VorTECH Polyethylene Pump Stations

Transcription

Operation and
Maintenance Manual
Table of Contents
1. Health and Safety ......................................................................................................................................................................... 3
1.1 United Kingdom Health & Safety at Work Act 1974 ...................................................................................................... 4
1.2 Safety Precautions ....................................................................................................................................................................... 6
1.3 Pump Servicing ............................................................................................................................................................................. 8
1.4 Sewage Gases - important safety precautions ................................................................................................................. 9
2. Installation.....................................................................................................................................................................................11
2.1 System Description .................................................................................................................................................................. 12
2.2 Use and Care............................................................................................................................................................................... 13
2.3 Pre-Installation Checklist ....................................................................................................................................................... 14
2.4 Tank Installation ........................................................................................................................................................................ 16
2.5 Electrical Installation............................................................................................................................................................... 26
2.6 Pump Installation ..................................................................................................................................................................... 28
2.7 Completion Checklist............................................................................................................................................................... 29
3.Operation and Maintenance .....................................................................................................................................................30
3.1 Operating Instructions............................................................................................................................................................. 31
3.2 Routine Maintenance .............................................................................................................................................................. 32
3.3 Troubleshooting......................................................................................................................................................................... 33
3.4 Vortech 1000mm diameter polyethylene pumping station.................................................................................... 35
4.Warranty and Service Information .........................................................................................................................................37
4.1 Warranty ....................................................................................................................................................................................... 38
4.2 Specific Details of this Installation..................................................................................................................................... 39
1. Health and Safety
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1.1 United Kingdom Health & Safety at Work Act 1974
Important - please read first.
Section 6(a)
Section 6 (a) of this Act requires manufacturers to advise their customers on the safety and servicing their
products.
The user’s attention is therefore drawn to the following:1. The appropriate sections of this manual must be read before working on the equipment.
2. Installation, operation and maintenance must only be carried out by suitably trained / qualified
personnel.
3. Normal safety precautions must be taken and appropriate procedures observed to avoid accidents.
Refer to Dutypoint for any technical advice or information on the equipment.
Note
It is the responsibility of the customer and/or the contractor to ensure that anyone working on the
equipment is using all necessary personal protective equipment, is aware of appropriate health & safety
warnings, and has read the information contained in this section of the manual.
Checklist
In addition to any safety instructions in the various equipment sections of this manual, it is also essential that all
persons involved in the operation and maintenance of the pump station are made aware of the dangers
associated with the entry of a pump station and take the necessary safety precautions. ONLY qualified personnel
with current Confined Space Entry certification should contemplate entering a pump chamber, and then only if
there is a second qualified person equipped with required safety equipment supervising.
The following checklist, although not comprehensive, must be followed:
• Conduct a risk assessment before entering the chamber, and fill out associated form. Do not enter a
pump station unless absolutely necessary.
• Never work alone. Use lifting harness, safety line and respirator. Do not ignore the risk of drowning.
Beware! Rungs can give way without warning.
• Check that lifting equipment is of an approved type and is in good and safe condition.
• Do not ignore the risk of electric shock. Use only equipment protected by an RCD. Isolate power at the
control panel before entering the chamber.
• Use a gas meter to make sure that there is sufficient oxygen and that there are no poisonous gases in the
working atmosphere so as to prevent suffocation and explosions at the installation site. Ensure adequate
forced ventilation.
• Check the explosion risk before welding or use of electric hand tools.
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• Place a suitable barrier around the work zone that meets local rules for safety at work.
• Make sure there is a clear path of retreat from the point of installation.
• Use all the necessary personal safety equipment such as helmet, safety goggles, rubber gloves and
protective footwear.
• Do not ignore the risk of infection. The highest standards of personal hygiene should be observed and
all local regulations observed.
• When removing a pump from the chamber, make sure that power is isolated to the pump and that it
cannot be accidentally turned on. Clean unit thoroughly before starting to work on it.
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1.2 Safety Precautions
Before installation, operation or maintenance of the pump system, read instructions and equipment
manufacturer’s specific instructions carefully.
System operation may cause injury. Take all necessary precautions. Wear necessary protective equipment. Any
maintenance of pump systems must be carried out by authorised qualified personnel only.
