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Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 1 of 41
Date 14/05/2018
Copyright Group Five. All Rights Reserved - This documentation is considered the intellectual property of Group Five.
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Document Number
Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 2 of 41
Table of Contents
LIST OF TABLES ....................................................................................................................................................... IV
3 OPERATING INSTRUCTIONS........................................................................................................................... 19
3.1 NORMAL OPERATIONAL PROCEDURES INCLUDING AUTOMATIC AND MANUAL OPERATIONS ...................................... 19
3.1.1 Return Activated Sludge Pumps............................................................................................................ 19
3.1.2 Bilge Pump ............................................................................................................................................. 29
3.2 RAS PUMP STATION VENTILATION SYSTEM ........................................................................................................ 34
3.2.1 Pre-Start-Up Checks .............................................................................................................................. 34
3.2.2 Remote Auto Operation ........................................................................................................................ 34
3.2.3 Remote-Manual Operation ................................................................................................................... 34
3.2.4 Local Operation ..................................................................................................................................... 35
3.2.5 Normal operating condition/readings .................................................................................................. 35
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Document Number
Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 3 of 41
Copyright Group Five. All Rights Reserved - This documentation is considered the intellectual property of Group Five.
Unauthorised reproduction or distribution of this documentation or any portion of it may result in severe civil and criminal
penalties, and violators will be prosecuted to the maximum extent possible under law.
Document Number
Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 4 of 41
List of Tables
Table 1-1 Output or Functionalities for System Definitions .................................................................. 23
Table 1-2 Specific Equipment Set Points (SP) .......................................................................................... 3
Table 2-1 Hazardous Identification Risk Assessment............................................................................... 7
Table 2-2 Electrical Equipment Safety Action Plan .................................................................................. 9
Table 2-3 Alarms, trips and interlocks description ................................................................................ 15
Table 2-4 RAS Pumps Specific Alarms, Trips and Interlocks................................................................... 16
Table 2-5 Bilge Pumps Specific Alarms, Trips and Interlocks ................................................................. 17
Table 3-1 Troubleshooting of RAS Pump ............................................................................................... 27
Table 3-2 Troubleshooting of the Bilge Pump ....................................................................................... 33
List of Figures
Figure 2-1 Emergency Response Structure ........................................................................................... 10
Figure 2-2 Emergency Evacuation Diagram ........................................................................................... 12
Figure 3-1 RAS Pump Local/PLC Switch ................................................................................................. 21
Figure 3-2 Automated Valves Local or Remote Control ........................................................................ 21
Figure 3-3 Suction Valve on Both SCADA and in the Field ..................................................................... 22
Figure 3-4 RAS Sump Level .................................................................................................................... 22
Figure 3-5 RAS Pump Interlock Alarm Status ......................................................................................... 23
Figure 3-6 Resetting Alarm Conditions .................................................................................................. 23
Figure 3-7 RAS Pump Field Panel ........................................................................................................... 26
Figure 3-8 Bilge Pump Local/PLC Switch ................................................................................................ 30
Figure 3-9 Bilge Pump Interlocks ........................................................................................................... 30
Figure 3-10 Bilge Pump Alarm Reset ..................................................................................................... 31
Figure 3-11 Bilge Pump Local Control Panel .......................................................................................... 32
List of Notes
1. Flowrate out of the RAS pump station to be confirmed by updated FDS …………………………... Page 8
2. Time of duty rotation to be changed with an updated FDS ………………………………………..……... Page 8
3. Valve opening time to be updated with an updated FDS ……………………………………………...…... Page 9
4. Outstanding information from Gauche Air ………………………………………………………..………...…... Page 9
5. Evacuation Plan to be updated with updated the Emergency Response Plan & Procedures
Template from Umgeni Water ……………………………………..…………………………..………...………..... Page 17
6. Outstanding documentation from Gauche Air ……………………………………………...………………... Page 41
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Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 5 of 41
List of Abbreviations
Abbreviations Definition
BOV Blow Off Valve
COD Chemical Oxygen Demand
DO Dissolved Oxygen
EC Emergency Coordinator
ER Emergency Response
FBDA Fine Bubble Diffused Air Aeration
FE Final Effluent
HIRA Hazardous Identification Risk Assessment
HMI Human Machine Interface
IGV Inlet Gate Valve
LCP Local Control Panel
MCC Motor Control Centre
MEIP Mechanical, Electrical, Instrumentation and Piping
MLSS Mixed Liquor Suspended Solids
OUR Oxygen Uptake Rate
P&ID Piping and Instrumentation Diagram
PLC Programmable Logic Controller
PST Primary Settling Tank
RAS Return Activated Sludge
SCADA Supervisory control and data acquisition
SP Set Points
SST Secondary Settling Tanks
UW Umgeni Water
VSDs Variable Speed Drives
VVD Variable Vane Diffuser
WAS Waste Activated Sludge
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PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 1 of 41
The FOGS Pump station forms part of an integrated system that pumps FOGS received from the inlet
works and PSTs (Primary Settlement Tanks) into the digesters for anaerobic digestion.
