2839_593_B.pdf

TP: 2839

(HM&E MANUAL)

TECHNICAL MANUAL

WASTE WATER COLLECTION SYSTEM

270’ WMEC “B” CLASS CUTTERS

ENVIROVAC, INC.

DISTRIBUTION STATEMENT D. - Distribution authorized to Department of Homeland Security, DoD and their contractors to protect publications required for official use or for administrative or operational purposes only;

determined on DATE 19 July 1991. Other requests for this document shall be referred to Commander, USCG Surface Forces Logistics Center, ESD – Tech Info Mgmt Br, 2401 Hawkins Point Road, Baltimore, MD 21226.

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties.

DESTRUCTION NOTICE. - For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

PUBLISHED UNDER AUTHORITY OF THE U.S. COAST GUARD

SWBS 593 19 July 1991

SECTION B

Department of Homeland Security

UNITED STATES

COAST GUARD

INSTRUCTION MANUAL

INSTALLATION, OPERATION, and MAINTENANCE With PARTS LIST

ENVIROVAC

WASTE WATER COLLECTION SYSTEM

United States Coast Guard

U.S.C.G. 270' B CLASS WMEC

R.E. DERECKTOR Purchase Order No. 10-0075

Gov't. Contract No. DTCG 23-81-C-30026

ENVIROVAC NO. E0271

ENVIROVAC INC.

1260 Turret Drive

Rockford, Illinois 61111

APR I L p 1983

I

TABLE OF CONTENTS

Page 1-1 1-1 1-1 1-1 1-1

SECTION I

SECTION If

SECTION III

SECTION IV

SECTION V

SECTION VI

SECTION VII

SECTION VI II

SECTION IX

Safety

1.1 General

1.2 Disease Hazards

1.3 Mechanical Hazards

1.4 Electrical Hazards

Introduction

2.1 General Description

2.2 Specifications

Waste Water Collection Tank

3.1 General

3.2 Installation

Control Panek-Forward Waste Water Collection System

4.1 General

4.2 Operating Modes

4.3 Abnormal Conditions

Control Panel--Aft Waste Water Collection System

5.1 General

Waste Water Collection System Discharge Pumps

6.1 General

6.2 Installation

Modes of Operation

7.1 General

7.2 No Discharge Mode

�7.3 Overboard Discharge Mode

7.4 Shore Discharge Mode

Adjustments

8.1 General

8.2 Undervoltage Relay Adjustment

8.3 Discharge Pump Mechanical Seal Pressure Adjustment

Operation

9.1 General

9.2 Controls and Indicators

9.3 Start-up Procedures

9.4 Automatic Operation

9.5 Manual Operation

9.6 Operation Under Full Tank Alarm

2-1 2-1

2-1, 2-2

3-1 3-1 3-1

4-1 4-1 4-1 4-1

5-1 5-1

6-1 6-1 6-1

7-1 7-1 7-1 7-1 7-1

8-1 8_1 8-1 8-1

9-1 9-1 9-1 9-1 9-2 9-2 9-2

TABLE OF CONTENTS cont.

10-1 10-1 10-1 10-1 10-1

SECTION X Preventive Maintenance

10.1 General

10.2 Control Panel

10.3-Sewage Discharge Pump

10.4 Waste Water Collection Tank

SECTION Xi Troubleshooting 11-1

Corrective Maintenance

12.1 Scope

12.2 Electrical Corrective Maintenance

12.3 Control Panel

12.4 Waste Water Discharge Pump

12.5 Motor Bearings

12.6 Liquid Level Control

12.7 Level Control Electrodes

Replacement Parts

13.1 Inquiry and Part Ordering Instruction

13.2 Waste Water Collection Tank

13.3 Forward Discharge Pump Assembly

13.4 Aft Discharge Pump Assembly

13.5 Waste Water Discharge Pump

13.6 Pressurized Shaft Seal Application

13.7 Pressure Cup Assembly

13'8 Forward Control Panel

13.9 Aft Control Panel

12-1 12-1 12-1

12-1, 12-2 12-3,12-4, 12-5, 12-6

12-6 12-6 12-7

13-1 13-1

13-2, 13-3 13-4, 13-5 13-6, 13-7

13-8 13-9

13-10 13-11, 13-12, 13-13, 13-14 13-15, 13-16, 13-17, 13-18

I SECTION XII

SECTION Xi II

SECTION XIV Drawings

14.1 Operating Modes

14.2 Aft Electrical Schematic No. 2800510

14.3 Forward Electrical Schematic No. 2800513

14.4 Aft Control Panel Connection Diagram No. 2800512

14.5 Forward Control Panel Connection Diagram No. 2800515

14.6 Aft Cable Routing Application No. 2700766

14.7 Forward Cable Routing Application No. 2700768

14.8 Aft Shipboard Connection Diagram No. 2700767

14.9 Forward Shipboard Connection Diagram No. 2700769

14.1 0 Aft Collection Tank No. 2700760, sh. 1 of 1

14.11 Forward Collection Tank No. 2700761, sh. 1 of 1

14.12 Aft Discharge Pump Assembly No. 2700776, sh. 1 of 1

14.13 Forward Discharge Pump Assembly No. 2700777,

sh. 1 of 1

14.14 Aft Tank Layout No. 2800526

14-1 14-2 14-3 14-4 14-5 14-6 14-7 14-8 14-9

14-10 14-11 14-12 14-13 14-14

14-15

III

TABLE OF CONTENTS cont.

