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HomeMy WebLinkAboutWTR2700600(1) W-600 SOUTH TALBOT HILL PUMP STATION WTR-10 1 #1 Operations Manual WTK"o to /,Oumyo :51awo tioNs BEGINNING OF FILE FILE TITLE Sft, /01(mP siah'o�u � I C),joekaho/vs71(a�uaL OPERATIONS MANUAL SOUTI, TALBOT RILL PUMP STATION DEPARTMENT OF PUBLIC WORKS CITY OF RENTON. WASHINGTON Prepared by CM2M HILL, Inc. 1500 - 114th Avenue SE Bellevue, Washington 98004 May 198' Project No. 13631.A2 Copy_, Ia3CCIDI CONTENTS I. Introduction II. Operation Domestic Pumps Pumps Station Control Settings III. Maintenance Routine Maintenance Equx?rent Records Maintenance Scheduling Supplies and Spare Parts Lubrication Warranty Provision la3Cc2DI I. INTRODUCTION South Talbot Hill pump Statior, is located on South 43rc, Street, just west of the bridge that crosses Highway S', 167. The purpose of the pump station is to pump water from the 100 pressure zone and boost it into the 350 pressure zone. The punped water serves two purposes: (1) domestic use and 12) fire :ghting. The 350 zone extends along Talbot Road from South 43rd to South 19th Streets. The South Talbot Hill Pump Station operates in conjunction with the t' )rth Talbot Hill Pump Station. The north pump station has a variable speed pump which is the primary source of watc,r for the 350 zone, The south pump station serves as the secondary source of water for the 350 zone should the north pump station variable speed pump be !•nable to meet the domestic demand or should the variable speed pump fail. 1t3dd1D1 II. OPERATION DOMESTIC PUMPS General There are two domestic pumps. Domestic pump No. 1 has a capacity of 120 gpm at 150 feet and domestic pump No. 2 400 gpm it 150 feet. The pumps will be modified in the future to meet the head needed for filling a future rese - voir. There is a lead-lag selector switch at the motor control center which allows either pump to be put in the lead mode. Normally domestic pump No. 1 is the lead pump. The pressure on ea^h pump is limited by the pump discharge control valve so that the domestic pump= allow primary pump- ing operation in the 350 zone by the variable speed pump. The two domestic pumps operate only when the variable speed pump cannot meet demand in the 350 zone. S tartin Normally pump starting is automatic. Starting is initiated from a pressure switch after a manually adjustable time delay. The time delay prevents unnecessary starting of the domestic pumps on temporary low pressure. After the time delay times out, the pump starts. The pump control valve 1s3dd2Di ' pilot solenoid valve energizes and the valve starts to open with a 30-second time delay starting. The control valve slowly opens. Valve opening time is adjustable and may be varied from 30 `_o 60 seconds. The valve limit switch closes its contacts when the valve is 5 percent open, and the pump remains running. The 30-second time delay shuts down the pump if the limit switch contacts do not close, indicating the control valve did not open. The pumps can also be started manually. Valve operation is the same. Stopping Normally pump stopping is automatic. Stopping is initiated from a 50 gpm low flow reading at the flow meter. The 1%,w flow set point is adjustable. After the low flow occurs, the control valve pilot solenoid valve is de-energized and the control valve starts to slowly close. A 30-second time delay starts. The valve limit switch opens when the control valve is 5 percent open and the pump motor is turned off. The 30-second time delay shuts off the pump if the valve lim'.t switch did not open before 180 seconds occur, indicat- ing that the valve did not close. After the pump shuts off, an adjustable timer starts which prevents the pump from automatically starting until the delay time occurs. This ls3dd3D1 prevents the pump from cycling, that is, coming on again immediately after shut-off, in order to allow the zone pres- sure to be built back up by the variable speed pump. The pumps can also be stopped manually. Valve operation is the same. FIRE PUMPS General There are two fire pumps. Each has a capacity of 3,500 opr.. at :10 feet and 5,000 gpm at 140 feet. The pump head is to prow:-4e sufficient flow to fight a fire either at the top or extrenity of the 350 service zone. One pump serves as a backup. Both cannot operate together. Tnere is a selector switch at the motor control center which allows either pump to be the base pump. Each pump has a control valve to bring the pump on or