entire

Omnipure product line.

This manual is intended to be used with the newer PLC (programmable logic controller)

controlled auto-maintenance unit. This manual addresses the most applicable

operation, maintenance and service related issues associated with the Omnipure unit. A

careful review and understanding of this manual should be achieved prior to operation

of this unit.

O&M, Rev. 5.4 Severn Trent De Nora, LLC


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Table of Contents

Table of Contents

The OmnipureMSD unit, as purchased, is described in detail throughout the following

Sections and Appendixs. This manual describes the operating, maintenance and

troubleshooting aspects of the MSD unit.

LIST OF CHARTS & TABLE DIAGRAMS ................................................................. SECTION A

MSD UNIT INSPECTION AND INSTALLATION........................................................ SECTION B

WARRANTY ............................................................................................................... SECTION C

Omnipure Performance Guaranty........................................................................................ C1

Limited Warranty.................................................................................................................. C2

WARNINGS, SYMBOLS, & SAFETY ......................................................................SECTION 1.0

Chemical Hazard..................................................................................................................1.1

Electrical Hazard..................................................................................................................1.2

Biological Hazard .................................................................................................................1.3

Fire/Explosion Hazard..........................................................................................................1.4

Warning & Safety Symbology ..............................................................................................1.5

OMNIPURE MSD UNIT ............................................................................................SECTION 2.0

General System Overview ...................................................................................................2.1

General Process Description ...............................................................................................2.2

FEATURES AND OPTIONS (IF APPLICABLE) ...................................................... SECTION 3.0

MAJOR COMPONENTS..........................................................................................SECTION 4.0

Control Panel .......................................................................................................................4.1

V-1 Surge Tank....................................................................................................................4.2

V-1 Surge Tank Level Switches...........................................................................................4.3

Macerator Pump...................................................................................................................4.4

Electrolytic Bookcell ............................................................................................................. 4.5

V-2 Effluent Tank .................................................................................................................4.6Positive Vent ........................................................................................................................ 4.7

COMMISSIONING....................................................................................................SECTION 5.0

Overboard Discharge Pump ................................................................................................5.1

Blower Option....................................................................................................................... 5.2

Water Powered Eductor Option ...........................................................................................5.3



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Table of Contents

COMMISSIONING (CONTINUED) ...........................................................................SECTION 5.0

Brine Option ......................................................................................................................... 5.4

Lift Station Coordination.......................................................................................................5.5

Sodium Sulfite Injection System (De-chlor)..........................................................................5.6

OPERATIONS ..........................................................................................................SECTION 6.0

Controls................................................................................................................................ 6.1

OIT Message and Alarm Index ............................................................................................6.2

Liquid Flow Paths.................................................................................................................6.3

Normal Operation.................................................................................................................6.4

Cell Flow Reversal Function ................................................................................................6.5

Manual V-2 Tank Blowdown & Auto V-2 Blowdown.............................................................6.6

Emergency V-1 and V-2 Pump Down .................................................................................. 6.7

TROUBLESHOOTING .............................................................................................SECTION 7.0

Firing Board Troubleshooting............................................................................................... 7.1

SCR and Diode Troubleshooting .........................................................................................7.2

MAINTENANCE .......................................................................................................SECTION 8.0

Macerator Pump...................................................................................................................8.1

Rectifier Firing Board ........................................................................................................... 8.2

Bookcell................................................................................................................................8.3

SPARE PARTS LISTINGS.......................................................................................SECTION 9.0

TABLES AND DIAGRAMS ....................................................................................SECTION 10.0

TEST REPORTS AND CERTIFICATIONS ............................................................SECTION 11.0

ENGINEERING DRAWINGS..................................................................................SECTION 12.0

UNIT BILL OF MATERIALS................................................................................... SECTION 13.0

EQUIPMENT DATA SHEETS ................................................................................SECTION 14.0

QA DOCUMENTS .................................................................................................. SECTION 15.0

VENDOR CUT SHEETS.........................................................................................SECTION 16.0



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Section A

SECTION A: LIST OF CHARTS & TABLE DIAGRAMS

Section/Figure/Table Number

Typical Liquid Flow Path for Normal Operation ......................................Figure 6-1

Manual Cell Draining ..............................................................................Figure 6-2

Manual V-2 Blowdown..........................................................................Figure 6-3A

Auto V-2 Blowdown ..............................................................................Figure 6-3B

Emergency V-1 Overboard Pumpdown................................................Figure 6-4A

Emergency V-2 Overboard Pumpdown................................................Figure 6-4B

Quick reference for Control Panel switches and alarms.......................... Table 6-1

SCR Assembly Test ...............................................................................Figure 7-2

MSD Troubleshooting Guide ................................................................... Table 7-1

Firing Board Troubleshooting Guide........................................................ Table 7-2

SCR and Diode Troubleshooting Guide .................................................. Table 7-4

Macerator Pump Parts Replacement Guide ............................................Table 8-1

Macerator Pump Mechanical Seal Replacement Guide .......................... Table 8-2

Macerator Pump Ball Bearing and Oil Seal Replacement Guide............. Table 8-3

Macerator Pump Axial Cutter Adjustment Guide ..................................... Table 8-4

Rectifier Firing Board Replacement Guide ..............................................Table 8-5

Firing Board Terminals and Signal Names ..............................................Table 7-3

Firing Board Rev. 7 and Earlier ............................................................Figure 7-1A

Firing Board Rev. 8...............................................................................Figure 7-1B

Drain, Inspect, and Clean the Bookcell.................................................... Table 8-7

Bookcell Cleaning and Electrode Replacement.......................................Table 8-8



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Section A

SECTION A: LIST OF CHARTS & TABLE DIAGRAMS (CONT.)

Section/Figure/Table Number

Ball Valve Replacement ..........................................................................Table 8-9

Overboard Discharge Pump Disassembly Table................................... Table 8-10

Overboard Discharge Pump Reassembly Table....................................Table 8-11

Typical Omnipure Diagram..............................................Section 10.1 Figure 10-1

Treatment Capacities Table.............................................. Section 10.1 Table 10-1

Unit Dimensions and Weights........................................... Section 10.1 Table 10-2

Unit Utility Connections and Connections......................... Section 10.1 Table 10-3

Customer Installed Piping Connections (standard unit).... Section 10.1 Table 10-4

Unit Functions at OIT Screen ........................................... Section 10.1 Table 10-5

Operating Current and Voltage chart................................ Section 10.1 Table 10-6

Daily Inspection chart ....................................................... Section 10.1 Table 10-7

Preventative Maintenance Schedule ................................ Section 10.1 Table 10-8

Bookcell Diagrams and Parts Table ................................................... Section 10.2

Macerator Pump Diagram .................................................................. Section 10.3

Macerator Pump Curve at 3450-RPM's.............................................. Section 10.3

Macerator Pump Parts........................................................................ Section 10.3



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Section B

SECTION B: MSD UNIT INSPECTION & INSTALLATION

Preliminary Inspection: Carefully examine the shipping crate (if applicable) or

other packaging for visible damage. If damage is noticed, DO NOT proceed with

uncrating or unpacking of the unit until the carrier is notified and an insuranceadjuster appears on the scene as a witness.

NOTE

DO NOT return the damaged goods to the factory. Severn Trent De

Nora (STDN) cannot assume responsibility for any shipping damage.

Uncrating: If no damage to the container is evident, proceed with unpacking.

Inventory the ejector, seawater strainer and other loose components against the

packing list. Examine the unit for damage, such as dented cabinets, broken piping,

and the like. If there are any irregularities, notify the carrier before proceeding

further. DO NOTattempt on-site repairs, which could invalidate the claim and void

the STDN warranty.

Equipment Location: Space considerations often dictate where the MSD will be

located in the vessel/platform. If possible, install the unit above the waterline (to

eliminate the need for an overboard discharge pump), immediately below the

sewage collection header or holding tank, and in an area subject to regular

inspection. Provide ample clearance around and over the skid for maintenance andservice. The skid may be bolted or welded to the deck.

Daily Inspection: The Omnipure unit should be inspected on a daily basis to

detect impending malfunctions early and to insure the MSD unit is operating

properly. See Table 10.7 for a Daily Inspection chart.