The boat structure comprises of a settling tank, a scraper that removes the FOGS from the settling
tank and drops it onto a conveyer belt that conveys the FOGS into the hoppers thereafter two positive
displacement pumps are used to transfer the FOGS to the digesters. Suction pipework comes from
the inlet works and PSTs and discharge pipework eventually lead to the digesters. There are also
break disks installed that are activated when a blockage is experienced. A bilge pump will be used for
drainage.
FOGS enters the boat in two ways, the inlet works FOG pump station and the FOGS from the PSTs will
enter the settling compartment where it is thought that there shall be enough settling time for the
Fats, Oil, Grease and Scum to separate from the water. FOGS Separator Trolley Drive, is used to
scrape the FOGS that has floated to the surface up the beach and onto the FOGS Separator Conveyor.
The FOGS Separator Conveyor, is used to deliver the FOGS that has been scraped off the surface of
the boat structure to the FOGS Hoppers, and ultimately the FOGS Digester Feed Pumps. FOGS
Digester Feed Pumps are designed to operate on a duty/standby arrangement. The duty pump shall
be defined by the chute position proximity switch ZS-1026 and ZS-1027. The level in hopper 1 and
hopper 2 shall be monitored by means of an ultrasonic level transmitter, When the sludge feed batch
is started, as determined by the level in the Thickened sludge sump which is located in the Digester
Feed Pump Station.
The method of control of the pump station is by means of the Supervisory Control and Data
Acquisition (SCADA) system, which is situated in the control room, it is not equipped with its own
Programmable Logic Controller (PLC), and rather it is controlled by PLC 11 which receives
communication from PLC 18 located in the SSPSthe SSPS and Digester complex respectively. Blended
sludge shall be fed into each digester on a batch system. This batch will be based on the mass as
measured by FIT-1801. A high level on the thickened sludge sump level LIT-1804 shall initiate a batch
feed process, at which point PLC 18 sends a request to PLC 11. PLC 11 confirms that the Hopper level
is sufficient and that at least 1 digester valve is open.
The FOGS Digester feed pumps are designed for one duty and one standby, however there are no
interlocks from preventing both running simultaneously once the duty discharge valve 11-M-1067 or
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G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 2 of 41
11-M-1068 is fully open, the duty FOGS Digester Feed Pump 11-M-1061 or 11-M-1063 shall start and
run until 11-LT-1025L reads 30% ##%, or 11-LT-1026L reads 30% ##%, as the case may be, is reached.
The pumps shall then stop, and continue to operate on an on/off basis providing least one digester
feed valve, 18-XV-1801, or 18-XV-1814, or 18-XV-1823 or 18-XV-1827 is open and one digester feed
pump 18 –M-1824 or 18-M-1825 is running. The temperature of the pump is monitored by a
temperature probe TIT1061 and TIT1063TAG!! and has a upper limit of 60 ⁰C.
