DVZ - SERVICES GmbH

Boschstrasse 9 D-28857 Syke

Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

FINAL DOCUMENTATION

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-40 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 INDEX

SECTION 01 TYPE APPROVAL CERTIFICATE

SECTION 02 SPECIFICATION
SECTION 03 INITIAL SPARE PARTLIST
SECTION 04 DIMENSION DRAWING
SECTION 05 INSTALLATION DRAWING
SECTION 06 ELECTRIC WIRING DIAGRAM
SECTION 07 INSTRUCTION MANUAL
SECTION 08 ANNEX Pump P1
SECTION 09 ANNEX Pump P2
SECTION 10 COMMISSIONING and MAINTENANCE
SECTION 11 SPARE PARTS Blower G1
SECTION 12 SPARE PARTS Pump P1
SECTION 13 SPARE PARTS Pump P2
SECTION 14 SPARE PARTS Pump P6
SECTION 15 SPARE PARTS Instruments
SECTION 16 SPARE PARTS Electrical Parts

Issue: 18.10.2011 813910-814410FD

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

TYPE APPROVAL CERTIFICATE

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 TYPENPRÜFT]NGSZEUGNIS
für Abwasser-Aufbereitungsanlagen
Certifcate o;fTypeApprotal for SewageTreatmentPlants
im NamenderRegierung
Ausgestellt
derBUNDESREPUBLIKDEUTSCHLANI)
dUTChdiE SEf,-Bf,RUFSGENOSSENSCIIAF,T

Iss el n.ler the authori\, oJthe

FEDERII REPUBLI(- OF GER.II4IVY
hr Su Bü ulsgetlossensch,1ft

Hiermit rirdbescheinigt, dassdie Abrasser-Arllbercitungsanlage

This ß to..tiiIt) that the iirydge Trcd|,re"t Pkttt

T\p: Dvz - sKA io "BroMAsrER"'- PLUS

Ausgelegter llüssigkeitsdurchsalz: ................

.. ::::-.. nf/Tag
hdrnlsd d.sisncdhydrdtlic loadit]Eatr nt:/.l

tu oryani.looditl. al kEper tt@'Biadpnial Otrqer Dcn'dnd (BAD)

AuslegunggcmaißZeichnurgen Nrn. : DVZ - SI',4 30 PLUS / MLCAATS

a"d af the desigt shawr a, D/ori,gs r!d. j

Hergestelltdurch: P..:.?!!-ll-..8i,\s...........
-D._y-2:',S,E8:YCE!.-G"In-b-114,-N\E-r(9..9rl_b,}r,Pe|''9,1]$Rll-"-.?-,
mil dcl IMo-ErtscbließungMEPC.I59(55),um die Arforderuryen
einerPrüftng urterzogenund in Lrbereinstimmrng
an den Betrieb gemäß Regel 9.1.1 der Anlage IV dcs Irternationalen ljbereinkonrncns 7-ur Verhütung der
Meeresversclürutzung d rch Schiffe,MARPOL 73178rlic geänderti[ EntschließungMEPC.115(51).zu ernil]eu.
zrrfiiedenste end erprobtr{rrde.
hds b.ü exdhined dnl Mtisfdcto,ib' te*ed h accotddrce vith the lttenanondL t/Idtitirtc Otqarizanoü re.tol!tiou I|EPL.159(5i) to
the op.nnordl tu.\ünehrenrsrcfetal to it RcA atian 9.L I of Anne\ Il/ of the hn.nldtiono I Corret niot for nE P.e,li o, af
"wI
Pothttionfta Ships.\aRPOL 7J/78a' b! re'alniot IIEPC I I5(51).
"todtf.d
Die Erprobüngen der Abwasser-Aufbereitungsänlage {urden durchgeflihd
The testsoü the sewSe Eeatmenttllant @ft.dt1icd out
an Landbei:

an Bord vor:

rurd abgescblossen
anl: 7.2008

Bei der Erprobungwlrde e Abfluss festgestellt.der nach der änal]lischen UntcrsuchungfolgendeAblänir€fe hat:
The seay tredtmeü pLdnt '|as ten.n and ptudüced dn .l.Itert ,hich. o, dralwis, pro.lßes:

(i) ein geometnschesMittel \on dclrt melu als 100fitalkoliforme Bakterie l00 rnl
(i) a Eeametricmea,afuortorethan100themotolerant califom6/l0ann:
(ii) ein geometdschesMittel der gesaintenSch$nrun- urd Sch$€bstotre\on l5 mg/l für an Land gelesleteAnlagen
odcr dcr MaximalNerl der gesamten Schrl.imn- und Schx€bstoffeübenteigt mcht 15 mg/l plus x mg/ nir das
urngebendeWasser-dasflir Spülzweckevemendet wird. bei Testsar Bord
(i, d Eeo"Etric hEa, oftotal sßpütded satid.t af35 nry/t {tetEd ashot. or the hdtiturht total sßp.rdc.l soliA.t not erccediüE 3i
ptlß ! tut/tfol the a,tbie,t water usedlaütushnts pt,"ases iftested an badü
(iii) ein geometrisches Mittcl dcsBiochcmischcnSauerstofibedafsnach füllf Tagen (BSBS)mit niclrt mellr als 25 m8,4
(iii) d g.ohedc m.d" of5lar Biochehticd I Aryse, Deründ lBoDlafüa narc than 25,tt t
(iv) ein geometdsches Miftel desChemischenSau€rstoffb€darfs II1itnichl lllehr als 125 mg/l
g, d seo,tetic ofche,ricat O'lsat De"nnd afnomorethar 125nts/l
(, der pH-Wert "'ea"
desAmflussesliegt zivischen6 und 8,5
(r) pH ofefflrert is betveen6 d"d 8,5
Zr assurys-Nr.;310.252
Ceftificdte Na.
 See-Berufsgenossenschaft
Prüf- und Zertifizierungsstelle
im BG-PRUFzERT
Europeannotifiedbody
ldentificationnumber0736
I n*'m.',xrl"
lglx I
EC-TypeExamination(ModuleB) Certificate
340.252
Certificate-No.

Nameandaddress
ofthe DVZ-SERVICES GMbH;Boschstraße
GMbH/ENVEKO 9: 28857Svke.
Germany
Dateof issue: 01.09.2008
Annex A.'1 ltem No & A.1/2.6- Sewagetreatmentplants
Item designation

Product
designation: Sewagetreatmentplant

Product
Type: - PLUS
DVZ-SKA30 ,,Biomastef'@
Sewagetreatmentplantsfor shipsacc. MARPOL73178,AnnexlV and
Helsinki-Convention

IMOResolution
MEPC.159(55) plantsin acc.with
for sewagetreatment
(specificstandard):
MARPOL73178,Annexlv, Reg.9

Thetypetesiedwastoundio be in compliancewith prevention

ihe [,,larine-po]lltior fequiremenis Directive
of l'rarineEquipment
(lVlED)96/98/Ec
as amendedby Directive
2008/67/EC subjecttoanyconditions in the schedue (partofthis

with modlle(s) D of F of E ofthis directlve.

Thiscertificaternayonlybe usedin connection

Erprydate 3't.10.2012
Frorolr-l
The appro€lofthe instaledeguipmentwillbein torcebeyondlhe validitydate unlllii ls revokedl
,//,

Note 1i This certiticatewill not be valid ifthe manulacturermakesany changesor modilicationsto the
equipment,which have not been notifiedto, and agreedwith the notifiedbody namedon this certificate.
/
(Se
si96ätLrre f,ru
Note2: Shouldthe specifiedregulations the product(s)
or standardsbe amendedduringthevalidityofthis certificate, is/areto be
r+approvedpriortoit'ltheybeingplacedor boardvesselsto whichthe amendedregulaiions or standards apply.
Note3: The l\,4ark Declaration
may onlybe alfixedto the abovetypeapprovedequipmentanda trlanufacturer's
of Conformity of
Conlormityissuedwhenthe production-controlphasemodule(D, E, or F)oiANNEXB ofthe Directiveis fullycompl'edwith and
controlledbv a writieni n aqreementwith a notified

Notc4: "Wheehnark"X'ormat
YY ta( iwo disits ofy.r nrak afljxed.

X)OX Notified Body numberundertalingsu eillancemodule

xxxx/yy

Tel 0 rol3 61 37-0

Fd: 040136137244
20zlo2lHambu€ 20457Hamburg
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

SPECIFICATION

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

SPECIFICATION BIOLOGICAL SEWAGE TREATMENT PLANT
DVZ-SKA-40 ”BIOMASTER“ – PLUS page: 1/5

PR0JECT: DAEWOO Shipbuilding & Marine Engineering Co., Ltd.

Hamburg Sued – 7,090 TEU Container
4230 - 4235
S P E C I F I C A T I O N: 813910-814410 date: 20.09.2010

TYPE: DVZ-SKA-40 ”BIOMASTER” -PLUS, in combination with a vacuum system,

type tested acc. to IMO MEPC 159(55) by See-Berufsgenossenschaft,
accepted by U.S.C.G. on non US-flag vessels.

MAKER: DVZ-SERVICES GmbH, Boschstr. 9, D-28857 Syke /Germany

SYSTEM CALCULATION

Persons on board: 40 persons

Black water(*): 25 l/day x 40 persons = 1.000 l/day

Grey water(*): 110 l/day x 40 persons = 4.400 l/day

Hospital grey water: 110 l/day x 1 person = 110 l/day

Total black- and grey water: = 5.510 l/day

Volume of integrated buffer

tank: = app. 1.350 l

max. hydraulic per hour: = approx. 340 l/h

The DVZ-SKA-40 “BIOMASTER” is designed for: 7,40 m³/day hydraulic load

5.15 kg/day organic load

Upon its technical data the DVZ-SKA-40 “BIOMASTER” is able to treat the sewage of 40
persons on board.

Remarks: Grey water from kitchen and galley should be lead through a grease trap.

The grey- and black water is collected in the integrated buffer tank.

(*) based on German SBG rules

DVZ-SERVICES GmbH Bankverbindung/banque account: Gerichtsstand und Erfüllungsort Syke
Geschäftsführer: Volksbank Syke e.G. Amtgericht Walsrode HRB 111011
Dipl.Ing.Jens van Züren (BLZ 291 676 24) Konto-Nr. 624/815 7753 200 Die gelieferte Ware bleibt bis zur
Boschstr. 6, D-28857 Syke DG Bank, Hamburg/GENO DE F1 SHR vollständigen Bezahlung Eigentum des
Tel.: ++49 4242-1693 8-0 SWIFT-Code: GENO DE FF 200 Lieferanten
Fax ++49 4242-1693 8-99
UST-ID-No/EEC VAT No: DE 812611118
SPECIFICATION BIOLOGICAL SEWAGE TREATMENT PLANT
DVZ-SKA-40 ”BIOMASTER“ – PLUS page: 2/5

TECHNICAL SPECIFICATION

The system will be delivered as a package unit. All components delivered by

DVZ - SERVICES are prepared with its internal cables and pipes.

The system is consisting of:

1. Biological Sewage Treatment Plant, Type: DVZ- SKA-40 PLUS,

Three chamber biological STP with membrane unit (BMSU).
Prefabricated and tested skit mounted unit, ready for operation. All wet contacted
parts made from stainless steel (316) or non corrosion material,
Rested on a mild steel base frame, welded construction with primer coating.
consisting of:
1st inlet chamber for raw sewage and pre-treatment, sludge removal system,
2 nd chamber with genuine DVZ submerged packed bed bio-reactor and special
ring- aeration and recirculation system,
3 rd chamber, compartment for control transfer- and BMSU feed pump,
Bio-mass separation unit with automatically conditioning- and fleshing system for
clean water (permeate) production.
connection flanges:

inlet black water: DN 50/DN100

inlet grey water: DN 150
aeration: DN 80
discharge: DN 50
flushing: DN 50

2. 2 Discharge pump (P6) with cutting device, with el. motor 1,7 kW, 440 V – 60 cs
pump capacity: 15 m³/h against 18 m WC (one in action, one in stand-by mode).
With pressure gauge

3. 2 Rotary fan blower (G1) with el. motor 440 V – 60 cs, 0,7 kW, with pressure
gauge (one in action, one in stand-by mode).

4. 1 Electric switch box with all necessary parts for automatically operation by PLC-
Control- System, E – power: 3x 440 V, 60 Hz., with transformer 3 x 440 V primary
and secondary 24V DC/22OV AC, level and pressure transmitter relays, motor
starter and protection relay, PLC operation panel for start/stop all drives in
automatic/manual operation, all necessary lamps, for control the process, all
mounted in a splash proof steel box, IP 54 protected.
The switch box with door stopper is ready mounted, tested and wired together

DVZ-SERVICES GmbH Bankverbindung/banque account: Gerichtsstand und Erfüllungsort Syke

Geschäftsführer: Volksbank Syke e.G. Amtgericht Walsrode HRB 111011
Dipl.Ing.Jens van Züren (BLZ 291 676 24) Konto-Nr. 624/815 7753 200 Die gelieferte Ware bleibt bis zur
Boschstr. 6, D-28857 Syke DG Bank, Hamburg/GENO DE F1 SHR vollständigen Bezahlung Eigentum des
Tel.: ++49 4242-1693 8-0 SWIFT-Code: GENO DE FF 200 Lieferanten
Fax ++49 4242-1693 8-99
UST-ID-No/EEC VAT No: DE 812611118
SPECIFICATION BIOLOGICAL SEWAGE TREATMENT PLANT
DVZ-SKA-40 ”BIOMASTER“ – PLUS page: 3/5

with halogen free, core numbered cables (acc. to DVZ’s standard) to all
electrically components

5. set 1 pc level-sensor, for automatic control STP, 3 switch points H, HH, L, with
electrodes for switch-relay,
1 pc pressure – transmitter, for control BMSU – unit, 0-6 bar, 4-20 mA, 2 set
points H, HH-alarm

6. 1 Sight glass made of acryl-glass, with shut-off valves

7. set Shut-off valves for service, pneum. control valves, 3-way-ball-valves for
process control, etc.,

8. 2 Set installation-and maintenance instructions, el. wiring diagrams,

dimension-and installation drawings, spare part lists in English language.

9. 2 Set type approval certificates from See-Berufsgenossenschaft

MED-certificate, shop test-certificate

10. 1 BMSU loading pump DVZ-ASC 25-1 (P2) for membrane, with el. motor
0,66 kW, 440 V – 50/60 cs pump capacity: 1,0 m³/h against 40 m WC

11. 1 BMSU overflow pump DVZ 80-160 (P1) for recirculation BMSU module, with el.
motor 3,0 kW, 440 V – 60 cs pump capacity: 107 m³/h against 7,4 m WC

12. 1 DVZ- BMSU Biomass/ clean water separation unit, with membrane module
type: (2) or (3), automatically flushing device and integrated CIP-System

13. 1 PL – unit for discharge permeat to overboard incl. pump 0,55 kW, 3x 440 V – 60
cs

14. Spare parts

- 1 set spare parts for blower
- 1 set spare parts for pump
(acc. to DVZ’s standard)

15. Colour:
- BSTP: made of stainless steel
- pumps, blowers: Munsell 7.5 BG 7/2
- control panel: Munsell 7.5 BG 7/2
- frame: Munsell 7.5 BG 7/2
DVZ-SERVICES GmbH Bankverbindung/banque account: Gerichtsstand und Erfüllungsort Syke
Geschäftsführer: Volksbank Syke e.G. Amtgericht Walsrode HRB 111011
Dipl.Ing.Jens van Züren (BLZ 291 676 24) Konto-Nr. 624/815 7753 200 Die gelieferte Ware bleibt bis zur
Boschstr. 6, D-28857 Syke DG Bank, Hamburg/GENO DE F1 SHR vollständigen Bezahlung Eigentum des
Tel.: ++49 4242-1693 8-0 SWIFT-Code: GENO DE FF 200 Lieferanten
Fax ++49 4242-1693 8-99
UST-ID-No/EEC VAT No: DE 812611118
SPECIFICATION BIOLOGICAL SEWAGE TREATMENT PLANT
DVZ-SKA-40 ”BIOMASTER“ – PLUS page: 4/5

16. Contacts for:

- common alarm

DIMENSION (preliminary)

overall dimensions: appr. L = 2720 x W = 1670 x H = 2200 mm

total electric consumption: app. 12.0 kW

all electric motors are of IP 54 protection, insulation class ”F”

This is a preliminary offer, necessary techn. modifications will be done without notice.

All DVZ units will be built and delivered according to DVZ’s technical specifications, technical
drawings, electrical wiring diagrams and normal Maritime standards if not otherwise
confirmed in written form by DVZ
Main Dimensions of the standard series skid mounted units

DVZ-SERVICES GmbH Bankverbindung/banque account: Gerichtsstand und Erfüllungsort Syke

Geschäftsführer: Volksbank Syke e.G. Amtgericht Walsrode HRB 111011
Dipl.Ing.Jens van Züren (BLZ 291 676 24) Konto-Nr. 624/815 7753 200 Die gelieferte Ware bleibt bis zur
Boschstr. 6, D-28857 Syke DG Bank, Hamburg/GENO DE F1 SHR vollständigen Bezahlung Eigentum des
Tel.: ++49 4242-1693 8-0 SWIFT-Code: GENO DE FF 200 Lieferanten
Fax ++49 4242-1693 8-99
UST-ID-No/EEC VAT No: DE 812611118
SPECIFICATION BIOLOGICAL SEWAGE TREATMENT PLANT
DVZ-SKA-40 ”BIOMASTER“ – PLUS page: 5/5

Approx. Main Dimensions

Type
L (mm) W (mm) H (mm)
DVZ-SKA-10 PLUS 2270 1220 1630
DVZ-SKA-20 PLUS 2550 1410 1630
DVZ-SKA-30 PLUS 2345 1670 2200
DVZ-SKA-40 PLUS 2720 1670 2200
DVZ-SKA-50 PLUS 3015 1840 2200
DVZ-SKA-70 PLUS 3640 1840 2200
Subject to technical modifications without notice

DVZ-SERVICES GmbH Bankverbindung/banque account: Gerichtsstand und Erfüllungsort Syke

Geschäftsführer: Volksbank Syke e.G. Amtgericht Walsrode HRB 111011
Dipl.Ing.Jens van Züren (BLZ 291 676 24) Konto-Nr. 624/815 7753 200 Die gelieferte Ware bleibt bis zur
Boschstr. 6, D-28857 Syke DG Bank, Hamburg/GENO DE F1 SHR vollständigen Bezahlung Eigentum des
Tel.: ++49 4242-1693 8-0 SWIFT-Code: GENO DE FF 200 Lieferanten
Fax ++49 4242-1693 8-99
UST-ID-No/EEC VAT No: DE 812611118
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

INITIAL SPARE PARTLIST

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

ERSATZTEILLISTE DVZ-SKA-40 „BIOMASTER“®-PLUS
Initial Spare part list Sewage Treatment Plant
PR0JECT: DSEC
Hull No.: HN H4230-4235
DVZ-Serial No.: 813910-814410

Pos. Menge Benennung

Item Qty. Description
1 1 Satz Reparatur-Satz Gebläse DVZ-SD2n
set spare part set blower
2 1 Satz Reparatur-Satz Pumpe DVZ-S40
set spare part set pump

delivery: with the sewage treatment plant, packed in the switch box of the unit.

Feb. 10 813910ISP
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

DIMENSION DRAWING

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

INSTALLATION DIAGRAM

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

ELECTRIC WIRING DIAGRAM

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

INSTRUCTION MANUAL

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 D v Z

DVZ-SERVICES

DVZ - SERVICES GmbH

Boschstrasse 9 • D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16938 -0
fax:++ 49 / 42 42 / 16938 -96
e-mail: Info@dvz-group.de
Web.: www.dvz-group.de

INSTRUCTION MANUAL
Mechanical Part
for

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ - SKA „BIOMASTER“- Plus

Plant size: SKA 10 to 70
Rev. Rev.
Date Author Date Author
No. No.
1 08.08 Gissou Sahebi
2 02.09 Gissou Sahebi
3 03.09 Gissou Sahebi
4 07.10 R&D
5 08.10 R&D

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 2 of 39

 TABLE OF CONTENTS:

1.0 GENERAL 5
2.0 FUNCTIONAL DESCRIPTION 7
2.1 DVZ- SKA “BIOMASTER” PLUS (IT) 9

2.2 Permeate Lift (PL): 10

2.3 Automatical conditioning-, flushing- and chemical

cleaning – system for BMSU: 11

3.0 TECHNICAL DATA 14

4.0 SAFETY INSTRUCTIONS 15
5.0 INSTALLATION INSTRUCTION 16
5.1 POSITIONING 16
5.2 PIPE CONNECTIONS 16
5.3 ELECTRIC 16
6.0 S T A R T U P 17
6.1 GENERAL PROCEDURE FOR START UP 17
6.2 SET UP FOR OPERATION 18
6.3 VALVE SETTINGS FOR OPERATION 18
6.4 CONTROL SETTINGS 18
7.0 MAINTENANCE 19
7.1 SLUDGE PUMP OUT 19
7.2 PUMPOUT PROCEDURE 19

8.0 SHORT TERM LAY UP 20

8.1 LONG TERM LAY UP I SHUTDOWN 20
9.0 TROUBLESHOOTING 20
9.1 ODOR 20
9.2 ODOR FROM TREATMENT TANKS VENT 20

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 3 of 39

 9.3 ODOR IN SPACE WHICH UNIT IS LOCATED 21
9.4 ODOR IN OTHER SPACES 22

9.5 POOR DRAINAGE (TOILETS DO NOT FLUSH PROPERLY) 22

9.6 FOAM FROM TREATMENT TANK VENT 22
9.7 EXCESSIVE BACK PRESSURE IN TREATMENT TANK 22
9.8 HIGH WATER LEVEL IN TREATMENT TANK 23
9.9 WATER SPILLING OUT OF THE CONTACT TANK VENT 23
9.10 AERATION BLOWER CIRCUIT 24
9.11 DISCHARGE PUMP CIRCUIT 24
9.12 ELECTRODE TYPE LEVEL SWITCH 24
9.13 HIGH WATER LEVEL 25
10 Technical Documentation 26

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 4 of 39

 1.0 GENERAL

This DVZ-SKA ”BIOMASTER” is type approved according to old IMO Resolution

MEPC 2.( VI). The DVZ-SKA ”BIOMASTER”- Plus system has been developed by using
the an additional Bio-Mass-Separation-Unit (BMSU). In addition with the BMSU, the
arrangement SKA with BMSU is type – approved according to the new IMO Resolurtion
MEPC 159 (55) (see following P&ID).