Installation of MSD Unit: With the exception of the Model 15MX, OmnipureMSD

units are designed to pass through hatchways and standard doorways. Some

disassembly may be required. Consult Section 12.0 for skid dimensions.

Section 10.0 will detail the weights, utility requirements, and recommended pipe

sizes for particular Omnipureunits.



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Section B


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Section B

Long Term Storage: To insure proper storage of the OMNIPURE MSDs for

prolonged periods of time:

1. Close all sewage, seawater feed, and air lines to the unit.

2. Flush all tanks, pumps and piping with fresh water until free of any sediment.

Completely drain the unit.

3. One of the following methods should be used to protect pump seals and

housings:

(A) Fill pumps with ethylene glycol solution (50% ethylene glycol, 50%

water) or automotive anti-freeze, which is ethylene glycol mixture.

Expected ambient temperature should not be less than temperature

rating of additive.

NOTE

Pumps should be rotated once per month.

(B) Remove rotating parts and seal sets from pumps, wrap in oilcloth

and place in anti-corrosion packing. This method offers maximum

protection.

4. Install desiccant pack in control panel, close door and then disconnect from

power.



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Section C

SECTION C: WARRANTY

The MSD Warranties and Guarantees are included in detail in the following sections.

C1: OMNIPURE PERFORMANCE GUARANTY

Severn Trent De Nora, LLC (STDN) guarantee that OmnipureSewage Treatment

Units will meet IMO and USCG Type II specifications applicable at the time of

manufacture when installed, operated and maintained in accordance with our

instructions.

C2: LIMITED WARRANTY

Severn Trent De Nora, LLC warrants the equipment of its manufacturer to be free

from defects in workmanship and materials for a period of 12 months after first

startup, or 18 months after shipment, whichever occurs first. This Warranty applies

only to the original BUYER for new and unused equipment and cannot be altered or

changed by STDN employees or its representatives. Warranty related repairs

attempted and/or executed by our authorized representatives shall only apply and is

extended when supported in writing by Severn Trent De Nora, LLC.

Where equipment sold hereunder is used with attachments and/or modifications,

which have not been recommended, or approved by STDN in writing, such use shall

not be considered normal and this Warranty shall not apply.

STDNs liability is limited to the replacement or repair of defective parts returned

freight prepaid by BUYER to a location to be specified by STDN. Repaired parts

shall be returned to BUYER F.O.B. shipping point. When circumstances permit,

STDN will invoke for the benefit of the BUYER, the Guarantee or Warranty of

STDNs vendor for equipment or materials furnished, but not manufactured by

STDN.

This Warranty does not extend to, and STDN assumes no liability for, consequentialand/or secondary damages, or loss of any kind sustained directly or indirectly as a

result of a defect in any equipment, material or installation. STDN shall in no event

be liable in an amount exceeding the purchase price on the equipment and

transportation charges thereon.



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Section C

Severn Trent De Nora, LLC makes NO Warranties regarding equipment

manufactured by it or no others (including without limitation, warranties as to

merchantability and fitness for a purpose), either expressed or implied, except as

provided herein. The foregoing shall constitute the exclusive remedies of BUYER

for any breach by STDN Corporation or its Warranties herein.

All information contained herein is based on data believed to be accurate, however,

errors and/or design changes are possible. It is the Buyers responsibility to

determine suitability for his own use of the products described.



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Section 1.0

SECTION 1.0: WARNINGS, SYMBOLS AND SAFETY

This section covers the general Warnings and Safety ideals associated with this

Omnipure Marine Sanitation Device (MSD) unit. Also, detailed in Section 1.5 is

the prescribed Warning and Safety symbology. These symbols are used throughout

this Operation and Technical manual as visual safety reminders. It must be noted

that the MSD unit is a device used in raw sewage treatment application where a

strong oxidizing agent is involved.

There are four broad groups of potential hazards that the user must be familiar with

when operating this equipment.

1.1: CHEMICAL HAZARD

This MSD unit generates a sodium hypochlorite solution through the electrolysis of

seawater during unit operation. The resultant concentration of the sodium

hypochlorite is very low at 300-ppm (maximum), as compared to 14,000-ppm for

household bleach. Although this concentration of sodium hypochlorite is fairly low,

caution must still be used due to the caustic nature of the hypochlorite product. As

detailed in Section 1.5, the user should exercise caution and wear suitable protective

safety gear when working around, or handling this sodium hypochlorite product.

Avoid prolonged exposure to the sodium hypochlorite vapors. Inhalation can result

in headaches, loss of coordination, irritation to bronchial passages and, in severe

cases, unconsciousness. Ingestion of the product can be lethal.

Muriatic Acid (dilute hydrochloric acid) is occasionally used in cleaning parts of this

MSD unit. Again, the user should exercise caution and wear suitable protective

safety gear when working around, or handling this form of acid.

DO NOT allow hydrochloric acid to come into contact with sodium

hypochlorite solution. Acid shall NEVER be allowed to enter the V-2

Effluent Tank; this would cause a chemical reaction that could generate

dangerous quantities of chlorine gas.

NOTE

Always add acid to water, NEVERwater to acid.



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Section 1.0

The following are the various associated treatment regimes for related injuries:

Treatment of Eye Burns Sodium Hypochlorite or Acid

Irrigate the eyes immediately, before moving the patient for medical

treatment. If an industry approved eyewash solution is not available, use agenerous amount of fresh water. Irrigate for at least 15 minutes, while

holding the eyelids open and rotating the eyes. Seek immediate medical

treatment.

Treatment of Skin Burns Sodium Hypochlorite or Acid

Apply generous amounts of fresh water onto the burned area. Carefully

remove the affected clothing. DO NOT neutralize acid with an alkaline

solution. Seek immediate medical treatment.

Treatment of Ingestion or Gassing Sodium Hypochlorite

Seek emergency medical assistance immediately. If the patient has been

gassed, remove him/her from the contaminated environment as quickly as

possible as soon as it is safe to do so. If NaOCl (sodium hypochlorite) has

been swallowed, DO NOT induce vomiting. Keep the patient warm and in a

restful state. If breathing stops, begin performing CPR and continue until the

patients care is taken over by trained medical personnel.

1.2: ELECTRICAL HAZARD

The MSD unit utilizes and produces electrical currents/voltages, which can be lethal.

DO NOT operate this device with the access panels removed. The user(s) must

ensure that no foreign objects are allowed to pierce the electrical interconnecting

cables or lying across the internal electrical connections, which will result in electrical

shorts.



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Section 1.0

Electrical Safety Lockout/Tagout method

STDN encourages utilization of the lockout/tagout safety procedure when servicing

any electrical circuit or any physical rotating gear associated with this equipment.

The lockout/tagout procedure will aid in the prevention of deadly electrical shock andother hazardous situations. A color-coded, industry standard, lockout and tagout kit

should be utilized for accomplishing a successful maintenance operation. Any

individuals responsible for overseeing of this equipment should be trained using the

lockout/tagout procedures.

The following is the suggested general lockout/tagout procedure:

1. Notify all affected personnel that a lockout function is to begin.

2. Initiate an equipment shutdown of the entire system per the operating

instructions of the equipment.

3. Locate the dedicated power feeder and its associated circuit breaking

protection devices.

4. Open the appropriate electrical service power feeders, removing electrical

power from the equipment.

NOTE

If the electrical power is shut down the servicing individual shall keep thepadlock key in his/her possession during the required maintenance

period. This will ensure that no person can re-apply power to the circuit.

5. Apply a lockable padlock to the lockout hasp from the lockout/tagout kit.

6. Before servicing the equipment, attach an industry tagout notification card to

the locked out service.

NOTE

A typical card will include areas for the servicemans name, department

and date of expected completion. This notification tag is to be solely

removed by the responsible serviceman who initiated the lockout

procedure.



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Section 1.0

7. After all service has been performed, the initiating service person shall

remove the notification tag and file it accordingly into the maintenance

records.

8. Remove padlock from the safety hasp.

9. Remove hasp from the opened circuit protection device.

NOTE

The padlock, padlock key and safety hasp should be returned to the

lockout/tagout kit for future use.