off line smoothly. Normally, a fire pump will be started on low pressure in the system. Once a fire pump is on, it must be turned off manually. The principle reason for manual shutoff of a fire pump is to eliminate automatic pump shutoff during a fire. A flashing red light, located on the roof of the rump station; provides visible indication that the pump is running. A pressure reducing feature on the pump control valve prevents the fire pumps 1s3dd4Dl from producing abnormally high pressure in the domestic water system, Starting Normally pump starting is automatic. Starting is initiated from a pressure switch. Tne pump control valve pilot solenoid valve energizes and the valve starts to cpe.i with a 60-second time delay starting. The control valve slowly opens, valve opening time is ad3ustable and may vary from 65 to 160 seconds. The valve limit switch closes its con- tacts when the valve is 5 percent open, and the pump remains running. The 60-second time delay shuts down the pump if the limit switch contacts do not close, indicating the con- trol valve did not optn. The pump can also be started manually. Valve operation is the same. Stopping The pump is stopped manually. When the swatch is placed in the off position, the control valve pilot solenoid valve is de-energized and the control valve starts to slowly close. The valve limit switch opens when the control valve is 5 pe- icent open and the pump motor is turned off. The 60-second ls3dd5D1 time delay shuts off the pump if the valve limit switch did not open. before 180 seconds occur, indicating that the valve did net close. Pump Station Control Settings Table 1 lists the pump station pressure control settings. Each is field adjustable and the listed ones are the initial settings. Change from these initial settings is to be ex- pected with more operating experience. Those control fea- tures which are not located at the pump station but directly relate to the operation of the pump station are identified. Table 7 lists the }amp station time control settings. Each timer is adjustable and the listed ones are the initial settings. As more experience is gained on the operation of the punp station, change from these initial settings can be expected to occur. Pump Station Operation The North Talbot Hill Pump Station variable speed pump is the primary source of water for the 350 zone. This pump has a capacity of 500 gpm at a constant head of 360 feet. As long as demand in the system is below 500 gpm, the South ls3dd6D1 w Talbot Hill Pump Station will remain off, as the va.iable speed pump handles all demand. As demand in the system increases beyond the capacity of the variable speed pump, system pressure will drop. When the system prere reaches 340 feet, it activates domestic No. 1 pressure switch which, starts time delay relay No. 10 (TDR- 10) . if the pressure remains below 340 feet for TDR-10's preset time, domestic pump No. 1 turns on. However, the pressure rises abova 340 feet while TDR-10 is still timing, TDR is overriden and domestic pump No. 1 does not come on. Once domestic pump No. 1 is on, it remains on until low flow occurs at the flow meter. This flow is initially set at 50 apm and has an adjustable range : 0-100 gpm, When the flow from domestic pump No. 1 falls below 50 gpm, it shuts Off. It is to be expected that this low flow setting wi.l change with future experienced gained in operation of the pump station. With both the variable speed and domestic No. 1 pumps on, they will handle system demand until the system pressure again starts to drop, thus exceeding their combined capaci- ty. When the system pressure drops to 330 feet, it acti- vates domestic No. 2 pressure switch which starts TDR-11. If the pressure remains below 330 feet for TDR-11's preset time, domestic pump No. 2 turns on. However, if the pres 1s3dd7Dl rises above 330 feet while TDR-11 is still timing, TDR-11 is overriden and domestic pump No. 2 does not come on. Onces domestic pump No. 2 is on, it remains on until low flow occurs at the flow meter. This flow is initially set at 100 gpm and has an adjustable range of 0-500 gpm. When the flow from, domestic pump No. ' falls below 100 gpm, it shuts off. It is tr be expected that this low flew setting will change with future experience gained in operation of the pump sta- tion. With the variable speed and two domestic pumps on, they will handle system until the system pressure again starts to drop, thus exceeding their combined capacity. It