1.3 1301260581 T9593-DC-MMC-010_0_0.PDF

T9593-DC-MMC-010

PUBLISHED BY DIRECTION OF COMMANDER MILITARY SEALIFT COMMAND

29 DECEMBER 2005

0910-LP-104-3007

TECHNICAL MANUAL

MARINE SANITATION DEVICE AND VACUUM

COLLECTION, HOLDING AND TRANSFER

SYSTEM FOR T-AKE

FOR

USNS LEWIS AND CLARK (T-AKE 1) CLASS

INSTALLATION, OPERATION, MAINTENANCE INSTRUCTIONS

(RED FOX ENVIRONMENTAL SERVICES, INC.)

CHEMIN AGREABLE ROAD, YOUNGSVILLE, LA

N00024-02-C-2300

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

T9593-DC-MMC-010

A

List of Effective Pages Date of original pages is:

Original . . . . . . 29 DECEMBER 2005

Total number of pages in this publication is 184 consisting of the following:

Page No. * Change No. Page No. * Change No.

Title/A

Index, Part I

1-1 through 1-89

Dwg 02 027 GA 001

Dwg 02 027 GA 009

Dwg 02 027 GA 01SL

Dwg 02 027 GA 02SL

Dwg 02 027 PI & D

Dwg 4041-150

Dwh 4041-151

Dwg 4041-160

Dwg 4041-161

Dwg 4041-162

Dwg 4041A290

Dwg 4041A291

Index, Part II

2-1 through 2-62

* Zero in this column indicates an original page

INDEX

PART 1: INSTALLATION AND OPERATION MANUAL

PART 2: LOGISTICS SUPPORT INFORMATION PACKAGE

THIS PAGE IS INTENTIONALLY LEFT BLANK

Environmental Services, Inc.

MSD and VCHT

Installation, Operation and Maintenance Manual

1513B Chemin Agreable Road Youngsville, Louisiana 70592

Telephone (337) 856-3709 / Fax (337) 856-9151 Email: sales@redfoxenviro.com Home: www.redfoxenviro.com

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Specification Data Sheet for MSD

&VCHT

Principles of Operation for MSD

&VCHT

Installation of Equipment

Commissioning

MSD Operation

Taking the System Out of Service

Maintenance

Sewage Treatment Unit Testing & Performance

Troubleshooting

Paint System for MSD &VCHT

Equipment Information

Suggested Biological Treatments, Supplemental & Cleaning Products

Structural & Electrical Drawings

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Section 1

Specification Data Sheet for MSD

Treatment Unit Information Model Number: RF-3000-M Serial Number: 4150 Red Fox Work Order Number: 14456 Date of Manufacturing: August 18, 2004 Shipping Weight (dry): 6,715 lbs.

Operating Weight (wet): 40,698 lbs.

Material of Construction: ASTM –A36 Electrical Requirement: 480V/3PH/60Hz/43 Amps (Total MSD & VCHT) Electrical Classification: NEMA 4X Control Panel, TEFC Pumps Air System: Rotary Lobe w/utility Air backup Fault Signal: Dry contact Disinfection Process: Chlorine drip Air Pressure Requirement: 4 psi.

USCG Type II Certification Number: 159.015/0610/0

Customer Information

National Steel and Shipbuilding Company (NASSCO) Harbor Drive and 28th Street San Diego, CA 92113

P.O. BOX 85278

San Diego, CA 92186-5278

P.O. # MUK425611-C

Hull # 471

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Specification Data Sheet for VCHT

VCHT Information Model Number: V700 Serial Number: V1001 Red Fox Work Order Number: 14456 Date of Manufacturing: August 18, 2004 Shipping Weight (dry): 4593 lbs.

Operating Weight (wet): 14874 lbs.

Material of Construction: ASTM – A36 Electrical Requirement: 480V/3PH/60HZ/43 Amps (Total MSD & VCHT) Electrical Classification: NEMA 4X Control Panel, TEFC Pumps, IP 68 VCHT Timers: Transfer Pump Off – 30 min. / Transfer Pump On – 7 sec.

Timers Password: Blue Fault Signal: Dry Contact

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Section 2

Principles of Operations for MSD & VCHT

2.1 DEFINITIONS FOR MSD AND VCHT

2.2 PROCESS PRINCIPLES FOR MSD

2.3 OPERATIONAL PRINCIPLES OF MSD

2.4 MSD EQUIPMENT OPERATIONS

2.5 OPERATION PRINCIPLES OF THE VCHT

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2.1 DEFINITIONS

The following terms are related to the biological sewage treatment process:

AEROBIC SEWAGE TREATMENT: Digestion of organic matter when the environment has a presence of oxygen. The byproducts from this process are CO2 and H2O. This is the type of process that the Red Fox Wastewater Treatment Unit utilizes.

ANAEROBIC SEWAGE TREATMENT: Digestion of organic matter when the environment has an absence of oxygen. The byproducts from this treatment process are CH4 and H2S.

BACTERIA: Microscopic one-celled animals that commonly utilize the organic compounds found in soil, sewage, and water as food supply.

BIODEGRADATION: The process of digesting waste through the use of microorganisms in the wastewater to convert unstable materials into stable compounds.

BLACKWATER: Sewage that contains only human waste from toilets and urinals.

BIOCHEMICAL OXYGEN DEMAND (BOD): A measurement of the dissolved oxygen used by microorganisms in the biochemical oxidation (digestion) of organic matter.

The oxygen demand in water is created by: (1) organic compounds that act as sources of food for microorganisms (2) oxidizable nitrogen produced by nitrate, ammonia and organic nitrogen compounds, which also serve as food for bacteria.