At least one digester inlet valve must be open at all times. Failure to open a digester 5, 6, 7 or 8 inlet
valve when the FOGS digester feed pumps are called to run shall raise an alarm.
Feed to digesters shall be on a batch process, as monitored by FT-4002, which shall be adjustable
from SCADA. Once a batch to a digester has been completed, the inlet valve of the following on-line
digester shall open. Once this inlet valve is open the inlet valve of the previous valve shall close,
maintaining at least 1 open valve at all times. This process shall be controlled by PLC 18, but is
relevant to the understanding required to run the Digester FOGS Feed Pumps.
To ensure system performance remains acceptable, the adjustment of various operating parameters
is usually limited to users with adequate skill to be able to make informed decisions when adjusting
the relevant parameters. The recommended level of authority of various users to change various
operating parameter set points is listed in
The RAS pumps specific operating SP are listed in Table 0-2Table 1-2. Note that many of these are
required for the safe operation of the RAS pumps and should only be adjusted in consultation with
the manufacturer.
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Document Number
Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 4 of 41
Copyright Group Five. All Rights Reserved - This documentation is considered the intellectual property of Group Five.
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Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 5 of 41
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OPERATING INSTRUCTIONS FOR RAS Pump Station Page 6 of 41
1. Pumps not stopping during interlock operation: pumps not stopping during interlock operation will
lead to over flow of the pipes to the biological reactors. In addition, excess suction from the wet
well occurring, leading to the wet well running dry, resulting in the pumps to run with no sludge
consequently damages the pumps.
2. Valves not opening or closing during interlock operation: if valves are closed and the pump
continues to run, there will be excess pressure build up in the pipe, causing leakages and possible
pipe bursts.
3. Occurrence of water hammer in the event of an emergency stop on the pumps: a water hammer is
a shock wave that travels down the pipe due to a sudden change in flow. As the emergency stop is
a very sudden change in flow there is a significant pressure rise. This may lead to pipe bursts,
structural damage and/or pump damage.
4. Leaking pipes: The pipes are filled with RAS which is a hazardous material containing pathogens, if
the pipes are leaking do not handle the sludge directly use the relevant PPE and fix pipes ASAP.
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Group Five
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Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 7 of 41
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portion of it may result in severe civil and criminal penalties, and violators will be prosecuted to the maximum extent possible under law.
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Group Five
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Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 8 of 41
Risk Ratings
Task Hazard/ Associated Risk Control Measures
A B C D RR
Opening/Activating the Slips and falls when using cat-ladder that Ensure that safety shoes are clean, free of mud or water.
Valves on the Plant could lead to serious injuries to employees. Ensure that safety harness is used where at climb is above 1.5m and hook it as you climb up, both hands 4 2 4 2 32
to be holding firm on the rails.
Working/walking in the Slips and falls on floors made slippery by Ensure the surface/walkways are clear of trips and falls, i.e. pipes, extension cables, etc.
2 2 2 2 16
plant sewage. Ensure surface is dry; clean any spillage immediately and safety footwear is always on.
Working on the plant Overhead loads from hoists. Prior to hoisting any material, ensure that communication is clear amongst your team that you intend
with overhead hoist People coming in contact with the load. hoisting material/load.
Loads falling on people. Ensure no one will be on the way or under the hoisted material, display signs or activate alarm/siren
within the plant before hoisting; the siren will serve a warning to unaware employees.
4 2 4 2 32
The meaning of the siren needs to be known by all plant users/visitors prior to going to the plant.
(Induction).
The plant area is strictly hard hat area, this reduces injuries to people should any objects hoisted are
accidentally dropped or fall.
Plant Operation Contact with moving machinery. Ensure that you have enough knowledge or information of what’s to be done.
Ensure that prior to manually opening any machinery to clear or release any blockage the machinery has
completely locked out to prevent an automatic start that could cause injuries.