10. Close electrical power feeding circuit to the serviced equipment.

11. Perform equipment system startup per operating procedure.

1.3: BIOLOGICAL HAZARD

The MSD unit collects and processes untreated sewage, which may be

contaminated with viral and organic parasites. These parasites are transmitted

orally, through mucus membranes, and through open wounds. Extreme caution

must be exercised to avoid direct contact with the sewage. Upon coming into

contact with sewage, immediately wash the contact area with a disinfectant soap,

shower and change into clean clothing. DO NOTeat, smoke, or perform any hand-

to-mouth activity until thoroughly decontaminated. Seek immediate medical

attention for cuts, abrasions and any puncture wounds that may have been exposed

to the sewage.

Clean up any spills that may have occurred and immediately disinfect the entire

MSD area.

1.4: FIRE/EXPLOSION HAZARD

A small quantity of hydrogen gas is produced as a byproduct of theelectrochlorination process of the MSD unit. The ventilation system must remain

functional at all times to ensure that the concentration of byproduct gas is kept below

the hydrogens explosive limit.



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Section 1.0

In the event of a suspected vent gas leak, shut down all electrical equipment in the

immediate area and any other possible ignition sources. Thoroughly vent all

overhead spaces to dissipate the suspected gas.

1.5: WARNING AND SAFETY SYMBOLOGY

A group of visual safety reminders are found throughout this operating manual. The

safety symbols are incorporated in this manner so as to afford the user or operator a

quick visual representation of a notable hazard or safety advisory.

The individual warning/safety symbols are shown in this section with a helpful

description of each symbol.

Due to the sensitive nature and potential hazards of the electrical

circuits involved in specific trouble shooting tasks, only knowledgeable

individuals should perform the electrical checks. If for any reason an

electrical component of this equipment is in question, or is not operating

properly, seek a qualified Electrician to perform any checks and/or

repairs.

The STOP symbol is used to denote an operational or functional task

that requires very explicit instructions and/or user qualification. Upon

any section of this manual where this symbol is noted. All instructions

should be fully read prior to performing any task.

The WARNING symbol is used throughout this manual to inform the

user(s) that the task to be performed may cause bodily harm or death, if

specific instructions and guidelines are not followed accordingly.

User (s) should understand that the particular chemical or chemical

combination is highly corrosive and can cause serious injury.

Appropriate personal safety precautions should be taken to ensure

user(s) safety.



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Section 1.0

First Aid required or seek professional medical assistance

-or-

Render specific medical aid.

The CAUTION symbol is used throughout this manual to inform the

user(s) that the task to be performed may cause equipment damage, if

specific instructions and guidelines are not followed accordingly.

Prior to working on equipment, place all switches, and circuit breakers

in their open (off) position, close valves lockout and tag them

DANGER, SHOCK HAZARD or DO NOT OPERATE. DO NOT

change position of any tagged switch.

ec an ndv dua


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Section 2.0

SECTION 2.0: OMNIPURE MSD UNIT

The Omnipure System manufactured by Severn Trent De Nora, LLC is a self

contained, Marine Sanitation Device (MSD) that meets the United States Coast

Guard (USCG) requirements of 33 CFR 159. This MSD is USCG Type II certified

and IMO (International Maritime Organization) approved for overboard discharge in

territorial and international waters. Copies of the applicable Certificates of

Compliance are contained in Section 11.0 of this manual.

All numerical data included in this manual and are in English and Metric units.

2.1: GENERAL SYSTEM OVERVIEW

The following is a MSD general description of the operating process. STDN also

produces a Process Module (PM) Omnipureunit where the V-1, Collection Tank

and V-2, Residence Tank are supplied by the customer and not provided on the

Omnipure skid unit. Process Modules are identical in function to standard skid

units with tanks. Process Modules use customer-constructed tanks or preexisting

tanks in the vessel to save space and/or simplify installation. The MSD unit is

versatile and may be installed on ocean going vessels, and fixed or mobile offshore

platforms. The complete skid mounted system consists of pre-assembled Schedule

80 PVC piping and valve works, mounting skid, tanks, control panel/power supply,

bookcell, and macerator pump. The process piping on the unit is divided into

replaceable sections via unions or union type ball valves. The piping and valves

included in this MSD unit meets ASTM D-1784 industry standards.

The following description is for an Omnipureunit, not a Process Module although

the general operation is the same. This generic overview does not specifically detail

every operating component of the system. The various components are described

in detail in Section 4.0 of this manual.

Process Modules CANNOT be factory calibrated for the proper

flowrate. Others supply the tanks and some piping, so the system

flowrates must be field set at the time of start-up.

See Section 3.0 for Custom features and operating notes.

NOTE



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Section 2.0

2.2: GENERAL PROCESS DESCRIPTION

Raw sewage is collected from toilets, sinks, showers, urinals, and associated

sanitary waste systems and is introduced into the MSDs V-1 Collection Tank. The

V-1 tank incorporates a float type level switch assembly. This level assembly

initiates the start and stop sequences of the MSD unit when the unit is in the Auto

mode. When V-1 tank level rises, the level switches are actuated and the treatment

unit starts. The raw sewage contained in the V-1 tank is finely ground, or

macerated, through a specially designed macerator pump. From macerator pump

discharge, a portion of the macerated sewage is returned to the V-1 tank through a

calibrated orifice plate. The remainder of the macerated sewage is then mixed with

a controlled amount of seawater as it is pumped through a second calibrated orifice

plate to the Omnipure Bookcell. Seawater enters the MSD unit between the

bookcell and the discharge of the macerator pump via a strainer and flow controller.

This flow controller limits the seawater flow to a predetermined value based on

specific treatment capacities of the various MSD units. The use of calibrated orifice

plates and the seawater flow controller allows liquid flow to the bookcell to be

maintained at the correct rate for each specific unit.

In locations where the ambient seawater salinity is low, an optional SALT ADD unit

can be supplied to allow proper operation.

The MSD unit oxidizes and disinfects raw sewage by means of an electrochemical

reaction in the bookcell. The electrochemical reaction is the result of D.C. voltage

applied to specially designed anode and cathode plates (electrodes) within the

bookcell. The sewage and seawater slurry from the macerator pump flows between

the charged electrodes. The seawater acts as an electrolyte for DC current flow

between the anode and cathode plates. The chloride salts of the seawater are

decomposed by electrolysis to form sodium hypochlorite. The electrochemicalreaction and the resulting production of sodium hypochlorite kills harmful coliform

bacteria and oxidizes the organic compounds in the sewage stream. One pass

through the bookcell kills nearly 100% of resident bacteria and oxidizes between 90

to 95% of the organic compounds found in normal sewage.



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Section 2.0

The electrical power required to operate the bookcell is derived from the treatment

units internal D.C. power supply. Each MSD model has a specific, fixed current

associated with its bookcell. The amount of D.C. current applied to the bookcell

determines the amount of sodium hypochlorite produced.

After the slurry of sewage and seawater has been electrolyzed in the bookcell, the

stream is routed into the MSDs V-2, Residence Tank. The stream enters the top of

V-2 tank through a vertical downcomer pipe. This pipe is internal to the V-2 tank.

The downcomer pipe outlet is near the bottom of the V-2 tank. The downcomer

reduces velocity of incoming process stream and encourages degasification. During

the electrolysis process, small amounts of hydrogen and other gases are produced

as byproducts. The downcomer works in conjunction with a positive vent system to

extract gases from the process and send them to the atmosphere.

The V-2 tank is sized to provide a minimum 30-minute retention time between the

entry of treated sewage (effluent) at the bottom of the V-2 tank and subsequent

discharge from the top of V-2 tank to the sea.

This 30-minute retention time assures that any remaining bacteria will be killed and

allows any partially oxidized particles to settle. These particles (consisting mostly of

cellulose) are recirculated into the V-1 tank for re-treatment through the blowdown

line during the backflush and blowdown maintenance procedure.

After retention time, the effluent overflows from the top of V-2 tank. It is normally

gravity drained overboard through customer piping. During installations where V-2

tank discharge is below the waterline, an optional stainless steel centrifugal

overboard pump can be supplied to discharge the treated effluent.

The United States Coast Guard (USCG) Certification, which STDN holds for each

Omnipure

model, strictly dictates the parameters for operation and quality ofeffluent discharged from the MSD system. The USCG Certificate in effect when this

Omnipuremodel was manufactured can be found in Section 11.0 of this manual.



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Section 3.0 Custom Features and Options

SECTION 3.0: CUSTOM FEATURES AND OPTIONS

This Omnipure MSD unit configuration incorporates the following Custom

Features. These additional features allow the MSD unit to perform in a manner

different from the standard MSD unit.