2-1 2-2

9-3, 9-4 10-1, 10-2 11-2, 11-3 11-4, 11-5 11-6, 11-7

12-5

6-2 13-2 13-4 13-6 13-8 13-9

13-10 13-11 13-12 13-15 13-16

TABLES

FIGURES

2.1 Forward Waste Water Collection System

2.2 Aft Waste Water Collection System

9.1 Controls and Indicators

10.1 Preventive Maintenance Schedule

11.1 System Troubleshooting

11.2 Electrical Troubleshooting

11.3 Mechanical Troubleshooting

12.1 Discharge Pump Normal Clearances, Diameters and Thickness

6.1 Discharge Pump Performance Curve Characteristics

13.1 Forward Waste Water Collection Tank

13.2 Forward Discharge Pump Assembly

13.3 Aft Discharge Pump Assembly

13.4 Waste Water Discharge Pump

13.5 Pressurized Shaft Seal Application

13.6 Pressurized Cup Assembly

13.7 Forward Control Panel, sh. 1 of 2

13.7 Forward Control Panel, sh. 2 of 2

13.8 Aft Control Panel, sh. 1 of 2

13.8 Aft Control Panel, sh. 2 of 2

IV

ENVIROVAC INSTRUCTIONS

SECTION I

SAFETY

1.1 GENERAL. TheENVIROVACWasteWaterCollectionsystemcollects,retainsand discharges all waste water that by gravity drains into the Waste Water Collection Tank. Personnel must at all times observe all safety regulations while performing maintenance adjustments or repairs to this equipment. While every practical precaution has been incorporated in the design and manufacture of this equipment, personnel should be aware of the following hazards.

1.2 DISEASE HAZARDS. Sewage is a common mode of transmission for parasitic organisms such as bacteria, protozoa, worms, viruses and fungi. Some of these are pathogenic, meaning that they can cause serious communicable diseases. Most diseases associated with sewage result from hand-to-mouth transfer of the pathogenic organisms. Good personal hygiene by those contacting and servicing the equipment cannot be overemphasized.

1.2.1 After coming in contact with sewage or contaminated equipment items, personnel should thoroughly cleanse themselves with a disinfectant soap solution before eating, drinking or smoking.

Personnel should obtain proper medical treatment for any skin abrasions or punctures. Protective clothing such as gloves, aprons, boots and coveralls made of impervious materials should be worn to eliminate prolonged or repeated contact. Contaminated clothing should be changed daily and stored in separate facilities. Protective creams and lotions can help to minimize skin contact. Areas should be maintained clean, orderly, sanitary and in a dry condition. Spills should be cleaned up immediately with the area being properly disinfected.

1.3 MECHANICAL HAZARDS. Authorized maintenance personnel can isolate various parts of the system by closing appropriate valves. Personnel should exercise caution when isolating compo-nents from working portions of the waste water system. Before maintenance is performed on motor driven equipment, personnel should de-energize, isolate and appropriately tag the equip-ment at the control panel. Coupling guards should be kept in place on the vacuum pump assembly.

1.3.1 Putrefaction of organic matters in the Waste Water Collection Tank will produce disagreeable odors and an oxygen deficient atmosphere. When removing access covers, fresh air should be supplied from an known outside source to the surrounding area. Personnel should enter a tank only after a fresh air supply is provided for tank ventilation. Under no circumstances should any person enter a tank without immediate presence or assistance of another capable of rendering aid. Person-nel should use proper respiratory equipment for extended periods in a tank.

1.4 ELECTRICALHAZARDS. Equipmentissuppliedbyvoltageswhicharedangerousandmay be fatal if contacted by operating personnel. Under no circumstances should any door, cover or safety interlock switch be removed or tampered with in any way. To avoid electrical shock, remove power by placing the control panel disconnect switch to the Off position.

1.4.1 In some instances, defective components can be replaced without disconnecting electrical power from the equipment. Only authorized maintenance personnel should isolate defective com-ponents by the operation of a pushbutton or selector switch, or be disconnecting the electrical leads at a terminal point. Personnel should appropriately tag selector switches when de-energizing motor drive equipment.

Page 1-1

SECTION 11

INTRODUCTION AND GENERAL DESCRIPTION

2.1 GENERAL. TheWasteWaterCollectionSystemforU.S.C.G.270'W.M.E.C.vesselsis manufacturedbyENVIROVAC,INC.TheWasteWaterCollectionSystemisanintegralpartoftheoveralI Vacuum Collection and Sewage Holding System which is also manufactured by ENVI ROVAC, INC. The Waste Water Collection System collects, holds and transfers waste water from all shipboard gravity drains.

2. 1.1 The Waste Water Collection System has two, independently operated, identical 138-gallon collection tanks with individual control panels and three 5 H.P. Waste Water Pumps.

2.1.2 Two waste water collection systems are installed. One Waste Water Collection Tank with a control panel and one waste water discharge pump are located in the Number 2 Auxiliary Machin-erySpace. Itcollectswastewaterfromforwardspacesbelowthemaindeck. Theforwardwaste water drains can also be gravity drained to the Sewage Holding Tank. Waste water drains from aft spaces below the main deck are routed to a Waste Water Collection Tank located in the engine room. The tank is equipped with a control panel and two discharge pumps. Waste water from spaces above the main deck can gravity drain overboard or to the Sewage Holding Tank.

2.1.3 The operation of the collection systems is automatic, independent and identical except that the aft discharge pumps operate on alternate pumping cycles. With either system in the automatic mode, the pump will be activated when the waste water reaches the 92-gallon level (2/3 tank volume) and deactivated when the level reaches 13 gallons (9%). A manual run/jog mode is pro-vided to run the pump at a tank level between automatic pump on and off, and to jog the pump at any tank level.

2.1.4 Discharge from the aft Waste Water Collection tank is routed to either the Sewage Holding Tank or overboard. Discharge from the forward Waste Water Collection tank is routed overboard.

The mode of operation is determined by whether the cutter is underway in restricted waters, underway in restricted waters or is in port. While underway in non-restricted waters, discharge from the aft collection tank is routed overboard and the forward waste water drains are routed over-board.

While underway in restricted waters and in port, all waste water is routed to the Sewage Holding Tank. Refer to diagram 14.1 for the various mode routings.

2.2 SPECIFICATIONS

TABLE 2.1 FORWARD WASTE WATER COLLECTION SYSTEM

Component Quantity Length Width Height Weight Capacity

Waste Water 1 34" 4111 74'f 750 lbs. 138 gals.