Biological Part of Sewage Treatment Plant (STP):

Stage 1: The STP is a biological sewage treatment plant with three compartments:

1. The 1st inlet – chamber is for mixing and conditioning the sewage,

2. The 2nd reactor – chamber is the biological reactor for treating process,

3. The 3rd outlet – chamber, collecting tank for biological treated water and pump
control tank,

The 1st -chamber which is the inlet chamber and it consists of an aeration-pipe and a
return sludge inlet (reject from BMSU).
A settling zone under the aeration pipe is considered beneath the first chamber for
collecting the solids. The aeration pipe supply the inlet sewage with oxigene and mixed
homogene incoming sewage with returne sludge.
The 2nd -chamber is the biological reactor (Aerated Submerged Fixed Film Unit). In this
chamber is located a submerged fix bed which rest on support and is considered as
settlement area for the microbes (immobilized). Forced by around air upstream, the
sewage will flow (circulation) over the fix bed.
The blower has to deliver the air for aeration the different chambers. After biological
treatment, the treated water passes the settling zone and over flows into the third
chamber (control chamber).

The 3rd chamber have two functions, collecting the biological treated water and control the
transfer pump (P5) and BMSU loading pump (P2).

Stage tow: Bio Mass Separation Unit (BMSU) for polishing up the clean water quality to
new IMO Resolurtion MEPC 159 (55).

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 5 of 39

 The above P&ID show the general principle of DVZ-SKA – “BIOMASTER” PLUS

Type-tested in accordance with IMO Res. MEPC 159 (55)

•
Approved by the US Coastguard for non-US flag vessels
•
Developed using the state-of-the-art ”Submerged fixed bed bio-film process”
•
Problem-free operation, low operating costs
•
Can be used in gravity systems and all vacuum systems
•
Use of all-aerobic sewage treatment method prevents methane gas forming
•
Custom-built systems for limited space availability or retrofitting
• Fixed bed bio-film process produces excellent treatment results
Up to 150 times more activated area than conventional systems
•
BMSU operated with a self cleaning undestructible metal-membrane
•
Minimal maintenance for the autom. Operation BMSU
•
Absolute constant high quality of clean water
•

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 6 of 39

 2.0 FUNCTIONAL DESCRIPTION
( S EE ABOVE P&ID AND FOLLOW DRAWING)

16 O2 O3 O5
12 15

O6

14

O7
O4

O1
10 O8
11

17 13
16
O9
01 Sewage inlet 10 MCC / PLC (LOGO)
02 Ventilation (air vent) 11 Pre Cleaning Tank
03 Air distribution pipe 12 Transfer Pump (P5)
04 Air Blower (G1) 13 BMSU over flow Pump (P1)
05 Level Sensor (electrodes) 14 BMSU loading Pump (P2)
06 CIP Tank for BMSU 15 PHV (pressare holding valve)
07 BMSU Membrane 16 control tank (STP outlet)
08 Discharge Pump (P6) 17 BMSU
09 Treatment Tank with Bio Reactor

Operating Principle Biological Sewage Treatment System DVZ-SKA-“BIOMASTER“

The sewage, grey water (GW) and black water (BW), is feed to the buffer tank by gravity
or vacuum pumps and will be delivered by transfer pump (P5) to STP. The pump (P5)
calibrat the volume flow so that the Membrane stage (BMSU) can smooth operate. The
capacity of BMSU is calculated for an operation time is 22 hours per day for treating the
daily total amond of sewage, with a 2 hours time buffer.
Sewage will be deliver from the transfer pump (P5) via the inlet 01 into the pre-treatment
tank 11, where intensive mixed with returne sludge (reject), by a pre-aeration tube,
placed on the under part of pre-treatment tank. The air (oxygen) will be delivered by the
blower
( 04 or G1).
The system is ventilated to the open deck (chimney) via the air vent pipe (02).

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 7 of 39

 The pre-treated ”sewage” flows through a special overflow into the bioreactor tank 09
containing the submerged fixed bed, which is positioned at the centre of the reactor tank.
The microbes are sitting on the suface the submerged fixed bed, as so called “biological
rasen” (immobilized biological reactor). The sewage has continiously circulate through the
submerged fixed bed. For that reason, a ring-aeration-tube is installed around the
submerged fixed bed. This aeration tube produced an upstream around the fix bed, for
continuous lift up the sewage and send over the reactor bed.
Fine air bubbles blown in and keep the sewage in suspension and supply the micro-
organisms with necessary oxygen.
Remaining activated sludge is fed back into the pre-treatment tank (11), by using a sludge
lifting pump (Mamut pump principle) for continoues force the process.
The biologically cleaned sewage is send via a inner guide system and a rising pipe to the
pre control tank (16).
The pre treatment tank have a free floating level and act as control tank for control the
STP. The level sensor 05, with three set points (L, H, and HH) activate the following
BMSU loading pump (P2) and the over fill alarm.
The discharge pump (08 or P6) have a double funktion, deliver flush water for clean the
modul head and foot and empty the STP.
In some cases an optional three-way-valve (Holding tank valve) for direct the STP filling to
holding tank.

Stage 2: BMSU post treatment System:

Separation system (BMSU)

The concept of SKA “BIOMASTER” PLUS series is an arrangement of conventional SKA

sewage treatment plant, type approved acc. to IMO Resolution MEPC 2.( VI) with adding
a BMSU system for polishing up the clean water and producing higher quality permeate
according to IMO Resolution MEPC. 159 (55).
Separating biomass from treated water will be done by “cross flow” method by using an
from DVZ-Services GmbH developed membrane module (DVZ-BMSU, module).
This BMSU have a compact 100% welded module construct without any seals or plastic
parts, with St. St. diaphragm tubes.
The “BMSU- over flow pump” (P1) generates a permanent high membrane over flow. In
these high speed over flow loop, the biological treated water/biomass mixture will be
delivered through the “BMSU- loading pump” (P2).
As a result of feeding, an over pressure will be created on the feed side of membrane.
Thereby, permeate flux will be forced through the membrane and the bio-sludge -all solids
and bacteria- will be send back to the STP. The “BMSU- loading pump” (P2) will be limited
by pressure holding valve (PHV). A part of flow (reject) will be fed back to the bioreactor
via the pressure holding valve. The ratio of the amount of loading to feed backing (reject)
will define the sludge concentration in the modules.

The amount of produced water (permeate) is controlled by adjusting the pressure holding
valve (PHV) and will be indicated by the flow indicator (FI 1).

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 8 of 39

 2.1 DVZ- SKA “BIOMASTER” PLUS (IT)
As a varius to the DVZ- SKA “BIOMASTER” PLUS serial is the
DVZ-SKA ”BIOMASTER”- Plus (IT)
Basic Principle of DVZ-SKA ”BIOMASTER”- Plus (IT)

a
DVZ-SKA “BIOMASTER” – PLUS, Plant size: from SKA 10 to SKA70

01 Sewage Inlet 09 Treatment Tank with Bio Reactor

02 Ventilation (Air Vent) 10 MCC / PLC (LOGO!)
03 Air Distribution Pipe 11 Pre Cleaning Tank
04 Air Blower (G1) 13 BMSU overflow Pump (P1)
05 Level Sensor (Electrode) 14 BSMU loading Pump (P2)
06 CIP Tank for BMSU 15 PHV (pressure holding valve)
07 BMSU Membrane 16 Control Tank
08 Discharge Pump (P6) 17 BMSU
Operating Principle Biological Sewage Treatment System DVZ-SKA-“BIOMASTER“ (with integrated tank)

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 9 of 39

 This type of STP (DVZ-SKA ”BIOMASTER”- Plus (IT)) is similar to the
DVZ-SKA “BIOMASTER” – PLUS, but the hole STP tank and the control tank is
dimensioned in bigger size (See (a) in above schema). This additional volume will be use
as buffer function, so that a separate buffer tank is not necessary.
If the sewage, black- and grey water feed direcly in the first chamber of STP (gravity
system), it is necessary to use a macerator for cutting large particle.
In case of vacuum system which feed the “black water” directly in the first chamber of STP
and “grey water” drain by gravity to the first chamber STP, an additional mazerator is not
necessary, because the vacuum pumps already have a mazerator equipment.
If grey water is not aviable, it is necessary to add dilution water.

Notice: For the technical equipment for dilution water and the correct volume of dilution
water, please ask DVZ Company.

Notice: For sampling the outlet quality, the sample shall be taken on the sample valve
(S), near permeate flow meter (FI 1).

2.2 Permeate Lift (PL):

Notice: Please notice that the back pressure to permeate connection shall not be more
than 0,5 bar. In case of higher back pressure, to lift permeate over board, it is to
install a DVZ-PL unit.

This permeate lift is designed as separate tank with a submerged pump

and controlled by level switches.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 10 of 39

 The permeate lift is an option and will be integrated in the STP, if the customer has
ordered it.

2.3 Automatical conditioning-, flushing- and chemical cleaning – system

for BMSU:

The BMSU system has a multiplex, automatical working conditioning-, flushing- and
chemical cleaning (CIP) system.
The membrane conditioning and membrane flushing works according to the PLC time
controlled.
The chemical cleaning will be done semi automatic. For that procedure, it is necessary to
switch some valves manually, which will be shown (guided) in PLC monitor.

Membrane conditioning:

Picture 1

The above picture shows the methode of membrane conditioning.

For conditioning the BMSU-Membrane the loading pump (P2) will be interrupt for app. 10
sec. and the BMSU over flow pump (P1) keep on running. Periode and interval is PLC
controlled. The over flow polishing the membrane (diaphragm) surface and flushed out
precipitated parts from the surface (see picture 1).

Flushing system (hydraulical cleaning) (see picture 2)

Depends on the pollution of sewage with hairs, paper rests and fibers, the flow against the ends
of diaphragm tubes will be blocked (mechanical blocking).
The module has an upper- (head) and under- (foot) flow against the tube ends.
Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 11 of 39
 An automatic controlled system is considered for permanent preventing blocking the
module head- and foot-blocking (coating) (side cleaning).
The module flushing will be done alternately by an adjustable time control system (PLC)
(Supplier`s adjusted).

Picture 2

The mechanical blocked module sides (head and foot) will be back washed with system
water, which will be delivered from the “discharge pump” (P6); through valves (V1) for
cleaning the module’s head and the module’s foots will be cleaned through valves (V2).
The cleaning cycle and duration can be set up manually (Supplier’s adjusted).
The washed out goods can be sent alternatively through the three-way valve (H15) back
to the system or optional to the buffer tank.

CIP equipment (chemical cleaning)

It is important to distinguish between automatic module conditioning -which makes clean
the head and foot of module from clogging- and an automatic membrane cleaning which
cleans the membrane diaphragm self and has a effect as anti-scaling. In case of
membrane scaling, the module has to be put out of operation and all involved valves have
to switch in CIP position.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 12 of 39

 Picture 3
Picture 3 shows all different plant parts which are involved in CIP procedure.

The necessity of membrane diaphragm cleaning can be found out usually by too high
working pressure (about 4 bar) and decrease of permeate flow, which can be checked
by flow indicator.

Normally, If the permeate flow rate decrease, it has to be adjusted by the pressure holding
valve (PHV). It can be adjusted by pressure holding valve (PHV) as long as the pressure
is less than 4 bars. In the moment that the adjustment is not possible ( 4 bar), he has to
start CIP cleaning for the concerned module.

For starting the CIP cleaning please look in Instruction Manual for electrical part.

NOTICE! The BMSU-Unit of the Sewage Treatment Plant DVZ-SKA-“BIOMASTER”-

PLUS is not allowed to be operated with a pressure 4 bar.
At 4 bar an alarm will occur that the membrane has to be cleaned (CIP) and the
STP will be stopped automatically.
We recommend to clean the membrane regularly to avoid the warning and alarm/stopping of
the STP.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 13 of 39

 3. TECHNICAL DATA

TYPE DIMENSION: SKA-“BIOMASTER DVZ-” PLUS

Persons Lenght Width Height Transport Operation Weight [kg]
[mm] [mm] [mm] Weight [kg]

SKA 10 PLUS 10 1.815 1.210 1.625 910

SKA 20 PLUS 20 2.255 1.210 1.625 925
SKA 30 PLUS 30 2.345 1.465 1.625 1055
SKA 40 PLUS 40 2.510 1.770 1.625 1215
SKA 50 PLUS 50 2.885 1.770 1.625 1.310
SKA 70 PLUS 70 2.885 1.770 1.625 1460
SKA 100 PLUS 100 4360 1870 2250 1640
SKA 150 PLUS 150 4360 1870 2250 2160
SKA 200 PLUS 200 3950 2750 2250 Part 1: 2160 kg
Part 2: 2280 kg

SKA 250 PLUS 250 3950 2750 2250 Part 1: 2160 kg

Part 2: 2680 kg

ELECTRIC POWER SUPPLY

Electric Power Supply: 3 x 400 V 50 cs / 3 x 440 V 60 cs
PIPE CONNECTIONS
A1 Sewage Inlet DN 40
A2 Air vent DN 100
A3 Discharge R 1 ½ female
A7 Flushing Water Inlet R 1 ½ female
technical modifications without notice

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 14 of 39

 4.0 SAFETY INSTRUCTIONS

Please observe the information in these operating instructions, to ensure that the
unit functions satisfactorily and remains serviceable for a long period:

When planning the application of the device, and during its operation, observe the
• general technical rules!
Take suitable measures to prevent unintentional operation or impermissible
• impairment!
Note that lines and valves must not be unscrewed from systems that are under
• pressure!
Always switch off the voltage supply before working on the system!
•
If this information is ignored, or if unauthorised work is carried out on the device, we
• will not accept liability of any kind, and the warranty will no longer be valid for the unit
and its accessories!
Work on the unit must only be performed by skilled personnel using suitable tools!
•
Always keep in mind during maintenance and repairs, that bacteria and viruses are
• present in the waste water. Health risks are minimal when good personal hygiene is
observed and proper precautions are taken. Use protective clothes, gloves, and
rubber boots where necessary.
DO NOT EAT, DRINK OR SMOKE when working on the sewage system. Always
wash up with water and preferably disinfecting soap after works.
Vapours and gasses: Make sure tanks are ventilated properly before entering.
• When access to a sewage tank is necessary, always arrange for a second person to
watch outside the tank to give help when needed.
Do not install this equipment in or expose it to an explosive atmosphere, unless the
• unit was especially designed for this purpose, see type shield on the unit
(Always refer to Supplier with type and serialnumber when not certain)
Do not exposure the Treatment Tank interior or its vent termination to an open flame
• or other source of ignition.
Installation of connecting pipeworks are subject to classification rules.
•
Do not use or dispose Pine Sol, Lysol, or other disinfectants in the toilets or other
• drains leading to the system. Powder or liquid detergents may be used as long as
they do not claim strong disinfecting properties.
Do not dispose of grease through drains leading to system, install greasetraps where
• necessary.
Paper towels, cigarette butts, sanitary napkins, condoms and rags should not be
• flushed down the toilets. Although it is unlikely that they could clog the unit, such
practices should be discouraged

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 15 of 39

 5.0 INSTALLATION INSTRUCTION

5.1 POSITIONING

The unit shall be positioned on a firm steel counter foundation, or flat surface.

There shall be sufficient free space around the plant for service and maintenance.
Front side needs to be accessible for maintenance of pump and electric equipment.
Top side: The manhole shall be easily accessable for cleaning and maintenance.
If fitted with level electrodes on the 3rd stage; the pull out length of level electrodes is
850 mm. Check that the system is approx. level. The stainless steel bottom plate have to
be secured to the foundation with bolts.

5.2 PIPE CONNECTIONS

1. Observe local and class rules when connecting the pipes to the system, for any local
or special requirements.

2. Standard inlet is DN100-PN10 flange acc. DIN standard, in centerline of the tank (can
differ in special cases) Connect the waste water pipe to this flange. It is strongly
advised to install a bypass with valves.

3. Vent is DN100-PN10 and shall be connected to a suitable vent ending on

weatherdeck or highest available point, to avoid smell. The vent shall have no
excessive resistance or "goose necks". Airflow is appr. 50m3/h, max. backpressure
35mBar.

4. We advise to have the discharge pipe at least 1 diameter step large connect to
suitable overboard with a checkvalve direct near the discharge pump, to prevent
backflow in to the treatment plant. If system level is above outside water level, install a
watertrap, to the same level as the tanktop and make sure that syphoning is avoided
in the discharge pipe (install breather pipe or valve at highest point of watertrap)
Overboard connection to be in accordance with applicable class. No valves are
included in DVZ-SERVICES delivery.

5. Vent on effluent tank: Open to space of installation. This is a safety overflow to

prevent overpressure on the system. In case class requirements prescribe connection
to above main-deck, a suitable 2" overflow connection with waterlock (400 mm depth
is sufficient) is advised.

5.3 ELECTRIC

6. Apply electric power to the unit from a main circuit breaker with fuses.
Installation to be in accordance with class and safety rules. Standard controls include
local circuit breaker and fuses. Free contacts NO/NC are available to connect to the
ship's alarm system, indicating general malfunction, see manual.
Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 16 of 39
 6.0 START UP

This procedure applies to start up of the newly installed system, after the unit has been
shut down, and after a "kill" of the culture requires air scour and pump out.

6.1 GENERAL PROCEDURE FOR START UP

1. Close all air and water valves, and inspect overall system visually.

2. Check motor rotations.

3. Check all motors for current draw.

4. Fill the Treatment Tank with water, NEVER start up a system with waste water. Use
the same water source, if possible, as used for sanitary service.
Fill Treatment tank until water spills into Contact tank and reaches a level 1/2 way up
the Contact tank sight glass. Check for leaks, if any, repair before start-up.

5. Set up for normal operation of applicable system as specified in Section „SET UP

FOR OPERATION“ below.

6. Start compressed air supply.

7. Bleed air out of centrifugal pump casing (if supplied). Check pump action by hand -
start (sight glass level falls) and, if necessary, fill with water again.

8. Gradually add more water to the Contact Tank and check for proper cycling of
pump(s)

9. Charge chlorine container with 15% Sodium Hypochloride solution, and check
pumping action of dosing pump.(manual control switch).

10. Valve sewage into Treatment Tank.

NOTE: It will take 5-10 days for the bacterial culture to grow to normal operating
strength. During this period system effluent may change from clear to cloudy.
If the bacterial culture has started properly it will revert to clear.

After starting up period of 2-3 weeks, check function of discharge pump, drain and flush
out contact tank. Repeat item 7 and 8.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 17 of 39

 6.2 SET UP FOR OPERATION

The system should be set up for normal, automatic operation as specified below. If
starting up the unit new or after shutdown, refer to section „SART UP“. The Contact tank
must be about half full as indicated by Contact tank sight glass.

6.3 VALVE SETTINGS FOR OPERATION

H12

H7 H5 H4
Discharge valves
Function Valve setting
H7 H5 H4 H12
Discharge of sludge from pre-treatment open close close Turne to over-
tank board
Discharge of sludge from Treatment close open close Turne to over-
Tank board
Discharge of disinfecting tank close close open Turne to over-
board

All valves must be either fully opened or fully closed.

6.4 CONTROL SETTINGS

Switch Position
Main circuit breaker ON
Blower Push ON to start
Pump AUTO

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 18 of 39

 7.0 MAINTENANCE

7.1 SLUDGE PUMP OUT

If the accumulated sludge at the bottom of the Treatment Tank is not removed, it will spill
over into the Contact tank. In general terms, if the water in the sight glass turns from clear
to grey or brown, a pumpout is required to keep the effluent quality above that required by
IMCO standards.

If it can be anticipated, that the ship will go to restricted waters, a sludge pump out shall
be performed a few days before, in open (unrestricted discharge) waters, to ensure full
operational time available without need of de-sludging. The procedure outlined below is
recommended if the system is to consistently produce a clear effluent. The frequence of
pumpout is determined by operating history and the owner's requirements. The time
period specified below is average and based on the system operating at 100 % of rated
capacity.

7.2 PUMP OUT PROCEDURE

1. Bypass sewage system or close sewage inlet valve.

2. Turn Discharge Pump off.

3. Close Disinfecting tank discharge valve V3.

5. Open the Pre-Treatment Tank valve V1 or Treatment Tank valve V2

6. Start discharge pump(s) manually (if provided) and drain or pump contents overboard,
if outside of regulated waters, or into a suitable receiver for disposal.

7. Turn discharge pump(s) off when tanks are empty. DO NOT RUN PUMP(S) DRY.

8. Close the Pre-Treatment Tank valve V1 or Treatment Tank valve V2

9. Refill the Treatment Tank with water immediately after pumpout to maintain the
bacteria and start up following procedure under „START UP“.