is not expected that their combined capacity will be ex- ceeded for 5 to 10 years Lecause the pumps have been de- signed to meet future demands. The only time their capacity is expected to be eyceeded is in the case of a fire. In this case, when the system pressures drops to 300 feet, the pressure reducing station at south 19th Street opens. Drop- ping of the system pressure to 290 causes the pressure re- ducing station at south 23rd Street to open. The total flow into the system at a time is 2,000 to 3,000 gpm and is ex- pected to provide fire fighting water to fires occurring in residential areas. For fighting large fires, such is at the Valley General Hospital, the system pressure will drop to 175 feet which activates the fire pump pressure switch. The fire pump starts immediately and remains on until manually shut off. ls3dd8D1 III. MAINTENANCE "An ounce of prevention is worth a pound of cure" - Poor Richard's Almanac. Systematic inspection and maintenance permits early correc- tion of faults before major defects and failures develop. Operation and maintenance are closely related. The superin- tendent and operator should establish a comprehensive plan covering routine maintenance, equipment records, maintenance scheduling, supplies and spare parts, lubrication, and war- ranty provision. ROUTINE MAINTENANCE A good maintenance program is essential in order to maintain successful operation of the pump station, The most impor- tant item is maintenance of the mechanical equipment; that is, pumps, valves, and other moving equipment. Building and grounds also require routine maintenance. A good maintenance program also requires a good record sys- tem that the operators must maintain. The record system will tell when maintenance is due and will provide a record of equipment performance. 1s3dd9D1 Responsibility for general and ; reventive maintenance and repairs of the system is incorporated in the duties of the operating personnel. It is vital that all personnel be knowledgeable and accept the responsible duties of genera.. and preventive maintenance of all facilities. Procedures and routine duties of facility maintenance as outlined in this section are to be followed as directed. In summary, operating personnel will; 1. Follow the outlined maintenance prograr, established Z. Thoroughly read and understand the manufacturer's main- tenance instruction manuals contained in the catalog maintained at the treatment plant 3. Critically evali > -e the maintenance and repair capabil- ity of operatorlsl and shop facilities; request adv:.ce when needed Building and d Grounds It is important that the buildings and grounds be kept in d clean, sanitary, and well-repaired condition at all times. People often judge the ability of the operator on the basin of pump station appearance. The buildings and grounds are designed to require a minimum of maintenance. A regular 1a3ddIOD1 schedule of weed control is -1visable. Painting is impor- tant and should be done on a routine basis. This not only helps keep up the appearance of the facilities but also is preventative maintenance; it prevents deterioration of the wood and metal surfaces. A time should be established, preferably in the spring of each year, to thoroughly inspect the structure and grounds and perforr., necessary maintenance. Operating personnel should, however, also be continuously alert to note problems that may require immediate repair to prevent serious damage or to maintain station operation. Annual inspection and maintenance should include: 1. Clean and paint doors, if required. 2. Inspect the building masonry; repair all cracks, de- teriorated mortar joints, broken brick, and other de- fects that may be found. 3. Inspect the roof; renew if badly deteriorated or if leaks have been observed. 1. I:ispect all concrete for cracks, leaks, and surfacv deteriorations repair as required. S. Inspect the plumbing system; repair all leaks. LMMMMIJ 1s3ddllDl 6. Clean and paint all fabricated metalwork, piping, and pipe supports and hangers as required. Equipment Maintenance is of prime importance in keeping equipment in good operating condition to maintain, peak performance. Disabled or improperly working equipment is a threat to the Pump station capability, and repair costs for poorly main- tained equipment will exceed the cost of maintenance. Operating personnel should thoroughly read the equipment manufacturer's information on the maintenance of equipment and understand the