Collection Tank

Waste Water 1 23.38" 17.63" 19.01, 275 lbs. 30 gpm Pump & Motor

Motor 5 H.P. 440 Volts 3 Phase 60 HZ

Page 2-1

TABLE 2.2 AFT WASTE WATER COLLECTION SYSTEM

Component Quantity Length Width

Waste Water 1 34ft 41f' Collection Tank

Waste Water 2 23.38" 35.63" Pump & Motor (1 unit)

Motor 2 5 H.P. 440 Volts 3 Pha

Weight

750 lbs.

Height

74"

19.01, Capacity

138 gals.

550 lbs. 30 gpm per pump se 60 HZ

Page2-2

SECTION III

WASTE WATER COLLECTION TANKS

3.1 GENERAL. TheENVIROVACWasteWaterCollectionSystemhastwoidenticalWaste Water Collection Tanks. The tank for the forward collection system is located in the Number 2 Auxiliary Machinery Space and the tank for the aft collection system is located in the engine room.

3.1.1 Thetanksarel38-gallonfoot-mounted,weldedsteelcylinderswithoneinletandoneventon thetopofthetank. Bothhave3"1251b.FFANSiflangeconnections. Oneoutletwitha2" 150 lb. FF ANSI flange connection is located at the base of the cone shaped portion of the tank.

3.1.2 Four conductivity sensors are provided for control of the level of the waste water in the tank and for warning if the high level in the tank is reached. One sensor activates the Waste Water Dis-charge Pump when the level of the waste water reaches 92 gallons. Another sensor deactivates the pump when the waste water level drops to 13 gallons. Another sensor is positioned to sound an alarm horn and light a warning light on the control panel when the waste water level in the tank reaches 124 gallons. The remaining sensor is the common. All of the sensors are set with an eight second delay before the pumps or alarms are activated or deactivated.

3.1.3 On the top of the tank is a 4" diameter viewing port and on the side of the tank is a 16" diameter access opening for service and cleaning.

3.2 INSTALLATION. Thewastewatercollectiontanksareequippedwithfourbasemounting pads. The ship's foundation must be capable of supporting approximately 1825 pounds (90% water filled weight). The tanks are secured to their foundation with four 3/4" bolts or by welding. The tank unit must be shimmed if necessary to mate with the foundation.

3.2.1 The tank unit must be electrically grounded to the ship's hull. The aft unit requires a 440 volt, 3 phase, 60 Hz, 20 amp power supply at the control panel with external 20 amp dual element fuses or an equivalent circuit breaker. The forward unit requires a 440 volt, 3 phase, 60 Hz, 15 amp power supply with external 15 amp dual element fuses or an equivalent circuit breaker. Electrical connections are made with the sewage discharge pumps. The control panels contain terminal points for an external alarm horn (1 15 volt A.C., 60 Hz, 50 Watts max., aft terminals No. 2 and No. 27 and forward terminal No. 2 and No. 14). In addition, machinery plant control monitoring system contacts are provided for full tank alarm (aft terminals No. 24 and No. 25, forward terminals No. 16 and No. 17).

Page 3-1

SECTION IV

CONTROL PANEL-FORWARD WASTE WATER COLLECTION SYSTEM

4.1 G E N E RA L. The Forward Waste Water Collection System Control Panel is located on the side of the Waste Water Collection Tank. It is the electrical control center for the Forward Waste Water Collection System. The panel requires 15 amp, 440 volt, 3 phase,60 Hz power with an exter-nal 15 amp dual element fuse or an equivalent circuit breaker.

4.1.1 Located on the front cover are the Main Disconnect Switch, the Control Power Reset Switch, the "Manual", "Off " and "Automatic" Selector Switch, the "Start", Roto Push Switch, the Control Power Reset Switch, the Discharge Pump Reset Switch, and the Alarm Silence Test Switch. Also located on the panel are the Alarm Horn Acknowledged Light, the Alarm Collection Tank Full Light, the Discharge Pump Motor Run Light and two indicator lights for Power On and Control Power On. The Tank Full Alarm Horn is also located on the front of the panel door.

4.1.2 The interior of the control panel contains the motor starter, the control relays for the motor starter and the alarm and sensing circuits.

4.2 OPERATING MODES. The control panel provides the following control functions:

4.2.1 Jog Manual Mode. With the three-position selector switch in the Man. position and the Start roto push switch in the Jog position, the discharge pump can be activated by depressing the roto push switch. It will remain energized until the switch is released. The Jog mode will activate the pump when the waste water is at any level in'the tank.

4.2.2 Run Manual Mode. With the three-position selector switch in the Man. position and Start roto push switch in the Run position, the discharge pump can be activated by depressing the roto push switch.

The switch must be depressed and held until the pump starts. If the waste water level is above the pump off probe (13 gallons), the pump will activate and remain energized until the level is lowered or either switch is turned to the Off position.

4.2.3 Automatic Mode. With the three-position selector switch in the Auto position, the discharge pump will be controlled by the start (92-gallon, 2/3 tank capacity) and off probes (13-gallon, 9% tank capacity). To avoid false signals from ship's roll and pitch, the level controls have an eight second delay before activating or deactivating.

4.3 ABNORMAL CONDITIONS.

4.3.1 Control Power Reset Button. In the event of a power outage or voltage drop, the pump control circuit will be de-energized by an undervoltage relay. The alarm circuit will remain opera-tional. To restore motor control, the Control Power Reset Button must be depressed.

4.3.2 Discharge Pump Reset Button. In the event of an overcurrent in the motor, the overload relay in the motor starter will de-energize the pump. The overload can be reset by depressing the reset button after the thermal element has cooled.

Page 4-1

SECTION V

CONTROL PANEL-AFT WASTE WATER COLLECTION SYSTEM

5.1 G EN E RA L. The Aft Waste Water Collection System Tank Control Panel is located on the side of the Waste Water Collection Tank. It is the electrical control center for the Aft Waste Water Collection Sys-tem. The panel requires a 20 amp, 440 volt, 3 phase, 60 Hz power supply with an external 20 amp dual element fuse or an equivalent circuit breaker.

5.1.1 The aft control panel is identical to the forward panel with the exception of dual discharge pump controls and independent motor circuit protectors. In the automatic mode the dischage pumps will oper-ate on alternate pumping cycles.