Chart on the next page lists specific information concerning purchased equipment.

The part number printed on the front cover of this manual can be broken down to

detail the equipment model and size, development level, supply power requirements,

standard options, and special customer requirements or features.

The part number below is an example only. This is to illustrate how the number can

be broken down for specific information.

Example: A150554AFTVS030

The part number is arranged as follows:

(A) = Omnipure Unit

(15) = Model 15MX

(05) = STDN Product Development Level

(5) = Voltage Designation(440-480VAC)

(4) = Ph/Hz Designation(3 Ph. / 60Hz)

(A) = Overboard Pump Option

(F) = Custom Skid

(T) = Dual Macerator Pumps

(V) = Ultrasonic Level Control System

(S030) = Description of Special Features and Options



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Sectio

PRODUCT LINEEX: (A)

MODEL IDENTIFIER(15)

PRODUCT DEV. LEVEL(05)

POWERREQUIREMENTS

(54)

UNIT SIZE

NUMBER 5=VOLTAGE DESTINATION

1 = 110V2 = 220V3 = 380V4 = 415V5 = 440-480V6 = 575-600V7 = 460V

NUMBER 6=Ph/Hz DESIGNATION

A

=OMNIPUREPRODUCT

PRODUCTDE

VELOPMENTLEVEL

Anydesign/componentchangewillincreasethe

developmentleveltothenextnumericalincrement.

01 = 4MS02 = 6MC03 = 6MPM04 = 6MS05 = 7ME06 = 8MC07 = 8MPM08 = 8MS09 = 12MC10 = 12MPM11 = 12M12 = 12MS13 = 12MX Unit14 = 12MXPM15 = 15MX Unit

16 = 15MXPM17 = 15MX Compact (Left)18 = 15MX Compact (Right)19 = 12MXPM w/Multi-Pass Cell20 = 15MXPM w/Multi-Pass Cell21 = 12MX Unit Multi-Pass Cell22 = 15MX Unit Multi-Pass Cell23 = 6MV24 = Next Available Std.

1 = 1 Phase, 50 Hz2 = 1 Phase, 60 Hz

3 = 3 Phase, 50 Hz4 = 3 Phase, 60 Hz5 = 1 Phase, 50/60 Hz6 = 3 Phase, 50/60 Hz

A =B =

D =H =M =P =E =F =G =I =

J =K =L =N =Q =

R =

T =U =V =W =X =Y =Z =Z1 =Z2 =Z3 =Z4 =Z5 =Z6 =



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Section 3.0 Custom Features and Options

SPECIAL FEATURES AND OPTIONS

This OmnipureMSD unit configuration includes CPVC piping as opposed to PVC.



24/175

Section 4.0 Major Components

SECTION 4.0: MAJOR COMPONENTS

This MSD unit as purchased is fitted with the standard major components listed on

the following pages. Please also see Section 3.0 if this MSD unit was constructed in

a custom configuration.



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Section 4.1 Control Panel

SECTION 4.1: CONTROL PANEL

Refer to system drawings in Section 12.0of this manual for control panel details and

electrical schematics.

The standard OmnipureControl Panel is a NEMA 4X rated enclosure located on

the MSD unit skid. The Control Panel is pre-wired to all components located on the

MSD skid and controls all MSD functions. All control logic elements, whether relay

or microprocessor based, are housed in the panel. Also contained in the panel are

the bookcell DC power supply, control voltage transformer, and motor-starters. Unit

status indicators including the bookcell voltage and current meters are located on

the control panel door along with the OIT required for operator control of the MSD.

The power rectification circuits (D.C. power supply) housed in the Control Panel,

changes the main unit supply power into usable high current, low voltage DC power

for the bookcell electrolysis process. The rectification circuits consist of SCR/diode

block(s) (Power Modules) controlled by a printed circuit Rectifier Firing Board. This

firing board drives the Power Module(s) to maintain a constant DC current to the

bookcell. Should variations occur in the salt content of the sewage slurry stream in

the bookcell, the conductivity of the sewage slurry will change. The Firing Board

compensates by increasing or decreasing the D.C. voltage to maintain the bookcell

current at the correct setting. If the salinity falls below minimum requirements

(approximately 1%), an over-voltage circuit activates to shut down the MSD. This

alarm condition actuates a set of relay contacts in the customer remote alarm circuit,

which can be used to notify operator that the MSD unit has shutdown. Other alarm

conditions include but are not limited to:

V-1 tank high level

Motor over-current

Bookcell high temperature

Vent high pressure on 12MX and 15MX units

Other alarms may be added when options are purchased



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Section 4.1 Control Panel

The MSD unit is operated via controls on the panels door front. The operator

selects a mode of operation at the OIT. When in the Hand mode, the systems

components run continuously without regard to the V-1 tank level. This mode is

used during the Manual Blowdown maintenance procedure. In the Auto mode, the

unit runs on demand as required by V-1 tank level. The Auto-Override function,

when installed, provides the operator with limited control of the bookcell. The

Override mode turns bookcell power off at all times, without affecting the other MSD

components. In Auto mode, the bookcell power is energized and de-energized as

the MSD starts and stops.



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Section 4.2 V-1 Surge Tank

SECTION 4.2: V-1 SURGE TANK

Refer to system drawings in Section 12.0 of this manual for Omnipure unit

mechanical details.

The standard Omnipure unit incorporates a V-1 Sewage Collection Tank to

accommodate the normal raw sewage flow into the MSD unit. During peak periods

of use it acts as a reservoir to contain surge flow. This permits the MSD unit to

operate at the correct treatment rate without regarding the incoming flow rate. The

tank allows the MSD unit to operate on demand, via the tanks level switches (see

Section 4.3). The surge tank has a "coal-tar" epoxy internal coating to prevent tank

corrosion.

The V-1 Surge Tank includes a clear site tube for visual indication of the liquid level.



28/175

Section 4.3 V-1 Surge Tank Level Switches

SECTION 4.3: V-1 SURGE TANK LEVEL SWITCHES

Refer to the system drawings in Section 12.0 of this manual for Omnipure unit

mechanical and electrical details.

As detailed in Section 4.2, the standard V-1 Collection Tank includes a level switch

assembly. This assembly contains three float type level switches. The switches are

comprised of a mercury switch connected to a length of 2 conductor #16 AWG type

SO cable. The switch and connected end of the cable are encapsulated in a hard

urethane ball for flotation. The switches are commonly noted on the Engineering

drawings as LSL-1 (Off), LSH-1 (On) and LSH-2 (High level alarm). The switches

are secured to a flange and stainless steel rod arrangement, which holds in place at

the correct levels. Electrical terminations are made in a junction box on top of the

flange. The three switches are in closed or made condition when liquid level in the

V-1 tank is low. The Level Switch Assembly is constructed to allow the three float

switches to be replaced individually in the event of failure.

If the MSD unit is in the Auto mode, it will start automatically when the level in V-1

tank rises above the ON level switch (LSH-1). The MSDs macerator pump will

begin to pump the V-1 tank down until the low-level point is reached and the

corresponding low-level switch (LSL-1) closes. This action will cause the MSD unit

to stop. In normal operation, the Omnipure unit starts and stops between these

two level switches.

In the event of an unusually high surge rate to V-1 tank, the high-level alarm level

switch (LSH-2) opens, and an alarm indication on the MSDs front panel is activated.

In addition, redundant start signal is sent to the macerator pump to ensure pumping

has started in the event the On switch LSH-1 has failed". This action also actuates

contacts in the customer remote alarm circuit to provide a remote alarm signal.



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Section 4.4 Macerator Pump

SECTION 4.4: MACERATOR PUMP

All Omnipure MSD units require a macerator pump as the prime mover for fluid

through the treatment system. Standard Omnipure MSD units use a specially

designed macerator, or grinder, pump produced by Severn Trent De Nora. This

Omnipure macerator pump takes suction from the V-1 tank. When the macerator

is in operation one stationary and two rotating cutter blades inside the macerator

reduce the solids in the sewage stream to between 1/8 and 1/16 particle size prior

to discharge. The reduction in the particle size is the first step in treatment process

and allows the bookcell to more effectively treating solids. The macerator pump

discharge is piped to both the V-1 tank return line and to the bookcell. The pumps

discharge flow is regulated by predetermined flow orifices installed in the process

piping.