WARNING - PUMP MAY START AT ANY TIME
In normal automatic mode, pumps may start automatically at any time. Before maintenance or any work is
carried out on pumps or motors, ensure proper isolation of motors at the relevant controller.
WARNING - SYSTEM IS PRESSURISED
Under normal operating conditions, the pipes, pumps and components or water supply and pressure systems are
pressurised. Before unbolting or dismantling any pipework or equipment, ensure water supply to the areas of
maintenance is isolated and water pressure relieved.
DANGER - HIGH VOLTAGE
Control boxes contain high voltage live wiring and terminals. Entry of control boxes is not permitted except by
qualified electrical personnel only. Ensure controller is correctly isolated before entering.
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CAUTION - EXPOSED MOVING PARTS
Keep clear of all moving parts on pumps, motors and couplings and keep the area around pump system clear at
all times.
WARNING - CONFINED SPACE
Pump pit should not be entered by persons. Systems are designed to facilitate pump removal and component
servicing from the surface. In the case of entry being unavoidable correct safety procedures should be carried out
in accordance with current OH&S requirements. Personnel entering should be certified for confined space entry,
have completed risk assessment, evacuated chamber of dangerous gases and be wearing breathing apparatus and
safety lifting lanyard/body harness attached to an approved lifting system.
WARNING - NOXIOUS AND DANGEROUS GASES
System may emit dangerous gases. Ensure area is well ventilated prior to removing pit cover/lid
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1.3 Pump Servicing
Before attempting to service a pump:
Disconnect and padlock off the electrical power supply to the equipment to ensure that the pump is disabled and
cannot be operated inadvertently by others during the servicing work.
1. Ensure that you are familiar with the servicing and maintenance procedures contained in this manual.
2. Allow the pump to cool if over-heated.
3. Close all relevant external inlet & outlet valves to isolate the pumping station completely. Refer to pumpspecific O&M manuals.
4. Vent the pump slowly and cautiously before draining. Refer to pump-specific O&M manuals.
PLEASE ALSO READ CAREFULLY THE IMPORTANT HEALTH INFORMATION ON THE FOLLOWING PAGE OF THIS
SECTION.
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1.4 Sewage Gases - important safety precautions
The following information is extracted from
HSE publication ND (G) 84L/2-90/70L.
Sewage gases are explosive and toxic. The equipment and the area immediately surrounding it should be subject
to the following safety precautions:Please read the following warnings carefully
•
•
•
•
NO SMOKING
No naked flames or sparks
Only qualified people may carry out maintenance / service work on the plant
Nobody may enter the sump until the atmosphere is checked for safety by means of a suitable portable
gas detector
• Nobody may enter the sump until the equipment is switched off/isolated electrically - and padlocked in
the OFF position
• Temporary barriers and warning signs must be erected around all open access covers
Leptospirosis - a risk that must not be ignored
• Leptospirosis takes two forms in the UK: Weil’s disease, which is transmitted by contact with the urine of
infected rats,
• and Hardjo Leptospirosis, which is transmitted from cattle. As well as people whose jobs involve close
contact with animals or carcasses - e.g. Farmers, Vets, Meat Inspectors, Butchers, Abattoir workers, etc.,
anyone who is in contact with sewage, river or canal water is at risk.
• Infection can often be as a result of the bacteria entering the body via cuts or skin abrasions or through
the mouth, throat or eyes after contact with an infected liquid.
• Symptoms of both forms are similar to influenza with a severe headache.
• To prevent infection, use waterproof plasters on all cuts and skin abrasions and wear protective clothing.
Wash thoroughly after handling any sewage or equipment in contact with sewage, and always do so
before eating, drinking or smoking.
• Report any illness to your doctor and inform him/her of your work - see medical information below. The
effects of Leptospirosis can be much less severe if treated promptly.
Note for the doctor:
This patient’s work may expose him/her to the danger of Leptospirosis (either L.icterohaemorrhagiae or L.hardjo).
Early diagnosis and treatment are vital in Weil’s Disease as jaundice is often absent in the early stages. The illness
in L.hardjo may be greatly shortened by appropriate antibiotic treatment. Your local Public Health Laboratory
Service or Hospital Consultant Microbiologist should be able to offer advice and serological testing.