DO NOT ALLOW SYSTEM TO REFILL WITH SEWAGE WITHOUT FIRST FILLING

WITH WATER.

For highest quality, drain Pre-Treatment Tank and Treatment Tank at 3 month intervals
maximum.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 19 of 39

 8.0 SHORT TERM LAY UP

If the crew will be off of vessel or platform for two weeks or less, electrical power should
be left on. Leave the system on line with the blower running. The system will begin to go
through a process known as endogenous respiration, during which the bacterial culture
will consume itself in absence of another food source. Normally the system is able to
restart without any problems within a period of one weeks. However, to ensure a high
quality effluent at all times, it is recommended to monitor the effluent quality by visual
inspection during the first days after starting up. If the vessel or platform is to be laid up or
shut down longer than two weeks, consult Section „LONG TERM LAY UP/SHUTDOWN“
and Section „ START UP“.

8.1 LONG TERM LAY UP I SHUT DOWN

1. There should be no flow into the unit, Valves in drains to the unit must be closed.

2. Discharge Pre-Treatment Tank and Treatment Tank contents into a suitable receiving
facility. Flush discharge pump with fresh water and drain to prevent freezing.
It is advisable to fill the pump with antifreeze mixture containing corrosion inhibitor.

3. Refill Pre-Treatment Tank and Treatment Tank with water and pump water overboard.

4. Add antifreeze to Treatment Tanks if water must be left in tank. Use antifreeze tester
to assure water will not freeze. Approximately one litre of antifreeze is required for
each litre water remaining in the Treatment tank.

5. Shut off electrical power to system.

6. Drain pump casing, all piping, fittings and traps containing water.

9.0 TROUBLESHOOTING

There are six major indicators of trouble; odor, poor drainage into the unit, foam coming
out of the Treatment Tank vent, poor effluent quality, high water level in Treatment Tanks,
and water spilling out of the Contact tank vent.

9.1 ODOR

If there is a smell of hydrogen sulfide (rotten eggs) coming from the Treatment Tanks
vent, or from a water sample, or if the water in the Disinfecting tank sight glass turns
black, this means that the air delivery into the water through the Air Lift is inadequate.

9.2 ODOR FROM TREATMENT TANKS VENT

1. Make sure the blower is running and has been running for the last several hours.
If not, leave the blower on and the odor will clear up in a few hours.
Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 20 of 39
 2. Take a water sample from the drain cock. Flush the drain cock before taking the
sample. The water should be odorless. If the water sample is odorless, the bacteria
have sufficient air, some "earth like", or carbondioxide odor is normal.

3. If the water sample is grey to black in colour and/or smells like rotten eggs (hydrogen
sulfide), open the inspection hatch. Each Air Lift should be pumping vigorously and
the water surface should be turbulent, indicating flow to all parts of the Treatment Tank.

4. If not, turn off blower, check silencer and inlet filter for blockage. Clean out or replace
element. Try airlift again. If no good result, continue at 5.

5. Turn the blower off. Centrifugal blower: check acc. enclosed manufacturers
documentation. (quick check: blower should generate at least 2 m.w.c. against closed
valve. Do NOT run for longer period against closed valve!)

6. Check if vent outlet is properly located and relocated if necessary to a less sensitive
area.

7. If the Air Lift is not operating and air is bubbling through the Bioreactor absolutely
sure the Air Lift valve is open. If they are properly set, the air header or the individual
piping leading from the air header to the Air Lifts may be damaged or disconnected.
Check and repair.

9. If you are absolutely certain that the air piping is defective, shut the system down as
per Section „SHORT TERM LAY UP“, then remove the inspection hatches and
physically inspect the air header, hoses and internal connections and repair as
necessary.

After taking appropriate measures, the odor in water clears up after 24 hours, and effluent
should be clear within 48 hours again.

9.3 ODOR IN SPACE WHICH UNIT IS LOCATED

1. Make sure ventilation air inlets are not picking up discharge from Treatment Tank
vent. If so, relocate vent termination.

2. With soapy water, check all flanges and penetrations above the Treatment Tanks
water level for leaks.

3. Check the wet well vent. If it smells like rotten eggs, or the water in the Contact tank
sight glass is grey, refer to Section „ODOR FROM MEDIA TANK VENT“.

4. If air is being forced out of the Disinfecting tank vent (regardless of the nature of the
odor) there is excessive back pressure in the Treatment Tanks which is blowing out
the Spillover water seal and allowing the Treatment Tank to vent into the space

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 21 of 39

 through the Disinfwecting tank vent. Refer to Section „EXCESSIVE BACK
PRESSURE IN TREATMENT TANK“.

9.4 ODOR IN OTHER SPACES

1. Make sure ventilation air inlets are not picking up discharge from the Treatment Tank.
If so, relocate vent termination.

2. If odor is coming from fixtures and air is bubbling up through the fixtures, there is
excessive back pressures in the Treatment Tank which is blowing out the influent trap
water seal and allowing the Treatment Tank to vent into the space through the
shallow fixture traps. Refer to section „EXCESSIVE BACK PRESSURE IN
TREATMENT TANK“.

3. Check for leaks in the Treatment Tank vent pipe.

9.5 POOR DRAINAGE (TOILETS DO NOT FLUSH PROPERLY)

1. Check the inlet trap, trap vent, and Treatment Tank vent for blockage.

2. Open the inspection hatch and check for excessive foam in the Treatment Tanks.

3. If the Treatment Tanks vent is blocked, it may be cleared with a stream of high
pressure water.

4. If the blockage cannot be found quickly, by-pass the unit so that you may have
sanitary facilities.

9.6 FOAM FROM TREATMENT TANK VENT

Make sure, a detergent with low foaming properties is used on board for cleaning
sanitary spaces. Instruct the personal NOT to empty buckets in drains that lead to the
treatment plant after cleaning

9.7 EXCESSIVE BACK PRESSURE IN TREATMENT TANK

1. Make sure that the Treatment Tanks vent is the size specified in the installation
instruction or larger throughout its entire length. The flame screen (if used) at the vent
termination must be at least two full pipe sizes larger than the vent pipe and free from
blockage. If not, skip to step 5 below.

2. Make sure that all horizontal portions of the Treatment Tank vent are sloped upward
and away from the Treatment Tank at least 1/2 inch per foot. If the run is aftward ship,
make sure that the slope is greater than the list of the vessel. Otherwise,
condensation will fill the vent and block airflow. If there is a low point, install a drain
Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 22 of 39
 valve at the low point and drain water as required until the piping error can be
corrected.

3. If the above cheek out, detergent foam may be blocking the Treatment Tanks vent
(this is possible but unlikely, since the vent and traps are sized for this worst case).

4. If the back pressure persists, wash down the Treatment Tank vent from its upper
termination with a stream of high pressure water to clear any possible blockage.
Before doing this, set discharge Pump(s) to ON and watch Disinfecting tank sight
glass to prevent flooding.

5. If the Treatment Tanks vent is not the correct size, back pressure will almost certainly
occur every time a highsuds detergent is introduced into the system..

9.8 HIGH WATER LEVEL IN TREATMENT TANK

Obvious, check all valve positions, also in external piping to the overboard connection,
if this is found in order.

There can be several causes; The spillover hose (inside treatment tanks, to disinfectin
tank) are clogged, the vent on the disinfecting tank is blocked, or the Treatment Tanks are
overdue pumpout.

1. To clean the spillover, open inspection hatch on top of the Treatment Tanks and wash
out the vent with a stream of water. It is preferred to flush- and pump out the contact
tank after this action.

2. To clean the spillover inside the Treatment Tanks by flushing with water.

9.9 WATER SPILLING OUT OF THE CONTACT TANK VENT

This almost certainly is caused by failure of the Discharge pump, its controls, or by
discharge valves being closed.

1. Check valve positions, also in connecting pipe to overboard discharge.

2. Make sure the pump switch is set to Auto and that power is present.

3. Make sure the suction valve from the Disinfection Tank „V3“ is open

4. Check out the starter, motor, (especially thermal protection switch) and pump.
Controls should be set per "Set-Up for Operation" of this manual. Check function by
manual start of pump, if this does not work, check level switch for proper function, if
needed, clean out or replace.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 23 of 39

 5. If the problem cannot be isolated and repaired quickly, bypass the sewage overboard
to provide the crew with sanitary facilities.

9.10 AERATION BLOWER CIRCUIT

1. Press the reset button on the overload protection inside the control panel and turn the
blower on to determine if the blower motor overloaded and dropped out of the circuit.

2. Make sure that all the overload protection on the blower starter is the size specified
on the electric scheme and set for current as indicated on the motor typeplate.

3. If the blower motor will not start and the blower starter is energised, the problem is in
the motor itself, the motor wiring, or the main contacts of the blower starter.

4. If the blower motor will only operate when the blower button is manually held on, the
blower starter auxiliary contacts are not closing in parallel with the blower button
contacts. Replace auxiliary relay and start again.

5. For mechanical malfunctions check the specific manufacturers documentation

enclosed in this manual.

9.11 DISCHARGE PUMP CIRCUIT

1. Press the reset button on the overloadprotection inside the control panel and turn the
pump on to determine whether the pump motor overloaded and dropped out of the
circuit.

2. Make sure that all overload heater coils on the pump starter are the size specified on
the electric scheme and check setting for current according motor type plate.

3. If the pump will not start and the pump starter is energised, the problem is in the motor
itself, the motor wiring, or the main contacts of the starter.

4. For mechanical malfunctions, check the specific manufacturers documentation

enclosed in this manual.

9.12 ELECTRODE TYPE LEVEL SWITCH

Clean tips of electrodes for dirt or corrosion. Clean with sandpaper, check isolation, for
specific values and test, refer to enclosed documentation for the level relay enclosed with
vendor's data. Function can be tested by simulation of waterlevels, just connect relevant
electrodes temporarily with electric wire. A low, save voltage is used on the levelcontroler.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 24 of 39

 NOTE: When replacing a defective level switch, the pipe threads must be sealed
with teflon tape or pipe dope.

9.13 HIGH WATER LEVEL

1. Silence the alarm

2. If the problem cannot be isolated and repaired quickly, bypass the sewage
overboard.

3. Make sure that all valve settings and control settings are in accordance with
section „SET UP FOR OPERATION“.

4. Check that the valves from the unit discharge connection to the overboard line is
fully open.

5. Inspect pump starter relay and verify that it is energised. Check that pump is
running. If running but no falling level (sightglass) De-aereate pump and observe
level again. If not cured, open up the pump for inspection.

6. If the system is operating properly, the problem is an excessive volume of water

entering the system. Check for stuck or leaking flush valves and fixtures.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 25 of 39

 10.0 Technical Documentations:
NIVEAU RELAIS / niveau relay
DVZ - ER 75-D / ER 76-D

DVZ GT 76 / ER 76

Anwendung Application

Das Steuerrelais ER 75-D / ER 76-D kann in Verbindung mit der The Control relay ER 75-D / ER 76-D can be used together with the
Niveau-Sonde NK 06 zur automatischen Kontrolle und Regelung level sensor 6N for the automatic monitoring and/or control of liquid
von Füllständen eingesetzt werden. levels.

Funktion Operation

Füllstandsrelais der Type ER 75-D / ER 76-D arbeiten als Level relays type ER 75-D / ER 76-D operate as three point
Intervallrelais. controllers with an input sensitivity in the range from 0-200 kΩ.
Die Ansteuerung erfolgt durch das Medium über die Sonden Typ They are operated via a sensor type 6 N by the rising and/or falling
NK 06, wobei die Eingangsempfindlichkeit im Bereich von 0-200 k level of the process medium.
Ohm liegt. To ensure a correct operation of the system, a minimum
Um ein einwandfreies Schalten des Relais zu gewährleisten, darf conductivity of 5 µS is required.
die Leitfähigkeit von 5 µS nicht unterschritten werden. The current flowing through the medium is a real AC, therefore
Durch das Medium fließt bei Kontaktgabe eine echte there will be no galvanic erosion of the electrodes.
Wechselspannung, wodurch eine galvanische Abtragung des The reference potential may be either a common electrode or the
Sondenmaterials verhindert wird. vessel depending on the application, on the location and on the local
Je nach Anwendungsfall, Einsatzort sowie örtlichen operating procedures.
Betriebsbestimmungen kann das Bezugspotential der When the system is powered up after completion of the electrical
Steuerelektroden sowohl durch eine gemeinsame Elektrode oder installation the relay will automatically be set to its "energized"
durch das Behältnis selbst gestellt werden. condition.
Nach Montage und elektr. Anschluß von Relais und Sonde wird das When the liquid level reaches the maximum setpoint, which is
Relais automatisch in Arbeitsposition gesetzt. predetermined by the mechanical construction of the sensor, the
Wird der durch den mechanischen Aufbau der Sonde vorgegebene relay will change contact status and go into the "deenergized"
Füllstand durch das Niveau des Mediums erreicht, so schaltet das condition. This condition will remain until the minimum setpoint is
Ausgangsrelais in Ruhestellung. Dieser Zustand bleibt solange reached, which again is predetermined by the mechanical
erhalten, bis der vom mech. Aufbau der Sonde vorgegebene min. construction of the level sensor. Upon reaching the minimum
Füllstand erreicht ist; d.h. beim Erreichen des min. Füllstandes wird setpoint, the relay will reset to the "deenergized" condition.
das Relais neu gesetzt. A power loss, a defective control relay or an interuption of the
Bei Ausfall der Versorgungsspannung, bei einem Defekt im sensor lines will cause the system to fail to the safe position; i.e. an
Steuerrelais oder bei Unterbrechung der Meßleitung geht overfilling of the vessel is impossible.
die Anlage in einen ungefährlichen Zustand; d.h.: ein Überfüllen des
Behälters ist nicht möglich.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 26 of 39

 Technische Daten / Technical Data
24 V, 50/60 Hz
Betriebsspannung / Power supply: 0 - 200 k Ohm
Eingangsempfindlichkeit / Input sensitivity: Intervallausführung (3-Punkt-Regelung) / 3-point control
Schaltungsfunktion / Operating mode: potentialtreier Umschaltkontakt / Potential free toggle contact
Kontaktausgang / Output contact: U = 250 V,I = 2 A, P = 250 VA / 50 W
max. Lastdaten / Contact rating: LED
Schaltzustandsanzeige / Indication of contact status: Schienenaufbau / Rail mounting 60 x 70 x 110
Gehäuse / Casing: auf allen Schiffen nach Richtlinien des Germanischen Lloyd,
Einsatzbereich / Applications: sonst nach örtlichen Vorschriften
On all ships according to GL regulations, otherwise acc. to
local rules and standards.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 27 of 39

 SENSOR - ELEKTRODE / sensing electrode
DVZ-NK06 - 150/270/670

Steckerbelegung
Steckfahne Nr.1 für kurze Elektrode
Steckfahne Nr. 2 für mittlere Elektrode
Steckfahne Nr. 3 für lange Elektrode

Plug Connection
pin terminal no. 1 for short electrode
pin terminal no. 2 for middle electrode
pin terminal no. 3 for long electrode

2
3

Anwendung Application

Niveau-Sonden dienen in Verbindung mit Transistor-Steuerrelais In connection with transistorized relays type GT 76 and ER 76,
Type GT 76 und ER 76 zur automatischen Kontrolle und Regelung these level sensors are used to monitor and/or control the level of
leitfähiger Flüssigkeitsstände. conductive liquids.

Funktion Operation

Sobald die Flüssigkeit die Elektroden benetzt, entsteht je nach In case of a rising level in the vessel, the liquid will contact the
Arbeitsweise eine leitende Verbindung von der Masseelektrode zu electrodes and will form a conductive connection between the
den anderen Elektroden oder von den Elektroden zum Behälter. grounded electrode and the measuring electrodes or between the
measuring electrodes and the wall of the vessel, depending on the
So können zum Beispiel operating mode.
- minimale oder maximale Füllstände in Behältern The minimum required conductivity of the liquid is 5 µS.
überwacht
-Pumpen vor Trockenlauf geschützt. Examples
The NK06 in connection with the GT 76 or ER 76 can
- monitor the liquid level in vessels for minimum or maximum
value
-prevent pumps from running dry.

Technische Daten / Technical Data

Anzahl der Elektroden / Number of Electrodes: 1-4

Betriebsdruck / Operating Pressure: 10 bar
Schutzart / Enclosure Classification: IP 65
El. Anschluß / Electrical Connection: Connector acc. to DIN 43 650 with GL - approval
Max. Mediumtemperatur / Max. permissible liquid temperature: 60 °C
Werkstoffe/ Construction Materials
Elektrodenkopf / Body: Messing / Brass
Elektrode / Electrodes: Stainless Steel 1.4305
Max. Elektrodenlänge / Max. Length of Electrodes: 1000 mm
Einschraubzapfen / Threaded Stem: G 1" male

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 28 of 39

 MANOMETER / pressure gauge
DVZ 63 0-1 bar H 1/4”, connection down

MANOMETER / pressure gauge

DVZ 63 0-1 bar H 1/4”, connection back side

MANOMETERHAHN / root valve for pressure gauge

DVZ 63 0-1 bar H 1/4”

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 29 of 39

 SEITENKANALVERDICHTER / lateral channel compressor
DVZ-SD-2n

Sicherheitsbestimmungen Safety Instructions

Die Unfallverhütungsvorschriften VBG 16 Verdichter sind zu The Regulations for the Prevention of Accidents VGB 16 -
beachten, insbesondere Abschnitt lllc ,Aufstellung" und IV ,Betrieb" Compressors - are to be considered, in particular Section lllc
sowie VBG 4 ,Elektrische Anlagen und Betriebsmittel". „Assembly" and IV,,Operation" as well as VBG 4,,Electrical
Umbauten oder Veränderungen an dem Verdichter können nur mit Installations and Means of Operation".
Zustimmung des Werkes erfolgen. Reconstructions or alterations at the compressor can only be done
after approval by the manufacturer.
Durch die Luftverdichtung entstehen an dem Verdichter hohe
Temperaturen, deshalb ist zu beachten: Due to the compression of the air, high temperatures occur at
- der Schutz vor Berührung heißer Oberflächen the compressor. Therefore, the following is to be borne in
- der Schutz der Verkehrsbereiche mind:
- das Anbringen von Warnhinweisen. - Protection against the contact with hot surfaces
- Protection of the service areas
Verwendungszweck - Attachment of warning hints.

Die Verdichter werden zur Erzeugung von Überdruck oder Application

Unterdruck eingesetzt.
Der Betrieb ist nur für neutrale technische Gase vorgesehen. Die The compressors are used for the generation of overpressure or
Verdichter arbeiten ölfrei. Die Ansaugung von ÖInebel ist zu underpressure. The operation has only been provided for neutral,
vermeiden. technical gases. The compressors operate without oil. It is to be
Die Kenndaten gelten bis zu einer H6he von 800 m über NN. avoided that oil mist is drawn in. The characteristic values apply to
an altitude of 800 m above sea level.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 30 of 39

 Transport und Lagerung Transport and Storage

Die Verdichter sind unbedingt trocken zu lagern und Kondensat It is to be ensured that the compressors are kept at a dry place.
durch Wasserdämpfe zu vermeiden. Condensate caused by water vapours is to be avoided.
Es darf nur mit geeigneten Anschlagmittein gehoben und Lifting and transport are only to be carried through with suitable
transportiert werden. lifting tackles.

Aufstellung Installation

Bei der Aufstellung ist der leichte Zugang für spätere When installing the compressor, easy access for
Wartungsarbeiten zu bedenken. later maintenance work is to be taken into consideration.
Um die Luftströmung für die Kühlung nicht zu behindern, müssen The distances to neighbouring walls in the free room must be at
die Abstände zu benachbarten Wänden im freien Raum mindestens least 10 cm so that the air flow for cooling is not hindered. The
10 cm betragen. Die Umgebungstemperatur darf 40°C nicht ambient temperature must not exceed 40°C.
aberschreiten. The use of sound control hoods has a negative influence on the
Die Verwendung von Schallschutzhauben beeintrdchtigt negativ die cooling conditions. For this reason, the manufacturer is to be
Kühlbedingungen, deshalb sind die Einsatzbedingen bei dem consulted regarding the conditions for this use.
Hersteller zu erfragen.
Assembly
Montage
During assembly, care is to be taken that the dimensioning is correct
Bei der Montage ist auf die richtige Dimensionierung und saubere and the pipelines are clean (no welding beads, chips or similar
Rohrleitungen (keine Schweißperlen, Späne oder ähnliche contaminations).
Verschmutzungen) zu achten. The connections are to be kept free from oil, grease, water or other
Die Anschlüsse sind von Öl, Fett, Wasser oder sonstigen contaminations.
Verschmutzungen freizuhalten. The caps for the protection against the invasion of dirt are to be
Bei Druckanschluß und Sauganschluß sind die Schmutzkappen zu removed for delivery and suction connection.
entfernen.
Motor connection
Motoranschluß
The compressors have to be included in energy supply in such a
Die Verdichter müssen so in die Energieversorgung eingebunden way that all applicable provisions are kept. Thereby, the EN 60204
werden, daß alle einschlägigen Vorschriften eingehalten werden. T1 is to be observed. The connection of the motor according to the
Dabei ist die EN 60204 T1 zu beachten. wiring diagram (in the terminal box) as well as plug constructions
Der Anschluß des Motors nach Schaltplan (im Klemmkasten) sowie that have already been prepared are to be executed by specialists in
fertig vorbereitete Steckerausführungen sind durch eine the field of electrical engineering. Thereby, the connected voltage
Elektrofachkraft auszuführen. Dabei ist auf die Anschlußspannung and frequency are to be considered. A protective motor switch is to
und Frequenz zu achten. be provided and set to the rated current of the motor.
Es ist ein Motorschutzschalter vorzusehen und dieser auf den (Data on the motor identification plate).
Nennstrom des Motors einzustellen (Daten auf dem If more than 20 switching operations per hour take place, a message
Motortypenschild). is to be given.
Es sind mehr als 20 Schaltungen pro Stunde zu vermeiden ,
The motor is to be started up for a short while and the
Der Motor ist kurz anlaufen zu lassen und die Drehrichtung direction of rotation (arrow on the housing) to be checked. In
(Pfeil auf dem Gehause) zu kontrollieren. Bei falscher case of wrong direction of rotation, the
Drehrichtung ist die Phase zu tauschen. phase is to be changed.

lnbetriebnahme Putting into operation

Die Druckleitung und die Saugleitung ist anzuschließen. The pressure line and the suction line are to be connected.