The SCP-1000 macerator pump is cast of Silicone Bronze. The rotating elements

are stainless steel and other corrosion resistant materials. The cutter blades are on

the suction side of the centrifugal pump impeller and discharge directly into the inlet

of the impeller. The pump shaft is sealed by a forced oil lubricated mechanical seal

and driven by a flexible coupled motor.

NOTE

NEVERoperate the pump(s) without the coupling guard in place.

A radial sleeve bearing, lubricated by oil, is located behind the seal and supports the

radial load from the pump impeller and cutter blades.

The oil lubricated duplex ball thrust bearing is held in an adjustable cap so that the

axial cutter and cutter ring axial clearance can be adjusted from the outside without

the use of shims.

A 2 H.P. (3450 RPM) motor is used on the 12MX, 15MX, and 18MX size units.

Although there is a flexible coupling between the two shafts, the mating surfaces of

the motor and pump are C" face configuration so no alignment is required.



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Section 4.4 Macerator Pump

All macerator pumps installed on MSD units manufactured after September 1999

incorporate a seawater seal flush system. This system allows pressurized

seawater to flush the pump seal cavity via a solenoid valve during operation. The

seawater flows around the mechanical seal to keeps debris away from seal faces

and also, keeps seal cool in the event the pump is run dry.



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Section 4.5 12MX Multi-Pass Electrolytic Bookcell

SECTION 4.5: THE MULTI-PASS BOOKCELL ASSEMBLY

The OMNIPURE 12MX multi-pass Bookcell consists of two machined PVC

sections that are hinged to open like a book. When the "Bookcell" is closed, the

front section or Door mates to the rear section or Base. The sections are sealed

with an O-ring around the perimeter that forms a watertight barrier. The primary

anodes, made of titanium and coated with a dimensionally stable anode (DSA)

coating, are mounted at the bottom of the bookcell. The terminal anodes connect to

the positive side of the DC power supply. The Hastelloy primary cathodes are

mounted at the top of the bookcell. The cathodes connect to the negative side of the

DC power supply. Eighteen (18) titanium bipolar plates are included in the assembly;

ten are on the inner Door face, and eight are on the inner Base face of the

bookcell. Half of each bipolar plate is coated with a DSA coating and acts as an

anode. The other half is uncoated bare titanium that serves as a cathode. The 18

bipolar plates are interchangeable.

The proprietary DSA coating on the bipolar plate and the terminal anodes extends

their life, reduces current consumption, and increases the efficiency of the

conversion process. Efficiency is further increased by use of the Hastelloy

cathode.



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The four primary electrodes and eighteen bipolar plates form two identical parallel

electrical circuits, which are side by side in the Bookcell. For simplicity, only one of

the circuits is described. Each circuit is a series of ten separate electrolytic

"CELLS". The primary anode is paired with cathode section of the highest bipolar

plate on the Door to form the first cell. Opposing anode and cathode halves of the

following staggered bipolar plates form eight additional cells. The anode half of the

lowermost bipolar plate on the Door and the primary cathode on the Base form

the tenth cell. The current path terminates at the upper cathode at the rear of the

bookcell body. The two identical electrical circuits are connected in parallel so that

they conduct an equal amount of current (25 ADC each, 50 ADC total) at an equal

voltage (50-100 VDC). This balance of current is monitored by the control panel to

prevent bookcell damage if there is a fault in one of the circuits.

When the bookcell is closed, a liquid flow path is formed between the plates on the

front, back, and middle sections. The sewage and saltwater slurry flowing in the

channel between the plates provides the conductive path to complete the electrical

circuit for sodium hypochlorite production. The flow path is approximately 96 in.

(2438 mm) long and 0.25 in. (6 mm) thick and 10 in. (254 mm) wide. This flow path

is made up of two sections between the Door and Base of the bookcell. These

sections are connected in series and the flow through the bookcell may be in either

direction. The flow direction is reversed to reduce the buildup of seawater deposits

on the electrodes. Flow reversal is accomplished by the actuation of a pair of three-

way valves. These valves are mounted at the top rear of the Bookcell. They actuate

to change flow direction each time the treatment system completes a cycle and

shuts down.



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BOOKCELL ALARMS

There are three bookcell safeguards provided that will alarm and shut down the

individual treatment units. The alarms are:

Bookcell High Temperature: When fluid temperature in bookcell exceeds 103 F

(113 F for special high temp locations)

Bookcell DC Current Unbalanced: Each bookcell has two parallel current paths

across the electrodes. If the current of the two paths is not equal, within 20% a

shutdown alarm occurs.

Bookcell Valve Position Incorrect: If the Bookcell flow reversing valves are out of

position for more than 20 seconds during flow reversal transition, a shutdown alarm

will occur.



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Section 4.6 V-2 Effluent Tank

SECTION 4.6: V-2 EFFLUENT TANK

Refer to the system drawings in Section 12.0 of this manual for the Omnipure

MSD unit mechanical details.

All MSD units require a V-2 Effluent Tank to retain the treated sewage during

residence time. The standard unit V-2 tank has a special coal-tar epoxy internal

coating, like the V-1 tank, to resist corrosion and provide long operational life of the

tank.

The V-2 Effluent Tank is sized to provide a 30 minute retention time between the

entry of effluent into the bottom of the tank via the downcomer pipe and the

subsequent discharge through the overboard overflow. The retention time ensures

contact with the sodium hypochlorite, so that any remaining bacteria will be killed.

The tank low internal velocity allows partially oxidized particles to settle. The

particles, consisting mostly of cellulose, are recirculated to the V-1 Surge Tank

through the blowdown line located at the bottom of the tank during a daily blowdown

operation.

The V-2 Effluent Tank includes an internal downcomer which encourages

degasification and stabilizes the incoming process flow stream. The V-2 tank is

operated in the flooded state so that the overflow discharge is continuously removed

from tank while the MSD is in operation. The downcomer works in conjunction with

the air ejector vent system to extract gases from the MSD unit and send them to the

atmosphere.



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Section 4.7 Positive Vent Blower Option (P)

SECTION 4.7: POSITIVE VENT BLOWER OPTION (P)

Refer to the system drawings in Section 12.0of this manual for OmnipureMSD

unit mechanical vent details.

All MSD units generate small amounts of gases during operation, primarily hydrogen

(H2) with some carbon dioxide (CO2). These gasses must be vented to atmosphere.

This venting is accomplished by maintaining a vacuum on the positive vent pipe

connected to the V-2 tank down comer pipe. On this unit the vacuum is generated

by use of an optional regenerative air blower. A blower is used when sufficient air

supply is not available to operate the standard air ejector as the vacuum source.

The vacuum is only used to evacuate gases from the unit and not to assist in effluent

treatment.

The blower suction is connected to the positive vent pipeline to maintain 2 W.C.

(water column) of vacuum during operation. The blower discharge is vented to

atmosphere. Two 3/8 vacuum break holes are drilled in the positive vent line

immediately adjacent to the suction of the blower. These holes allow dilution air to

be drawn into the vent line to be mixed with vent gasses.

A pressure switch is included with 12MX and 15MX units and serves as a vent high-

pressure alarm device for the positive vent pipe.

DO NOT TRAP OR POCKET VENT LINES. The positive vent

pipeline from the unit must be installed in such a way as to prevent any

section of piping from holding water without draining. A pocketed

portion of any vent line may form a liquid seal and prevent proper

evacuation of flammable gases. This could cause damage to the unit

and a condition hazardous to personnel.

A continuous upward slope must be maintained throughout the venting

system, to allow any condensation or liquids that may have formed in

the vents, to flow back into the system.



36/175

Section 4.7 Positive Vent Blower Option (P)

The blower must be mounted at least 20 feet (6M) above the V-2 Effluent Tank. A

motor starter in the MSD controls panel controls the blower.

The blower stops and starts with the unit operation. The blower is shipped loose

and the installer must make all pipe and wiring connections between the blower and

control panel.