You or your doctor can obtain further information from the Employment Medical Advisory Service.
WARNING - DEEP PIT
Removal of pit access cover or incorrect fitting/installation of pit access cover may cause injury. Never leave an
open pit unattended. Always have adequate barricading and warnings to prevent accidental falling. Ensure lid or
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cover is correctly reinstalled and sealed after removal. Removal of cover/lids must only be performed by
authorised personnel.
CAUTION - CORROSIVE LIQUIDS
System may contain corrosive liquids/gases that may cause injury or equipment damage. Avoid all contact with
skin and thoroughly wash/treat any equipment that contacts liquid.
WARNING - BIOLOGICAL RISK
The system may contain bacteria, infectious disease and other harmful substances. Exercise extreme care when
near or working on the system. Avoid direct contact with components that have been in contact with waste liquids
or gases.
Finally, take care and use common sense when working on or near system and report all faults to whoever is
responsible for the system.
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2. Installation
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2.1 System Description
Congratulations on your purchase of a Vortech® Package Pumping Station. This pump station reflects a high level
of engineering excellence and is designed using the best available technology. It is for use where site conditions
will not allow the gravity disposal of raw sewage, stormwater or effluent.
The wastewater pump package is approved by all relevant authorities and comprises a sealed holding tank with
twin submersible pumps installed in such a way as to enable easy removal and reinstallation without the need to
enter the chamber.
The pump station is delivered to site pre-assembled ready for installation in the excavation. Connection of the
plumbing and electrical services by others. Installation of the chamber should be carried out by a qualified civil
contractor to ensure correct base preparation and backfill procedures, with extra ballast where necessary.
Some pumps for sewage applications are supplied with an integral cutting device designed to reduce solids size.
Pumps are automated by separate probes, floatswitch or other level sensor wired to an electrical control panel
mounted adjacent to the installation. Faults are indicated by red alarm light and beeper.
A check valve is fitted on the discharge pipework on each pump to prevent backflow into the chamber when the
pump finishes its cycle. It also prevents the duty pump discharging back through the standby pump. A gate valve
isolates the pump station from the rising main for maintenance purposes.
The pump station is designed to be fully automatic and give reliable unattended operation. However, we strongly
recommend regular programmed maintenance be carried out to ensure the equipment is maintained in
serviceable condition. To facilitate cleaning of equipment and pit walls, a hose reel should be provided adjacent to
installation.
In this manual (section 3.4) you will find a schematic drawing showing the general arrangement of the station
components.
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2.2 Use and Care
With proper care and by following a few simple guidelines your submersible pump will give you many years of
dependable service.
Usage - Sewage Pump Stations
The Vortech® pump station is designed to handle domestic sewage.
Solid waste materials should be disposed of in a waste bin. While your station is capable of accepting and
pumping a wide range of materials, regulatory agencies advise that the following items should never be
introduced into any sewer either directly or through a kitchen waste disposal:
•
•
•
•
•
•
•
Glass
Metal
Nappies
Socks, rags or cloth
Plastic objects (e.g. toys, utensils, etc.)
Sanitary napkins or tampons or similar such products.
Sand, rocks, stones or any other debris
In addition, you must NEVER introduce into any sewer:
•
•
•
•
•
Explosives
Flammable material
Lubricating oil and/or Grease
Strong chemicals
Gasoline
Power Failure
Your wastewater pump cannot dispose of wastewater or provide an alarm signal without electrical power. If
electrical power service is interrupted, try to minimise waste input to the system and arrange for tanker emptying
if necessary.
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2.3 Pre-Installation Checklist
Caution:
• Installation should be carried out by experienced and qualified persons.
• Before digging, contact any relevant authorities and study site plans to locate any underground lines or
cables.
• If the installation of a pump station requires the prior approval of local authorities, questions relating to
this should be directed to a responsible officer of the local council and/or other relevant authority.
Dutypoint are unable to supply this information.
The following information must be regarded as a guide only and is to be read in conjunction with printed detail
sheet for the particular tank installation proposed.