Wartung Maintenance

Die besten Arbeitsergebnisse werden durch eine regelmäßige The best operating results are achieved by a regular maintenance of
Wartung der Verdichter erzielt. Dabei sind die lntervalle vom Einsatz the compressors. Thereby, the intervals depend on the use and the
und den Umgebungsbedingungen abhängig. ambient conditions.

Vor Beginn der Wartungsarbeiten ist der Motor stromlos zu Before beginning the maintenance work, the motor is to be
schalten. Ein unbeabsichtigter Wiederanlauf ist zuverlässig zu switched to a dead state. Unintended restarting is urgently to
verhindern. be avoided.

Abhängig vom Staubanfall sind die Filter regelmäßig zu reinigen Depending on the occurrence of dust, the filters are to be cleaned
bzw. zu wechseln. and changed at regular intervals. For this purpose, the filters are
Hierzu werden die Filter von innen nach außen mit Druckluft cleaned by blowing compressed air from the inside and outside.
durchgeblasen. Clogged, oily and greasy cartridges are to be renewed.
Verstopfte, ölige und fettige Patronen sind unbedingt zu erneuern.
The antifriction bearings cannot be re-lubricated and should be
Die Wälzlager können nicht nachgeschmiert werden und sollten, je exchanged after 10,000 to 12,000 working hours, depending on the
nach Einsatzbedingungen, nach 10000 - 12000 Betriebsstunden conditions of operation. Original antifriction bearings are only to be

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 31 of 39

 gewechselt werden. Es sind nur originals Walzlager zu verwenden, used because they have been filled with a special grease.
da diese mit einem Spezialfett gefüllt sind.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 32 of 39

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 33 of 39
 KREISELPUMPE / centrifugal pump
DVZ-S 32/40/50

EINFÜHRUNG INTRODUCTION

Die Betriebsanleitung enthält wichtige Hinweise, die Pumpen sicher, The instruction manual contains important information on how to
sachgerecht, und wirtschaftlich zu betreiben. Ihre Beachtung hilft, operate the pump safely, properly and most efficiently Observing
Gefahren zu vermindern, Reparaturkosten und Ausfallzeiten zu these instructions helps to avoid danger, to reduce repair costs,
senken und die Zuverlässigkeit und Lebensdauer der Pumpe zu downtimes and to increase the reliability and life of pump.
erhöhen.
The operating instructions must always be available wherever the
Die Betriebsanleitung muß ständig am Einsatzort der Pumpe pump is in use.
verfügbar sein.
The operating instructions must be read and applied by any person
Die Betriebsanleitung ist von jeder Person zu lesen und in charge of carrying out work on the pump.
anzuwenden, die mit Arbeiten mit/an der Pumpe beauftragt ist.
Observe the mandatory rules and regulations for accident prevention
Neben der Betriebsanleitung und den im Verwenderland und an der and environmental protection in the country and place of use of the
Einsatzstelle geltenden verbindlichen Regelungen zur pump. The generally recognized technical rules for safe and proper
Unfallverhütung sind auch die anerkannten fachtechnischen Regeln working must also be observed.
für sicherheits- und fachgerechtes Arbeiten zu beachten.
SAFETY
SICHERHEITSHINWEISE
A pump that is installed incorrectly, operated wrongly or maintained
Eine Pumpe die nicht korrekt installiert ist, falsch bedient wird oder poorly can present a hazard. If the following considerations are
wenig gewartet wird, kann eine Gefahr darstellen. Falls die overlooked, the safety of personnel or satisfactory operation of the
folgenden Hinweise nicht beachtet werden kann die Sicherheit des pump may be endangered.
Personals gefährdet werden.
Attention must be given to the safe handling of all items. Where
Vorsicht ist geboten bei der Handhabung aller Teile. Wenn Pumpen, pumps, pump units or components weigh in excess of 20 kg (44 lb.),
Aggregate oder Teile davon mehr als 20 kg (44 lb.) wiegen, wird die it is recommended that suitable lifting equipment should be used in
Benutzung geeigneter Hebemechanismen empfohlen um Schaden the correct manner to ensure that personal injury or damage to pump
an Pumpe oder Personal zu vermeiden. components does not occur.

ACHTUNG: Ösen die nur an einige Teile wie Pumpe oder Motor NOTE that lifting eyes fitted to individual pieces such as pump and
befestigt sind, dürfen nur diese abheben, nicht das ganze Aggregat. motor are designed to lift only this part and not the complete
assembly.
Bevor eine Pumpe zerlegt wird, müssen alle
Sicherheitsvorkehrungen getroffen werden, insbesondere wenn das Before starting to dismantle a pump all relevant and appropriate
geförderte Medium gefährlich oder giftig ist. Bei Zweifeln fragen Sie safety precautions must be taken, particularly if the pumps have
einen Arzt oder den Hersteller. been handling hazardous or toxic products. Seek advice from

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 34 of 39

 your safety officer or the manufacturer if you have any doubts.
Wenn die Pumpe giftige oder gefährliche Mittel gefördert hat muß
beim Zerlegen immer eine geeignete Schutzkleidung und Always wear adequate protective clothing and eye protection when
Schutzbrille getragen werden. Atmungshilfen könnten notwendig dismantling pumps that have been used to pump toxic or hazardous
sein. products. Breathing apparatus may be necessary.

Vor jeglicher Arbeit muß die Pumpe elektrisch isoliert werden. Es Always isolate the pump electrically before dismantling. Ensure that
muß gesichert werden, daß während der Arbeit der Strom nicht the electrical switch gear cannot be operated whilst any work is
zufällig wieder angeschlossen werden kann being carried out on the pump.

Pumpe entleeren, bevor sie aus der Anlage ausgebaut wird. Always drain the pump casing of product before removing the pump
from its associated pipework.
Mit einer kompatiblen Flüssigkeit ausspülen. Die Flüssigkeit dann in
einen sicheren Ort abfließen. Flush out the pump casing and shroud with a compatible flush and
drain away to a safe area.
Mit dem Anlagenbauer nachprüfen ob besondere
Entseuchungsprozesse durchgeführt werden müssen. Check with your process people to see if any special
decontamination procedures have to be followed before working on a
Alle Pumpen die für die Wartung zurückgegeben werden, müssen pump.
entseucht sein und einen Hinweis auf besondere Vorsichts-
maßnahmen für das Wartungspersonal tragen. All pumps returned for factory servicing must be decontaminated
and labeled to inform what precautions should be taken before
LAGERUNG dismantling.

Wenn die Pumpe nach Auslieferung nicht sofort eingesetzt wird, STORAGE
sollte sie wieder eingepackt werden und in einen passenden Ort
gelagert werden. Schutzfolien auf nicht lackierte Stellen sollten auf After receipt and inspection, a pump not immediately installed should
Beschädigungen geprüft werden. Unlackierte Stellen ohne be repackaged and placed in suitable storage.
Rostschutzmittel sollten behandelt werden. Protective coatings on unpainted surfaces should be inspected and
Plastikkappen oder Deckel sollten nicht abgenommen werden. left intact. Unpainted surfaces, not factory treated with a rust
Die Pumpen sollten in einen sauberen und trockenen Ort lagern, inhibiting coating, should have a protective coating applied. Plastic or
andernfalls Pumpe mit feuchtabweisende Hauben schützen. gasket type port covers should be left in place. Pumps received
wrapped with corrosion inhibiting treated material should be
SELBSTANSAUGUNG rewrapped.
Select a clean, dry storage location. When moist, dusty atmosphere
Vor der ersten Inbetriebnahme Deckel oder Verschlußschraube must be used for storage, further protect the pump or unit with a
oben am Pumpengehäuse entfernen. moisture repellent cover until it is to be installed.

Pumpe vollständig mit der geförderten PRIMING

Flüssigkeit füllen.
Open the priming cover or plug on the top of pump.
Deckel oder Verschlußschraube wieder schließen.
Fill pump chamber completely with the liquid to be pumped.
Die Drehrichtung der Welle muß mit dem Pfeil am Pumpen-gehäuse
übereinstimmen (im Uhrzeigersinn wenn von der Welle oder vom Close cover or plug and start the pump.
Motor gesehen).
Check that direction of rotation is the same as shown by the arrow
BETRIEBSSTÖRUNGEN on the back of the pump (clockwise when looking from the shaft or
motor end).
DIE PUMPE SAUGT NICHT AN
OPERATING TROUBLES
a) Luft dringt in die Saugleitung ein. Defekte oder falsch
verschraubte Gewindeanschlüsse. PUMP DOES NOT PRIME

b) Pumpengehäuse leer oder zu wenig aufgefüllt. a) Air leaks in the suction line (through couplings,
threads, flanges, gaskets, hose clips, cuts, etc.).
c)Luft dringt durch die Gleitringdichtung ein, weil beschädigt oder
nicht geschmiert. Gleitringdichtung auswechseln. b) Level of liquid inside pump casing is too low or
empty
d) Falsche Drehrichtung oder Drehzahl zu niedrig.
c) Air leaks through the mechanical seal because of damage or lack
e) Spiralgehäuse durch abrasive Flüssigkeit abgenutzt. of lubrication.

f) Überhitzung der Flüssigkeit in der Saugkammer. Kalte Flüssigkeit d) Wrong direction of rotation or too low speed
nachfüllen.
e) Leading edge of the volute is worn out by the abra-
g) Überdruck in der Druckleitung. Luft kann nicht ausweichen. Luft sive action of the liquid.
durch den Auffülldeckel ablassen oder Entlüftungsventil in der
Druckleitung anbringen. f) Liquid inside pump chamber overheated. Allow
liquid to cool down or refill it.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 35 of 39

 h) Laufrad abgenutzt oder gebrochen.
g) Delivery line does not let the air escape. Exhaust air
DIE PUMPE BRINGT ZU GERINGE LEISTUNG through priming cover or install an automatic airrelease valve.

b) Saug- oder Druckleitung verstopft oder Gummischlauch geplatzt. h) Clogged, broken or worn impeller.
Prüfen und Hindernis entfernen.
LOW CAPACITY
c) Hohe Druckverluste in der Saugleitung. Krümmungen, Engstellen
oder Ventile entfernen. a) Suction delivery lines clogged. Locate and remove obstruction.

d) Saughöhe zu groß. Pumpe so nah wie möglich an das Medium b) High friction losses in the line. Get rid of unneces-
aufstellen. sary curves, valves and constrictions.

e) Drehzahl zu niedrig. b) Static suction lift too high. Place the pump as close
as possible to the surface of liquid to be pumped.
f) Laufrad verstopft. Reinigen durch Inspektionsdeckel oder durch
Demontage des Pumpengehäuse selbst. d) Low rotation speed. Increase RPM.

g) Laufrad oder Verschleißplatte abgenutzt oder gebrochen. e) lmpeller clogged. Free impeller through the inspection cover.
Ersetzen.
f) lmpeller and/or wear plate(s) worn out. Replace.
SCHMIERUNG DER KUGELLAGER (für Modelle mit Lagerträger)
BEARING LUBRICATION (for models with bearing housing)
Modelle ohne Schmiernippel haben auf Lebenszeit geschmierte
Kugellager und brauchen deshalb keine Wartung. Models without grease nipple have lifetime lubricated ball bearings
and do not require maintenance.
Modelle mit Schmiernippel kommen mit geschmierten Lager und
brauchen keine Wartung für die ersten 1500 Arbeitsstunden. Models with grease nipple are supplied with lubricated bearings and
do not require to grease for the first 1500 hours.
Niemals mit Fett übertreiben, da dies zu Überhitzung und später zu
Beschädigung der Kugellager führen kann. STORAGE

5. LAGERUNG Drain all the liquid out the casing, through the drain cover or plug.

Pumpe durch den unteren Deckel oder Verschlußschraube völlig If the pump is to be left out in open air, protect it by waterproof
entleeren. canvas.

Wird die Pumpe im freiem gelagert, so muß sie mit einer Never forget water inside pump casing during cold weather!
wasserdichten Haube abgedeckt werden. Water may freeze and break the pump casing!

Niemals Wasser während der kalten Jahreszeit im Gehäuse

lassen!
Das Wasser kann frieren und das Gehäuse brechen!

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 36 of 39

 SCHNEIDVORSATZ CUTTING DEVICE

Der Schneidvorsatz besteht aus einem axialen Überhang an der The cutting device consists of an axial part attached to the wear
Verschleißplatte, der einen Schereffekt mit dem dicht anliegenden plate. Because of the close distance to the impeller solids sheared or
Laufrad verursacht. cutted.

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 37 of 39

 SCHNITTBILD SECTION DRAWING

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 38 of 39

Issue: 16.08.2010 Instruction Manual DVZ-SKA “BIOMASTER“-PLUS Page 39 of 39
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

ANNEX Pump P1

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 DVZ - SERVICES GmbH
Boschstrasse 9 • D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
www.dvz-services.de

INSTRUCTION MANUAL
(ANNEX P1)

FOR

BMSU OVERFLOW PUMP P1

FOR

SEWAGE TREATMENT PLANT

DVZ SKA-“BIOMASTER®-PLUS“
 General this operating manual must be read and understood
Caution: This product has been developed in both by the installing personnel and the responsible
accordance with state-of-the-art technology; it is trained personnel / operators prior to installation and
manufactured with utmost care and subject to commissioning, and it must always be kept close to
continuous qualitycontrol. the location of operation of the machine / unit for
These operating instructions are intended to easy access. Not only must the general safety
facilitate familiarization with the unit and its instructions laid down in this chapter on ”Safety” be
designated use. The manual contains important complied with, but also the safety instructions
information for reliable, proper and efficient outlined under specific headings.
operation. Compliance with the operating Marking of instructions in the manual
instructions is of vital importance to ensure reliability
The safety instructions contained in this manual
and a long service life of the unit and to avoid any
whose non-observance might cause hazards to
risks.
persons are specially marked with the symbol
These operating instructions do not take into
account local regulations; the operator must ensure
that such regulations are strictly observed by all,
including the personnel called in for installation. general hazard sign to ISO 7000-0434

This pump / unit must not be operated beyond The electrical danger warning sign is
the limit values for the medium handled, capacity,
speed, density, pressure, temperature and motor
rating specified in the technical documentation.

Make sure that operation is in accordance with the

instructions laid down in this manual or in the safety sign to IEC 417 - 5036,
contract documentation. Contact the manufacturer, if
required.The name plate indicates the type series /
size, main operating data and identification number; The word Caution
please quote this information in all queries, repeat
orders and particularly when ordering spare parts. If is used to introduce safety instructions whose non-
you need any additional information or instructions observance may lead to damage to the machine and
exceeding the scope of this manual or in case of its functions. Instructions attached directly to the
damage please contact DVZ SERVICES GmbH. machine, e.g.
- arrow indicating the direction of rotation
Safety - markings for fluid connections
These operating instructions contain fundamental must always be complied with and be kept in a
information which must be complied with during perfectly legible condition at all times.
installation, operation and maintenance. Therefore

Issue: 03.05.2011 CIP-Process for DVZ-SKA-”BIOMASTER”-PLUS Page 2 of 6

SKA-PLUS-ANNEX P1-Eng
 Personnel qualification and training Safety instructions for maintenance,inspection
All personnel involved in the operation, and installation work
maintenance, inspection and installation of the unit The operator is responsible for ensuring that all
must be fully qualified to carry out the work involved. maintenance, inspection and installation work be
performed by authorized, qualified specialist
Personnel responsibilities, competence and
personnel who are thoroughly familiar with the
supervision must be clearly defined by the
manual.
operator.If the personnel in question is not already in
The pump must have cooled down to ambient
possession of the requisite know-how, appropriate
temperature, pump pressure must have been
training and instruction must be provided. If
released and the pump must have been drained.
required, the operator may commission the
Work on the machine / unit must be carried out only
manufacturer / supplier to take care of such training.
during standstill. The shutdown procedure described
In addition, the operator is responsible for ensuring
in the manual for taking the unit out of service must
that the contents of the operating instructions are
be adhered to without fail.
fully understood by the responsible personnel.
Pumps or pump units handling media injurious to
Non-compliance with safety instructions health must be decontaminated.
Non-compliance with safety instructions can
jeopardize the safety of personnel, the environment Immediately following completion of the work, all
and the machine / unit itself. Non-compliance with safety-relevant and protective devices must be re-
these safety instructions will also lead to forfeiture of installed and / or reactivated.
any and all rights to claims for damages. In Please observe all instructions set out in the chapter
particular, non-compliance can, for example, result on “Commissioning/Start-up”before returning the
in: unit to service.
- failure of important unit/system functions,
Unauthorized modification and manufacture of
- failure of prescribed maintenance and servicing spare parts
practices, Modifications or alterations of the equipment
- hazard to persons by electrical, mechanical and supplied are only permitted after consultation with
chemical effects, the manufacturer. Original spare parts and
- hazard to the environment due to leakage of accessories authorized by the manufacturer
hazardous substances. ensure safety. The use of other parts can invalidate
Safety awareness any liability of the manufacturer for consequential
damage
It is imperative to comply with the safety instructions
contained in this manual, the relevant national Unauthorized modes of operation
health and safety regulations and the operator’s own
internal work, operation and safety regulations. The warranty relating to the operating reliability and
safety of the unit supplied is only valid if the
equipment is used in accordance with its designated
Safety instructions for the operator / user use as described in the following sections of this
manual. The limits stated in the data sheet must not
- Any hot or cold components that could pose a
be exceeded under any circumstances.
hazard must be equipped with a guard by the
operator.
Installation at site
- Guards which are fitted to prevent accidental
Safety regulations
contact with moving parts (e.g.coupling)must not
Electrical equipment operated in hazardous
be removed whilst the unit is operating.
locations
- Leakages (e.g.at the shaft seal) of hazardous must comply with the relevant explosion protection
media handled (e.g.explosive, toxic, hot)must be regulations.This is indicated on the motor rating
contained so as to avoid any danger to persons or plate.
the environment. All relevant laws must be If the equipment is installed in hazardous locations,
heeded. the applicable local explosion protection regulations
- Electrical hazards must be eliminated.(In this and the regulations of the test certificate supplied
respect refer to the relevant safety regulations with the equipment and issued by the responsible
applicable to different countries and/or the local
energy supply companies.)

Issue: 03.05.2011 CIP-Process for DVZ-SKA-”BIOMASTER”-PLUS Page 3 of 6

SKA-PLUS-ANNEX P1-Eng
 approval authorities must be observed and complied Servicing / maintenance
with. The test certificate supplied must be kept close General instructions
to the location of operation for easy access The operator is responsible for ensuring that all
(e.g.foreman’s office). maintenance, inspection and installation work be
performed by authorized, qualified specialist
Commissioning,start-up / shutdown personnel who are thoroughly familiar with the
Commissioning manual.
A regular maintenance schedule will help avoid
Caution: Before starting up the pump make sure expensive repairs and contribute to trouble-free,
that reliable operation of the pump with a minimum of
- the pump unit has been properly connected to the maintenance expenditure and work.
electric power supply and is equipped with all
protection devices; Work on the unit must only be carried out with
- the pump has been primed with the liquid to be the electrical connections disconnected. Make
pumped; sure that the pump set cannot be switched on
- the direction of rotation has been checked; accidentally (danger to life!).
- all auxiliary connections have been properly
connected Pumps handling liquids posing health hazards
must be decontaminated. When draining the
Final check medium see to it that there is no risk to persons or
It must be easy to rotate the shaft by hand. the environment. All relevant laws must be adhered
Check the integrity and proper functioning of all to (danger to life!).
connections.
Servicing / inspection
Start-up Supervision of operation
Always make sure that the shut-off valve in the
discharge line is closed before the pump is started
Caution: The pump must run quietly and free
from vibrations at all times.
up! Only after the pump has reached full rotational
The pump must never be allowed to run dry.
speed shall the shut-off valve in the discharge line be
opened slowly and adjusted to comply with the duty
Do not run the pump against a closed shut-off
point.
valve for prolonged periods of time so as to avoid
heating up of the fluid pumped.
Caution: After the operating temperature has been Max.permissible room temperature 40 ºC.
reached and/or in the event of leakage, switch off Bearing temperature may exceed room
the unit and retighten hex.nuts. temperature by up to 50 ºC but must never rise
above +90 ºC (measured externally on the motor
Shutdown housing).
Close the shut-off valve in the discharge line.
If the discharge line is equipped with a non-return or During pump operation the shut-off valve in the
check valve, the shut-off element may remain open if suction line must not be closed.
there is back pressure. The mechanical seal shows only slight or invisible
(vapour) leakage during operation.It is
The shut-off valve in the suction line must not be maintenance-free.
closed when switching off the pump. Any stand-by pumps installed shall be switched on
Switch off the motor, making sure that the unit runs and then immediately off again once a week to
down smoothly to a standstill. keep them operational.
Depending on the type of installation, the pump Attention shall be paid to the correct functioning of
should have a sufficient after-run time – with the heat the auxiliary connections.
source shut off – until the medium handled has
cooled down sufficiently to avoid aheat build-up in Lubrication and lubricant change
the pump. Lubrication
The rolling element bearings in the IEC motor are
For prolonged shutdown, close the shut-off valve in
grease-lubricated.The lubricant change intervals as
the suction line. Close the auxiliary connections.
well as the required quantity and quality are
In the event of frost and/or prolonged shutdowns, the specified below.
pumpmust be drained or otherwise protected against
freezing.