BOD5: A standard laboratory test used to evaluate the potential for treated or untreated wastewater to absorb oxygen from the receiving body of water. BOD5 measures the quantity of oxygen used by bacteria in consuming organic matter in a sample of wastewater over a five-day period at a temperature of 68oF under aerobic conditions. The BOD5 test is widely accepted as the measurement of the pollutional strength of wastewater since it gives results in terms of dissolved oxygen that would be consumed if the wastewater were discharged into a natural body of water. The larger the BOD5 value the greater the pollution.

DISSOLVED OXYGEN: A compound freely available in water and is required to sustain aquatic life in bodies of water, such as rivers, lakes and oceans. Dissolved oxygen can become depleted by an accumulation of pollutants which draw dissolved oxygen from the water during the natural process of stabilizing pollutants.

Dissolved oxygen is an important factor when biologically treating wastewater aerobically, such as in a Red Fox unit. If the amount of dissolved oxygen in the water is not adequate, the aerobic bacteria will die, allowing the anaerobic bacteria to dominate.

EDUCTOR – A device that receives motive fluid from a source such as a pump and through a jet nozzle creates a source of vacuum. The device has (3) fluid connections 1) motive connection – where the motive fluid enters the eductor, 2) suction connection – where the vacuum is created and wastewater enters the eductor & 3) discharge connection – where both motive and wastewater fluids mix and exit the eductor.

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EFFLUENT: Treated or untreated wastewater that flows from a process to the surrounding environment.

EXTENDED AERATION BIOLOGICAL TREATMENT: A process utilized by the redFox® Conventional system to treat domestic wastewater. See Sections 2.2 and 2.3 for a complete description of the entire process.

FECAL COLIFORM: A type of bacteria found in water pollution that is nonpathogenic (not disease causing) and is utilized as a guide to the presence of pathogenic (disease) causing bacteria. In wastewater, pathogenic bacteria are fewer in number and much harder to identify compared to fecal coliform. This is why fecal coliform is utilized as the guide to detect the likelihood of pathogenic organisms being present. It is assumed that if the wastewater is free of fecal coliform then it is free of pathogenic organisms.

FREE CHLORINE: Chlorine is often used in the disinfection process after the treatment of the wastewater but before it is discharged into the environment. A reading of free chlorine in the effluent exhibits a complete kill of pathogenic bacteria. This is because all of the chlorine required to disinfect the effluent has been converted to another substance, leaving only “free chlorine” molecules.

GRAY WATER: The wastewater from laundries, sinks, showers, washing machines, etc.

NONBIODEGRADABLE: Substances that do not degrade using natural processes.

PATHOGENIC BACTERIA: Those bacteria carried by feces that are capable of producing diseases in man, animals and plants.

pH: A value used to indicate the acidity or alkalinity of a solution. The range of values for pH is 1-14. A value of 1 is the extreme reading of an acid solution. A value of 14 would be the extreme reading for a caustic solution while an indication of 7 is a neutral solution. Aerobic bacteria, which are the bacteria utilized by the Red Fox Units, in a biological system will begin to die if their environment becomes too acidic or too caustic. The allowable range of pH for an aerobic biological sewage system is 6.5 – 9.0.

PPM (PARTS PER MILLION). The units ppm and mg/l (milligrams per liter) can be used interchangeably.

SLUDGE: A homogenous matter in a biological sewage treatment unit consisting primarily of microorganisms, non-biodegradable solids, and organic waste material.

TSS (TOTAL SUSPENDED SOLIDS): The total amount of particulate matter suspended in the fluid is TSS. A high TSS in the effluent can cause detrimental environmental effects such as blocking light essential for the growth of algae, as well as clogging fish gills. A high value is usually an indication of high BOD5 because of suspended organic sludge carry-over. The value of TSS is determined by laboratory testing.

VACCUM COLLECTION HOLDING TANK(VCHT) - A tank that is utilized to create vacuum on a sewage collection piping system and also hold the collected wastewater in retention.

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2.2 PROCESS PRINCIPLES

Naturally occurring (naturally present in the wastewater) aerobic bacteria are used for biological sewage treatment systems in the majority of municipal applications. This is the chosen process because it has been proven through decades of usage and is more economical than alternate methods. Because of the proven effectiveness of aerobic biological treatment on wastewater, all redFox® wastewater treatment units utilize this principle. The key feature of the biological wastewater treatment process is the microorganisms (mostly bacteria) that remove the organic pollutants from domestic wastewater. When the wastewater is placed in the proper environment, such as a redFox® sewage treatment unit, these microorganisms reduce the organic pollutant of domestic wastewater very effectively and efficiently. The microorganisms actually utilize (consume) the organic pollutants in the wastewater as their energy source (food) for their cell activity (life).

Another naturally occurring biological process utilized for wastewater treatment is through the use of anaerobic bacteria. This process occurs when there is a lack of oxygen present in the wastewater. The anaerobic treatment process has not been widely used to treat wastewater because the process releases explosive gases (methane and hydrogen sulfide) and offensive odors. It requires longer retention times (larger tankage) than aerobic treatment systems.

The preferred microorganisms for the treatment of wastewater are the oxygen-requiring aerobic bacteria which are utilized in redFox® wastewater treatment systems. Aerobic bacteria rapidly consume the organic waste material in the sewage and release carbon dioxide and water vapor as by-products of their respiration and synthesis process. This does not result in an odor or explosive hazard.