Page 5-1

SECTION VI

WASTE WATER COLLECTION SYSTEM DISCHARGE PUMP

6.1 G E N E RA L. The Waste Water Collection System is supplied with two Waste Discharge Pump Assem-blies. The forward system has one discharge pump and motor and the aft system has two discharge pumps with motors mounted side-by-side on a common mounting plate.

6. 1.1 The discharge pump consists of a 440 volt, 3 phase, 1800 rpm, 5 horsepower, dripproof, squirrel cage induction motor that is close-coupled to a horizontal, non-clog 2" size centrifugal pump. The pump is equipped with a single passage end suction cast iron impeller (termed bladeless design), making the pump suitable for pumping raw sewage with solids up to 1-1/2" in diameter. The pump casing is cast iron, volute-type and vertically (radially) split between the back adapter and the volute. In operation, the front head directs the sewage to the eye of the impeller. The rotating impeller imparts a velocity energy to the sewage by centrifugal action. The spiral shaped volute guides the sewage to the discharge port and transforms some of the velocity energy to static pressure (head) by gradually increasing the cross sectional opening through the spiral. The pump shaft rotates counter clockwise as viewed from the driven end of the pump. Rotation is always toward the dischage outlet.

6.1.2 A double endface, mechanical seal is mounted inside the seal chamber. Two sealing surfaces prevent the leakage of sewage or air around the shaft. One stationary ceramic seal creates a static seal at the back-head by means of a recessed seat and seat ring. A second stationary seal is similarly held in the seal housing.

Two rotating, carbon seals are assembled between the ceramic seals around the shaft sleeve. Rotating sleeve bellows prevent leakage between the rotating seals and shaft sleeve. A compression spring maintains con.

tact between the carbon and ceramic faces. The contacting surfaces are polished and lapped to form a liquid tight sealing surface. The seal housing is pressurized with an SAE grade detergent oil by a spring loaded reservoir and interconnecting piping. Seal housing pressure must be greater than the pressure that is devel-oped behind the impeller to maintain contact between the seal faces. A lower pressure would permit waste to enter the housing and foul the seal. Likewise, all air must be bled from the housing. The pressure can be adjusted by the cap screw on the oil reservoir. Sufficient pressure (25-40 psi) maintains seal contact and prevents leakage from the pump casing. A compound pressure gauge indicates the seal housing pres-su re.

6.1.3 Both the inlet and outlet on the pump have 2" 125 lb. ANSI flanges with flexible couplings.

6.2 INSTALLATION. The sewage discharge pumps are supplied on base assemblies (two aft, one for-ward). The bases are drilled with 1 " diameter mounting holes. Distortion of the base plate must be avoided to minimize strain on the pump. The base must be shimmed if necessary to mate with the founda-tion. The foundations must be capable of supporting approximately 560 and 280 pounds (aft and forward wet weights).

6.2.1 Flexible couplings are furnished on the suction discharge f langes of the pump. Interconnecting piping must be independently supported.

6.2.2 The pump assemblies must be grounded to the ship's hull. Electrical connections are made with the control panel motor starters. Cable entrance locations are preferred at the bottom of panel enclosures.

For wire connection to the motors refer to the connection diagram supplied by the motor manufacturer on the nameplate or inside the connection box.

Page 6-1

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ENVIROVAC INSTRUCTIONS

HORIZONTAL END SUCTION NON-CLOG CENTRIFUGAL PUMP

IMPELLER: 7 INCH

EYE AREA: 5.95 SQ. INCH

NO. OF VANES: 1

SIZE: 2-INCH

SPEED: 1750 RPM

MODEL: 2" 5452K-JM

SOLIDS: 1-1/2 INCH

Figure6.1 DISCHARGEPUMPPERFORMANCECURVECHARACTERISTICS

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Page 6-2

U.S. G PM

SECTION VII

MODES OF OPERATION

7.1 GENERAL. The WasteWater Collection System operates in three modes; No Discharge Mode, Overboard Discharge Mode and Shore Discharge Mode. In all modes, the controls for the waste water collec-tion should remain in the automatic mode (discharge pump three-position selector switch in Auto position).

Valve alignment of the waste water drain and discharge lines may vary depending on the operating mode.

Refer to Diagram 14.1 for a routing sequence.

7.2 NO DISCHARGE MODE. The system is in the No Discharge Mode while the ship is underway in restricted waters as defined by 33 CFR 15.9. All waste water is routed overboard. In the No Discharge Mode, waste water drains from forward spaces below the main deck are routed to the forward waste water tank, the discharge line from the aft waste water collection tank is routed overboard and the drains from spaces above the main deck are routed overboard.

7.3 OVERBOARD DISCHARGE MODE. The system is in the Overboard Discharge Mode when the ship is underway outside restricted waters. All waste water is routed to the sewage holding tank. In the Over-board Discharge Mode, waste water drains from forward spaces below the main deck, the discharge line from the aft waste water collection tank and drain lines from spaces above the main deck are all routed to the sewage holding tank.

7.4 SHORE DISCHARGE MODE. The system is in Shore Discharge Mode while the ship is tied up where a deck connection is available. Valve alignment is the same as the Overboard Discharge Mode.

Page 7-1

SECTION VI II

ADJUSTMENTS

8.1 GENERAL. The following adjustments are performed in conjunction with placing the system in full operation.

8.2 UNDERVOLTAGE RELAY ADJUSTMENT. The motor control circuitof the electrical system is equipped with low voltage protection. I rithe event of a power failure or voltage drop, an undervoltage relay (UVR) will de-energize and prevent the vacuum and discharge pumps from operating. To reset the motor control circuit, depress the Control Power Reset Button.

8.2.1 The UVR is mounted inside the control panel and has adjustable pickup and dropout ranges. The pickup knob should be set at the factory match mark (corresponding to approximately 1 00 volts from the twelve to one o'clock position). The dropout knob should be set at the minimum setting (approximately 90 volts). After the relay is initially set, further adjustment should not be necessary.

CAUTION

Trying to set the differential between pickup and dropout to less than 2.0 volts may result in an unstable condition.