4 2 4 2 32
When you done, please be satisfied that you have close and all moving components are tightly closed
before restarting.
Wear appropriate PPE for the task.
Working in the Plant Diseases caused by infectious agents present Ensure that when working in the plant you always wear your PPE, mandatory PPE being safety shoes,
in the raw sewage. appropriate musk, appropriate hand gloves, hard hat and reflective clothing.
Diseases caused by toxins released by Avoid eating or drinking in the area.
infectious agents. Wash your hands and sanitise immediately upon leaving the plant.
Check with your SHE personnel for appropriate immunisation when working at the plant.
Dermatoses caused by exposure of the skin
to wastewater. Always wear long sleeves clothing, avoid any skin contact with any chemicals or sludge splashes, should 4 2 4 2 32
that happen please leave the area and rinse yourself thoroughly with clean water and soap.
Notify your supervisor or SHE representative and get medical help should you experience or notice any
of the following. Respiratory (asthma, chronic bronchitis, and chronic sinusitis), gastronomic (abdominal
pain and bloating, nausea, vomiting, diarrhoea, constipation), skin (skin rash, ulcer on the skin) or
systemic (a headache, fever, chest pain or discomfort, muscle spasms)
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portion of it may result in severe civil and criminal penalties, and violators will be prosecuted to the maximum extent possible under law.
Document Number
Group Five
G5-113248-12.07-001
Revision Number
PROJECT MANAGEMENT SYSTEM
01
Page Number
OPERATING INSTRUCTIONS FOR RAS Pump Station Page 9 of 41
Hard hat
Safety shoes/gumboots
Visible vest
Overalls
Gloves and Nose masks (when cleaning)
Safety harness (if working at heights)
Ear plugs
Item
Do’s Don’t
no.
1. Switch OFF the main switch in an emergency Don't work inside motor control panels
2. Keep the MCC room clean. Don't try to adjust control devices
Don't switch OFF the main switch or other
circuit breakers unnecessarily. This causes
3. Keep visitors out of the MCC room
abnormal wear and tear and can lead to back-up
battery failure
Keep a logbook or diary and let service persons
Don’t keep on starting motors which keep on
4. fill in their Particulars, dates and the work, which
tripping. Report the problem.
they have done.
Read the voltmeters and ammeters daily.
Don’t keep on resetting equipment, which keep
5. Report any abnormal occurrence or motor noise
on tripping. Report the problem.
immediately to servicepersons.
Don't work on any pump set before switching off
Be present in or around the station when pumps
6. the starter main switch and pressing the lock-
are in operation.
stop button on the motor.
7. Lock the MCC room when not in operation. Don’t touch rotating shafts or machine Parts.
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PROJECT MANAGEMENT SYSTEM
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OPERATING INSTRUCTIONS FOR RAS Pump Station Page 10 of 41
Item
Do’s Don’t
no.
8. Keep electrical equipment and motors dry Don't leave operating equipment unattended.
Don't let untrained persons operate pumping
9.
equipment.
10. Don’t run pumps dry.
1
Evacuation Plan to be updated with updated the Emergency Response Plan & Procedures Template
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In the event of an incident, the individual that discovers it will report it to the responsible
management member, namely the supervisor/ manager/ systems manager/ work superintendent,
depending on the working environment. The responsible management member will then analyse the
situation and activate the emergency procedure, or notify the emergency coordinator (EC) to make a
decision. In cases that warrant so, the ER team and plan will be activated and the relevant response
will be taken, the local emergency services will be utilised as required.
The EC is then to inform and give details of the incident to the UW BCM coordinator. Depending on
the severity of the incident the BCM coordinator will inform the crisis management team (CMT)
leader and decisions will be made to activate the CMT and procedure.
1. Command Centre: The control room acts as a command centre in the event of an emergency.
However, if the control room cannot be used the main gate guard house will be used as the
command centre.