Issue: 03.05.2011 CIP-Process for DVZ-SKA-”BIOMASTER”-PLUS Page 4 of 6

SKA-PLUS-ANNEX P1-Eng
 Reassembly Mechanical seal
Pump Reassembly is effected in reverse order to
The pump shall be reassembled in accordance with dismantling.
the rules of sound engineering practice. The following rules must be observed when fitting a
The locating surfaces of the individual components mechanical seal:
must be coated with graphite or similar before Extreme care and cleanliness.
reassembly. The same applies to bolted The protective wrapping of the contact faces shall
connections. only be
O-rings shall be examined for signs of damage and removed immediately before assembly takes place.
replaced by new ones, if necessary. Take care not to damage the seal faces and O-
Gaskets shall always be replaced by new ones. rings.
Make sure that new gaskets have the same Clean the shaft and the seat ring location in the
thickness as the old ones. discharge
Gaskets of asbestos-free materials or graphite must cover and gently remove any deposits.
always When fitting the seal, shaft sleeve may be wetted
be fitted without using lubricants. with
Avoid the use of mounting aids as far as water to reduce the friction forces.
possible.Should a Caution: Ethylene propylene rubber elastomers
mounting aid be required after all, use a must never come into contact with oil or
commercially available contact adhesive (e.g.Pattex) grease.Water shall be used as a lubricant during
or sealing agent (HYLOMAR or Epple 33). The fitting.
adhesive shall only be applied at selected points and Press the seat ring into discharge cover by hand or
in thin layers. Do not use cyanoacrylate adhesives fingers only. Make sure that the pressure is applied
(quick-setting adhesives). evenly.
If the seal area between the impeller neck and the
casing Motor
wear ring is worn, the casing wear rings (if fitted) Reassembly is effected in reverse order to
must be replaced by new ones. dismantling.
Clearances: Caution: When mounting shaft onto the motor
new 0.3 mm in diameter shaft stub, make sure that the keyway of the motor
max.permissible enlargement to 0.9 mm in diameter shaft end aligns with the slot in shaft.
Reassembly is effected in reverse order to
dismantling. Make sure to assemble the components
in their correct sequence.

Issue: 03.05.2011 CIP-Process for DVZ-SKA-”BIOMASTER”-PLUS Page 5 of 6

SKA-PLUS-ANNEX P1-Eng
 Trouble - shooting

Excessive rise of temperature inside the pump

Motor protection switch trips the pump

Excessive leakage at the shaft seal

Pump delivers insufficient flow rate

Vibrations during pump operation

Excessiv bearing temperature

Leakage at the pump

Motor is overload

Cause Remedy 1)
Pump delivers against an excessively high Re-adjust to duty point.
discharge pressure.
Excessively high back pressure. Check plant for impurities.

Pump or piping are not completely vented or Vent and/or prime.

primed.
Suction line or impeller clogged Remove deposits in the pump and/or piping.
Formation of air pockets in the piping. Alter piping layout.
Fit a vent valve.
Suction head is too high/NPSH- available Check/alter liquid level.
(positive suction head) is too low. Fully open shut-off valve in the suction line.
Change suction line, if the friction losses in the
suction line are too high.
Check any strainers installed/suction opening.
Wrong direction of rotation. Interchange two of the phases of the power supply
cable.
D Wear of internal pump parts. Replace worn components by new ones.
D Pump back pressure is lower than specified in Adjust to duty point.
the purchase order.
2)
The density or viscosity of the fluid pumped is
higher than specified in the order.
D Defective gasket Fit new gasket between volute casing and discharge
cover.
D Worn shaft seal. Fit new shaft seal.
D Score marks or roughness on shaft sleeve. Fit new shaft sleeve.
Fit new shaft seal.
D Vibrations during pump operation Improve suction conditions.
Increase pressure at the pump suction nozzle.
DPump is warped Check pipeline connections and secure fixing of
pump;if required, reduce the distances between the
pipe clamps.
Fix the pipelines using anti-vibration material.
Increased axial thrust.2) Clean balancing holes in the impeller.
Fit new wear rings.
Insufficient or excessive quantity of lubricant or Top up, reduce or change lubricant.
unsuitable lubricant.
Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
DRotor is out of balance. Clean the impeller.
Re-balance the impeller.
Defective bearing(s). Fit new bearings.
D DD Insufficient rate of flow. Increase the minimum rate of flow.
Incorrect setting of motor protection switch Check setting.
Fit new motor protection switch
Transport lock has not been removed from the Remove.
shaft groove.
1) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
2) Request particulars.

Issue: 03.05.2011 CIP-Process for DVZ-SKA-”BIOMASTER”-PLUS Page 6 of 6

SKA-PLUS-ANNEX P1-Eng
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

ANNEX Pump P2

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 DVZ - SERVICES GmbH
Boschstrasse 9 • D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
www.dvz-services.de

INSTRUCTION MANUAL
(ANNEX P2)

FOR

BMSU LOADING PUMP P2

FOR

SEWAGE TREATMENT PLANT

DVZ SKA-“BIOMASTER®-PLUS“
 Safety receive training and instruction. If required, this can be
These operating instructions contain basic information provided on behalf of the user by the manufacturer/sup-
that must be observed during installation, operation and plier. In addition, the user must ensure that the contents
maintenance. Therefore, prior to final installation and of the operating instructions are fully understood by the
commissioning, these operating instructions must be personnel.
read by the installation engineer, as well as by the
supervising personnel/operator, and must always be Dangers in the event of non-compliance with the
available at the place of installation of the machine/plant. safety information
Non-compliance with the safety information may result
Not only is the general safety information listed under in danger not only to persons, but also to equipment and
the main heading of „Safety“ to be observed, but also the environment. Non-compliance with the safety
the special safety hints provided under other main information will lead to the loss of any damage compen-
headings, e.g. for private use. sation claims.

Marking of hints in the operating instructions In detail, non-compliance may, for example,result in the
The safety hints contained in these operating instructions, following dangers:
relating to situations which may cause danger to –Failure of important functions of the machine/plant
personnel in the event of non-compliance, are specially –Failure of specified procedures for maintenance and
marked with the general hazard symbol servicing
–Danger to persons due to electrical, mechanical and
chemical influences
–Danger to the environment due to leakage of hazard-
ous substances.

Safety-conscious working
The safety hints provided in this operating manual, the
And, for warnings relating to electrical voltage, with current national accident prevention regulations, as well
as the user’s in-house operating and safety regulations,
must be observed.

Safety hints for the user/operator

– If hot or cold machine parts are dangerous, these parts
must be protected against accidental contact on site.
– Guards for moving parts must not be removed when the
For safety hints where non-compliance may cause machine is in operation.
danger to the machine and its operation, the word – When operating pump aggregates in a dust-laden
ATTENTION enviroment (e.g. milling, chipboard manufacture,
is used. bakeries), the surfaces of the pumps and motors must be
cleaned at regular intervals, depending on local conditions,
Safety hints attached directly to the machine, such as, in order to maintain the cooling effect and eliminate the
for example: possibility of spontaneous combustion. Please also see
–Rotation arrow explosion protection regulations (BGR 104).
–Labels for fluid connections – Leakages (e.g. from the shaft seal) of hazardous
must always be observed and kept in completely legible pumping liquids (e.g. explosive, toxic, hot) must be drained
condition. in such a way that no danger is caused to persons or the
environment. Legal regulations must
Qualification and training of personnel be observed.
Personnel engaged in operation, maintenance, inspec- - Provisions must be taken against electrical hazards
tion and assembly must have appropriate qualifications (for details please refer to the regulations of the VDE
for these tasks. Area of responsibility, competence and and the local electricity board).
supervision of personnel must be precisely controlled
by the user. Personnel with inadequate knowledge must

Issue: 04.05.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 2 of 6

SKA-PLUS-ANNEX P2-Eng
 Safety hints for maintenance, inspection and Foundation
assembly The foundation design depends on the size of the pump
The user must ensure that all maintenance, inspection and and/or the pump aggregate and the local installation
assembly tasks are performed by authorised and qualified conditions.
expert personnel, who have adequately informed For exact data on the pump and aggregate dimensions,
themselves by thoroughly studying the operating please refer to our table of dimensions.
instructions. The foundation may be designed as a concrete founda-
On principle, work on the machine must only be performed tion or load-carrying foundation frame, for example of
when the machine is at a standstill. The procedure for the steel type.
shutting down the machine as described in the operating All foundation designs are subject to the following: The
instructions must be observed without fail. foundation must be designed so that it can take the
Pumps or units handling noxious liquids must be de weight of the pump aggregate on the entire surface.
contaminated.
Arrangement of a steel foundation plate
All safety and protective devices must immediately be A steel foundation plate must be designed in such a way
refitted and made operational on completion on the that the base plate makes full contact and can be secured
work. with bolts or by welding.
Before re-starting, the items listed in the „Commissioning“ ATTENTION: If only some of the areas of the base plate
section must be observed. are supported, the plate sags in the center or the pump
aggregate can be twisted. This influences the alignment of
Unauthorised modifications and genuine spare parts the pump aggregate and can cause high noise emission
Modifications or changes to the machine are only per- and damage.
missible after consultation with the manufacturer.
Safety can only be ensured by using genuine spare parts Arrangement of concrete foundations
and accessories authorised by the manufacturer. If other Concrete foundations must be horizontal, straight and
parts are used the manufacturer cannot be held liable for clean and must fully absorb the load exerted on the
the consequences. foundations. Concrete foundations must be designed in
such a way that the base plate makes full contact and can
Transportation and intermediate storage be secured with suitable bolts drawing)
Packing ATTENTION: If only some of the areas of the base plate
The graphic symbols on the packaging must be observed. are supported, the plate sags in the center or the pump
During transport and storage, the suction and discharge aggregate can be twisted. This influences the alignment of
and the auxiliary connections of the pump must be the pump aggregate and can cause high noise emission
plugged. The plugs must be removed when the pump and damage.
unit is installed.
Space requirements for maintenance and servicing
Transportation ATTENTION: The pump must be accessible from all
Due to their weight, lifting equipment must be used to sides, allowing necessary inspections to be performed with
transfer progressive cavity pumps and all pump units to ease.
their final location. Sufficient space must be provided for maintenance and
servicing operations, especially for the replacement of
The generally applicable saftey regulations for lifting pumping elements. The space required for removing the
loads must be observed. The crane device and cables stator and rotor is given in the pump or pump unit
must not be attached to the attachment eyes of the motor. dimensional or general arrangement drawings. In addition,
When transporting the pumps by means of a crane, the it must be ensured that all piping can be removed and
sling ropes must be placed safely around the suction replaced without obstruction.
casing.
In case of complete pump aggregates, a rope must be Installation of pipework
additionally fixed to the driving motor. Nominal diameters
The sling ropes must be placed around the pump and/or The nominal diameters of the suction and discharge
the pump aggregate so that when being lifted, they are in pipes should be designed in accordance with the nominal
exact balance. diameters of the pump flanges. In the event of severe
ATTENTION: During transportation ensure that the deviations, especially on the suction side, the factory must
aggregate is secured against toppling over. be consulted.

Transport damage Supports and flange connections

ATTENTION: Check the pump for damage on receipt. Any The pipework must be connected in a stress-free manner,
damage detected must be notified immediately. via the flange connections, to the pump. Supports should
be provided close to the pump, and the connections
Installation/Mounting should be easy to make, in order to prevent any distortion.
Installation After loosening the bolts, the flanges should be neither
The pumps can be installed horizontally or vertically, skewed nor springy, nor should they rest on each other
with bearings arranged at the top under pressure. Appropriate measures (e.g. the

Issue: 04.05.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 3 of 6

SKA-PLUS-ANNEX P2-Eng
 installation of compensators) must be taken to keep any Control of the direction of rotation
thermal stress occurring in the pipework away from the The normal direction of rotation of the pump is anti-
pump. clockwise, looking from the drive towards the hollow
shaft. The suction connection is located on the shaft
Cleaning the pipework before connection seal side, therefore the shaft seal is balanced. In spezial
The suction pipework, the gate valves and shut-off valves cases, e.g. with vacuum suction or when pumping media
must be flushed and/or cleaned before installation of the that will not bear gas inclusions, the pump operates in the
pump. clockwise direction, in which case the suction and delivery
Items left over from installation, such as screws, nuts, sides are exchanged.
welding beads, metal items, etc. will damage the internal ATTENTION: The direction of rotation of the pump must
elements of the pump. Any damage caused by such items correspond with the rotation arrow on the pump name
is not covered by our warranty. Flange gaskets must not plate. Incorrect direction of rotation can result in damage
protrude inwards. Blanking flanges, plugs, protective film to the pump. To check the direction of rotation, briefly
and/or protective paint on flanges and seals must be activate the on/off switch of the motor.
removed completely.
Commissioning
Installation of auxiliary pipework for accessories Start-up
All auxiliary pipework for feeding the shaft seal and, where Prior to start-up, all shut-off devices installed in the
appropriate, the double shell casing for heating and cooling suction and discharge pipes must be open.
the pump, must be connected without stress or leakage.
The pipes for the quench liquid in the case of a single- Drive
action mechanical seal with quench (type G0Q) and the Switch motor on.
sealing liquid in the case of a double-action mechanical ATTENTION: Be aware of product-specific peculiarities of
seal (type G0D) should be installed with as large a flow the drive. Please refer to the manufacturer’s operating
cross-section as possible. The quench or sealing liquid instructions.
emerges at the uppermost connection of the mechanical
seal. Checking the pump performance
In order to ensure self-venting, the pipes must be installed When the drive reaches its operating speed, suction and
with a gradient, with low flow resistance and kept as short discharge pressure must be checked using a vacuum
as possible. gauge and a pressure gauge.
The formation of air pockets or gas bubbles must be The motor must not be overloaded. The power
prevented. Venting connections must be provided if consumption can be checked by means of an ammeter.
necessary. The heating/cooling liquid outlet must be The temperature and viscosity of the pumping liquid must
connected at the uppermost connection of the double shell be checked against the order data sheet or performance
casing, if fitted. test report.

Protection against dry running

Commissioning/Decommissioning If there is an interruption in the flow on the suction side
Preparation for commissioning of the progressive cavity pump, the thermal energy in the
Filling the pump with liquid pump elements caused by dry friction and flexing work is
ATTENTION: The pump must not run dry! The pump must not sufficiently transferred. This leads to the thermal
be filled with liquid for initial start-up and after prolonged destruction of the stator elastomer within a very short
standstill periods. space of time. A range of dry run protection devices,
Just a few revolutions without liquid may cause damage to suited to the specific operating conditions, is available for
the stator. For this reason, prior to start-up, the suction the protection of the pump elements.
casing must be filled with water or pumping liquid, in order
to lubricate the stator and the rotor. After a prolonged Decommissioning
standstill, i.e. if it is to be assumed that the liquid remaining
Shut-down
in the pump has evaporated, or after a repair, the filling
Switch the motor off.
process must be repeated.
After filling, the pump self-primes. Venting is not required,
Measures for prolonged shut-down periods
as a liquid/gas mixture can be easily handled.
If a longer shut-down period is planned and there is a
danger of frost, the pump must be drained. In order to do
Releasing the pump this, remove the screw plug from the suction casing. The
In the event of a re-start or after a prolonged standstill, pump must then be preserved.
it should be ensured that the pump is rotated easily by
the drive unit. If this is not possible, e.g. because of the
high degree of adhesion between the rotor and the sta-
tor, it is possible to provide assistance using an appro-
priate tool on the hollow shaft behind the shaft seal.
ATTENTION: The hollow shaft must not be damaged
during this process.

Issue: 04.05.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 4 of 6

SKA-PLUS-ANNEX P2-Eng
 Maintenance/Service mechanical seal.
Maintenance
–The information given in Section „Safety“ is to be 1. Gland packing
observed during maintenance and service operations. Increased leakage from the gland packing during the
Regular monitoring and servicing of the pump and drive initial operating hours usually diminishes of its own
will prolong their service life. accord during the running-in period.
If necessary, tighten the hexagon nuts (202) slightly at
the gland (203).
General monitoring
It should be noted that the gland packing should leak
1.The pump must not run dry.
slightly. This ensures that the frictional heat generated at
2.The drive motor must not be overloaded.
the sealing surface is dissipated.
3.Check suction and discharge pipelines for leaks.
If the leakage increases excessively and cannot be
4. An installed gland packing must drip slightly during
reduced by repeated, slight tightening of the
operation.
hexagonalted nuts (202), the packing rings have lost their
An installed mechanical seal must have no substantial
elasticity and must be replaced.
leakage.
5. Pressure and temperature monitoring devices must
- Removing the old packing rings and cleaning the
be observed and compared with the order data sheet
gland housing
and/or performance test report
After reducing the pump pressure and removing the
6. Monitor auxiliary shaft seal systems, such as flushing,
gland, the old packing rings can be removed by means of
sealing or quenching (if provided).
a packing puller tool with a flexible shaft.
7. Monitor auxiliary heating or cooling systems in the gland
The gland area and the hollow shaft rings must then be
housing and/or suction casing (if provided).
carefully cleaned in the area around the packing rings.
Worn hollow shafts must be replaced (please see
Maintenance of components disassembly and assembly instructions).
Universal joints on the coupling rod
The universal joints on the coupling rod are lubricated - Fitting the packing rings
with special joint oil Type B or ET 1510 ISO 460 oil from ATTENTION: Basically, the packing rings fitted must be
Tribol Lubricants GmbH, Mönchengladbach. suitable for the operating conditions of the pump.

ATTENTION: We have not tested other lubricants and we When cutting to size,we recommend a straight cut
cannot therefore recommend them! perpendicular to the shaft. In order to obtain gap-
free, parallel contact of the cut packing ring ends, the
The joints are lubricated for life. However, if the pump cutting angle should be approx. 20°to both cut ends
must be opened for other reasons, we recommend that (see Figure 1).
the tightness of the joint packing is checked and that
the joint oil is changed after 8000 operating hours. When
changing the joint oil, please refer to the disassembly and
assembly instructions.

Shaft seal
The shafts are sealed either by a gland packing or a

Issue: 04.05.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 5 of 6

SKA-PLUS-ANNEX P2-Eng
 Servicing (disassembly and assembly
instructions)
General
Trained service engineers will be available for installa-
tions and repairs on request.
When repairs are performed by the user’s own personnel
or by our service engineers, it is essential that the pump is
completely drained and cleaned.
This applies particularly to pumps that are returned for
repair to our factory or to one of our authorised service
centres.
In order to protect our staff and for the sake of environ-
Figure 1: Cutting packing rings to size mental protection, repairs on pumps filled with pumping
liquid will be refused. Otherwise, we will have to charge
Pre-pressed packing rings or rings cut to size must the customer/user for the costs of ecological waste dis-
carefully be opened axially and radially just far enough posal.
for them to be pushed over the shaft. Bending the rings If repairs are required on pumps that have handled
up may result in damage due to buckling. hazardous materials and/or liquids that are harmful
When fitting in the packing area, the packing rings must to the environment, the customer/user must voluntarily
be carefully bent back into their ring shape. The cut joints inform his own or our installation personnel of this on
must be staggered by 90°. Each ring must be pushed into site. This also applies if such a pump is returned to our
the gland housing with the cut ends first, with the factory or to one of our authorised service centres. In
assistance of the gland. Lantern rings or flushing rings are this case, evidence of the liquid pumped, for example in
to be fitted in the correct sequence. the form of a DIN safety data sheet, must be submitted
ATTENTION: Sharp tools must never be used for to us when the request for a service engineer is made.
installation, as there is a danger of damaging the shaft and
deforming the packing material. For all work executed on site, the user’s own personnel
and/or our service engineers must be alerted to dangers
–Commissioning the gland packing after re-packing that may arise in connection with repairs.
The gland packing should only be lightly tightened before
commissioning. During pump start-up, a leakage rate of 50 The most important disassembly and assembly operations
to 200 drops per minute is permitted. are described in these instructions. The assembly steps
Within 30 minutes of start-up, the leakage must be described in the individual sections must be consistently
gradually and evenly reduced to a minimum of 2 to 20 followed.
drops per minute by adjusting the gland (203) by means of
the hexagonal nuts (202). Disassembly of the progressive cavity pump
ATTENTION: During this process the temperature the Before commencing disassembly, the following operations
gland packing must not rise abnormally. Approx. 20 to must be performed:
60°C above the temperature of the liquid pumped is - Disconnect the power supply cable to the motor.
permissible. If the temperature rises suddenly, the gland It must not be possible to start the motor.
must be slackened immediately, and the start-up - Close all shut-off devices in the suction and discharge
procedure repeated. lines.
The leakage can be drained via the tapped hole located in - Drain the pumped liquid from the suction casing by
the drip pan of the motor bracket. removing the screw plug (502).
Note:Use a drip pan to collect the drained liquid.
- Disconnect the suction and discharge pipelines as well
Damage to people and the environment due to
as all auxiliary piping.
leakage of hazardous materials must be prevented.
- Unscrew the bolts at the pump feet.
2. Mechanical seal
Removal of the stator
Non-balanced mechanical seals are used in all material
- Remove hexagon nuts (609) and washers (610) from the
combinations and models. The mechanical seal is
connecting bolts (611).
maintenance-free.
- Pull off the discharge housing (504).
In the event of severe leakage due to wear, the
- Remove connecting bolts (611) and stays (612), if
mechanical seal must be replaced (please see
provided.
disassembly and assembly instructions).
- Pull the stator (402) off the rotor (401).
ATTENTION: As dry running of mechanical seals must be
Note: If difficulty is experienced, rotate the stator (402)
avoided, the pump must only be started in filled condition
with a chain wrench at the same time. In order to do this,
and with auxiliary devices connected, if provided.
secure the hollow shaft (125).
- With plastic or metal stators, remove the stator gaskets
(403) and (404).