8.3 DISCHARGE PUMP MECHANICAL SEAL PRESSURE ADJUSTMENT. The pressure gauge con-nected to the discharge pump seal box should indicate a reading from 25 to 40 psi. If the pressure is below 25 psi turn the adjustment screw on top of the pressure cup clockwise. This pressure exceeds the discharge pump casing pressure and is sufficient to prevent the sewage from entering the seal area. A double mechan-ical seal is installed inside the seal box, but the working mechanism is not exposed to the sewage. The seal box and the pressure cup assembly are factory filled with oil and pressurized at approximately 1 0 psi for shipment. A continuous pressure drop indicates a seal leak which must be repaired prior to operating the discharge system. Some seals will leak slightly when first run but this should cease within a short period of time. During normal operation there will be a slight loss of oil between the sealing surfaces. This loss will require periodic adjustment of the seal pressure.

8.3.1 When the proper adjustment cannot be obtained, an SAE grade detergent oil (1 0 weight minimum, 30 weight maximum) must be added to the oil reservoir. To add oil, remove the pressure cap and reservoir cup. Remove the two pressure plates by inserting a small diameter tool through the fitting at the bottom of the cup and force outward. Reinstall the reservoir cup and fill to the top, Loosen the 1/4" vent plugs on the interconnecting piping and seal housing, and position the pressure plates on the reservoir cup.

Bleed air and excess oil through the two 1/4" vents by forcing downward on pressure plates. Tighten vent plugs after all air has been removed and the pressure plates are positioned so that the pressure cap can be reinstalled. Adjust seal pressure between 25 and 40 psi.

CAUTION

Running the seal with an air-bound box and/or insufficient pressure will result in seal failure.

Page 8-1

SECTION IX

OPERATION

9.1 GENERAL. This section contains procedures for startup of the forward aft waste water collection systems and for operation under alarm conditions. After being placed in operation, the systems will oper-ate automatically and independently with only casual observation by operating personnel.

9.1.1 The aft system collects all waste water from aft spaces below the main deck and discharges either overboard (No Discharge Mode) or to the sewage holding tank (Overboard or Shore Discharge Mode).

The forward system collects waste water from forward spaces below the main deck and discharges over-board (No Discharge Mode) or the waste water is routed by gravity to the sewage holding tank (Overboard or Shore Discharge Mode). Each system has a retention capability but it is not a normal operating function.

Manual operation is also covered but is performed only whe n servicing or testing the system, under emer-gency conditions, or just prior to leaving dockside discharge facilities.

9.2 CONTROLS AND INDICATORS. The pump controls and alarm indicators are contained on separ-ate panels, each mounted on their respective collection tanks. Other indicators are the discharge pump mechanical seal pressure gauges and the collection tank viewing ports. Shipboard piping provides valves for pump isolation and routing of the collection and discharge lines. Refer to Table 9.1 for the controls and indicators, their location, purpose and normal condition.

9.3 STARTUP PROCEDURES. The following steps will serve as a preoperational check list. Some of the steps may not be necessary since the controls may already be in the required position.

9.3.1 At the forward and aft waste water collection units make the following checks prior to placing the system into operation.

1. On the control panels, place the pump selector switches, circuit breakers and main disconnect switch to the Off position.

2. In the control panel, check the setting on the undervoltage relay iUVR) as referenced in Section 8.2.

Note: To open the control panel door, place the disconnect switch to the Off position, turn the release screw (located above the door handle) full counter clockwise and hold.

Turn the handle counter clockwise and open.

3. On the sewage transfer pumps, check that the discharge pump mechanical seal pressure is between 25 and 40 psi. Refer to Section 8.3 for adjustment procedures.

9.3.2 Place the Waste Water Collection Systems into operation as follows.

1. Align the waste water drain line valves and discharge line valves according to the current mode of operation; No Discharge, Overboard Discharge or Shore Discharge. Refer to Section 7.

Page 9-1

2. Place the main disconnect switch on the panels to the On position. Allow several seconds for the control and alarm relays to stabilize and observe that the control Power On Light remains energized.

3. On the aft control panel, place both pump circuit breakers-to the On position.

4. Check rotation of each discharge pump by placing the corresponding selector switch to the Man. position, place the roto push Start switch to the Jog position and momentarily depress the roto push switch. Rotation should be counter clockwise, as viewed from the driven end.

9.4 AUTOMATIC OPERATION. With the selector switch in the Auto position, pump operation will:be controlled by the tank level probes (pump on at 92-gallon level/66% full, pump off at 13-gallon level/9% full). On the aft system, the dual pumps will operate on alternate cycles.

9.5 MANUAL OPERATION. Two manual modes of operation are provided to override the automatic controls. With the selector switch in the Man. position, the corresponding Start switch initiates operation.

9.5.1 RUN MODE. For pump down to the pump stop electrode, place the Start roto push switch to Run, depress and hold the button until the pump starts. The pump will remain energized until the waste water level reaches the pumpoff probe or the three-position selector switch is turned to the Off position.

9.5.2 JOG MODE. To override the start/stop electrode curcuit, place the Start roto-push switch to Jog, depress and hold the button. The pump will remain energized until the button is released.

9.6 OPERATION UNDER FULL TANK ALARM. The alarm is indicated by an audible (horn) and visual (red light) warning on the panel. The conditions are similar for both the forward and aft waste water collection systems.

9.6.1 An acknowledge pushbutton and indicating light are provided on Lhe control panel. The Alarm- Reset-Test pushbutton cancels the alarm horn and energizes the Alarm Horn Acknowledged light. The alarm and acknowledge will remain energized until the condition is corrected. The pushbutton also tests the alarm lights and horn on its respective panel.

9.6.2 The tank full condition warns that the waste water level has reached the 90% full point (1 24 gallons). Approximately 14 gallons of capacity remains before the tank tops off. Immediate steps should be undertaken to lower the level.

9.6.3 If the alarm occurs while the discharge pump selector is in the Auto postion, a malfunction is indicated in the discharge system. Refer to the troubleshooting tables for possible causes and remedies.

If the alarm occurs while the switch is in the Man. or Off position, refer to section 9.3 to initiate pumpout.