procedures. E�IPMERT RECORDS A listing of each piece of equipment, together with all pertinent data (capacity, 'ufacturer, model and serial number, electrical and mechanical data, and maintenance) , should be prepared in card file form. These cards should reference the library of ranufacturer's information and data sheets containing more detailed and specific information that has been provided during construction. Appendix A contains a list of equipment maintenance summaries that contain pertinent lubrication and maintenance information. ls3ddl2Dl MAINTENANCE SCHEDULING A card file system should be established to ensure that thorough and timely preventive maintenance tasks are per- formed. Basically, this system should consist of a series of 50 cards, color coded by frequency of maintenance task. For a specific piece of equipment, several cards may be prepared, each of which defines a specific maintenance item and each of which bears a different color tab. These cards would be contained in a calendar `ilo and, as a specified task is performed, it is initialed and placed in the position in the file corresponding to its next scheduled performance. As an example, a task required to be done monthly and drawn from the March (current month) file would be initialed complete and placed in the April (next scheduled performance) file. A task performed every 3 months would be drawn from the March file and placed in the June file upon completion. Each card would contain pertinent data on the task, lubri- cants, special considerations, and space for date, initials, and remarks. Corrective maintenance should be recored in a log that pro- vides for equipment name, nature of breakdown or failure, materials and labor used, and special remarks. 1s3dd13Dl SUPPLIES AND SPARE PARTS Recommended lists for spare parts for each major equipment items should be obtained from the __ A separate list of spare parts should be maintained in the storeroom with space to indicate the date they were used and containing informa- tion necessary for reorder. LUBRICATION The manufacturer's maintenance datd and the maintenance summary forms contain suggested lubricants and cross-references by manufacturer. WARRANTY PROVISION For the first year of operation after final acceptance, the contractor is responsible for the repair or replacement of anything that fails to perform prnperly because of defective material or workmanship. All the equipment is likewise guaranteed for the first year of operation. During this time the operators are responsible for preventative mainte- nance but should not perform any corrective maintenance or alter the equipment in any way without first telling the contractor. Corrective maintenance and other repairs are the contractor's resporsibility, though the contractor and ls3ddl4Dl plant operator may agree to have the plant operator do the work and be paid for it by the contractor. If the plant operator should do any corrective maintenance without first notifying the contractor, the contractor may not have to pay for it. ls3ddlSDI Table 1 PIMP STATION PRESSURE CONTROL SETTINGS Control Control Equi ment Descri tion Control Adjustment �— p �Setting Range Feet Pressure, Dsi N rth Talbot Hill Varible Speed Pump Controller 360 13, Domestic Pump No. I Pressure Switch 340 128 10-200 psi Domestic Pump No, 2 Pressure Switch 330 124 10-200 psi Pressure Reducing Valve at S. 19th St. 300 ill -- Pressure Reducing Valve at S. 23 rd St. 290 107 Fire Pump Pressure Switch 275 100 10-200 psi Domestic Pump No. I Control Valve 345 130 75-200 psi DOlnestic Pump No. 2 Control Valve 335 126 75-200 psi Fire Pump Control Valve 367 140 75-200 psi Surge Relief Valve 190 150 75-200 psi ls3eelDl Table 2 PUMP STATION TIME CONTROL SETTINGS Adjustable Time Time Setting, No. function Pump Period, Sec Sec 1 Pump shutdown on motor Fire pump No. 1 and 2 1.5 - 15 9 failure to start 2 Pump shutdown on valve Fire pump No. 1 and 2 6 - 500 60 • failure to open/close Pump shutdown on valve Domestic pump No. I and 2 0 - Soo 30 tailure to open/close 5 Pump shutdown on motor Domestic pump No. 1 and 2 1.5 - 15 9 failure to start 10 Time delay :`ter low pre%- Domestic pump No. 1 0 - So0 60 sure reading 11 Time delay after low pres- Domestic pump No. 2 0 - 500 90 sure reading 19 Time delay on pump starting Domestic pump No. I and 2 0 - 590 60 • after shutdown Is3ff1D1 U)7-k-0* 10 eNo�ic fmy7*6/L)3 QF FIL FILE TITLE STa [ bo N�[[ {pump 57faf ia 10 � I QP.weafiaNs )OoNu ,#L