An aerobic sewage treatment process will convert to an anaerobic process if the air supply is cut off for twelve to thirty-six hours. The sewage will become septic and turn black as the solids disintegrate and decompose. The dissolved oxygen levels gradually decrease and produce hydrogen sulfide, causing strong odors to be emitted. However, the process will revert back to an aerobic process within 12 to 24 hours after the air supply has been restored.

The Marine Style Red Fox sewage treatment unit utilizes an aerobic biological treatment process commonly known as “extended aeration activated sludge”, or “extended aeration”. The extended aeration treatment concept requires a large enough sewage treatment unit to retain and aerate the daily average sewage flow for 18 to 24 hours in order to keep the supply (sewage) essentially constant. In this type of process, the bacterial cell population exceeds the available food supply, causing some of the cells to starve to death and become food for the survivors. The result of this process is a minimization of bacterial cell sludge accumulation in the sewage treatment unit. In systems that do not employ this process, bacteria are exposed to a steady food supply, causing their population to increase to a point where continuous drain off and disposal of sludge is necessary.

The microorganism or bacterial cell mass that is generated by cell reproduction is separated from the liquid being treated prior to discharge when utilizing the extended aeration process and reintroduced with the incoming sewage. This causes the introduction of a dense population of active bacteria that increases the rate of removal of the organic waste coming into the system.

This arrangement is called an “activated sludge” process.

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2.3 OPERATION PRINCIPLES OF A RED FOX MARINE SANITATION DEVICE

Four separate operations are involved in redFox® Environmental’s sewage treatment system.

See Figure 2.3.1 below for component identification in the following verbiage which is marked in bold.

The first operation is a coarse screening process. The influent passes through a BAR SCREEN

(A) which prevents large trash items such as rags, plastic bags, etc. from entering the system.

The influent can contain a mixture of black water only or black and gray water.

The second operation is the aeration process. After passing the bar screen, the sewage enters the AERATION CHAMBER (B). The size of this chamber is based on the daily average flow volume of sewage generated. The chamber is sized to retain the influent in aeration for 18 to 24 hours which is required in order for the system to operate on the extended aeration biological treatment process. The extended aeration biological treatment process allows for full conversion

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1-9 n54824 of organic pollutants to non-pollutant substances thus no excess sludge is developed with this process. The sewage entering the system is mixed with water that contains a large concentration of very active aerobic bacteria that consume the organic waste material in the sewage. Air flowing up through the liquid from the AIR DIFFUSERS (C) keeps the bacteria in suspension, and also provides the necessary amount of oxygen required by the bacteria for their respiration and digestion process. The airflow through the liquid also provides the agitation necessary to keep solids from settling on the bottom and helps break up solid waste material.

The bacteria in the aeration chamber will gather together onto the organic pollutants/solids in little flakes called “biofloc”, “floc” or sludge that becomes uniformly mixed in with the water.

This floc/sludge is an organic pollutant and cannot be discharged from the unit.

The organic pollutants are physically separated from the non-pollutants (water) during the third operation, separation process, which occurs in the CLARIFICATION CHAMBER (D). As new sewage enters into the inlet of the unit, this causes the fluid within the unit to be displaced from the AERATION CHAMBER (B) into the CLARIFICATION CHAMBER (D).

The CLARIFICATION CHAMBER (D) is designed to keep the fluid in retention for 6 hours and as still as possible. In order to keep the fluid still even with motion from the ship/vessel, the CLARIFICATION CHAMBER (D) is kept under a head pressure by placing the top of the CLARIFICATION CHAMBER (D) below the waterline of the AERATION CHAMBER (B).

The CLARIFICATION CHAMBER (D) is divided into (2) sections, inside baffle area (towards the aeration chamber) and outside baffle area (towards the disinfection chamber) by a CLARIFIER BAFFLE (G). This CLARIFIER BAFFLE (G) prevents the fluid from short cycling and leaving the chamber without the proper retention time in the chamber and also promotes the proper settling effects.

The organic pollutants/biofloc/sludge settles to the bottom of the CLARIFICATION CHAMBER (D) and a zone of clear liquid forms at the top of the CLARIFICATION CHAMBER (D) on the outside baffle area. The clear liquid is eventually displaced from the clarifier by new fluid entering into the unit through the EFFLUENT MANIFOLD (J) and then into the disinfection process before being discharged. The sludge or floc at the bottom is continuously drawn up by the airlift SLUDGE RETURN LINE (F) and discharged back into the aeration chamber. Any floating material contained in the inside baffle area is drawn into the SKIMMER RETURN LINE (H) and then discharged back into the aeration chamber for reprocessing.

An AIR SUPPLY SYSTEM (K) is provided as an air source for the required air supply to the AIR DIFFUSERS (C), SLUDGE RETURN LINE (F) and SKIMMER RETURN LINE.

The air source injects air into the AIR DIFFUSERS (C) which supplies the necessary oxygen for the biological aerobic process as well as agitation to keep the solids in suspension in the AERATION CHAMBER (B). The air source also injects air into the skimmer and sludge return lines creating the air lift system. As the resulting air bubbles rise in these return lines, they displace the liquid in the lines causing a suction at the inlet of each line drawing the settled or floating substances into the line and lift back into the AERATION CHAMBER (B).

The fourth treatment operation is the disinfection of the clear liquid collected from the clarifier.

There are many different options of disinfection offered on the redFox® Marine Style Units (sodium hypochloride generation, ozonation and UV) but the most popular is described below.

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This option is not necessarily applicable to your unit; see Section 11 for your exact disinfection option and principles of operation for your option.