2. Forward Control Point: The forward return point is to be used by the fire department on site
and will be located at the command centre. The primary purpose of the forward control point
is to act as a location where the ER team can convey information to the Fire department and
other emergency services.
3. Emergency Assembly Points: a minimum of two (2) assembly points are located within each
workstation, i.e. a primary point, located on site, and a secondary point for large-scale
evacuations, located at a suitable distance away from buildings or working areas,
alternatively, the secondary point could be located off-site. The following locations act as an
emergency assembly points, refer to Figure 2-2 below:
a. Assembly Point A: From the alum dosing area, through to the aerators, proceeding to the
main buildings passing through to the workshops and go left.
b. Assembly Point B: From the alum dosing area, through to the aerators, proceeding to the
main buildings passing through to the workshops and go right to the canteen.
c. Assembly point C: From the chlorine area, through to the main pump station, proceed to
the head of works, and go right to the inlet.
From the Digester area, through to the PST and go straight to the inlet.
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PROJECT MANAGEMENT SYSTEM
01
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OPERATING INSTRUCTIONS FOR RAS Pump Station Page 12 of 41
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ER 24 084 124
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PROJECT MANAGEMENT SYSTEM
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OPERATING INSTRUCTIONS FOR RAS Pump Station Page 14 of 41
Cyril Gamede 033 341 1041 / 082 771 1840 Overarching BCP Team Leader
Thandeka Zulu 033 – 719 7300 / 083 383 2135 Deputy Overarching BCP Team Leader
Ingrid Cawood 033 341 1244 / 083 292 5060 BCM Coordinator
Dan Naidoo 031 719 7300 / 083 272 4436 Deputy BCM Coordinator
Steve Gillham 033 341 1164 / 083 453 0240 GM: Engineering & Scientific Services
Msizi Cele 033 3411308 / 060 5773 246 GM: Operations
Thami Hlongwa 033 341 1507 / 082 818 8300 GM: Finance
Mokete Mayongo 033 3411011 / 060 521 7475 GM: Corporate Services
Thulasizwe Shangase 033 341 1012 / 083 459 8550 GM: Human Resource
Nonhlanhla Gumbi 033 341 1006 / 083 244 2310 GM: Supply Chain Management
Copyright Group Five. All Rights Reserved - This documentation is considered the intellectual property of Group Five.
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Sipho Zulu 033 341 1135 /082 437 3329 GM: Property Services
Bradley Sampson 033 346 1583 / 083 642 7733 GM: ICT
Sunil Maharaj 083 274 3013 96290) Regional Manager
Eric Nene 083 345 6708 (6265) Area Manager
Ntsiki Baai 083 289 1450 (6372) Asset Manager
Mulalo Murigwathoho 078 801 1181( 6965) Systems Manager
Goodman Ngcemu 084 444 3815 (6897) Superintendent DARVILL WWW
Table 2-3 identifies each of the alarm categories proposed for the system and the level of
acknowledgment necessary.
CATEGORY DESCRIPTION
LEVEL 0 Where there is a change in operation status of equipment and instrumentation
(NOTIFICATION) on the plant during normal operating mode. The alarm is generated as a line
statement on the ALARM SCREEN in BLUE print.
LEVEL 1 An alarm condition that warns the Senior Operator of impending negative
(FAILURE) impact on process performance, plant integrity, personnel safety or
environmental safety. The alarm is generated as a line statement on the ALARM
SCREEN in RED print. The text will change to BLUE print if the ALARM CONDITION
is rectified before the Senior Operator acknowledges the alarm. The Senior
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NB: For plant equipment specific trips and interlocks, please refer to FDS documents found in
Operation and Maintenance Manual, R.A.S Pump Station, Volume 2, File XXX.
NB: After a trip, the operator should first investigate and rectify the cause of the trip before the
equipment can be restarted.
Table 2-4 and Table 2-5 identifies the specific alarms, trips and interlocks, the associated equipment
and the severity of each trip, of the RAS pumps and bilge pump respectively.