Page 9-2

TABLE 9.1 CONTROLS AND INDICATORS

CONTROL NORMAL POSITION

or INDICATOR LOCATION PURPOSE or CONDITION

Alarm-Waste Water Tank Full Indicating Light

Alarm Horn

Control Power Reset Pushbutton

Control Panel

FWD, AFT

Control Panel

FWD, AFT

Control Panel

FWD, AFT

Indicates that the waste water collection tank is 90% full (124 gals.).

Provides an audible indi-cation of an alarm condition.

Energizes the motor control circuits.

De-energized

De-energized

Depress for control power

Conteol Panel

FWD, AFT

Control Panel

FWD, AFT

Control Panel

FWD, AFT

Indicates that electrical power is supplied to the motor control circuits.

Disconnects ship's electri-cal supply from the control panel.

Indicates that electrical power is supplied to the control panel.

Energized

On

Energized

Control Power On Indicating Light

Main Disconnect Switch

Power On Indicating Light

Discharge Pump Motor Run Lights

Control Panel

FWD, AFT

Indicates that the corres-ponding pump is operating.

Energized during pump run

Control Panel

AFT, FWD

(11 pump)

Permits the corresponding Auto pump to be operated man-ually by means of the Start switch. Automatic operation is controlled by the start/stop probes in the collection tank.

Discharge Pump No. 1 and No. 2 Man.-Off-Auto Selector Switch

Discharge Pump No. 1 and No. 2 Start Roto push switch, Run position

Control Panel

AFT, FWD

(1 pump)

With the corresponding selector switch in the Man.

position, permits the pump to be manually started and automatically stopped by means of the stop electrode in the collection tank.

Depress until pump starts

Page 9-3

TABLE 9.1 CONTROLS AND INDICATORS con't.

CONTROL NORMAL POSITION

or INDICATOR LOCATION PURPOSE or CONDITION

Control Panel

AFT, FWD

(1 pump)

Depress and holdDischarge Pump No. 1 and No. 2 Jog Roto Push Switch, Jog Position

Discharge Pump Reset Pushbutton

Alarm-Reset-Test Pushbutton

Alarm Horn Acknowledged Indicating

Compound Pressure Gauge

With the corresponding selector switch in the Man.

position, permits the pump to be operated manually, overriding the control probes in the collection tank.

Used to reset correspond-ing pump motor starter overload relay.

Acknowledges an alarm condition by canceling the alarm horn and energizing the acknowledge light. Also tests the alarm light andi horn.

Indicates that an alarm occurred and the reset was depressed.

Indicates the oil pressure in the pump's mechanical seal housing.

Control Panel

AFTFWD

(1 pump)

Control Panel

AFT, FWD

Control Panel

AFT, FWD

Waste water Discharge Pumps

Unrestricted move-ment

Depress for reset or test

De-energized

25-40 psi

Page 9-4

SECTION X

PREVENTIVE MAINTENANCE

10.1 GENERAL. This section contains information for maintaining the Waste Water Sy stem in good working condition throughout the equipment life cycle. The frequency of all preventive maintenance and overhaul actions should be performed on a scheduled basis as presented in Table 10-1.

CAUTION

Personnel must at all times observe all safety regulations. Review Section 1, Safety, prior to performing maintenance on the system.

10.2 CONTROL PANEL. Observe the control panel daily for any alarm indication. Refer to Section 9 for the possible cause and corrective action. Check daily that the selector switches are in the desired posi-tion for the current mode of operation and that the main disconnect switch is in the On position.

10.2.1 Monthly, check the condition of all alarm lamps by depressing the reset/test pushbutton. Check all other indicating lamps during operation. Before replacing a lamp, check for proper contact between the base and socket.

10.2.2 Semi-annually, check the condition of the vacuum pumps and discharge pump motor starters stationary and movable contacts for excessive wear. Do not replace any contacts until a portion of the contact pad is completely worn away down to the cross bar. Discoloration and/or pitting is not suffi-cient justification for contact replacement.

10.3 SEWAGE DISCHARGE PUMP. Observe daily the discharge pump for any unusual noise or other visual malfunction. The mechanical seal pressure gauge must indicate a pressure range of 25 to 40 psi (as bracketed by red on the compound pressure gauge in the oil buffer piping). Slight losses of oil may require periodic adjustment.

10.3.1 lncreasepressuretothemechanicalsealbyturningtheadjustmentnutclockwise(locatedontop of the oil reservoir). When the proper adjustment cannot be made, replenish the oil supply according to the procedures outlined in Section 8.3. A continous pressure drop indicates a worn mechanical seal or a leak in the interconnecting piping.

10.4 WASTEWATERCOLLECTIONTANK.Thevacuumcollectiontankshouldbeinspectedannually, internally and externally for evidence of corrosion. Check for evidence of seepage through cracks, and for security of all mounting flanges. Thoroughly clean any affected area and repair as required.

TABLE 10.1

PREVENTIVE MAINTENANCE SCHEDULE

FREQUENCY EQUIPMENT ITEM ACTION REQUIRED

Daily Discharge Pump Mecha nical Check for pressure 25-40 psi Seal Pressure Gauge

Page 10-1

TABLE 10.1

PREVENTIVE MAINTENANCE SCHEDULE con't.

FREQUENCY EQUIPMENT ITEM ACTION REQUIRED

Daily Control Panel Check operating modes

Monthly Control Panel Check indicating lamps

Yearly Waste Water Collection Tank Inspect interior and exterior

Page 10-2

SECTION XI

TROUBLESHOOTING

11.1 GENERAL. If the Waste Water Collection System is not operating or is operating unsatisfactorily, determine if the problem is a system, electrical or mechanical malfunction and consult the appropriate table.

1 1.1.1 In the event that the system cannot be restored to operating condition, ENVI ROVAC, INC. will provide technical assistance by trained personnel from its Field Support Department.

.1 1.1.2 To obtain the services of a technician, call ENVIROVAC, INC. at 815/654-8300. A purchase order is required.