1. Determine the best location for your tank and control panel (if applicable).
2. Correct appraisal of site conditions is essential before installation of sewage and storm water tanks.
Installers must recognise that whilst many sizes have a greater mass than the water they displace, other
tank sizes can be affected by high water table conditions. Should the upthrust exceed the station dry
weight, concrete ballast should be poured around the base of the tank. Please consider:
1. Drainage, particularly at the tank base
2. The rise in water due to
▪ Tidal conditions
▪ Saturation of the ground during heavy rain
▪ Likelihood of flooding or run-off water from any source
3. The quality of available backfill
4. Where tanks are installed under adverse site conditions, the utmost care is required to prevent
any chance of the vessel being forced out of the ground by the upward pressure of the water. This
can occur if the base is not properly drained.
5. For installations where the water table is above the base of the tank, it recommended that the
tanks be bedded on the cement slurry (see installation procedure). This will prevent the base of
the tank buckling.
6. Do not install a Vortech tank where water table/groundwater exceeds 2m above the base of the
tank - refer to Dutypoint Technical if this is required.
3. Check for any damage to tanks. During transport and handling over rough ground, be careful to avoid
“bruising”. Contact with solid surfaces, lifting accessories or dropping of the tank may result in damage to
the concrete surface, which must be repaired before installation. Refer to supplier.
4. Minimise the use of elbows on the inlet line. If required, use only 45 degree elbows.
5. Determine where the incoming power will be supplied from and if it can handle the rated load for your pump
station.
6. Mount the control panel, when applicable, in accordance with electrical codes and where the alarm light can be
easily seen.
7. Make sure you have all the necessary equipment and supplies before starting your installation.
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8. Determine the length of electrical cable required as all the joints in cables must be made by approved
submersible splice. Only extend cables with cable of equal or greater submersion rating and current carrying
capacity.
9. Finish ground level in relation to tank lid, as tank lid risers are not normally recommended. Also, the lid must
not be buried at any time.
Plan your installation location carefully to ensure that the inlet pipe stays within the allowable inlet height.
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2.4 Tank Installation
Model Information
TANK MODEL
NOMINAL DEPTH
TOTAL CAPACITY
T06.100
990mm
280 litres
T06.200
1980mm
550 litres
T10.110*
1020mm
800 litres
T10.120
1200mm
800 litres
T10.150*
1400mm
1100 litres
T10.160
1600mm
1100 litres
T10.190*
1800mm
1400 litres
T10.200
2000mm
1400 litres
T10.240
2350mm
1750 litres
T10.250
2550mm
1650 litres
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T10.290
2750mm
2050 litres
T10.350
3500mm
2450 litres
T10.400
4000mm
2850 litres
T15.250
2480mm
3000 litres
T18.230
2220mm
4000 litres
T18.330
3200mm
6000 litres
T18.430
4150mm
9000 litres
1. Tank Construction
8mm polyethylene manufactured in accordance with strict quality control procedures.
2. Tank Installation
Check the depth (invert) of the inlet pipe as this will determine the excavation depth see tank inlet specification.
In any case the minimum height from the bottom of the tank to the underside of the inlet pipe must be 600mm
(24”).
The minimum size of the excavation hole should be 300mm (12”) more than that of the tank.
1. Lay a minimum of 100mm (4”) of 20mpa concrete in the bottom of the excavation hole if there is no
potential water ingress or flooding problem.
2. Whilst the base cement or concrete is still slurry and using suitable lifting equipment - lower the
Pumping Station gently onto the base, ensuring that no stones or other sharp objects are allowed to fall
in at the same time, or damage to the tank may result.
3. Once the tank is roughly in place, check for level and position, and adjust / prop as necessary before
leaving it for the slurry to set, ensuring that the top of the excavation is covered with a tarpaulin or
suitable PE sheeting to protect it from rain or wildlife.
4. Fill the tank with water up to and over the first rib - or in any case, at least 500 - 600mm in depth.
5. Ensuring the tank is secure on its base and will not move laterally, pour concrete up to at least the level
of the first reinforcing rib on the tank. See note to Step 7 below.