The liquid from the clarifier flows into the DISINFECTION CHAMBER (E) where it is mixed and disinfected with an incoming mixture of liquid chlorine which is stored in a LIQUID CHLORINE TANK (L). Adequate time must be provided to allow the chlorine to come in direct contact with all the bacteria, or disinfection will not be complete. The DISINFECTION CHAMBER (E) is sized for a minimum 30-minutes retention time at designed maximum hydraulic flow rates. The DISINFECTION CHAMBER (E) contains a DISINFECTION CHAMBER MIXING BAFFLE (M) that promotes mixing and prevents short cycling of the chlorine with the liquid.

As the treated liquid accumulates in the DISINFECTION CHAMBER (E), it is either discharged by gravity or pumped out. The discharge arrangement depends on the elevation of the sewage treatment unit in relation to the final discharge point.

2.4 MSD EQUIPMENT OPERATION

General System Description:

The marine sanitation device (MSD) will process wastewater, both black and gray, for the T- AKE Navy vessel. In general the MSD will receive the black water and gray water from the VCHT transfer system and the vessel’s gray water transfer pumps. The collected fluids will pass through the MSD by gravity flow and the treated effluent will be will be discharged by two effluent pumps.

Component Description: (see P & ID provided in Section 13)

• P3 & P4 – (2) discharge pumps

• B1 – (1) air blower

• LS2 – (1) pressure transmitter

System Operation (see the attached P&ID in Section 13 for piping details and system arrangement): The MSD will receive black water and a small amount of gray water from the VCHT transfer system. The majority of the gray water will be transferred to the MSD by the ship’s gray water transfer pumps through a throttle valve (located at the inlet of the MSD) which controls its flow rate to the unit. The ship’s gray water transfer pumps will not be controlled by Red Fox’s scope. These two streams will collect in the aeration chamber and by gravity, flow through the clarifier chamber, and eventually collect in the final MSD chamber called the chlorine contact chamber where it will be pumped out by two submersible pumps (P3 & P4).

In the aeration chamber, the wastewater from the collection tank and gray water transfer system is collected and aerated. The two streams are pumped through two manually set throttle valves so that the flow rate of the incoming fluid can be controlled. An electrically driven air blower (B1) will supply air to the aeration chamber. This blower will be setup to operate 24 hours a day continuously but does have the capability of alternating the blower on and off every hour if the system dictates the need. Under normal circumstances, the blower WILL OPERATE IN MANUAL POSITION functioning 24 hrs per day. If the vessel becomes low on personnel (under ¼ of its design accommodation capacity), the blower is to be placed into automatic for off and on alternation for biological reasons.

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The fluid flows from the aeration chamber by gravity into the clarifier. The clarifier utilizes (3) return lines that recycle a portion of the liquid back to the aeration chamber. These return lines utilize air to lift & return this portion of the fluid & the air is supplied by the same blower (B1) as the aeration chamber. All controls in the clarifier are manually set and do not require any electrical control.

In the chlorine contact chamber, disinfection of the water and the pumping of the fluid out of the MSD overboard are accomplished. Pumps P3 and P4 are utilized to pump the fluid over board and operate on a lead and lag principle. A level sensor (LS2) is setup to sense the fluid levels in this chamber in order to control the pumping functions. The level sensor (LS2) is a fluid level pressure transducer which gives a 4 to 20 milliamp signal linearly proportional to the water depth in the chamber. The milliamp signal for each level will be recorded at the factory and incorporated into the PLC logic. The fluid level operations points are as follows:

• Stop (6”) – will stop the pump cycle until it reaches the start position.

• Start (1’- 8”) – will start one pump.

• Normal (1’- 4”) – will stop one pump if two were running due to a high fluid level reading.

• High (1’- 10”) – will start the second pump since the 1st pump could not keep up with the incoming flow or the 1st failed to operate.

• High High (2’- 2”) – will signal an alarm but will not interrupt the pumping functions.

Each pump will have a manual setting where it will pump down the chamber until it reaches the stop level setting.

note: levels given are marked from the bottom of the tank

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2.5 OPERATION PRINCIPLES OF VCHT

The VCHT package will collect the sewage from the toilets by vacuum system, hold the fluid in retention for up to (2) days and operate as a buffer tank so that the fluid can be batch fed to the MSD. The VCHT will also collect a small portion of gray water by gravity.

The system will operate in three different modes. The first mode (vacuum mode) produces a vacuum in the wastewater collection main leading from the toilets and collects the fluid from the toilets into the holding tank. The second mode (transfer mode) transfers the fluid from the holding tank to the MSD. The third mode (manual mode) transfers the holding tank fluid to the MSD, overboard or shore side and also creates vacuum manually by bypassing the vacuum sensor.

Figure 2.5.1

Vacuum Mode (see Figure 2.5.1 for system diagram)

In the first mode (vacuum mode), the VCHT system produces a vacuum in the main sewage collection lines leading from the vacuum operated toilets. Pumps (P1 & P2) take suction from the holding tank and pump this fluid through the eductors (E1 & E2) and then back to the holding tank. As this fluid is pumped through the eductor, it creates a vacuum/suction in the collection main piping pulling the wastewater fluid from the toilet mains into the eductor where it mixes with the fluid from P1 & P2 and is sent to the holding tank. The operating vacuum range on the collection main is 14” Hg to 18” Hg. The pumps will operate on a lead and lag principle with the lead pump starting at 14” Hg and stopping at 18” Hg. If the vacuum falls below 12” Hg, the lag pump will start and both pumps will run until 18” Hg is created in the collection main. A

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1-12 n54824 1-10 n54824 1-12 1-10 low vacuum alarm will be issued when the vacuum on the collection main falls below 8” Hg for

(2) minutes. If the vacuum pumps run for over 30 minutes and fails to reach 18” of vacuum, the system will sound an alarm. The vacuum sensor (VS1) will monitor the vacuum levels. A fluid level sensor (LS1) will monitor the fluid level in the holding tank and the description of the operation of this sensor will be discussed below in the second mode of operation.