Page 1 1-1

TABLE 1 1-1 SYSTEM TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE REMEDY

Loss of system power, Main Disconnect Switch DSI in Turn main disconnect switch all indicator lights out, Off position (AFT system). DS1 to On position discharge motors will not start. Motor Circuit Protector MCP Check for system over-loads tripped (forward system), Refer to electrical Trouble- External power supply Failure. shooting power supply.

Defective transformer T1 Replace transformer T1.

in control panel.

Defective Main disconnect Replace main disconnect switch DSI in control panel. switch DSI.

Blown fuses F1 or F2. Replace and check for overload .

Loss of control power Temporary system voltage Check T1 secondary voltage, to Waste Water pumps drop caused under voltage must be above 100 volts A.C.

(Power On light energized, relay to drop out. Reset UVR by pressing Control Power On light Power Control Reset button.

de-energized).

Defective transformer TI See above.

in control panel

Defective UVR. Check adjustments, Refer to Sec. 8.2

Place discharge pump selector switch in Auto position.

Waste Water Tank Full Level Alarm Indicator On.

Discharge pump selector switch in Off position.

Malfunction in discharge pump motor circuit.

Malfunction in waste water tank high level alarm circuit.

Refer to electrical troubleshooting, Discharge Pump Motor.

Refer to electrical trouble-shooting waste water tank high level alarm circuits.

Page 11-2

TABLE 1 1-1 SYSTEM TROUBLESHOOTING con't.

TROUBLE POSSIBLE CAUSE REMEDY

Refer to mechanical troubleshooting discharge pump and check that all line valves in the discharge system are open.

Malfunction in discharge pump or closed line valve.

Waste Water Tank Full Level Alarm Indicator On.

Refer to electrical section discharge pump control.

Determine level through view port. Remove and clean electrodes.

Malfunction of automatic circuit for discharge pump control.

Electrodes in tank are fouled with solid matter allowing continuous fake signal.

Page 1 1-3

TABLE 11.2 ELECTRICAL TROUBLESHOOTING

DISCHARGE PUMP MOTORS-MAIN DISCONNECT AND 115V CONTROL POWER ENERGIZED

TROUBLE POSSIBLE CAUSE REMEDY

Discharge pump fails to stop when waste water level has been pumped down below pump Off probe.

Repair or replace LCL ..

check operation according to corrective maintenance section.

Defective relay LCL.

Defective motor starter DP1.

Pump off probe fouled.

Repair or replace motor starter DP1.

Remove probe from circuit by disconnecting wires No. 27 (Aft) or No. 19 (Forward). If pump stops, clean probe.

Discharge Pump Motor Run indicator light L1; Ll or L2 fails to light while discharge pump is running.

Loose or burned out lamp in indicator light L1; Ll or L2, Tighten or replace lamp.

Loose electrical connection in 120 volt circuit to indicator light Ll; Ll or L2.

Defective auxiliary contact in motor start DP1.

Locate and repair loose electrical connection.

Replace defective auxiliary contacts.

Check LCL and LCH.

If energized check probes.

Discharge pump fails to start in Auto mode (Full tank alarm energized).

Probes fouled.

Defective relay LCH (pump on) or LCL (pump off).

Motor starter overload tripped.

Check operation according to corrective maintenance section. Repair or replace.

Reset by depressing Discharge Pump Reset pushbutton.

Check motor amperage and mechanical binding.

Page 1 1 -4

TABLE 11.2 ELECTRICAL TROUBLESHOOTING con't.

TROUBLE POSSIBLE CAUSE REMEDY

Discharge pump fails to Probes fouled Check relay LCL. If start in Man. Run mode de-energized, check probes.

(Tank level above pump off probe).

Defective relay See above

LCL

Motor starter See above overload tripped

Aft discharge pumps Defective relay CR1 Replace fails to alternate.

Defective auxiliary contact Replace on motor starter DP1 or DP2

ALARM CIRCUITS-MAIN DISCONNECT AND 115V POWER ENERGIZED

Probes fouled Remove probe from circuit by disconnecting wire No. 29 (Aft) or No. 21 (Forward).

If alarm stops, clean probe.

Full Tank Alarm energized.

No apparent system malfunction.

Defective relay AL

Defective relay AR 1 or AR2

Check operation according to corrective maintenance sec-tion. Repair or replace.

Replace

Page 1 1 -5

TABLE 11.3 MECHANICAL TROUBLESHOOTING

DISCHARGE PUMP

TROUBLE POSSIBLE CAUSE REMEDY

Pump running - no discharge. Plugged suction or discharge Check for casing pressure by line or plugged impeller. removing volute plug. If more, remove front bead and check impeller and suction line.

Wrong direction of rotation. Reverse the connections of any two of the three elec-trical leads to the motor ter-minals at the motor junction box or the motor starter located in the control panel enclosure.

Pump not primed. Check for correct valve alignment.

Pump running -insufficient discharge.

Partially plugged suction or discharge line, or par-tially plugged impeller.

IRefer to above remedy for a totally plugged suction or dis-charge line, or plugged im-peller. If pump disassembly is required, check for a dam-aged impeller.

Air leaks from damaged shaft seal.

Speed too slow.

Volute O-ring or head gaskets defective.

Impeller clearance incorrect.

Refer to corrective maintenance section for repair.

Check motor voltage. If voltage is proper, check for mechanical binding as evi-denced through overheating, vibration or excessive noise.

.Observe for leakage and replace as required.

Refer to corrective mainten-ance section for adjustment.

Page 1 1-6

TABLE 11.3 MECHANICAL TROUBLESHOOTING con't.

TROUBLE POSSIBLE CAUSE REMEDY

Overheating Worn or damaged bearings. Disassemble pump sufficiently to replace the bearings.

Bentshaft. Disassemble pump sufficiently to replace the shaft.

Vibration or excessive noise. Loose mounting hardware. Retighten all mounting hardware.

Impeller binding Check for blockage.

Worn or damaged bearings. Disassemble pump sufficiently to replace the bearings.

Pump cavitation Clear pump intake piping of possible blockage, check for air leak in suction piping.

Also, reduce possible excessive pumping rate.