37/175

Section 4.7.1 Sprayhead Assembly Unit

SECTION 4.7.1: SPRAYHEAD ASSEMBLY UNIT (12MX & 15MX SIZE UNITS)

The sprayhead assembly is shipped loose for installation on top of the V-2 Tank

down comer in the field. The Sprayhead Assembly Unit performs two functions:

The first function of the device is to take a measured amount of seawater (2.56

gpm) and pass it through an electronically controlled solenoid valve to an internal

sprayer (cone type). This seawater sprayer aids in keeping any foam, generated

by the electrolytic process, from migrating up the positive vent pipe.

The sprayhead solenoid valve is controlled via logic in the Main Control Panel.

This valve is energized only when the Macerator pump is energized.

The secondary function is to allow a sensing port for a vent high-pressure switch.

A vent high-pressure switch is shipped loose with the sprayhead assembly for

installation in the field. This pressure switch continuously monitors the pressure

inside the positive vent pipe. On increasing vent pressure, this switch will

activate, causing the Omnipure unit to shut down.

Refer to Section 10 for sprayhead assembly details.



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Section 5.0 Commissioning

SECTION 5.0: COMMISSIONING

All MSD units are individually tested and calibrated per testing procedures at the

factory. However, vibration and shock during shipment and installation can damage

piping and sensitive electrical components. Flow rates for process modules cannot

be factory set. Flow rate adjustments MUST be made at time of commissioning.

Failure to do so will result in improper MSD unit operation.

Mechanical and electrical connections should be verified with engineering drawings

in Section 12.0.

Electrical Test

1) Inspect and verify all mechanical and electrical connections have been

made according to engineering drawings in Section 12.0.

2) Locate main electrical disconnect switch/breaker for MSD.

3) Lockout/Tagout disconnect.

NOTE

Section 1.2 of this manual should be used as a guide for this

procedure if one does not exist in your organization. This safety

procedure should be followed each time you see Lockout/Tagout

in the commissioning procedure.

4) Open control panel and remove all fuses.

5) Note location of each fuse or refer to their position on control panel layout

drawing as they are removed.

6) Press "OFF" button.

7) Energize power to MSD unit.

8) Verify voltage is available at incoming supply terminals and correct to +/- ten

percent (10%) of voltage required.

9) Lockout/Tagout main power.

10) Replace main transformer T-1 primary fuses, control voltage transformer

primary fuses, firing board transformer, primary fuses and pump motor-

starter fuses.

11) Energize main power.



39/175


12) Verify secondary voltage of transformers and voltage on load side of pump

fuses.

13) Remove lockout/tagout device.

14) Turn power "ON" to unit via users main circuit breaker.

15) Verify (using a voltmeter) voltage at T-1 isolation transformer is within 20%

of the no load reading.

NOTE

If voltage does not meet these specifications, shut the unit down,

reapply the lockout device, and contact STDN for instructions.

Leave the prescribed Lockout/Tagout procedure in place until

resolution has been made on this matter.

16) Lockout/Tagout main power.

17) Replace remaining fuses.

Hydraulic Test

1) Rotate all pumps and motors by hand for a minimum of 5 revolutions. The

pump(s) and motor(s) should turn smoothly with no binding or noise.

NOTE

The macerator pump-coupling sleeve, which connects the pump and

motor shafts, must NOTbe installed for the next step.

STDN supplied pumps have counter-clockwise rotation direction as

viewed from the suction end of the pump. To prevent reverse

rotation damage to the Macerator, it has been shipped with the

motor coupling removed. When Counter-clockwise rotation has

been verified, insert the coupling between the pump and motor unit.

2) Energize main power.

3) Press "Hand" key then quickly press "OFF" button to manually actuatepump motor(s) by.

4) Verify motor(s) turns clock-wise when viewed from fan end.

5) Correct rotation, if required, by reversing two phases of motor leads.



40/175


Setting Unit Parameters

NOTE

If an optional blower or water-powered eductor is used in place of

the standard air ejector, read the special instructions at the end of

this section before continuing.

1) Turn on air supply to filter/regulator for ejector.

2) Close needle valve connected to regulator discharge.

3) Set regulator pressure to 6 psi.

4) Open needle valve two full turns as an initial setting.

NOTE

The final setting will be made during operation. The regulator is

adjusted by pulling up on the yellow top knob and twisting.

5) Open seawater inlet supply valve to MSD unit.

6) Verify water is available at pump seal flush solenoid(s).

7) Press "AUTO" button.

RESULT: The V-1 tank will fill with seawater from the seawater flow

control valve (FCV). Adding water from an alternate source

may decrease the V-1 tank fill time.

8) Fill V-1 tank until unit starts automatically, (about 1/3 full).9) Press "AUTO" button.

10) Allow tank to continue filling until High Level Alarm message is displayed.

11) Turn Auto-Off-Hand switch to "AUTO" position or press "AUTO" button.

12) Measure each motors current phase with a clamp on ammeter after unit

starts.

13) Verify current readings do not exceed full load current listed on motor tag(s)

for rated voltage.

14) Select "AUTO" at Auto-Override Function and observe bookcell current and

voltage rise and stabilize at correct values.

REFERENCE: Section 10.0 for bookcell current/voltage chart).



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15) Verify air ejector maintains 2 W.C. (water column) vacuum on positive vent

pipe while cell is in operation.

NOTE

This vacuum does not assist in treating the sewage but is for the

evacuation of the by-product gasses of the Bookcell electrolysis.

16) Adjust needle valve to set vacuum to 2 W.C.

NOTE

Too much vacuum can cause vent pipe blockage, too little

vacuum can cause gas build up in the vent.

The next step is to check the unit flow rate, which will begin as

soon as the MSD unit shuts down on low level. This test is for

MSD units, with tanks that have been factory calibrated.

Process modules cannot be factory calibrated. Process module

flow rates must be set during commissioning.

17) Isolate sewage inlet valve and any other sources of water to V-1 tank except

for seawater entering through flow control valve (FCV).

18) Begin timing when MSD unit shuts down, at V-1 tank low level.

NOTE

When the unit starts it automatically records the tank fill time and

begins measuring the pump down time.

19) Compare fill time and pump down time after MSD unit is shutdown on V-1

tank low level:

If they are equal the flow rate is correct.

If pump down time is longer than fill time, then flow rate is too slow.

If pump down time is shorter than fill time, then flow rate is too fast.

If flow rate is incorrect by more than ten percent (10%), contact STDN

for instructions.

NOTE

The MSD unit is now ready to be put into service.

20) Open sewage inlet valve and remove all test connections.



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Optional Equipment:

5.1: OVERBOARD DISCHARGE PUMP

If an overboard pump is fitted to your MSD unit it is very important that seal flush

water is available to the solenoid and the solenoid is operational. In new

commissioning and startups after the V-2 tank has been drained the overboard

pump will run dry for 30 minutes before the V-2 tank is filled and overflows to the

pump suction. To prevent damage to the mechanical seal the seawater solenoid

must provide flush water to the pump when it is operating.

5.2: BLOWER OPTION

If an electric blower option is installed, the operation is very similar to the standardair ejector. The difference is a regenerative fan (blower) generates vacuum on the

powered vent pipe. The blower starts and stops with the MSD unit operation.

Vacuum in the vent line is adjusted by drilling air bleed holes in the suction of the

blower manifold. (See engineering drawings for specific details).

5.3: WATER POWERED EDUCTOR OPTION

If water powered eductor is installed to provide vacuum for the positive vent line, the

principal of operation is very similar to the standard air ejector with a few exceptions:

Water is used as the motive force in place of compressed air.

The powered vent discharge is below the waterline, instead of the

atmosphere.

NOTE

Dilution air is drawn into the powered vent pipe from the atmosphere

vent pipe through a vacuum control valve.

When adjusting vacuum, a 1 valve is used to control water flow in the same

manner the needle valve is used to control airflow to the standard ejector.



43/175


Installations where a water-powered eductor is used are usually customized to the

particular vessel. For this reason initial set-up of the eductor will be slightly more

difficult than the standard air ejector.

1) Prior to starting the MSD unit, all overboard discharge valves must be

opened and seawater should be turned on to the eductor.

2) Slowly open eductor seawater inlet valve to establish and maintain a

vacuum reading of 2 W.C.

5.4: BRINE OPTION

Prior to beginning commissioning the brine add system, the brine tank connection

must be verified with the engineering drawings (Section 12.0). Clean pressurized

seawater or potable water must be available at the level control valve connection

and the tank should be filled with salt (40lbs. minimum) several hours prior to

commissioning.