Transfer Mode (see Figure 2.5.1 for the system diagram)

The second mode (transfer mode) will transfer the fluid from the holding tank to the MSD.

Pumps P1 and P2, following the same lead and lag principle from the vacuum mode, will transfer the fluid from the holding tank to the MSD. They will be operated on a timed principle where a pump will transfer fluid from the holding tank to the MSD. This timer is factory set into the PLC programming but is adjustable through the PLC interface screen to give the operator the ability to tune the system hydraulically. In order for the same pumps to pull vacuum with the eductors and transfer the fluid to the MSD, motorized valves (MV1 & MV2) will be placed at a tee junction before each eductor to allow fluid flow to the MSD. Valves MV1 and MV2 are two way valves (open or close positions) that open to allow a portion of the flow from P1 and P2 to the MSD. When transferring fluid to the MSD, a portion of the fluid stream will always go through the eductors helping to keep the flow to the MSD as low as possible with such high volume pumps. This transfer mode can be bypassed when the vessel requires the collected fluid to be held in the VCHT. This is accomplished by choosing in between (2) buttons, normal operation and hold operation, on the PLC interface screen. The normal operation button operates the transfer process as described above and the hold operation button halts the transfer process.

There are other issues to address in order for mode one and two to operate simultaneously. A fluid level sensor (LS1) will sense 5 fluid levels (low low, low, normal low, normal high, high and high high. The level sensor (LS1) is a fluid level pressure transducer which gives a 4 to 20 milliamp signal linearly proportional to the water depth in the chamber. The milliamp signal for each level will recorded at the factory and incorporated into the PLC logic. Each level will accomplish the following controls for each mode:

• Low Low Level (28") – if the fluid falls to this level, this point will shut down the vacuum collection system in manual and automatic modes.

• Low Level (30”) – if the fluid falls to this level, this point will disengage the transfer system from operating in both automatic and manual mode. If the fluid level reaches the low low level point, the vacuum system will reengage once the fluid level reaches this point in automatic and manual mode.

• Normal Low Level (32”) – if the fluid falls to the low level point, the transfer system will reengage once the fluid rises to this point in automatic and manual mode.

• Normal High Level (68”) – if the fluid reaches the high level point, the timer override transfer process will stop at this point.

• High Level (72”) – if the fluid rises to this level, this point will disengage the vacuum system and start the transfer process (overriding the timer transfer process) with the lead pump. The lag transfer pump will stop at this point if the fluid level reached high high level.

• High High Level (78”) – if the fluid rises to this level, this point will sound the alarm and second pump engages into the transfer process. The alarm will disengage below this point.

note: levels given are marked from the bottom of the tank

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Manual Mode

The third mode (manual mode) will operate the pumps in manual modes for vacuum or transfer.

A button on the PLC screen will toggle to select the pump’s manual selection for transfer or vacuum only. In manual transfer mode, each pump will transfer the holding tank fluid (MV1 and MV2 in open position when each pump is running) utilizing pumps P1 and P2 until the level reaches the low level condition and not reengage until it reaches normal low level. In manual vacuum transfer mode only, each pump will run to pull vacuum only (MV1 and MV2 closed).

The vacuum level will NOT shut down the pumps but the fluid level at low low level will. The manual vacuum will not engage again until the VCHT fluid level reaches low level. A jog button (momentary type) is placed on the PLC screen along with the level of the VCHT tank to override fluid levels for each pump for maintenance reasons.

Two valves (V3 and V4) will be installed in the line leading from the VCHT to the MSD. These

(2) valves will give the operator the ability to transfer the fluid to a shore side or overboard connection by passing the MSD. THIS IS NOT A NORMAL OPERATION PROCEDURE

BUT IS INSTALLED TO GIVE THE SYSTEM DIVERSITY AND OVERRIDING ABILITY.

V1 and V2 are manually operated valves by the vessel’s crew and do not play as part of Red Fox’s scope of work.

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Section 3

Installation of Equipment

3.1 L IFTING/HANDLING THE MSD

3.2 SELECTING THE MSD’S LOCATION

3.3 ANCHORING DOWN THE MSD

3.4 MSD INLET AND OUTLET COLLECTION

ARRANGEMENTS

3.5 VENT CONNECTION FOR MSD

3.6 DRAIN PIPING FOR MSD

3.7 ELECTRICAL CONNECTION FOR MSD

3.8 AIR CONNECTION FOR MSD

3.9 LIFTING/HANDLING THE VCHT

3.10 SELECTING THE VCHT LOCATION

3.11 ANCHORING DOWN THE VCHT

3.12 VENT CONNECTION FOR VCHT

3.13 ELECTRICAL CONNECTION FOR VCHT

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3.1 LIFTING/HANDLING THE MSD

The treatment unit incorporates (4) padeyes for the lifting and handling of the equipment. A typical lifting arrangement for Marine Style treatment units can be found in Figure 3.1.1 of this Section. The sizing of the shackles and slings must be in accordance with the recommendations of the manufacturer of the lifting devices for the dry weight given in Section 1 lifted by a (4) part sling arrangement. The important detail is to keep the slings at a maximum angle of 60o as shown in Figure 3.1.1 to avoid side loading the padeyes. Ensure that all of the fluid is drained from each compartment of the unit before it is lifted.