Bentshaft. Disassemble pump sufficiently to replace the shaft.

Impeller loose on shaft. Disassemble pump sufficiently to tighten impeller nut. Check impeller and suction cover for damage and replace if req u i red.

Leakage at mechanical seal.

Insufficient lubricant pressure .

Turn screw on pressure cup until pressure gauge indicates 40 psi. Replenish lubrication in pressure cup, if required, with an SAE grade oil.

Page 1 1-7

SECTION Xi I

CORRECTIVE MAINTENANCE

12.1 SCOPE. This section contains corrective maintenance instructions for the Waste Water System com-ponents supplied by ENV I ROVAC., INC., 1260 Turret Dr., Rockford, I Ilinois 61 11 1. The instructions are intended as a guide for personnel with experience in repairing electrical and mechanical equipment.

The instructions refer to the appropriate illustrations where required and describe the procedures for properly removing and reinstalling replaceable units. The need for performing corrective maintenance is determined either by inspection or by troubleshooting the equipment (Section XI).

12.2 ELECTRICALCORRECTIVEMAINTENANCE.

GENERAL. Electrical corrective maintenance is essentially restricted to replacement of defective parts.

The following general procedures should always be followed to insure personnel safety and proper corn-penent replacement.

CAUTION

Personnel must at all times observe all safety regulations.

Review Section 1, Safety, prior to performing corrective maintenance on the vacuum sewage system.

1 .When disconnecting electrical leads from a defective component, tag the leads as they are disconnected to insure proper reconnection.

2. All electrical wiring should be terminated with lug terminals.

3. During routine maintenance, check the electrical wiring for damaged insulation, loose connec-tions, defective terminals or any other evidence that requires replacement.

4. When replacing electrical leads, always use the same conductor type, size, and insulation type as on the original installation.

12.3 CONTROL PANEL. The control panel is provided with a hook and interference plate mechanism that prevents the door from being open with the equipment energized.

Open the control panel door as follows with the disconnect switch in the Off position:

1. Turn the safety door interlock release screw (located above the interlock handle) full counter clockwise with a screwdriver and hold in this position. The screw is recessed, preventing the use of a coin or other similar objects.

2. Turn the interlock handle counter clockwise and pull the enclosure door open.

Page 12-1

An interlock defeater is built into the disconnect switch permitting the interlock to be bypassed for test purposes. Open the control panel door as follows when the disconnect switch is in the On position.

WARNING

'Steps to be followed when opening the enclosure door while the equipment is energized are below. When implementing this procedure, use extreme caution to prevent an accidental and possibly fatal shock. This procedure is to be performed by authorized personnel only.

1. Turn the safety door interlock release screw full counter clockwise and hold in this position.

2. Turn the interlock handle counter clockwise and exert a light pull on the handle. Continue to pull on the handle through the remaining steps.

3. Disengage the screwdriver from the release screw. Use the screwdriver and turn the operator defeat screws (located beneath the disconnect switch lever) counter clockwise.

4. Again turn the safety door interlock release screw full counter clockwise and open the door.

With the control panel door open, accessability to all enclosed components is provided. If the interlock was bypassed, proceed with due caution when performing any testing or other corrective maintenance.

If the interlock was not bypassed, the equipment is not energized, excluding the input contacts on the dis-connect switch.

Repair of the control panel is limited to replacement of the individual components. To replace a lamp, unscrew the appropriate lens, remove lamp and replace. To replace a defective plugin relay, pull out the defective relay and with the replacement key oriented with the socket keyway, press in the replacement relay. To replace a liquid level control assembly, or the undervoltage relay, disconnect the electrical leads, remove the mounting screws and install replacement. To replace a defective contact block on the selector switches or pushbutton, disconnect the electrical leads, unscrew the attaching hardware, and install the replacement in the original position. To replace a defective fuse, remove fuse with a fuse puller and replace with an identical fuse. .

To replace individual parts of the motor starters, proceed as follows:

1 . To replace a defective heater coil, remove the attaching screws and heater, install replacement with the pointed terminal in the same position as the defective heater.

2. To replace a defective contact block, disconnect the electrical leads, remove the contact block attaching hardware, install and secure in position the replacement contact block and reconnect the electrical leads.

3. The power pack consists of the magnetic assembly, moveable contacts and coil. To replace a power pack, disconnect the electrical leads, remove the two attaching gold colored screws and pull the power unit. Plug in the replacement power unit, secure with the removed gold colored screws and reconnect the electrical leads.

Page 12-2

4. A se't of stationary contacts is mounted on the molded base and are inspected by removing the plug in power unit. A stationary contact and a power terminal are attached to the molded base with one common screw. These contacts should be replaced whenever a power pack is replaced.

5. To replace an operating coil, remove the cover and its attaching screws, remove the armature and spring plate, and unplug the coil from its mounting. Since the coil contains stab connectors, no wiring needs to be removed. Install the replacement coil in the reverse order of removal.

12.4 WASTEWATERDISCHARGEPUMP.

Removal:

1. lsolatethedischargepumpfromtheWasteWaterCollectionTankbyclosingthesuctionline ball valve. Turn the discharge pump selector switch to the Off position and disconnect the electrical leads at the pump motor.

WARNING

Tag the selector switch and cap the electrical leads to prevent accidental shock.

Remove the attaching hardware securing the discharge pump to the suction and discharge lines.

Remove the mounting screws, nuts, and lockwashers securing the motor to its base.

Remove the pump and motor.

V:

2.

3.

4.

Disassembl, 1 . Refer to the cross-sectional view of the discharge pump (Fig. 13.4) for disassembly. Begin disassembly from the suction cover.

2. Remove; the capscrews (1 7) and pull the volute (1) complete with the front head (2) away from the adapter (1 5). Remove the O-ring (1 6).

3. Remove the bolts (4) and front head (2) to replace the volute gasket (3).

4. Lock the impeller, being careful not to chip or crack the casting. Remove the capscrew (9) and pull the impeller (22) away from the shaft. Remove the shaft key (20).

5. Remove the capscrews (13). Pull the seal housing (1 1) and seal housing gland (10) away from the shaft.