Issue: 04.05.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 6 of 6

SKA-PLUS-ANNEX P2-Eng
 - Pull the rotor (401) from the coupling rod (307).
Disassembly of the rotor and the joint on the rotor side
- Drive the guide bushes (303) completely out of the
The rotor and the rotor-side joint are disassembled after
rotor (401) using a tapered brass drift.
removal of the stator (402).
- Remove hexagon nuts (607) and serrated lock washers
Disassembly of the coupling rod and the joint on
(608) as well as hexagon head bolts (606).
- Pull off the suction casing (505) over the rotor (401), the drive side
taking care that the precision-machined rotor is not The coupling rod and the drive-side joint are
damaged in the process. disassembled after removal of the stator (402) and the
- Remove the suction casing gasket (501). rotor (401).
- Cut the lock on the clamping band (306) with a metal saw - Disassemble the drive-side joint as described before.
and press out on both sides using a screwdriver. - Pull the coupling rod (307) off the hollow shaft (125).
Remove the clamping band (306) from the cover sleeve - Press out the coupling rod bush (302) from the
(308) (see Figure 2). coupling rod (307).
- Drive the guide bushes (303) completely out of the
hollow shaft (125) using a tapered brass drift.

Removal of the shaft seal and the hollow shaft

Note: For pumps with a shaft seal provided by gland
packing, the packing rings can be changed, as
described before, without removing the hollow shaft. It
is only necessary for the hollow shaft to be removed if
the pump is equipped with a mechanical seal. In cases
Figure 2: Removing the clamping band. where the hollow shaft has been damaged in the area
of the shaft seal, the pump must likewise be
- Lift the cover sleeve (308) with a screwdriver and pull it disassembled, as described below.
off axially in the direction of the coupling rod (307). - Remove stator (402).
- Drain the oil content into a container. - Remove hexagon nut (607) and serrated lock washer
- Drive the retaining sleeve (304) over the flange of the the (608) as well as hexagon head bolt (606).
coupling rod (307). Do not twist the coupling rod (307) in - Pull the suction casing (505) off over the rotor (401).
the p rocess (see Figure 3). Take care that the precision-machined rotor surface
is not damaged in the process.
- Remove the suction casing gasket (501).
- Remove the splash ring (123) from the clamp set
(123).
- Loosen the clamp screws of the clamp set (123)
uniformly and sequentially.
If necessary, rotate the hollow shaft (125) in order to
do this. If the outer ring of the clamp set is not
automatically released from the inner ring, a few
clamp screws can be unscrewed and inserted into the
adjacent pull-off threads. Release can now be easily
achieved.
Figure 3: Removing the retaining sleeve
Never unscrew the clamp screws completely
- Push out the coupling rod pins (301). (danger of accidents).
- Drive both guide bushes (303) halfway out using a
tapered brass drift. To do this, tilt the coupling rod (307) - Pull the hollow shaft (125), together with all parts of
(see Figure 4). the shaft seal and the clamp set (123), from the motor
bracket (122).
- Pull the clamp set (123) from the hollow shaft (125).

Disassembly of the gland packing

- Remove the hexagon nut (202) and gland (203).
- Pull the gland housing (204) from the holl ow shaft
(125).
- Remove the gland packing (207) from the gland
housing (204).

Figure 4: Removing the guide bushes

Issue: 04.05.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 7 of 6

SKA-PLUS-ANNEX P2-Eng
 Disassembly of the single action mechanical seal Installation of single action mechanical seal
- Pull the mechanical seal housing (214), together with the - Drive retaining pin (220) into the mechanical seal
atmospheric-side stationary seal face of the mechanical housing (214).
seal (219), from the hollow shaft (125). - Press the stationary seal face (219), together with the
Note: Particular care should be taken to ensure that the O-ring, concentrically into the cleaned seal housing
housing, together with the stationary seal face, is pulled (214).
off concentrically, without tilting, in order to avoid Note: Ensure that the pressure is evenly distributed
damaging the stationary seal face. and that the retaining pin (220) does not protrude
- Press the stationary seal face and the O-ring out of the inside the mechanical seal housing.
mechanical seal housing (214). Ensure that the pressure - Push the rotating part of the mechanical seal (219)
is evenly distributed. over the hollow shaft (125).
- Drive out the retaining pin (220). Note: Precisely observe the installation dimension
- Loosen the grub screws, if fitted, in the rotating part of the and/or position of the mechanical seal as marked
mechanical seal housing (219), and pull the mechanical during disassembly.
seal from the hollow shaft (125). - Insert the grub screws (if provided) into the rotating
ATTENTION: Before loosening the grub screws, mark or part of the mechanical seal (219), using a liquid
measure the position of the mechanical seal housing on retention agent such as Loctite no. 241, and tighten.
the hollow shaft. Do not push the O-rings over the drag - Push the mechanical seal housing (214) together with
marks made by the grub screws. the stationary seal face (219) over the hollow shaft
(125).
Assembly of the progressive cavity pump Note: Care should be taken not to tilt the mechanical
General seal housing when pushing it onto the hollow shaft, in
After careful cleaning, the particular pump parts are order to avoid damaging the stationary seal face.
assembled accordingly in reverse order.
Installation of the hollow shaft
Installation of the shaft seal - The clamp sets (123) are delivered ready for
Installation of the gland packing installation. They should not, therefore, be
- Slide the gland housing (204) onto the hollow shaft with disassembled before initial installation.
the O-ring (235). - Clamp sets (123) that have been removed do not
- Insert the gland packing (207) into the gland housing need to be disassembled and re-lubricated before re-
(204). For shaft seal type P02, also insert the flushing installation.
ring (208), and for types P03 and P04, also insert the - Only clean and re-lubricate the clamp set (123) if it is
lantern ring (209). contaminated.
Please see also Section „Fitting new packing rings“. - A solid lubricant with a friction coefficient of µ= 0.04
must be used.
Installation of the mechanical seal (general) - If the conical surfaces are damaged, the clamp set
Mechanical seals are high quality, precision-machined must be replaced.
parts. The mechanical seal manufacturer’s assembly - Grease the clamp bolt threads and the contact surface
instructions must be observed. Careful handling and of the heads with Molykote. Tighten the clamp bolts
extreme cleanliness during installation are essential for manually, until the bolt heads are in full contact with
proper functioning. To facilitate assembly, surfaces over the inner ring of the clamp set.
which O-rings slide can be lubricated with a suitable ATTENTION: Do not tighten the clamp bolts until the
lubricant, for example, silicon oil, Polydiol or soft soap. hollow shaft (125) has been pushed over the shaft of
ATTENTION: Do not use ordinary oil. the drive.
Note: Parts that slide on top of one another must always ATTENTION: Clean and degrease the shaft of the
be exchanged in pairs. When using double PTFE sheathed drive and the bore of the hollow shaft (125).
O-rings, please ensure that the joint of the outer sheathing - Slide the splash ring (123) onto the hollow shaft (125).
faces in the correct direction for assembly, as otherwise - Lightly grease the seat of the clamp set (123) on the
the sheathing may open or be pulled off (see Figure 5). hollow shaft (125) and push the clamp set (123) onto
the hollow shaft (125) as far as the stop.
- Push the hollow shaft (125) onto the drive shaft as far
as the stop.
- Tighten the bolts of the clamp set (123) successively
in several turns, rotating the hollow shaft if necessary.
ATTENTION: All clamp bolts must be tightened until
the front surfaces of the outer and inner rings are
flush and the fastening torque of the bolts increases
sharply (see operational condition in Figure 6). The
permissible fastening torque is marked on the clamp
Figure 5: Joint of outer teflon sheathing faces in the set (123).
correct direction for assembly.

Issue: 04.05.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 8 of 6

SKA-PLUS-ANNEX P2-Eng
 - Raise the cover sleeve (308) by lifting at the top with a
screwdriver, guide the oil can spray pipe beneath the
sleeve, and fill the joint area with special joint oil Type
B or ET 1510 ISO 460 oil.
- Check that the bent loop of the clamping band (306) is
resting against the clamping band lock. If not, press it
against the lock with a pair of standard flat pliers (see
Figure 8).

Figure 8: Press bent loop of clamping band against the

clamping band lock.
Figure 6: Clamp set assembly
- Correct positioning of the clamp set (123) on the hollow - Place the clamping bands (306) in the grooves of the
shaft (125) must be checked, in accordance with Figure cover sleeve (308) and tighten.
6, item X.
- Pull the splash ring (123) onto the clamp set (123) (please Installation of the stator
see Section Assembly of the rotor and the joints). - Before installation, lubricate the stator (402) and rotor
(401) with a sliding agent (silicon oil, Polydiol, soft
Installation of the rotor and the joint soap or similar).
- Drive the guide bushes (303) halfway into the rotor (401) ATTENTION: Do not use ordinary oil.
and the hollow shaft (125) using a tapered brass drift. - For plastic or metal stators, insert stator gaskets (403)
- Push clamping bands (306), cover sleeves (308) and and (404).
retaining sleeve (304) onto the shaft of the coupling rod Note: With plastic stators, the stator gasket (403) and
(307). the O-ring must always be located on the discharge
- Push the coupling rod (307) into the head of the rotor side.
(401) or the hollow shaft (125). - Pull the stator (402) over the rotor (401).
- Push coupling rod pins (301) into the coupling rod bush Note: If difficulty is experienced, rotate the stator
(302) and drive in guide bushes (303) completely. (402) at the same time, using a chain wrench. Secure
- If necessary, emery the outside of the retaining sleeve the hollow shaft (125) in order to do this.
(304) and pull it over the head of the rotor (401) or the - Bolt together the discharge casing (504), the stator
hollow shaft (125). (402) and the suction casing (505) with the
- After installing the retaining sleeve (304), secure it against connecting bolts (611) and hexagon nuts (609).
axial movement on the head of the rotor (401) or hollow Uniformly tighten the hexagon head bolts.
shaft (125).
ATTENTION: To do this, drive the face of the retaining
sleeve (304) into the groove on the head of the rotor
(401) or hollow shaft (125) using a centre punch (see
Figure 7).

Figure 7: Securing the retaining sleeve

Issue: 04.05.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 9 of 6

SKA-PLUS-ANNEX P2-Eng
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

ANNEX Pump P5

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
www.dvz-services.de

INSTRUCTION MANUAL
(ANNEX P5)

FOR

TRANSFER PUMP P5

FOR

SEWAGE TREATMENT PLANT

DVZ SKA-“BIOMASTER®-PLUS“
 Safety receive training and instruction. If required, this can be
These operating instructions contain basic information provided on behalf of the user by the manufacturer/sup-
that must be observed during installation, operation and plier. In addition, the user must ensure that the contents
maintenance. Therefore, prior to final installation and of the operating instructions are fully understood by the
commissioning, these operating instructions must be personnel.
read by the installation engineer, as well as by the
supervising personnel/operator, and must always be Dangers in the event of non-compliance with the
available at the place of installation of the machine/plant. safety information
Non-compliance with the safety information may result
Not only is the general safety information listed under in danger not only to persons, but also to equipment and
the main heading of „Safety“ to be observed, but also the environment. Non-compliance with the safety
the special safety hints provided under other main information will lead to the loss of any damage compen-
headings, e.g. for private use. sation claims.

Marking of hints in the operating instructions In detail, non-compliance may, for example,result in the
The safety hints contained in these operating instructions, following dangers:
relating to situations which may cause danger to –Failure of important functions of the machine/plant
personnel in the event of non-compliance, are specially –Failure of specified procedures for maintenance and
marked with the general hazard symbol servicing
–Danger to persons due to electrical, mechanical and
chemical influences
–Danger to the environment due to leakage of hazard-
ous substances.

Safety-conscious working
The safety hints provided in this operating manual, the
And, for warnings relating to electrical voltage, with current national accident prevention regulations, as well
as the user’s in-house operating and safety regulations,
must be observed.

Safety hints for the user/operator

– If hot or cold machine parts are dangerous, these parts
must be protected against accidental contact on site.
– Guards for moving parts must not be removed when
For safety hints where non-compliance may cause the machine is in operation.
danger to the machine and its operation, the word – When operating pump aggregates in a dust-laden
ATTENTION enviroment (e.g. milling, chipboard manufacture,
is used. bakeries), the surfaces of the pumps and motors must be
cleaned at regular intervals, depending on local
Safety hints attached directly to the machine, such as, conditions, in order to maintain the cooling effect and
for example: eliminate the possibility of spontaneous combustion.
–Rotation arrow Please also see explosion protection regulations (BGR
–Labels for fluid connections 104).
must always be observed and kept in completely legible – Leakages (e.g. from the shaft seal) of hazardous
condition. pumping liquids (e.g. explosive, toxic, hot) must be
drained in such a way that no danger is caused to
Qualification and training of personnel persons or the environment. Legal regulations must
Personnel engaged in operation, maintenance, inspec- be observed.
tion and assembly must have appropriate qualifications - Provisions must be taken against electrical hazards
for these tasks. Area of responsibility, competence and (for details please refer to the regulations of the VDE
supervision of personnel must be precisely controlled and the local electricity board).
by the user. Personnel with inadequate knowledge must

Issue: 18.10.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 2 of 6

SKA-PLUS-ANNEX P5-Eng
 Safety hints for maintenance, inspection and Foundation
assembly The foundation design depends on the size of the pump
The user must ensure that all maintenance, inspection and/or the pump aggregate and the local installation
and assembly tasks are performed by authorised and conditions.
qualified expert personnel, who have adequately informed For exact data on the pump and aggregate dimensions,
themselves by thoroughly studying the operating please refer to our table of dimensions.
instructions. The foundation may be designed as a concrete founda-
On principle, work on the machine must only be tion or load-carrying foundation frame, for example of
performed when the machine is at a standstill. The the steel type.
procedure for shutting down the machine as described in All foundation designs are subject to the following: The
the operating instructions must be observed without fail. foundation must be designed so that it can take the
Pumps or units handling noxious liquids must be de weight of the pump aggregate on the entire surface.
contaminated.
Arrangement of a steel foundation plate
All safety and protective devices must immediately be A steel foundation plate must be designed in such a way
refitted and made operational on completion on the that the base plate makes full contact and can be secured
work. with bolts or by welding.
Before re-starting, the items listed in the „Commissioning“ ATTENTION: If only some of the areas of the base plate
section must be observed. are supported, the plate sags in the center or the pump
aggregate can be twisted. This influences the alignment
Unauthorised modifications and genuine spare parts of the pump aggregate and can cause high noise
Modifications or changes to the machine are only per- emission and damage.
missible after consultation with the manufacturer.
Safety can only be ensured by using genuine spare parts Arrangement of concrete foundations
and accessories authorised by the manufacturer. If other Concrete foundations must be horizontal, straight and
parts are used the manufacturer cannot be held liable for clean and must fully absorb the load exerted on the
the consequences. foundations. Concrete foundations must be designed in
such a way that the base plate makes full contact and
Transportation and intermediate storage can be secured with suitable bolts drawing)
Packing ATTENTION: If only some of the areas of the base plate
The graphic symbols on the packaging must be are supported, the plate sags in the center or the pump
observed. aggregate can be twisted. This influences the alignment
During transport and storage, the suction and discharge of the pump aggregate and can cause high noise
and the auxiliary connections of the pump must be emission and damage.
plugged. The plugs must be removed when the pump
unit is installed. Space requirements for maintenance and servicing
ATTENTION: The pump must be accessible from all
Transportation sides, allowing necessary inspections to be performed
Due to their weight, lifting equipment must be used to with ease.
transfer progressive cavity pumps and all pump units to Sufficient space must be provided for maintenance and
their final location. servicing operations, especially for the replacement of
pumping elements. The space required for removing the
The generally applicable saftey regulations for lifting stator and rotor is given in the pump or pump unit
loads must be observed. The crane device and cables dimensional or general arrangement drawings. In
must not be attached to the attachment eyes of the addition, it must be ensured that all piping can be
motor. removed and replaced without obstruction.
When transporting the pumps by means of a crane, the
sling ropes must be placed safely around the suction Installation of pipework
casing. Nominal diameters
In case of complete pump aggregates, a rope must be The nominal diameters of the suction and discharge
additionally fixed to the driving motor. pipes should be designed in accordance with the nominal
The sling ropes must be placed around the pump and/or diameters of the pump flanges. In the event of severe
the pump aggregate so that when being lifted, they are in deviations, especially on the suction side, the factory
exact balance. must be consulted.
ATTENTION: During transportation ensure that the
aggregate is secured against toppling over. Supports and flange connections
The pipework must be connected in a stress-free manner,
Transport damage via the flange connections, to the pump. Supports should
ATTENTION: Check the pump for damage on receipt. be provided close to the pump, and the connections
Any damage detected must be notified immediately. should be easy to make, in order to prevent any
distortion. After loosening the bolts, the flanges should be
Installation/Mounting neither skewed nor springy, nor should they rest on each
Installation other under pressure. Appropriate measures (e.g. the
The pumps can be installed horizontally or vertically,
with bearings arranged at the top

Issue: 18.10.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 3 of 6

SKA-PLUS-ANNEX P5-Eng
 installation of compensators) must be taken to keep any Control of the direction of rotation
thermal stress occurring in the pipework away from the The normal direction of rotation of the pump is anti-
pump. clockwise, looking from the drive towards the hollow
shaft. The suction connection is located on the shaft
Cleaning the pipework before connection seal side, therefore the shaft seal is balanced. In spezial
The suction pipework, the gate valves and shut-off valves cases, e.g. with vacuum suction or when pumping media
must be flushed and/or cleaned before installation of the that will not bear gas inclusions, the pump operates in
pump. the clockwise direction, in which case the suction and
Items left over from installation, such as screws, nuts, delivery sides are exchanged.
welding beads, metal items, etc. will damage the internal ATTENTION: The direction of rotation of the pump must
elements of the pump. Any damage caused by such items correspond with the rotation arrow on the pump name
is not covered by our warranty. Flange gaskets must not plate. Incorrect direction of rotation can result in damage
protrude inwards. Blanking flanges, plugs, protective film to the pump. To check the direction of rotation, briefly
and/or protective paint on flanges and seals must be activate the on/off switch of the motor.
removed completely.
Commissioning
Installation of auxiliary pipework for accessories Start-up
All auxiliary pipework for feeding the shaft seal and, where Prior to start-up, all shut-off devices installed in the
appropriate, the double shell casing for heating and suction and discharge pipes must be open.
cooling the pump, must be connected without stress or
leakage. Drive
The pipes for the quench liquid in the case of a single- Switch motor on.
action mechanical seal with quench (type G0Q) and the ATTENTION: Be aware of product-specific peculiarities
sealing liquid in the case of a double-action mechanical of the drive. Please refer to the manufacturer’s operating
seal (type G0D) should be installed with as large a flow instructions.
cross-section as possible. The quench or sealing liquid
emerges at the uppermost connection of the mechanical Checking the pump performance
seal. When the drive reaches its operating speed, suction and
In order to ensure self-venting, the pipes must be installed discharge pressure must be checked using a vacuum
with a gradient, with low flow resistance and kept as short gauge and a pressure gauge.
as possible. The motor must not be overloaded. The power
The formation of air pockets or gas bubbles must be consumption can be checked by means of an ammeter.
prevented. Venting connections must be provided if The temperature and viscosity of the pumping liquid
necessary. The heating/cooling liquid outlet must be must be checked against the order data sheet or
connected at the uppermost connection of the double performance test report.
shell casing, if fitted.
Protection against dry running
If there is an interruption in the flow on the suction side
Commissioning/Decommissioning
of the progressive cavity pump, the thermal energy in the
Preparation for commissioning
pump elements caused by dry friction and flexing work is
Filling the pump with liquid not sufficiently transferred. This leads to the thermal
ATTENTION: The pump must not run dry! The pump destruction of the stator elastomer within a very short
must be filled with liquid for initial start-up and after space of time. A range of dry run protection devices,
prolonged standstill periods. suited to the specific operating conditions, is available
Just a few revolutions without liquid may cause damage for the protection of the pump elements.
to the stator. For this reason, prior to start-up, the suction
casing must be filled with water or pumping liquid, in
Decommissioning
order to lubricate the stator and the rotor. After a
Shut-down
prolonged standstill, i.e. if it is to be assumed that the
Switch the motor off.
liquid remaining in the pump has evaporated, or after a
repair, the filling process must be repeated.
After filling, the pump self-primes. Venting is not required, Measures for prolonged shut-down periods
as a liquid/gas mixture can be easily handled. If a longer shut-down period is planned and there is a
danger of frost, the pump must be drained. In order to
do this, remove the screw plug from the suction casing.
Releasing the pump The pump must then be preserved.
In the event of a re-start or after a prolonged standstill,
it should be ensured that the pump is rotated easily by
the drive unit. If this is not possible, e.g. because of the
high degree of adhesion between the rotor and the sta-
tor, it is possible to provide assistance using an appro-
priate tool on the hollow shaft behind the shaft seal.
ATTENTION: The hollow shaft must not be damaged
during this process.