3.2 SELECTING THE MSD’S LOCATION

Special care should be taken when choosing the treatment unit’s location. The unit should be installed on a level area with the capability for supporting the weight of the unit when full, see Section 1 for this information. Adequate space must be allowed around and above the unit for the necessary access to all equipment for maintenance as well as inspection hatches and ladders. The actual maintenance envelope is left to the owner’s discretion but care should be taken to provide proper access for the items mentioned within this section and Section 7.

The redFox® treatment system works best and reduces possible maintenance issues when placed in a gravity inflow and outlet flow condition, see Section 3.4 for a complete description of this issue. With this in mind, consideration of this issue should be taken into account when locating the treatment unit.

3.3 ANCHORING DOWN THE MSD

The unit should be fastened in its location so that the motion of the vessel does not cause the location of the unit to shift. There are (3) suggested ways of fastening the unit 1) welding, 2) clips and 3) bolting.

The 1st anchoring option, welding, can be accomplished by actually welding the unit’s skid to the vessel’s deck or foundation supporting the unit. A complete fillet weld around the perimeter of the skid to the deck is not necessary but redFox® recommends at least spot fillet welds between the deck/foundation 3” long every 3’ of skid length with a minimum of (1) fillet on each side of the skid, see Figure 3.3.1 for a typical welding detail.

After welding the skid to the deck, paint repairs must be conducted to the unit as per the enclosed paint repair procedures located in Section 10.

The 2nd anchoring option, clips, allows the owner to actually design their own fastener connection of the units skid to the deck. A typical clip detail is shown in Figure

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3.3.2. redFox® suggest locating at least (8) clips on each skid with (2) per side per skid. redFox® can provide these clips as an option if requested with the unit.

The 3rd anchoring option, bolting, allows redFox® to design a bolt pattern into the skid. The skid of the unit would then be placed over existing studs on the vessel’s foundation and fastened in place. If the MSD was ordered with this option, then a drawing of this bolt pattern would be provided in Section 13.

3.4 MSD INLET AND OUTLET COLLECTION ARRANGEMENTS

The unit is to be installed as per the P&ID provided in Section 13. Red Fox recommends that all galley drains connected to the unit should have a grease trap so that grease residue from the kitchen does not reach the unit. Consult your redFox® representative for the proper sizing and purchase of the correct grease trap.

Certain items were required to be removed from the unit for shipping purposes and an assembly drawing to reasseble these loose parts can be found in section 13 titled RF-3000-M Loose Items Installation.

3.5 VENT CONNECTION FOR MSD

The unit has (2) vent connections on the small to mid size units and (3) on the larger size units that must be connected, see Section 13 for the MSD’s General Arrangement drawing to locate these connection points along with their type and size. The size of the piping leading from the unit should not be reduced. The vent line piping should terminate at a point open to the atmosphere (weather deck). When designing the piping run, steps should be taken to avoid any horizontal runs if possible and definitely avoid piping loops and pipe runs that direct downward which could collect water and work as p-trap stopping air from escaping the unit. The straighter the piping run from the MSD the longer the vent will function without causing problems. The unit is designed structurally, as per the USCG Type II regulations, for a water column of 7’ of head above the unit’s vent connection. Due to this fact, vent runs should not be taller than 7’ or possible structural problems might be incurred in the future. Consult redFox® or your redFox® representative for your available options if it is not possible to reach a weather deck within a 7’ of rise. The USCG as well as vessel classification societies have rules and regulations that govern MSD ventilation that should also be considered.

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3.6 DRAIN PIPING FOR MSD

Each chamber (aeration, clarifier and disinfection) on the treatment unit contains a drain connection for periodic cleaning or reduction of solids in the aeration chamber, see Section 13 for the connection type and size. Most redFox® treatment units are not supplied with a discharge header or any type of valving at the drain connection upon order. The General Arrangement drawing in Section 13 will show the details of the unit’s discharge arrangement as ordered. The actual piping arrangement for the draining of the unit is the operator/owners discretion, but should be arranged to drain the unit within the environmental regulations of the area of the vessel’s operation when conducting the cleaning process. Red Fox does suggest installing a drain manifold or at least a drain valve for each drain connection if the unit was not ordered with such. A good suggestion when designing the manifold, if a discharge pump was required in order to discharge the effluent, is to allow the means of draining by gravity the aeration and clarification chamber into the disinfection chamber so that the fluid contained in the aeration and clarifier chambers as well as the wash water can be pumped by the unit’s discharge pump. A suggested piping arrangement for the drain connections/manifolds is provided in Figure 3.6.1.

3.7 ELECTRICAL CONNECTIONS FOR MSD

Most redFox® treatment units will require electrical power to operate. The electrical power requirements are given in Section 1. If electrical power is required, an electrical wiring diagram can be found in Section 13 for the treatment unit if applicable. This diagram will give the electrical connection points needed to install the treatment unit as well as the electrical design of the control panel(s). The electrical supply should be connected to a current protection device properly sized for the amperage draw given in Section 1.

3.8 AIR CONNECTION FOR MSD

Some redFox® treatment units utilize utility air in place of the air blower system or as a backup system to the air blower system. The utility air system on redFox® treatment units consist of an air filter/dryer and air pressure regulator. This utility air system is to be connected to the facilities utility air system consisting of an air supply range of 80 to 100 psi. The actual utility air connection size and type can be found on the unit’s General Arrangement drawing located in Section 13. The amount of air required and pressure the unit operates at after the pressure regulator can be found in Section 1.