1) Verify V-1 tank is partially filled with freshwater or seawater with a low salt

content (>1%).

2) Start MSD unit.

3) Open brine flow control valve FI-1 completely.

4) Observe book cell voltage.

NOTE

When the voltage exceeds 90 VDC (180 for 15MX) the brine

solenoid should open to allow brine to be drawn into the process

stream. After a delay of 10 15 seconds the voltage should begin

to fall. When voltage falls below 70 VDC (160 VDC for 15 MX) the

brine solenoid will close to stop the flow of brine.

The control logic has an overvoltage alarm delay, which is actuated

when the brine solenoid is actuated. The unit may activate the

alarm and have to be reset several times before the brine line from

the tank is purged of air and brine flows to the unit properly.

Once high and low voltage setpoints have been verified, the brine

flow control valve must be adjusted.



44/175


5) Turn MSD unit on and wait for brine solenoid to actuate.

6) Adjust FI-1 valve until Bookcell voltage stabilizes at 80 85 VDC. (170-180

VDC for 15MX).

NOTE

The brine system is now operational. Its actuation is automatic. Ifthe Briner is to be used the tank should be filled to the top with salt.

5.5: LIFT STATION COORDINATION

If the sewage collection system contains a lift station or remote collection tank that

pumps to the MSD unit, the coordination between the two systems is important. The

lift station must pump to the MSD unit only then the MSD is shut down with the V-1

tank at low level.

When the MSD unit pumps down to the low level point and stops, permissive

contacts for lift station transfer actuate. If sewage is available in the lift station

tank the transfer pump should start.

When the level in V-1 tank reaches the " ON" level point and the MSD unit

starts, transfer from the lift station must stop.

This cycle will repeat until available sewage has been processed and the

MSD unit stops at low level.



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5.6: SODIUM SULFITE INJECTION SYSTEM (DE-CHLOR)

When properly installed, the De-chlor system operation is automatic. The injection

pump starts and stops as the treatment unit starts and stops. To properly adjust the

injection system, chlorine residual samples must be taken and the output of the

injection pump adjusted until the residual is within the required limits. These limits

are set by the governing authority where the vessel or platform is operating.

Initial adjustment may be estimated by assuming a 10 mg/l residual. A table is

shown below as a guideline for initial pump set-up. During operation, the residual

will typically fluctuate. Use the table below for initial set-up of the injection pump and

Sodium Sulfite consumption reference for your particular installation.

Initial Injection Pump Settings(Stroke Rate at 50% Stroke Length)

Unit Size: 12MX 15MX 18MX

Unit Discharge Rate (L/min): 38.6 77.3 85.03

PPM

1 4.32 2.16 4.75

2 8.65 4.32 9.52

3 12.97 6.48 14.27

4 17.30 8.64 19.03

5 21.62 10.80 23.78

6 25.95 12.96 28.55

7 30.27 15.12 33.30

8 34.60 17.28 38.06

9 38.92 19.43 42.81InitialChlorineRe

sidual

10 43.24 21.59 47.56

NOTE

For pump dial settings, round desired number up to next whole number.



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Helpful Notes:

PPM (parts per million) = mg/l (milligrams per liter) Metric measurement will

be used to simplify calculations.

2 parts of Sodium Sulfite (Na 2SO3) are required to neutralize 1 part ofchlorine.

A saturated solution of Na 2SO3and water @ 20 C is 269 g/l (grams per liter)

The injection pump capacity is 0.265 ml/stroke and 100 strokes/min max

The treatment rates for individual Omnipure units are shown below.

The following is an example of an Omnipure unit with a treatment flowrate of 4l/min.

Residual concentration multiplied by flow rate.

10 mg/l x 4 l/min = 40 mg/min chlorine

Saturated Na2SO3solution multiplied by volume per stroke.

0.269g/ml x .265ml/st roke = 71.3mg/stroke

Residual mg/min divided by pump mg/stroke.

40mg/min .71.3 mg/stroke = .56 stroke/min .

Amount of chlorine multiplied by two equals the amount of Na2SO3 required to

neutralize.

0.56 stroke/min x 2 = 1.12 strokes per minute.

Per the pump manufacturers recommendation, a faster stroke rate is desirable, so

the stroke length should be reduced from 100% to 50 %. This will double the

required number of strokes per minute to 2.24.



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Section 6: Operations

SECTION 6.0 OPERATIONS

All Omnipure units must function in accordance with the USCG Certificate

requirements under which the MSD units are designed. The process operation and

specific functionality of any Omnipure unit may not be changed from that which is

declared in the USCG Certificate.

The general process operation for every MSD unit is essentially the same.

NOTE

Field modifications and/or changes to the treatment unit that are not

Authorized by STDN will void the equipment warranty!



48/175



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AUTO MODE

When F2 is pressed, the unit will go into AUTO MODE. AUTO IDLE or AUTO

MODE OPERATING will be displayed in the Mode Message box. BOOKCELL INAUTO will be displayed in the Display Message box directly below the Mode

Message Box.

If the unit has a high tank level in the V1 tank, it will display HIGH TANK LEVEL

on the main screen in the message box. The PLC will initiate a redundant start

signal and if the high level goes away the unit will automatically clear the internal

PLC latch within 10 seconds, and the appropriate message will be displayed. A

high level alarm will not shut the unit down.

HOURMETER SCREEN

Displays the following:

Macerator pump hours of operation

Max time is 32,767 hours. After this timer reaches 32,767 hours it rolls to

00000 hours.

Bookcell hours of operation

Max time is 32,767 hours. After this timer reaches 32,767 hours it rolls to

00000 hours.

Displays current time and date.

Also, while in the OFF MODE, the user can cycle the cell flow reversal valves by

pressing F4while in the HOURMETER SCREEN. The CELL VALVES will cycle.

When the CELL VALVES CYCLE the following message will be displayed in the

MODE Message Box, on the main screen. CELL VALVE CYCLING

The following text is scrolling at the bottom of the HOURMETER screen.

F1 = MAIN MENU, F2= CELL OVERRIDE, F3= BLOWDOWN, F4 = VALVE

CYCLE



50/175


See chart below for Function Key modes.

Function

Key

Function

OFF Turns MSD off when pressed

AUTO Enables MSD to operate automatically when pressed

RESET Resets all MSD alarms

HAND Operates macerator pump for 30 seconds each time button is pressed

ESD Turns MSD off in Emergency stop condition

Blowdown Causes blowdown cycle to occur as soon as MSD stops in Auto Idlemode when pressed. Also causes 24 hour timer to be reset so that the

next blowdown cycle will occur 24 hours from the time the button ispressed

Valvecycle

Causes bookcell valves to manually cycle and reverse flow throughbookcell

NOTE

Function Keys are OIT Screen Dependent. Each specific OIT screen

incorporates its own set of particular Function Keys.

ALARM HISTORY

If the unit has an alarm, the alarm will immediately be indicated at the OITscreen. By pressing F4 from the main screen, the alarm can be acknowledged.

By pressing F4 again, this will release the latching logic internal in the logic

controllers (CPU). If the alarm was not cleared then ALM LATCHED PRESS F4

will be displayed in the Mode Message box. The operator needs to clear the

alarm and then press F4again.

The last 50 alarms (date, time, and description) will be stored in the OIT. From

the Main Menu press the DWN ARROW= ALARM HISTORY. By using the UP

and Dwn keys the alarms can be scrolled through. When the 51st alarm occurs

the oldest alarm will be erased and all of the alarms will be pushed down one.

The following is scrolling at the bottom of the ALARM HISTORY screen:

F1= MAIN SCREEN, F2 = STATUS, F4= ALARM ACK



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CELL VALVE LIMIT SWITCH FAILURE

The cell has dual water paths and these cell valves will cycle when the unit stops.

This helps to keep the cell clean by reversing the cell flow. This shutdown has a20 second delay. Determine problem and then press F4 to clear alarm. Report

problem to STDN Service Manager to avoid damage to the cell. Manually cycle

the cell by putting the unit in OFF MODE and cycling the cell valve.

VENT HIGH PRESSURE

If the vent high-pressure switch opens for 5 consecutive seconds the PLC will

display this alarm, this is not a shutdown it is strictly an alarm. If the unit is

getting vent high-pressure alarms, report the problem to the STDN Service

Manager to avoid damage to the unit.