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6. Make all pipework connections for inlet and discharge pipework. Note that the pump chamber should be
vented from one of the 110mm spigot pipe connections below the access cover. A 110mm cable duct is
required between the pump chamber and the control panel location and should be connected to one of
the 110mm spigot pipe connections just below the manhole cover. A draw cord should be installed and
secured in the duct during installation. Check that the pipework connections to and from the tank are
secure and leak free, and ensure that all unused connections are plugged and properly sealed.
7. NOTE: Local regulations and site conditions will determine whether concrete should be used further up
than the first rib, or simply a suitable backfill material (e.g. sand or pea-shingle which will compact
easily). It is recommended that no backfilling is undertaken until formal approval of the installation
has been obtained from the Building Inspector.
8. Finish around the tank top at ground level, ensuring the area is adequately protected from access by
vehicles or wildlife (e.g. secure fencing) see specification sheet for details of cover (lid) used and its load
rating.
9. If the tank is sited in a driveway it must be surrounded in concrete, and a reinforced concrete slab (min.
200mm thick) must be used to spread the load away from the tank on to a firm surround.
3. Cover
When using cast iron load bearing cover, tie cover in with surrounding concrete continuing or support cover by
continuing concrete up sides to top of tank. If the pit is supplied with an aluminium cover, this must be installed in
a way that precludes direct loading (e.g. with the use of bollards).
4. Pipework
Inlet pipe and pit penetrations to be made on site will require rubber wall seals. The wall seal will require a
circular hole to be cut in the tank using a hole saw in the correct position. Once the hole is cut, debur the hole and
insert the rubber wall seal. Once the seal is inserted, insert the pipe through the wall seal to create waterproof
seal. (see pics below)
5. Electrical
Electrical pumps and level sensors are supplied with cable (10m) as standard. The controller should be located
maximum 4-5m and in clear view of pump pit. Install 2No. 50mm conduit or 1No. 100mm PVC duct sealed
through tank wall using rubber wall seal. Use only bends and not elbows, and go to next size conduit for runs
longer than 5 metres or more than one bend. Check minimum power supply run before commencing installation.
If controller box is further than 4-5 metres from pump pit a water proof below ground junction and cable
extension is necessary. All joints must be totally water proof either glue filled heat shrink or epoxy filled joint.
(Electrical install further detailed in manual)
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6. Check
Before connecting power supply to starter, check all connections and relays for any loose connections that may
have occurred during transport. When commissioning, set overloads to pump nameplate amps. Check voltage and
running current whilst pump under load. (Electrical install further detailed in manual)
7. Rising Main
Discharge pipework finished with a common outlet outside the pit for rising main connection.
8. Level Control - Float Switch
Adjust start float switch to give a minimum of one start per day under normal operating conditions, with a
maximum of 6 starts per hour continuous, or for intermittent 10 starts per hour. Set high-level alarm float level
with the lowest inlet invert level. It is critical that pumps do not run dry for any period of time. Setting the pump
stop float switch above the volute of the pump will stop this happening and will prevent air locking the pumps.
2 float switch
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3 float switch
20
4 float switch
21
4 float switch
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Level Control - Probe
The Vortech Probe has pre-set switch points that cannot be adjusted so the unit needs to be installed to the
correct height. The most important switch point is the Pump 1 start level as it is critical that the pump is cooled
sufficiently which occurs when the pump motor is completely submersed.
The lowest pump 1 start level should be either level with the top of the motor or higher.
The probe has a high level alarm switch which is pre-set 200mm above the Pump 2 start level which in some
tanks especially larger tanks will not be high enough. An additional float switch can be installed at the required
level and connected in the alarm terminals in the control panel. (Please see separate control panel drawings
supplied with the Package)
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9. Maintenance
• Tank to be regularly cleaned by hand held hose, and pump and alarm float operation checked. In high
grease applications tank should be degreased on a regular basis by a waste removal contractor.
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• Pump to be removed for service and operation of the system should be checked on a 12 monthly cycle.
(Maintenance further detailed in manual). The Probe and floats should be cleaned.
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2.5 Electrical Installation
Electrical work must only be carried out by qualified and competent personnel.
Electrical connections and all wiring should be carried out in accordance with local regulations
Read all wiring diagrams and instruction sheets supplied before attempting an electrical connection. If in
doubt, contact Dutypoint Service for advice and copies of wiring diagrams or instruction sheets.