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3.9 LIFTING/HANDLING THE VCHT

The VCHT incorporates (2) padeyes for the lifting and handling of the equipment. A typical lifting arrangement for VCHT can be found in the illustration (see Figure 3.9.1) The sizing of the shackles and slings must be in accordance with the recommendations of the manufacturer of the lifting devices for the dry weight given in Section 1 lifted by a (2) part sling arrangement. The important detail is to keep the slings at a maximum angle of 60o as shown in the illustration to avoid side loading the padeyes. Ensure that all of the fluid is drained from the VCHT before it is lifted.

Figure 3.9.1

3.10 SELECTING THE VCHT’S LOCATION

Special care should be taken when choosing the VCHT’s location. The unit should be installed on a level area with the capability for supporting the weight of the unit when full, see Section 1 for this information. Adequate space must be allowed around and above the unit for the necessary access to all equipment for maintenance as well as inspection hatches and ladders.

The actual maintenance envelope is left to the owner’s discretion but care should be taken to provide proper access for the items mentioned within this section and Section 7.

3.11 ANCHORING DOWN THE VCHT

The VCHT should be fastened in its location so that the motion of the vessel does not cause the location of the VCHT to shift. The anchoring procedure, can be accomplished by actually welding the VCHT’s skid to the vessel’s deck or foundation supporting the unit. (for other anchoring procedures refer to Section3.3 and follow the MSD anchoring procedures) A complete fillet weld around the perimeter of the skid to the deck is not necessary but redFox® recommends at least spot fillet welds between the deck/foundation 3” long every 3’ of skid length with a minimum of (1) fillet on each side of the skid, see the illustration for a typical welding detail.

After welding the skid to the deck, paint repairs must be conducted to the unit as per the enclosed paint repair procedures located in Section 10.

Figure 3.11.1

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3.12 VENT CONNECTION FOR VCHT

The unit has (1) vent connection that must be connected, see Section 13 for the VCHT’s General Arrangement drawing to locate the connection point along with the type and size. The size of the piping leading from the VCHT should not be reduced. The vent line piping should terminate at a point open to the atmosphere (weather deck). When designing the piping run, steps should be taken to avoid any horizontal runs if possible and definitely avoid piping loops and pipe runs that direct downward which could collect water and work as p-trap stopping air from escaping the unit. The straighter the piping run from the VCHT the longer the vent will function without causing problems.

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3.13 ELECTRICAL CONNECTIONS FOR VCHT

A redFox® VCHT requires electrical power to operate. The electrical power requirements are given in Section 1. An electrical wiring diagram can be found in Section 13. This diagram will give the electrical connection points needed to install the VCHT as well as the electrical design of the control panel. The electrical supply should be connected to a current protection device properly sized for the amperage draw given in Section 1.

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Section 4

Commissioning

4.1 PREPARING THE MSD FOR START-UP

4.2 STARTING-UP THE MSD AIR SYSTEM (Air Blower

Option)

4.3 STARTING-UP THE MSD AIR SYSTEM (Utility Air

Option)

4.4 STARTING-UP THE MSD EFFLUENT DISCHARGE

PUMP SYSTEM (Optional)

4.5 PREPARING THE VCHT FOR START UP

4.6 DESCRIPTION OF MSD & VCHT CONTROL

SYSTEM

4.7 PLACING SYSTEM INTO OPERATION

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4.1 PREPARING THE UNIT FOR START-UP

Each component can be identified in Figure 4.1.1 which can be found at the end of Section

4.3. This Section marks all components found in Figure 4.1.1 bolded with a component identification letter. Figure 4.1.1 is provided as a guide for these directions but pay special attention because your unit might vary in some instances due to the variety of options available. The General Arrangement Drawing for your unit showing the exact layout is located in Section 13.

1. Check the drain plugs (A) on each chamber to ensure they are tight. If the unit is equipped with a drain manifold, ensure that all drain valves (B) are closed.

2. Open the aeration chamber hatch (C) and disinfection chamber hatch (D) and fill the unit through the aeration chamber hatch (C) with water utilizing a hose/water source having the same characteristics (fresh or salt water) as that used in the sanitary system. Do not fill the unit with untreated sewage!! Fill the unit with water until the water starts to flow into disinfection chamber (E).

3. See Section 1 for the type of disinfection system supplied with the treatment unit.

Follow the disinfection system preparation guide given in Section 11 for your type of disinfection system.

4. Open the air diffuser valve(s) (F) to ¾ open. Unit sizes RF-1000-M and smaller utilize a single air diffuser valve while sizes RF-1500-M and above utilize (2) air diffuser valves.

5. Open the clarifier skimmer air feed line valve(s) (G) to ½ open. Unit sizes RF-350-

M and smaller utilize a single skimmer air feed line valve while sizes RF-500-M and above utilize (2) skimmer air feed lines.

6. Open the clarifier sludge return air feed line valve (H) to ½ open.

7. Open the black and grey water inlet valve. Grey water valve should be adjust to not allow more than 5 gpm. into the unit.(see the unit GA drawing in section 13 to locate this valve)

4.2 STARTING-UP THE MSD AIR SYSTEM (Air Blower Option)

The Red Fox treatment system is offered with different types of air supply options. Check Section 1 of this manual for your type of air supply and Section 11 for operational procedures. If your unit contains a utility air connection in lieu of an air blower, then skip this Section and proceed with Section 4.3. If your unit contains an air blower system, then proceed with the following steps. Some units contain both an air blower system and utility air system as backup. If your unit contains both, then proceed with the following steps and then proceed with Section 4.3 after completing Section 4.2.