POWER LOSS OCCURRED

When the unit initially starts or if there is a power interruption to the unit, this

alarm will be displayed. Determine problem and then press F4to clear alarm.

BLOWDOWN VALVE FAILED TO OPEN

If the blowdown valve fails to fully go to the right or left and if the PLC was telling

it to not do a blowdown this alarm will be displayed. This shutdown has a 10second delay. Correct valve position or repair valve and then press F4 to clear

the alarm.

BLOWDOWN VALVE FAILED TO CLOSE

If the blowdown valve fails to fully go to the right or left and if the PLC was telling

it to do a blowdown this alarm will be displayed. This shutdown has a 10 second

delay. Correct valve position or repair valve and then press F4to clear alarm.

BLOWER MOTOR STARTER TROUBLE

When the logic controllers CPU tries to either open or close the blower motor

starter, and if the motor starter does not respond in a specified time (1 sec.), the

above alarm will occur. Determine problem and then press F4to clear alarm.



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OVERBOARD MOTOR STARTER TROUBLE

When the logic controllers CPU tries to either open or close the overboard-motor

starter, and if the motor starter does not respond in a specified time (1 sec.), the

above alarm will occur. Determine problem and then press F4to clear alarm.

6.3: LIQUID FLOW PATHS

Liquid is routed through the MSD unit by manually operated valves. There are four

possible modes of operation.

Normal operation

Sewage flows to V-1 tank, then to the macerator. From the macerator, it mixes

with incoming seawater and goes through the cell and to effluent V-2 tank for

subsequent discharge. Some of the sewage is recycled through the orifice plate

to V-1 tank. When the unit is not operating, the seawater flows into V-1 tank.

See Sheet 3 of the Flow Diagram for Normal Operation.

Cell Flow Reversal Function

This enhanced Bookcell incorporates two (2) 3-way actuated valves at the top of

the cell. These valves are piped to allow the process flow through the Bookcell to

be automatically reversed after each treatment cycle. This change of flow

direction at each treatment cycle aides in the breakdown of any sizable mineral

deposits from the electrode plates in the cell. The internal PLC controller initiates

this valve cycling sequence as needed. These cell reversal valves may also be

cycled if the user is in the HAND mode of the units control.

NOTE

This cell flow reversal function is meant to aide in the prolonging of the

Bookcell operational life. It is not intended to replace the need for

manual, periodic opening and cleaning of the Bookcell electrode plates.



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V-2 Blowdown Modes

Untreated solids in V-2 tank are recycled back to V-1 tank for treatment. Since

this MSD is equipped with the Automatic blowdown feature, no manual

manipulations of hand valves are required during normal operation. This system

uses an automatic actuated valve to divert the macerator pump flow through a

liquid eductor (venturi), which draws untreated solids from the V-2 tank and

returns the flow to the V-1 tank for retreatment. This Automatic Blowdown

function occurs once every 24 hrs for a timed period of one (1) minute. See

Sheet 3 of the Flow Diagram. It is also possible for the user to perform a Manual

Blowdown of the V-2 tank. In the Manual blowdown operation, the macerator

pump takes suction from the bottom of V-2 tank back to and discharges through

the return orifice to V-1 tank. This manual function requires the user to stop the

treatment system for handvalve repositioning, and then run the Macerator pump

in HAND mode. See Sheet 3 of the Flow Diagram for manual handvalve

operations.

Emergency Pump Down

Allows liquid in the V-1 and V-2 tanks to be directly discharged overboard by the

macerator pump. See Sheet 3 of Flow Diagram.



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6.4: NORMAL OPERATION

To operate the MSD unit in Normal Treatment Mode:

1. Align unit hand valves as shown for Normal Operation on Sheet 3 of the Flow

Diagram. Note: All Automated actuated valves are controlled via the internal

PLC controller.

2. Open compressed air supply to vent air ejector.

3. Open pressurized seawater inlet valve to unit (customer supplied).

4. PressAUTO button. The MSD unit will start if required by the liquid level in

V-1 tank or pressAUTO button.

5. Clear any alarms by pressingALARM RESETpush-button if necessary.

RESULT: The MSD unit will start and stop automatically as required by the

liquid level in V-1 tank.

NOTE

When the unit starts, bookcell operation will be indicated after a short

delay by the voltage and amperage meters. See Section 10.0 for the

bookcell operating currents and voltages.



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6.5: CELL FLOW REVERSAL FUNCTION

This enhanced Bookcell incorporates two (2) 3-way actuated valves at the top of the

cell. These valves are piped to allow the process flow through the Bookcell to be

automatically reversed after each treatment cycle. This change of flow direction at

each treatment cycle aides in the breakdown of any sizable mineral deposits from

the electrode plates in the cell. The internal PLC controller initiates this valve cycling

sequence as needed. These cell reversal valves may also be cycled if the user is in

the HAND mode of the units control.

NOTE

This cell flow reversal function is meant to aide in the prolonging of the

Bookcell operational life. It is not intended to replace the need for

manual, periodic opening of the bookcell and cleaning of the internal

electrode plates.

6.6: MANUAL V-2 TANK BLOWDOWN & AUTO V-2 BLOWDOWN

Untreated solids in V-2 tank should be recirculated back to V-1 tank for treatment

upon completion of the daily bookcell backflush procedure. The purpose is to

provide a flow path from the V-2 tank to the V-1 tank. Follow the steps below:

1. Press OFFbutton.2. Set manual valves as shown in Sheet 3 of Flow Diagram.

3. Ensure following valves are in the proper position:

4. Go to OVERRIDEMode.

5. Press HAND button.

RESULT: The macerator pump will start.

6. Press OFFbutton after 30 seconds.

7. Re-Set MSD valves for normal operation (Flow Diagram, Sheet3).8. PressAUTO button.



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6.7: EMERGENCY V-1 AND V-2 PUMP DOWN

Situations may arise when it is necessary to pump untreated sewage from V-1 tank

overboard or to a shore connection. The same procedure can be used to pump

down the V-2 effluent tank if the situation arises. Follow the steps below:

1. Press OFFbutton.

2. Position valves as shown in Sheet 3 of Flow Diagram.

NOTE

A direct path from V-1 and V-2 to the emergency bypass line is

provided through the macerator pump.

3. Go to OVERRIDE Mode.

4. Press HAND button.

5. Observe liquid level in V-1 tank sight glass.

6. Press OFFbutton.

NOTE

When macerator pump suction inlet is no longer flooded, then the

last few inches of liquid below pump suction must be removed

manually through the clean out.

If the MSD unit is to be used in the bypass configuration for an

extended period, press "AUTO" button.

When the unit is used in the bypass mode, the overboard pump

motor fuses should be removed if overboard pump is installed

without seal flush water connections. This will prevent damage to

the overboard pump mechanical seal.



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Section 7: Troubleshooting

SECTION 7.0 TROUBLESHOOTING

PPE

Table 7-1 MSD Troubleshoot ing Guide

SYMPTOM PROBABLE CAUSE REQUIRED ACTION

Low seawater salinity Suspend system operation untilship moves into area of highersalinity

Or

Add salt to the Briner tank (ifinstalled)

No seawater entering thesystem at flow controller

Verify seawater supply at skid.

Clean seawater strainer

Bookcell electrodes dirty Open and clean bookcell (seeSection 8.0)

Bookcell electrode damagedor out of place

Replace electrodes (see Section8.0)

Bookcell power wireconnection loose

Clean and tighten connection

CELL OVER-VOLTAGE/OVERCURRENTmessage displayed

and

Rectifier Firing Board OVLED is lit

SCR firing board malfunction Troubleshoot Firing Board (seeSection 7.0)

Bookcell power wire loose Clean the wire and tightenconnection

Current signal wire to RectifierFiring Board loose

Clean the wire and tightenconnection

SCR shorted Troubleshoot SCR (see Section7.0)

CELL OVER-VOLTAGE/OVERCURRENTmessage displayed

And

Rectifier Firing Board OCLED is lit

SCR firing board malfunction Troubleshoot SCR firing board(see Section 7.0)

Low flow through the Bookcell See Low Treatment Flow Rate CELL HIGH TEMP message isdisplayed

Bookcell electrodes are dirty Open and clean Bookcell

Documents

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