Power Supply
Ensure available power supply complies with electrical data on pump and control panel nameplates.
Power should be supplied via a main isolating switch. If the pump is not installed close to the switch, it must be of
a lockable type.
A clearly marked dedicated circuit of an adequate capacity must be used. Pay careful attention to voltage drop
regulations.
Control Panels
Connection to control panels must be made as per instruction sheets and wiring diagrams supplied. All unused
wires are to be terminated in insulated connectors.
Mount control panels in a vibration-free position as close as practical to the pit. Allow at least 1m x 1m clearstanding space in front of the control panel and position well away from possible damage by vehicles/machinery
etc.
Thermal overloads fitted should be adjusted to full load amps noted on pump nameplate.
Keep clear of unprotected impeller.
Conduits
All wiring from control panel to pit must be in approved heavy duty conduit or trunking.
Conduits from pit to control panel must be adequately sized with a minimum amount of bends to allow easy
insertion/withdrawal of wires. Minimum 2 x 50mm conduit with long radius bends is standard procedure for dual
system.
All conduits entering control panel must be sealed internally with silicone or similar to prevent ingress of moisture
or fumes from the pit.
Cables
Do not allow cable ends to be submersed.
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Joints in cables must be made by an approved submersible splice. Only extend cables with cable of equal or
greater submersion rating and current carrying capacity. Leave enough slack cable in pit to allow easy and
complete removal of equipment from pit. Ensure that this loose cable is secured at the pit manhole to prevent
float switch fouling or entry into pump impeller.
Pumps and float switches are fitted with 20 metres of cable. Whenever possible, cables should be run directly to
the controller.
Junction boxes must not be installed in wet well pump chamber. Any connection, other than those made in pump
control panel must have protection rated to IP68 using approved waterproof heat shrink or epoxy resin joints.
Failure to comply will void warranty and could cause serious damage to pumps and other equipment.
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2.6 Pump Installation
Pumping Do's
• Check pump upon delivery for any damage during transportation
• Check that pump model is according to specification.
• Check that the actual delivery head is within the performance capabilities of the pump by reading the
performance curve.
• Always have electrical connection and disconnection performed by qualified personnel.
• When installing 3 phase pumps, always check for correct direction of operation before installing into the
pit. (If the pumps are running in reverse rotation flow will be down by about 40%) and damage to the
pump will occur if not immediately corrected.
Pumping Don't's
• Do not run pumps dry.
• Never lift the pumps by their power cables.
• Do not allow the pump to operate for long periods with the motor fully exposed. All submersible pumps
require the liquid around them to keep them cool and prevent overheating.
• Do not install the pump(s) on soft or lose ground.
• Do not leave the pump installed in the pit or exposed area for long periods of time (i.e. greater than 2
months) without operation
Installation of Pumps
Pumps should be placed on a solid flat surface in the vertical position. It is recommended to have the pumps on a
raised surface rather than on the floor of the pit. This will allow sedimentation of grit and particles, thereby
preventing strainers of pumps becoming clogged. Freestanding pumps must have unions fitted to discharge
pipework.
Ensure that the pit is of adequate size to allow for pumps and floats to operate without obstructions. If the pit is
too small cycling will result, which can cause failure.
The incoming pipe into the pit should be fitted with an elbow and dropper. This will direct the liquid straight down
into the pit. This is especially critical when the inlet to the pit is at a high level. High level entry will enable the
falling water to aerate the liquid in the pit and air bubbles will enter the pump inlet thus causing air blocks and
preventing the pump to discharge water.
Where pumps are installed on sites where new buildings have been erected it is common for excess sand silt and
rubbish to be flushed down the pipes into the pit. Ensure that the pit and pipe work is cleaned upon completion of
construction so that all debris is removed.
Do not use the power cable for supporting the weight of the pump. Always use the chain. This will allow easy
removal of the pump from the pit when necessary.
Do not operate the pump in sludge or mud.
Always install a check valve on the discharge of each pump so as to prevent “backflow”. Check valves must be flap
or swing check type. Spring valves are not suitable and must not be used for these types of systems.
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2.7 Completion Checklist
Before Commissioning
1.
2.
3.
4.
5.
6.
7.
8.