Issue: 18.10.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 4 of 6

SKA-PLUS-ANNEX P5-Eng
 Maintenance/Service mechanical seal.
Maintenance
–The information given in Section „Safety“ is to be 1. Gland packing
observed during maintenance and service operations. Increased leakage from the gland packing during the
Regular monitoring and servicing of the pump and drive initial operating hours usually diminishes of its own
will prolong their service life. accord during the running-in period.
If necessary, tighten the hexagon nuts (202) slightly at
the gland (203).
General monitoring
It should be noted that the gland packing should leak
1.The pump must not run dry.
slightly. This ensures that the frictional heat generated
2.The drive motor must not be overloaded.
at the sealing surface is dissipated.
3.Check suction and discharge pipelines for leaks.
If the leakage increases excessively and cannot be
4. An installed gland packing must drip slightly during
reduced by repeated, slight tightening of the
operation.
hexagonalted nuts (202), the packing rings have lost
An installed mechanical seal must have no substantial
their elasticity and must be replaced.
leakage.
5. Pressure and temperature monitoring devices must
- Removing the old packing rings and cleaning the
be observed and compared with the order data sheet
gland housing
and/or performance test report
After reducing the pump pressure and removing the
6. Monitor auxiliary shaft seal systems, such as flushing,
gland, the old packing rings can be removed by means
sealing or quenching (if provided).
of a packing puller tool with a flexible shaft.
7. Monitor auxiliary heating or cooling systems in the
The gland area and the hollow shaft rings must then be
gland housing and/or suction casing (if provided).
carefully cleaned in the area around the packing rings.
Worn hollow shafts must be replaced (please see
Maintenance of components disassembly and assembly instructions).
Universal joints on the coupling rod
The universal joints on the coupling rod are lubricated - Fitting the packing rings
with special joint oil Type B or ET 1510 ISO 460 oil from ATTENTION: Basically, the packing rings fitted must be
Tribol Lubricants GmbH, Mönchengladbach. suitable for the operating conditions of the pump.

ATTENTION: We have not tested other lubricants and we When cutting to size,we recommend a straight cut
cannot therefore recommend them! perpendicular to the shaft. In order to obtain gap-
free, parallel contact of the cut packing ring ends, the
The joints are lubricated for life. However, if the pump cutting angle should be approx. 20°to both cut ends
must be opened for other reasons, we recommend that (see Figure 1).
the tightness of the joint packing is checked and that
the joint oil is changed after 8000 operating hours. When
changing the joint oil, please refer to the disassembly and
assembly instructions.

Shaft seal
The shafts are sealed either by a gland packing or a

Issue: 18.10.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 5 of 6

SKA-PLUS-ANNEX P5-Eng
 Servicing (disassembly and assembly
instructions)
General
Trained service engineers will be available for installa-
tions and repairs on request.
When repairs are performed by the user’s own personnel
or by our service engineers, it is essential that the pump
is completely drained and cleaned.
This applies particularly to pumps that are returned for
repair to our factory or to one of our authorised service
centres.
In order to protect our staff and for the sake of environ-
Figure 1: Cutting packing rings to size mental protection, repairs on pumps filled with pumping
liquid will be refused. Otherwise, we will have to charge
Pre-pressed packing rings or rings cut to size must the customer/user for the costs of ecological waste dis-
carefully be opened axially and radially just far enough posal.
for them to be pushed over the shaft. Bending the rings If repairs are required on pumps that have handled
up may result in damage due to buckling. hazardous materials and/or liquids that are harmful
When fitting in the packing area, the packing rings must to the environment, the customer/user must voluntarily
be carefully bent back into their ring shape. The cut joints inform his own or our installation personnel of this on
must be staggered by 90°. Each ring must be pushed into site. This also applies if such a pump is returned to our
the gland housing with the cut ends first, with the factory or to one of our authorised service centres. In
assistance of the gland. Lantern rings or flushing rings this case, evidence of the liquid pumped, for example in
are to be fitted in the correct sequence. the form of a DIN safety data sheet, must be submitted
ATTENTION: Sharp tools must never be used for to us when the request for a service engineer is made.
installation, as there is a danger of damaging the shaft
and deforming the packing material. For all work executed on site, the user’s own personnel
and/or our service engineers must be alerted to dangers
–Commissioning the gland packing after re-packing that may arise in connection with repairs.
The gland packing should only be lightly tightened before
commissioning. During pump start-up, a leakage rate of The most important disassembly and assembly
50 to 200 drops per minute is permitted. operations are described in these instructions. The
Within 30 minutes of start-up, the leakage must be assembly steps described in the individual sections must
gradually and evenly reduced to a minimum of 2 to 20 be consistently followed.
drops per minute by adjusting the gland (203) by means
of the hexagonal nuts (202). Disassembly of the progressive cavity pump
ATTENTION: During this process the temperature the Before commencing disassembly, the following
gland packing must not rise abnormally. Approx. 20 to operations must be performed:
60°C above the temperature of the liquid pumped is - Disconnect the power supply cable to the motor.
permissible. If the temperature rises suddenly, the gland It must not be possible to start the motor.
must be slackened immediately, and the start-up - Close all shut-off devices in the suction and discharge
procedure repeated. lines.
The leakage can be drained via the tapped hole located in - Drain the pumped liquid from the suction casing by
the drip pan of the motor bracket. removing the screw plug (502).
Note:Use a drip pan to collect the drained liquid.
Damage to people and the environment due to - Disconnect the suction and discharge pipelines as well
leakage of hazardous materials must be prevented. as all auxiliary piping.
- Unscrew the bolts at the pump feet.
2. Mechanical seal
Non-balanced mechanical seals are used in all material Removal of the stator
combinations and models. The mechanical seal is - Remove hexagon nuts (609) and washers (610) from
maintenance-free. the connecting bolts (611).
In the event of severe leakage due to wear, the - Pull off the discharge housing (504).
mechanical seal must be replaced (please see - Remove connecting bolts (611) and stays (612), if
disassembly and assembly instructions). provided.
ATTENTION: As dry running of mechanical seals must - Pull the stator (402) off the rotor (401).
be avoided, the pump must only be started in filled Note: If difficulty is experienced, rotate the stator (402)
condition and with auxiliary devices connected, if with a chain wrench at the same time. In order to do
provided. this, secure the hollow shaft (125).
- With plastic or metal stators, remove the stator gaskets
(403) and (404).

Issue: 18.10.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 6 of 6

SKA-PLUS-ANNEX P5-Eng
 - Pull the rotor (401) from the coupling rod (307).
Disassembly of the rotor and the joint on the rotor
- Drive the guide bushes (303) completely out of the
side
rotor (401) using a tapered brass drift.
The rotor and the rotor-side joint are disassembled after
removal of the stator (402).
Disassembly of the coupling rod and the joint on
- Remove hexagon nuts (607) and serrated lock washers
the drive side
(608) as well as hexagon head bolts (606).
The coupling rod and the drive-side joint are
- Pull off the suction casing (505) over the rotor (401),
disassembled after removal of the stator (402) and the
taking care that the precision-machined rotor is not
rotor (401).
damaged in the process.
- Disassemble the drive-side joint as described before.
- Remove the suction casing gasket (501).
- Pull the coupling rod (307) off the hollow shaft (125).
- Cut the lock on the clamping band (306) with a metal
- Press out the coupling rod bush (302) from the
saw and press out on both sides using a screwdriver.
coupling rod (307).
Remove the clamping band (306) from the cover sleeve
- Drive the guide bushes (303) completely out of the
(308) (see Figure 2).
hollow shaft (125) using a tapered brass drift.

Removal of the shaft seal and the hollow shaft

Note: For pumps with a shaft seal provided by gland
packing, the packing rings can be changed, as
described before, without removing the hollow shaft. It
is only necessary for the hollow shaft to be removed if
the pump is equipped with a mechanical seal. In cases
where the hollow shaft has been damaged in the area
Figure 2: Removing the clamping band. of the shaft seal, the pump must likewise be
disassembled, as described below.
- Lift the cover sleeve (308) with a screwdriver and pull it - Remove stator (402).
off axially in the direction of the coupling rod (307). - Remove hexagon nut (607) and serrated lock washer
- Drain the oil content into a container. (608) as well as hexagon head bolt (606).
- Drive the retaining sleeve (304) over the flange of the the - Pull the suction casing (505) off over the rotor (401).
coupling rod (307). Do not twist the coupling rod (307) Take care that the precision-machined rotor surface
in the p rocess (see Figure 3). is not damaged in the process.
- Remove the suction casing gasket (501).
- Remove the splash ring (123) from the clamp set
(123).
- Loosen the clamp screws of the clamp set (123)
uniformly and sequentially.
If necessary, rotate the hollow shaft (125) in order to
do this. If the outer ring of the clamp set is not
automatically released from the inner ring, a few
clamp screws can be unscrewed and inserted into
the adjacent pull-off threads. Release can now be
easily achieved.

Figure 3: Removing the retaining sleeve Never unscrew the clamp screws completely
(danger of accidents).
- Push out the coupling rod pins (301).
- Drive both guide bushes (303) halfway out using a - Pull the hollow shaft (125), together with all parts of
tapered brass drift. To do this, tilt the coupling rod (307) the shaft seal and the clamp set (123), from the
(see Figure 4). motor bracket (122).
- Pull the clamp set (123) from the hollow shaft (125).

Disassembly of the gland packing

- Remove the hexagon nut (202) and gland (203).
- Pull the gland housing (204) from the holl ow shaft
(125).
- Remove the gland packing (207) from the gland
housing (204).

Figure 4: Removing the guide bushes

Issue: 18.10.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 7 of 6

SKA-PLUS-ANNEX P5-Eng
 Disassembly of the single action mechanical seal Installation of single action mechanical seal
- Pull the mechanical seal housing (214), together with the - Drive retaining pin (220) into the mechanical seal
atmospheric-side stationary seal face of the mechanical housing (214).
seal (219), from the hollow shaft (125). - Press the stationary seal face (219), together with the
Note: Particular care should be taken to ensure that the O-ring, concentrically into the cleaned seal housing
housing, together with the stationary seal face, is pulled (214).
off concentrically, without tilting, in order to avoid Note: Ensure that the pressure is evenly distributed
damaging the stationary seal face. and that the retaining pin (220) does not protrude
- Press the stationary seal face and the O-ring out of the inside the mechanical seal housing.
mechanical seal housing (214). Ensure that the - Push the rotating part of the mechanical seal (219)
pressure is evenly distributed. over the hollow shaft (125).
- Drive out the retaining pin (220). Note: Precisely observe the installation dimension
- Loosen the grub screws, if fitted, in the rotating part of and/or position of the mechanical seal as marked
the mechanical seal housing (219), and pull the during disassembly.
mechanical seal from the hollow shaft (125). - Insert the grub screws (if provided) into the rotating
ATTENTION: Before loosening the grub screws, mark or part of the mechanical seal (219), using a liquid
measure the position of the mechanical seal housing on retention agent such as Loctite no. 241, and tighten.
the hollow shaft. Do not push the O-rings over the drag - Push the mechanical seal housing (214) together with
marks made by the grub screws. the stationary seal face (219) over the hollow shaft
(125).
Assembly of the progressive cavity pump Note: Care should be taken not to tilt the mechanical
General seal housing when pushing it onto the hollow shaft,
After careful cleaning, the particular pump parts are in
assembled accordingly in reverse order. order to avoid damaging the stationary seal face.

Installation of the shaft seal Installation of the hollow shaft

Installation of the gland packing - The clamp sets (123) are delivered ready for
- Slide the gland housing (204) onto the hollow shaft with installation. They should not, therefore, be
the O-ring (235). disassembled before initial installation.
- Insert the gland packing (207) into the gland housing - Clamp sets (123) that have been removed do not
(204). For shaft seal type P02, also insert the flushing need to be disassembled and re-lubricated before re-
ring (208), and for types P03 and P04, also insert the installation.
lantern ring (209). - Only clean and re-lubricate the clamp set (123) if it is
Please see also Section „Fitting new packing rings“. contaminated.
- A solid lubricant with a friction coefficient of µ= 0.04
Installation of the mechanical seal (general) must be used.
Mechanical seals are high quality, precision-machined - If the conical surfaces are damaged, the clamp set
parts. The mechanical seal manufacturer’s assembly must be replaced.
instructions must be observed. Careful handling and - Grease the clamp bolt threads and the contact
extreme cleanliness during installation are essential for surface of the heads with Molykote. Tighten the
proper functioning. To facilitate assembly, surfaces over clamp bolts manually, until the bolt heads are in full
which O-rings slide can be lubricated with a suitable contact with the inner ring of the clamp set.
lubricant, for example, silicon oil, Polydiol or soft soap. ATTENTION: Do not tighten the clamp bolts until the
ATTENTION: Do not use ordinary oil. hollow shaft (125) has been pushed over the shaft of
Note: Parts that slide on top of one another must always the drive.
be exchanged in pairs. When using double PTFE ATTENTION: Clean and degrease the shaft of the
sheathed O-rings, please ensure that the joint of the outer drive and the bore of the hollow shaft (125).
sheathing faces in the correct direction for assembly, as - Slide the splash ring (123) onto the hollow shaft
otherwise the sheathing may open or be pulled off (see (125).
Figure 5). - Lightly grease the seat of the clamp set (123) on the
hollow shaft (125) and push the clamp set (123) onto
the hollow shaft (125) as far as the stop.
- Push the hollow shaft (125) onto the drive shaft as far
as the stop.
- Tighten the bolts of the clamp set (123) successively
in several turns, rotating the hollow shaft if
necessary.
ATTENTION: All clamp bolts must be tightened until
the front surfaces of the outer and inner rings are
flush and the fastening torque of the bolts increases
Figure 5: Joint of outer teflon sheathing faces in the sharply (see operational condition in Figure 6). The
correct direction for assembly. permissible fastening torque is marked on the clamp
set (123).

Issue: 18.10.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 8 of 6

SKA-PLUS-ANNEX P5-Eng
 - Raise the cover sleeve (308) by lifting at the top with
a screwdriver, guide the oil can spray pipe beneath
the sleeve, and fill the joint area with special joint oil
Type B or ET 1510 ISO 460 oil.
- Check that the bent loop of the clamping band (306)
is resting against the clamping band lock. If not,
press it against the lock with a pair of standard flat
pliers (see Figure 8).

Figure 8: Press bent loop of clamping band against the

clamping band lock.
Figure 6: Clamp set assembly
- Correct positioning of the clamp set (123) on the hollow - Place the clamping bands (306) in the grooves of the
shaft (125) must be checked, in accordance with Figure cover sleeve (308) and tighten.
6, item X.
- Pull the splash ring (123) onto the clamp set (123) Installation of the stator
(please see Section Assembly of the rotor and the - Before installation, lubricate the stator (402) and rotor
joints). (401) with a sliding agent (silicon oil, Polydiol, soft
soap or similar).
Installation of the rotor and the joint ATTENTION: Do not use ordinary oil.
- Drive the guide bushes (303) halfway into the rotor (401) - For plastic or metal stators, insert stator gaskets
and the hollow shaft (125) using a tapered brass drift. (403) and (404).
- Push clamping bands (306), cover sleeves (308) and Note: With plastic stators, the stator gasket (403)
retaining sleeve (304) onto the shaft of the coupling rod and the O-ring must always be located on the
(307). discharge side.
- Push the coupling rod (307) into the head of the rotor - Pull the stator (402) over the rotor (401).
(401) or the hollow shaft (125). Note: If difficulty is experienced, rotate the stator
- Push coupling rod pins (301) into the coupling rod bush (402) at the same time, using a chain wrench.
(302) and drive in guide bushes (303) completely. Secure the hollow shaft (125) in order to do this.
- If necessary, emery the outside of the retaining sleeve - Bolt together the discharge casing (504), the stator
(304) and pull it over the head of the rotor (401) or the (402) and the suction casing (505) with the
hollow shaft (125). connecting bolts (611) and hexagon nuts (609).
- After installing the retaining sleeve (304), secure it Uniformly tighten the hexagon head bolts.
against axial movement on the head of the rotor (401) or
hollow shaft (125).
ATTENTION: To do this, drive the face of the retaining
sleeve (304) into the groove on the head of the rotor
(401) or hollow shaft (125) using a centre punch (see
Figure 7).

Figure 7: Securing the retaining sleeve

Issue: 18.10.2011 DVZ-SKA-”BIOMASTER”-PLUS – Pump P2 Page 9 of 6

SKA-PLUS-ANNEX P5-Eng
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

ANNEX PL

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
www.dvz-services.de

INSTRUCTION MANUAL
(ANNEX PL)

FOR

DVZ-Permeate Lift Unit (DVZ-PL)

FOR

SEWAGE TREATMENT PLANT

DVZ SKA-“BIOMASTER®-PLUS“
 The DVZ-PL is necessary to increase the pressure head if the counter pressure at
the overboard connection A13 is 0,5 bar or more.

Outlet to Vent
Overboard

Inlet from
DVZ-BMSU

Submerged
Pump inside

Pressure
Switches

The treated water (permeate) from the BMSU will be collected in the PL-Unit. The
pump inside the PL-Tank is controlled by automatic pre-adjusted pressure
switches. For the protection of the pump, a LowLow-Signal is installes, if Low
Signal fails. This prevents the submerged pump from dry running.

Issue: 18.10.2011 CIP-Process for DVZ-SKA-”BIOMASTER”-PLUS Page 2 of 2

SKA-PLUS-ANNEX PL-Eng
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

COMMISSIONING

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 Abschnitt :
COMMISSIONING QMF 47
DVZ-SKA-„BIOMASTER“-PLUS

DVZ-SERVICES GmbH Boschstrasse 9 D-28857 Syke

Tel. ++49 4242 16 93 8-0 Fax ++49 4242 16 93 8-99 info@dvz-services.de

serial-no.: type: date:

customer: place: vessel/NB:

NOTE: Please, observe the informations and safety instructions in the operating instructions, to ensure
that the unit functions satisfactorily and remains serviceable for a long period.

BEFORE PUTTING INTO OPERATION FOR THE FIRST TIME O.K. REMARKS
1. Check the installation of the Sewage Treatment Plant (STP)
according to project drawings (pipings, foundation, please
ground-surface). Look also for obvious damages caused by
transport or installation.
2. The minimal dimension of air vent is to be installed as
the same diameter as it is present on the STP.
3. Check all pipe connections. They needs to be tighten well to
avoid leakages.
4. Chech the power supply on the control panel. It has to
correspond to the project-specifications and to the type-plate of
the STP.
5. Check the turning-directions of the electric motors on the STP.
If the electric motors should have the wrong turning-direction,
please change the related phases of the power supply
connection. There are no changes necessary on the connection
of the electric motors.
6. Check the correct electrical connections of loose supplied
equipment (transfer pumps etc.), potential free output contact
for external alarms etc. and the level-controls from holding and
buffer tank where it is installed. (Please refer to the projet
relaed wiring diagram)
7. Check the compressed-air-supply, and adjust it with the
pressure regulating valve (PRV) to 4-6 bar.
8. Check all impellers of the delivered pumps and blowers for
easy-of-movement.

Rev.- Nr.: 00 page: 1/6 QMF47

 Abschnitt :
COMMISSIONING QMF 47
DVZ-SKA-„BIOMASTER“-PLUS

DVZ-SERVICES GmbH Boschstrasse 9 D-28857 Syke

Tel. ++49 4242 16 93 8-0 Fax ++49 4242 16 93 8-99 info@dvz-services.de

STARTING UP AND COMMISIONING O.K. REMARKS

1. Filling up the STP
1.1 Connect a temporary water-source to connection A7 of the
STP, and fill it with freshwater until the level of the control tank
of STP reaches approx. 75% in height of the sight glass. Ball
valve H4, H5 and H8 need to be open.
Close ball valve H8 when level is reached
NOTE! Keep ball valve H7 closed!
REMARK! Never use sewage for first start up! If
possible, the same fresh water-source as for sanitary
systems should be used.
Check the system for leakages during filling process!
1.2 To fill the Bio-Mass-Separation-Unit (BMSU), proceed as
follows:
1.2.1 Please close the ball valves H4 and H5. Ball valves H7, H11.1,
H12, H12.1, H13.1, H14.1, H15 (if installed), H16, H17 (if
installed) and the overboard valve needs to be opened resp. in
“OPERATION” position.
1.2.2 Open the vent valve on top of the membrane, and fill it with
temporary fresh water through connection D0 (optional A15 if
supplied), until water is visibly coming from the vent valve
(clear plastic hose).
Take care that the water is free from air bubbles.
Close the vent valve and the fresh water supply on connection
D0 (optional A15 if supplied)
1.2.3 If a PL-Pump without extra tank is installed, open the vent plug
of the pump and fill in water by hand.
1.2.4 Check function of the pneumatic control valves V1.1 and V2.1
(also V1.2, V1.3, …, V2.2, V2.3, … , V3.1, V3.2, V3.3, … if
installed) by activating the solenoid pilot valve manually.
1.2.4 Switch “ON” the main switch of the control panel. Wait approx.
10 seconds until the system has booted. Then push button F1
“start up/alarm receipt” on the LOGO!TD display.
- The display should now indicate “start up OK”. Please
wait again approx. 10 seconds until the STP is ready
for operation.