Each component can be identified in Figure 4.1.1 which can be found at the end of Section

4.3. This Section marks all components found in Figure 4.1.1 bolded with a component identification letter. Figure 4.1.1 is provided as a guide for these directions but pay special

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1. Prepare the air supply system for startup as described in Section 11.

2. Ensure all switch for all equipment on the control panel is in the off position. Turn on power to control panel. Ensure Disconnect is in “on” position.

3. Turn blower HOA switch to “manual” position and immediately ensure the blower is operating in correct rotation (see Section 11 blower information for the proper blower rotation direction). If the blower is turning in the wrong direction, immediately turn off the blower and make the proper electrical wiring corrections to get the correct blower rotation.

4. Adjust the air diffuser valve(s) (F) (evenly if your unit has two air diffuser valves) to achieve a constant agitation and gentle uniform rolling motion throughout the aeration chamber (L). Unit sizes RF-1000-M and smaller utilize a single air diffuser feed line and valve while sizes RF-1500-M and above utilize (2) air diffuser lines and valves.

5. Adjust the clarifier skimmer air feed line valve(s) (G) (evenly if your unit has two air feed line valves) until a 1/3 full pipe is returning to the aeration chamber from the clarifier skimmer return line(s) (J). Unit sizes RF-350-M and smaller utilize a single skimmer line while sizes RF-500-M and above utilize (2) skimmer lines

6. Adjust the clarifier sludge return air feed line valve (H) until a 1/3 full pipe is returning to the aeration chamber (L) from the sludge return line (K).

7. Steps 4 through 6 might need to be repeated several times until the required aeration agitation/fluid motion in the aeration chamber is accomplished and the return line volumes are accomplished as described. Each time anyone of the air valves are adjusted, the air flow to each line is effected and will required fine tuning of the other valves to offset this effect.

4.3 STARTING-UP THE AIR SYSTEM (Utility Air Connection Option)

The Red Fox treatment system is offered with many different types of air supply options.

Check Section 1 of this manual for your type of air supply and Section 11 for operational procedures. If your unit contains a utility air system as backup to the main air blower system, ensure the blower is turned off before conducting the following steps.

Each component mentioned is shown in bold and can be identified in Figure 4.1.1 which can be found at the end of this section.

If the utility air system is utilized for back up follow steps 1 and 2 only. If the utility air system is the sole air source, follow steps 1, 3 and 4 skipping step 2.

1. Open the air supply valve (M) to the unit’s utility air system.

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2. Adjust the air regulator (N) until the same effects with the aeration agitation, skimmer return and sludge return lines are achieved as with the final step of 4.2. An air pressure gauge (P) is provided as an indicator/guide to the required air pressure helping the adjustment process (see Section 1 for the pressure requirement), but the actual pressure and volume required is driven by the necessary properties to achieve the required aeration fluid agitation, skimmer return line volumes and sludge return line volume.

3. If the utility air connection is the sole source for air supply to the unit, then open the air regulator until the required air pressure is achieved, see Section 1 for this figure. This is the starting point but may required additional adjustment after accomplishing step 4.

4. Set the air diffuser valve(s) (F), clarifier skimmer air feed line valve(s) (G) and clarifier sludge return air feed line valve (H) as explained in Section 4.2 steps 4 through 6 (additional adjustment of the air regulator may be required during these steps to keep the necessary air pressure and volume to the unit’s air system).

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4.4 STARTING-UP THE MSD EFFLUENT DISCHARGE PUMP SYSTEM

Each component can be identified in Figure 4.1.1 which can be found at the end of Section 4.3.

This section marks all components found in Figure 4.1.1 are bolded and marked with a component identification letter.

1. Ensure all switches for all equipment on the control panel is in the off position. Turn on power to control panel. Ensure the electrical disconnect is in “on” position.

2. Place discharge pumps #1 and #2 in “auto” position.

3. Add water to the disinfection chamber through the disinfection chamber hatch (D) opening.

Allow the water to fill the disinfection chamber until the discharge pump system has completed a whole cycle as described in the operation principles of the MSD discharge pumps in section 2.3

4. Replace the disinfection chamber hatch (D).

5. Start-up/initiate the disinfection system at this point. See Section 1 for your type of disinfection system supplied with the treatment unit and Section 11 for your guide to preparing and starting-up the disinfection system.

4.5 PREPARING THE VCHT FOR START – UP

1. Check the drain plugs on the VCHT to ensure they are tight.

2. The unit is provided with a wash down connect to be utilized to fill the unit instead of opening the hatch.

3. Fill the unit with water through the wash down connection until the water level is approximately 36”. Utilize the PLC screen under metering menu to view the fluid level.

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4.6 DESCRIPTION OF MSD &VCHT CONTROL SYSTEM

The MSD & VCHT control system operates the air blower, discharge pumps, vacuum pumps and VCHT actuated valves for the vacuum system and MSD.

The VCHT vacuum pumps functions to create vacuum on the sewage collection main, collect the wastewater and transfer the collected wastewater to the MSD, overboard or shore side (Red Fox recommends transferring the collected wastewater to the MSD for biological operation reasons).

The control panel operates the vacuum pumps in automatic or manual mode through the vacuum HOA switches located on the control panel. In automatic mode, the pumps create vacuum and transfer fluids to the MSD as described in Section 2.5. The transfer system to the MSD can be halted (operating the VCHT in collection mode only/holding mode) by selecting the “Manual Control Operation” button from the Main PLC interface screen menu (see figure 4.6.1) and then selecting the “Hold Operation”…