All penetrations sealed off.
Conduits installed.
Vent installed and completed
Rising main completed and tested.
Manhole covers installed and sealed.
Permanent power completed.
Test water available.
Pit dry and cleaned out (sand, gravel, concrete etc.)
Please be advised that if the above list is incomplete, extra charges may be incurred for extra work or lost time.
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3. Operation and Maintenance
31
3.1 Operating Instructions
General
Dutypoint Packaged Submersible Pump stations are designed to efficiently effect the transfer of wastewater where
gravity discharge is not practical or possible.
Stations comprise of pump pit with cast-in benched base and cover with access for servicing requirements.
Warning
The pump pit should not be entered by persons unless absolutely necessary. The system is designed to facilitate
pump removal and component servicing from the surface. In the case of an entry being unavoidable correct
safety procedures should be carried out in accordance with current H&S requirements. Personnel entering should
be certified for confined space entry, have completed risk assessment, evacuated chamber of dangerous gases and
be wearing breathing apparatus.
Operation
The system is automatically controlled and activated via level sensors. Pumps automatically alternate in dual
pump systems. Level sequence is as follows.
LEVEL PROBE OPERATION (3 probes)
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3.2 Routine Maintenance
When a pump station is initially commissioned it should be checked daily for the first week to check that all the
systems are working correctly. Particular care should be taken with a new installation that foreign matter such as
concrete, silt, gravel, timber or tools do not foul the pump.
The wet well should be hosed down and pumped to its minimum level each day to check for such foreign matter.
All such material should be removed. Do not use the pump to remove silt or gravel as abrasives will ruin
tolerances; use a vacuum tank/truck.
Routine maintenance and servicing are essential to maintain the plant in a serviceable condition.
Each time the pump station is visited, readings of the hours run, voltage and current should be taken and recorded
on the System Fault and Maintenance Record log. Abnormalities in these readings are often the first sign that
maintenance is required on the pump unit.
The station should be visited on a monthly basis to check the pumps operation, record the above data and hose
off any build-up of fats or foreign material in the wet well, and grease the pump station access lids.
A high degree of cleanliness of the equipment and surrounding area should be maintained as this will assist in the
detection of minor defects, which, if no action was taken, could lead to more serious problems.
The main factors in determining if a major overhaul is required is a falling off in the pump discharge pressure to
an unsatisfactory level or a significant increase in power consumption or pump running time.
Depending on operation and environmental conditions with a comparison of previous inspections, the frequency
of inspections can be altered to maintain satisfactory operation of the plant to suit established operation routines.
The checks and inspections carried out during the running-in period will often establish the frequency of future
inspections (minimum of 12 month service intervals).
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3.3 Troubleshooting
The following is a guide to diagnose and rectify the most common problems that may arise. This guide should
only be used by qualified maintenance personnel. As with any troubleshooting procedure, start with the simplest
solution first: always make the above ground checks before removing the pump from the pit. Before embarking on
any trouble shooting action ensure you read all the warnings at the beginning of this manual.
Problem: Pump(s) Will Not Start
• Check if visual/audible alarm on control panel is activated
• Check for voltage at panel. "Power On" light should be illuminated.
If not, report to electrician.
• Fuses are blown or circuit breakers are tripped
• Check if pump can be started manually
Licensed personnel to replace fuses to reset breakdown. Report findings to those responsible for the system.
Pump(s) start but then cut out immediately
• Check that overload is on the correct amperage setting
• Electrician to check the voltage on all three phases
Adjust if necessary.
• Check that the liquid does not contain suspended solids.
Dilute with more water.
Pumps are cycling (turning off and on quickly)
• Check the check valves are closing properly, otherwise backflow will cause tank to fill again.
Replace if faulty.
• Level control incorrectly set OR turbulence in water is causing floats to go up and down
Reset level control and eliminate turbulence
• Check that the pit is not too small
Consult with technical staff
Pump(s) runs but does not deliver water
• Gate valve is closed
34
Open gate valve
• Check if valve is blocked.