Rev.- Nr.: 00 page: 2/6 QMF47

 Abschnitt :
COMMISSIONING QMF 47
DVZ-SKA-„BIOMASTER“-PLUS

DVZ-SERVICES GmbH Boschstrasse 9 D-28857 Syke

Tel. ++49 4242 16 93 8-0 Fax ++49 4242 16 93 8-99 info@dvz-services.de

1.2.5 Put the selection switch “manual-0-auto” (12S3) into “auto”

position.
Now:
- Blower(s) G1.1 (or G1.2 or … if installed) starts running
- Pump P6.1 (or P6.2 or… if installed) is in stand-by
mode
- Pump P1.1 (P1.2, P1.3, … if installed) starts running
- Pump P2 starts running (because of STP’s control tank
level)
- Pump P5 (if installed) starts running depending on
buffer tank level and the STP’s control tank level
Vacuum pumps VP1 and VP2 (if installed) are ready for
operation (please refer to commissioning guide and manual of
the vacuum pumps)
1.2.6 The BMSU loading pump (P2) is now feeding water from the
STP’s control tank into the BMSU, and the BMSU overflow
pump (P1) is circulating the water through the membrane.
After a short while a permeat flow will be visible inside the flow-
indicator FI1.1 (FI1.2,…).
As soon as all remaining air-contents from the membrane have
disappeared (pumped out) there will be a steady permeate-flow
visible on the flow indicator.
1.2.7 The PL-Unit (if installed) needs a counter pressureof 1,5-2 bar
(please refer to the name plate of the PL-Unit). If this is not
available in the overboard pipe system, the flow needs to be
throttled by using valve H16.
If the counter pressure is adjusted, the pressure on the suction
side of the PL-pump needs to be adjusted to -0,1 - -0,5bar by
using valve H17 (if installed).
During the normal operation those adjustments do not need to
be adjusted again.
1.2.8 Check the correct function of the transfer pump P5 by
observing the level of the control tank via sight glass.
1.2.9 Check the correct function of the BMSU side cleaning, by
pressing the push button F2 “manual side cleaning”.

Rev.- Nr.: 00 page: 3/6 QMF47

 Abschnitt :
COMMISSIONING QMF 47
DVZ-SKA-„BIOMASTER“-PLUS

DVZ-SERVICES GmbH Boschstrasse 9 D-28857 Syke

Tel. ++49 4242 16 93 8-0 Fax ++49 4242 16 93 8-99 info@dvz-services.de

NOTE: If the STP has stand-by pumps or blowers (P5.1/P5.2, P6.1/P6.2 and/or G1.1/G1.2) one of this
pumps need to be pre-selected by using the F button on the PLC. Please refer also to the
instruction manual “control panel”.

REMARK: The STP has to be desludged minimum once a month. If the water from the side-cleaning was
led by valve H15 (if installed) to the STP and not back to buffer tank, the STP has to be
desludged once a week. The desludging periode depends on the amount of blackwater also.

MEMBRANE GENERAL OPERATION TEST

BMSU
BMSU Permeate Flux Rate Operation Pressure
Temperature
Nom. Measured
Max.Flux Measured Nom. Measured
No. Membrane Flux Temperature
Type Flux (l/h) Pressure (bar) Pressure (bar)
(l/h) (l/h) (°C)
Type (1) 250
Type (2) 450
BMSU 1 0,6-4
Type (3) 450
Type (4) 700
Type (1) 250

BMSU 2 Type (2) 450

0,6-4
if installed Type (3) 450
Type (4) 700
Type (1) 250

BMSU 3 Type (2) 450

0,6-4
if installed Type (3) 450
Type (4) 700
Type (1) 250

BMSU 4 Type (2) 450

0,6-4
if installed Type (3) 450
Type (4) 700
Type (1) 250

BMSU 5 Type (2) 450

0,6-4
if installed Type (3) 450
Type (4) 700
Type (1) 250

BMSU 6 Type (2) 450

0,6-4
if installed Type (3) 450
Type (4) 700

Rev.- Nr.: 00 page: 4/6 QMF47

 Abschnitt :
COMMISSIONING QMF 47
DVZ-SKA-„BIOMASTER“-PLUS

DVZ-SERVICES GmbH Boschstrasse 9 D-28857 Syke

Tel. ++49 4242 16 93 8-0 Fax ++49 4242 16 93 8-99 info@dvz-services.de

ALARMS
1.1 Protective motor switch O.K. REMARKS
1.1.1 Protective motor switch pump VP1
1.1.2 Protective motor switch pump VP2
1.1.3 Protective motor switch pump P1.1
1.1.4 Protective motor switch pump P1.2 (if installed)
1.1.5 Protective motor switch pump P1.3 (if installed)
1.1.6 Protective motor switch pump P1.4 (if installed)
1.1.7 Protective motor switch pump P1.5 (if installed)
1.1.8 Protective motor switch pump P1.6 (if installed)
1.1.9 Protective motor switch pump P2
1.1.10 Protective motor switch pump P4 (if installed)
1.1.11 Protective motor switch pump P5.1
1.1.12 Protective motor switch pump P5.2 (if installed)
1.1.13 Protective motor switch pump P6.1
1.1.14 Protective motor switch pump P6.2 (if installed)
1.1.15 Protective motor switch pump PL (if installed)
1.1.16 Protective motor switch blower G1.1
1.1.17 Protective motor switch blower G1.2 (if installed)

1.2 Pressure Alarm O.K. REMARKS

1.2.1 BMSU Pressure PS1 (Alarm)
1.2.2 Control tank High Level LS
1.2.3 Control tank Low Level LS

1.3 Vacuum System

Low vacuum alarm active On bar Off bar
1.3.1 PS1
1.3.2 PS2
1.3.3 PS3

Rev.- Nr.: 00 page: 5/6 QMF47

 Abschnitt :
COMMISSIONING QMF 47
DVZ-SKA-„BIOMASTER“-PLUS

DVZ-SERVICES GmbH Boschstrasse 9 D-28857 Syke

Tel. ++49 4242 16 93 8-0 Fax ++49 4242 16 93 8-99 info@dvz-services.de

1.4 Membrane O.K. REMARKS

1.4.1 Membrane 1 has to be cleaned (FS1.1*)
1.4.2 Membrane 2 has to be cleaned (FS1.2), if installed
1.4.3 Membrane 3 has to be cleaned (FS1.3), if installed
1.4.4 Membrane 4 has to be cleaned (FS1.4), if installed
1.4.5 Membrane 5 has to be cleaned (FS1.5), if installed
1.4.6 Membrane 6 has to be cleaned (FS1.6), if installed
* FS = Flow Switch, if installed

ACCECEPTANCE TEST O.K. REMARKS

All system functions are tested
Unit is accepted

__________________ __________________ __________________

DVZ-SERVICES GmbH Customer Date

Rev.- Nr.: 00 page: 6/6 QMF47

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

SPARE PARTS Blower G1

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 Rotary Fan Blower G1.1 (Part no. 0450419016)

Pos. Catalogue Name Art. No. Quantity PC/SET

No.
G1 3 impeller 0450419043 1,00 pc
G1 7 wire mesh guard 0450419002 2,00 pc
G1 8 plastic foam 0450419030 2,00 pc
G1 10 washer 0450419048 1,00 pc
G1 11 bush 0450419042 1,00 pc
G1 12 bearing cap 0450404003 1,00 pc
G1 15 motor 0450413005 1,00 pc
G1 23 ball bearing 0450411004 1,00 pc
G1 24 ball bearing 0450411007 1,00 pc
G1 28 key 0450419032 1,00 pc
G1 39 space washer 0450404000 1,00 pc
G1 40 space washer 0450404001 1,00 pc
G1 41 space washer 0450404002 1,00 pc
Other parts than listed on request

Issue: 04.05.2011 DVZ-G1-0450419016-ETK Page 1 of 1

Technical modifications will be done without notice

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

SPARE PARTS Pump P1

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

BMSU Overflow Pump P1 (Part no. 0580102032)

Pos. Catalogue Name Art. No. Quantity PC/SET

No.
P1 102 housing cpl. 0600512025 1,00 pc
P1 163.1 pressure cover 0600512026 1,00 pc
P1 210 shaft cpl. 0410123004 1,00 pc
P1 230 Impeller 140mm 0600512012 1,00 pc
P1 341 drive lantern 0410123010 1,00 pc
P1 400.1 flat gasket 04202060006 1,00 pc
P1 400.2 flat gasket 04202060005 1,00 pc

Issue: 20.10.2011 DVZ-P1-0580102032-ETK

Technical modifications will be done without notice
Pos. Catalogue Name Art. No. Quantity PC/SET
No.
P1 433 mechanical seal 04101107034 1,00 pc
P1 502.1 casing wear 04101107035 1,00 pc
ring spherical
P1 515 tension ring 0410123011 1,00 pc
P1 523 shaft sleeve 0410123005 1,00 pc
P1 550.1 washer 0410123012 1,00 pc
P1 68-3 cover plate 0600512027 2,00 pc
P1 901.3 screw 04202060009 2,00 pc
P1 902.1 screw 04202060010 2,00 pc
P1 902.2 screw 04202060011 4,00 pc
P1 902.5 screw 04202060012 4,00 pc
P1 903 lock screw 04202060013 2,00 pc
P1 914 screw 04202060014 1,00 pc
P1 920.1 nut 04202060015 1,00 pc
P1 920.4 nut 04202060016 6,00 pc
P1 920.5 nut 04202060017 4,00 pc
P1 930 spring washer 0410123013 1,00 pc
P1 931 lock washer 0410123014 2,00 pc
P1 940 key 0410123015 1,00 pc

Issue: 20.10.2011 DVZ-P1-0580102032-ETK

Technical modifications will be done without notice
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

SPARE PARTS Pump P2

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 BMSU Loading Pump P2 ASC25-1 (Part no. 0410105063)

Pos. Catalogue Name Art. No. Quantity PC/SET

No.
P2 0122 lantern bracket 0410112006 1,00 pc
P2 0123 locking assembly 0410119036 1,00 pc
P2 0125 hollow shaft 0410119303 1,00 pc
P2 0201 stud bolt 0410119402 2,00 pc
P2 0202 self locking nut 0410127001 2,00 pc
P2 0203 gland-half 0410119500 2,00 pc
P2 0204 shaft sealing housing 0410119509 1,00 pc
P2 0207 stuffing box packing 0410116008 1,00 set
P2 0301 coupling rod pin 04101107002 2,00 pc
P2 0303 bush for joint bolt 04101107022 4,00 pc
P2 0304 joint sleeve 04101107008 2,00 pc
P2 0305 special-joint oil type B 04101107024 1,00 pc
P2 0306 clamping band 04101107037 4,00 pc
P2 0307 clamping rod 04101107044 1,00 pc
P2 0308 cover sleeve 04101107019 1,00 set
P2 0401 rotor 0410118004 1,00 pc
P2 0402 stator 0410119034 1,00 pc
P2 0501 suction casing gasket 0410104013 1,00 pc

Issue: 18.10.2011 DVZ-P2-ASC25-1-0410105063-ETK Page 1 of 2

Technical modifications will be done without notice

 Pos. Catalogue Name Art. No. Quantity PC/SET
No.
P2 0502 screwed plug 0600512016 1,00 pc
P2 0503 sealing tape 0410104014 1,00 pc
P2 0504 pressure casing 0410104015 1,00 pc
P2 0505 suction casing 0410119038 1,00 pc
P2 0602 round head grooved pin 0410108003 4,00 pc
P2 0606 hexagon screw 0410127007 4,00 pc
P2 0607 hexagon nut 0410127008 4,00 pc
P2 0608 fan-type lock washer 0410106001 4,00 pc
P2 0609 hexagon nut 0410127008 4,00 pc
P2 0610 washer 0410127006 4,00 pc
P2 0611 tie rod 0410119041 4,00 pc
P2 * gear-motor-assembly on request 1,00 pc

Issue: 18.10.2011 DVZ-P2-ASC25-1-0410105063-ETK Page 2 of 2

Technical modifications will be done without notice

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

SPARE PARTS Pump P5

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 BMSU Loading Pump P5 ASC25-1 (Part no. 0410105063)

Pos. Catalogue Name Art. No. Quantity PC/SET

No.
P2 0122 lantern bracket 0410112006 1,00 pc
P2 0123 locking assembly 0410119036 1,00 pc
P2 0125 hollow shaft 0410119303 1,00 pc
P2 0201 stud bolt 0410119402 2,00 pc
P2 0202 self locking nut 0410127001 2,00 pc
P2 0203 gland-half 0410119500 2,00 pc
P2 0204 shaft sealing housing 0410119509 1,00 pc
P2 0207 stuffing box packing 0410116008 1,00 set
P2 0301 coupling rod pin 04101107002 2,00 pc
P2 0303 bush for joint bolt 04101107022 4,00 pc
P2 0304 joint sleeve 04101107008 2,00 pc
P2 0305 special-joint oil type B 04101107024 1,00 pc
P2 0306 clamping band 04101107037 4,00 pc
P2 0307 clamping rod 04101107044 1,00 pc
P2 0308 cover sleeve 04101107019 1,00 set
P2 0401 rotor 0410118004 1,00 pc
P2 0402 stator 0410119034 1,00 pc
P2 0501 suction casing gasket 0410104013 1,00 pc

Issue: 18.10.2011 DVZ-P5-ASC25-1-0410105063-ETK Page 1 of 2

Technical modifications will be done without notice

 Pos. Catalogue Name Art. No. Quantity PC/SET
No.
P2 0502 screwed plug 0600512016 1,00 pc
P2 0503 sealing tape 0410104014 1,00 pc
P2 0504 pressure casing 0410104015 1,00 pc
P2 0505 suction casing 0410119038 1,00 pc
P2 0602 round head grooved pin 0410108003 4,00 pc
P2 0606 hexagon screw 0410127007 4,00 pc
P2 0607 hexagon nut 0410127008 4,00 pc
P2 0608 fan-type lock washer 0410106001 4,00 pc
P2 0609 hexagon nut 0410127008 4,00 pc
P2 0610 washer 0410127006 4,00 pc
P2 0611 tie rod 0410119041 4,00 pc
P2 * gear-motor-assembly on request 1,00 pc

Issue: 18.10.2011 DVZ-P5-ASC25-1-0410105063-ETK Page 2 of 2

Technical modifications will be done without notice

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

SPARE PARTS Pump P6

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

 Discharge Pump P6.1 (Part no. 0640305000)

Pos. Catalogue No. Name Art. No. Quantity PC/SET

P6 02 wear plate 0600523000 1,00 pc

P6 03 impeller 0600512000 1,00 pc
P6 10 suction flange 0640304009 1,00 pc
P6 16 plug 0600512009 1,00 pc
P6 19 head 0600507005 1,00 pc
P6 21 discharge flange 0640304004 1,00 pc
P6 25 mechanical seal 0600507000 1,00 pc
P6 33 nut, impeller 0600512003 1,00 pc
P6 60 key, impeller 0600518002 1,00 pc
P6 62 circlip 0600523005 1,00 pc
P6 66 washer, impeller 0600523006 1,00 pc
P6 70 grease lubricator 0600507002 1,00 pc
P6 80 motor On request 1,00 pc
P6 84 gasket set 0600518000 1,00 set
Other parts than listed on request

Issue: 04.05.2011 DVZ-P6-0640305000-ETK Page 1 of 1

Technical modifications will be done without notice

 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

SPARE PARTS Instruments

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

Instruments
Pos. Size Name Art. No. Quantity PC/SET

CV1 1“ non return valve 0410300114 1,00 pc

CV2 1 ¼“ non return valve 0410318002 1,00 pc
CV4.1 ¾“ non return valve 0410300110 1,00 pc
CV6 1 ¼“ swing check valve 0410300119 1,00 pc
CV8.1 1“ non return valve 0410300114 1,00 pc
D0 1“ L-Type 3-way ball valve 0410311033 1,00 pc
D3.1 1“ drain valve 0410311024 1,00 pc
D5 ½“ drain valve 0410311006 1,00 pc
D6 1“ drain valve 0410311024 1,00 pc
FI1.1 DN20 flow meter 060204002 1,00 pc
H4 1 ½“ ball valve 0410311000 1,00 pc
H5 1 ½“ ball valve 0410311000 1,00 pc
H7 1 ½“ ball valve 0410311000 1,00 pc
H8 1 ½“ ball valve 0410311000 1,00 pc
H11.1 1“ L-Type 3-way ball valve 0410311033 1,00 pc
H12 1 ½“ L-Type 3-way ball valve 0410311037 1,00 pc
H12.1 1 ½“ T-Type 3-way ball valve 0410311001 1,00 pc
H13.1 1“ L-Type 3-way ball valve 0410311033 1,00 pc
H14.1 1“ L-Type 3-way ball valve 0410311033 1,00 pc
H16 1 ¼“ gate valve 0410313224 1,00 pc
HS6.11 1 ½“ T-Type ball valve 0410311001 1,00 pc
HS6.12 1 ½“ T-Type ball valve 0410311001 1,00 pc
LS0 135/535/835 sensor electrode 0460119030 1,00 pc
LS1 ¼“ level switch 0480319085 1,00 pc
LS1 cap for level switch 0480319086 1,00 pc
LS2 ¼“ level switch 0480319085 1,00 pc
LS2 cap for level switch 0480319086 1,00 pc
LS3 ¼“ level switch 0480319085 1,00 pc
LS3 cap for level switch 0480319086 1,00 pc

Issue: 19.10.2011 Instruments 813910-814410

Technical modifications will be done without notice
Instruments
Pos. Size Name Art. No. Quantity PC/SET

PHV1 1“ pressure holding valve 0610204004 1,00 pc

PI0 -1 – 5bar U pressure indicator 0410313212 1,00 pc
PI1.1 -1 – 5bar H pressure indicator 0410313213 1,00 pc
PI2 -1 – 5bar H pressure indicator 0410313213 1,00 pc
PI6 -1 – 5bar U pressure indicator 0410313212 1,00 pc
PI12 -1 – 5bar H pressure indicator 0410313213 1,00 pc
PIA1 0-1bar H pressure indicator 0410313206 1,00 pc
PRV ¼“ pressure reducing unit 0410304016 1,00 pc
PRV holder for pressure 0410304017 1,00 pc
reducing unit
PS1 ½“ pressure switch 0480319118 1,00 pc
S1.1 ¼“ sample valve 0440213018 1,00 pc
SV1 ½“ x ¾“ safety valve 0410319020 1,00 pc
TI ½“ thermometer 0410320002 1,00 pc
TS1 ½“ temperature switch 0440220028 1,00 pc
V1.1 1“ pneumatic operated valve 0410311042 1,00 pc
V1.1 ¼“ 5/2-way solenoid valve 0410313117 1,00 pc
V2.1 1“ pneumatic operated valve 0410311042 1,00 pc
V2.1 ¼“ 5/2-way solenoid valve 0410313117 1,00 pc

Issue: 19.10.2011 Instruments 813910-814410

Technical modifications will be done without notice
 DVZ - SERVICES GmbH
Boschstrasse 9 D-28857 Syke
Germany
phone:++ 49 / 42 42 / 16 93 8-0
fax:++ 49 / 42 42 / 16 93 8-99
e-mail: info@dvz-services.de
web: www.dvz-group.de

SPARE PARTS Electrical Parts

FOR

BIOLOGICAL SEWAGE TREATMENT PLANT

DVZ SKA-30 “BIOMASTER®”-PLUS

Project: DSEC Hull No.: H4230-4235
DVZ-Project No.: 813910-814410

Issue: 18.10.2011 813910-814410FD

Electrical Parts
Pos. Name Art. No. Quantity PC/SET

6A1 power supply terminal 0480313035 1,00 pc

6A5 circuit breaker 0480312069 1,00 pc
6A5 adapter 0480313038 1,00 pc
6K7 under voltage relay 0480313034 1,00 pc
6A9 compact starter 0480313032 1,00 pc
6A12 compact starter 0480313032 1,00 pc
6Q1 main switch 0480312031 1,00 pc
6Q1 aux. contact 0480308017 1,00 pc
7A1 extension block 0480313036 1,00 pc
7A2 compact starter 0480313033 1,00 pc
7A6 compact starter 0480313032 1,00 pc
8A1 extension block 0480313037 1,00 pc
8A2 compact starter 0480313032 1,00 pc
8A6 compact starter 0480313032 1,00 pc
6A10 compact starter 0480313032 1,00 pc
9F2 transformer fuse 0480319116 1,00 pc
9T2 transformer 0480320008 1,00 pc
10A5 control panel 0480312070 1,00 pc
10A7 PLC main module 0480312100 1,00 pc
10A10 PLC extension module 0480312072 1,00 pc
10A12 PLC extension module 0480312072 1,00 pc
10A14 PLC extension module 0480312072 1,00 pc
11K2 output interface 0480312038 1,00 pc
12S3 selector switch, cpl. 0480323003 1,00 pc
12S8 selector switch, cpl. 0480323003 1,00 pc

Issue: 20.10.2011 E-Parts 813910-814410

Technical modifications will be done without notice
Electrical Parts
Pos. Name Art. No. Quantity PC/SET

18K15 output interface 0480312038 1,00 pc

21N2 level relay 0480313044 1,00 pc
21N5 level relay 0480313044 1,00 pc
21N9 level relay 0480313044 1,00 pc

Issue: 20.10.2011 E-Parts 813910-814410

Technical modifications will be done without notice