Unblock
• Inlet of pumps is blocked
Hose and clean out pit
Pump(s) run but deliver too little water
• Inlet partially blocked
Hose and clean out pit
• Excessive wear on impeller and/or wear plate
Contact service engineer
Pit smells
• Pit lids are sealed
Hose and clean our pit
• Pump station is vented and vent is unblocked
Evacuate chamber, regrease lids.
Review operational procedures to ensure waste is not going septic prior to station.
35
3.4 Vortech 1000mm diameter polyethylene pumping station
Installation Notes
1. Tank construction is min 8mm polyethylene manufactured in accordance with strict quality control
procedures.
2. Compact a 100mm sand bed to a finished depth 100mm deeper than tank depth. Bed tank down in fresh
concrete and pour additional concrete around sides to cover at least first rib. If bottom of tank is below
maximum ground wate level, consult ballast chart to confirm amount of ballast required. Concrete to be
continued to top of tank on all installation within the foundations of a building. When using cast iron
load-bearing cover, tie cover in with surrounding concrete or support cover by continuing concrete up the
sides to top of tank. Note- set top of tank below ground level to allow for thickness of cast iron cover.
3. Vent and conduit penetrations to be made as close as possible to top of tank and at right angles to tank
wall. Vent to be sealed through tank wall using 100mm spigot pipe, but to suit direction. Install 2no.
50mm or 1no. 100mm cable duct in straight line to control panel location and ensure joint is sealed
36
4.
5.
6.
7.
either using moulding spigot or using rubber wall seal. Use long radius bends not elbows. Always install a
suitable nylon rope to assist pulling cables through.
Electrician to connect pumps and level probes/flots, and seal cables inside ducts to prevent gases venting
into pump controller. Check for adequate power supply before commencing installation.
Before connecting power supply to pump controller, check all connections and relays for any
misplacement that may have occurred during transport. When commissioning, set overloads to pump
nameplate amps. Record voltage and running current whilst pump is under load. IMPORTANT: on three
phase units, direction of rotation must be physically sight checked by lifting pump.
Adjust start level to a minimum of one start per day under normal operating conditions with a maximum
of 10 starts per hour continuous, Set high-level alarm float at least 100mm above start switch.
Tank to be regularly cleaned by hand held hose, and pump and alarm operation checked. In high grease
applications, tank should be degreased on a regular basis by a waste removal contractor Pump to be
removed for service on a maximum 12 monthly cycle.
37
4. Warranty and Service Information
38
4.1 Warranty
Warranty is limited to replacement or repair, at Manufacturer’s discretion, of any parts or equipment without
removal and reinstallation cost for a period of twelve months from date of invoice, provided such part of
equipment that is deemed by the respective manufacturer to be faulty. Any work done on site to inspect or
remedy faults that are subsequently not accepted as being under warranty by the manufacturer, or are caused by
misuse, fair wear or not following operating procedures, will be charged at parts and labour and travelling time
rates applicable at the time.
If the buyer requires our services in respect of site inspection or service outside of what is covered by
Manufacturers’ warranties, then Buyer should enter into a separate agreement with Dutypoint Ltd in respect to the
same. In the event of no such separate agreement, all operations, calibrating, cleaning and maintenance of plant
are the responsibility of the buyer.
Dutypoint Ltd have not acted as a consultant nor charged design fees on this project, and are in no way
responsible for, nor guarantee any particular level or performance of the treatment plant supplied or effluent
quality unless such guarantee is specially given in writing.
Under no circumstances is Dutypoint Ltd liable for any direct or consequential loss or damage to persons or
properties of any nature due to any cause whatsoever.
Application of warranties is conditional on Dutypoint Ltd having received in cash the total contract price.
Furthermore, Dutypoint Ltd reserves the right to withdraw any code compliance, British/European Standard
compliance or selection compliance, should the contract not be paid in full.
Warranty is subject to Dutypoint standard terms and conditions available at www.dutypoint.com.
39
4.2 Specific Details of this Installation
Note: Please also refer to relevant technical data, drawings etc. from equipment and component manufacturers.
For any queries relating to this equipment or for the supply of any spare parts - as well as service and full
technical support please contact:
Dutypoint Systems, Shepherd Road, Gloucester, GL2 5EL
T: +44 (0)1452 300592 W: www.dutypoint.com
40

VorTECH Polyethylene Pump Stations

Transcription

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