ITEM EQUIPMENT
EQUIPMENT TRIP DISPLAYED ON SCADA CATEGORY
NO. TAG
1. - Mains Off Level 2
2. - Emergency Stop Level 2
3. MS-2004A/B/C VSD Fault Level 2
TT-2001A/B
4. TT-2002A/B PTC Fault Level 2
TT-2003A/B
5. FT-2057/8 No Flow Level 1
TT-2001C/
6. Grunfos Fault Level 2
2002C/ 2003C
7. M-2107/8/9 Auto Level 1
8. PIT-2006/7/8 Duty Pump Level 1
ZS-2027/28/
9. Delivery Line Route Off Level 2
29/33
10. M-2107/8/9 Delivery Valve Open Level 1
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ITEM EQUIPMENT
EQUIPMENT TRIP DISPLAYED ON SCADA CATEGORY
NO. TAG
1. - Mains Off Level 2
2. - Emergency Stop Level 2
3. M-2123 E300 TRIP Level 1
4. Earth Leakage Level 2
5. M-2123 Comm Loss Level 1
6. M-2123 Auto Level 1
7. LS-2004 Start Level Level 2
It is to be noted that whether you are the owner, operator, or maintenance person for this machine,
safety is your responsibility. You are responsible for operating and maintaining this equipment in
compliance with these instructions and for using common sense. It is extremely important that you
read, understand, and follow the safety messages and regulations carefully before handling the
machine.
The following special messages warn of potential hazards or to call attention to information that
clarifies or simplifies a procedure.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING/ATTENTION
WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.
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CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE addresses practices not related to physical injury including certain environmental hazards, potential
damage or loss of data.
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OPERATING INSTRUCTIONS FOR RAS Pump Station Page 19 of 41
3 Operating Instructions
3.1 Normal Operational Procedures Including Automatic and Manual Operations
3.1.1 Return Activated Sludge Pumps
There are 3 RAS pumps, two duty and one standby, that can be operated in the aforementioned
modes of operation. For equipment general operation, maintenance and fault finding, refer to
Operation and Maintenance Manual, Return Activated Sludge Pump Station Area, Volume 2. For specific
control philosophy refer to the Functional Design Specification, Volume 2.
Step 4. The operator ensures that discharge valves KGV-2056A/2056B/2056C are open.
Step 5. The operator is to bleed the pressure lines of any air by opening the relevant valves GV-
2001/2002/2003.
Step 6. From the SCADA, the operator ensures wet well water level is between operating limits, as
illustrated in Figure 3-4.
Step 7. From the filed the operator is to check that the wet well is free from any debris.
Step 8. From both the SCADA and field, the operator ensures at least one delivery line is available
and valves KGV-2059A/2059B are in the correct position for flow through desired delivery
line, and if pump 2 is running that the relevant valves KGV-2057/2058
Step 9. Check the alarm status of the duty/standby motors by clicking on the motors, as illustrated
in Figure 3-5.
Step 10. Reset any present alarm conditions, as illustrated in Figure 3-6.
Step 11. PLC Confirm duty call as required by LT-2002 (With Control Band).
Step 12. Start available duty pump- check for lowest hours for non-running pump (runs at minimum
speed).
Step 13. When discharge valve fully opens, PLC runs motor at set speed (motors accelerate until set
point is reached).
Step 14. Second Duty pump required as determined by the level transmitter LT-2002, at the sump
level of 60%.
Step 11.1. From SCADA, Operator confirms pump is available- check for lowest hours for non-
running pump.
Step 11.2. From the field and SCADA, operator confirms the relevant suction valve KGV-
2056A/B/C is open.
Step 11.3. PLC reduces speed of running pump to minimum speed (motor decelerates to
minimum speed).
Step 11.4. When duty P1 is at minimum speed, PLC starts duty P2 on minimum speed (both
motors run at minimum speed.)
Step 15. Second duty pump no-longer required as determined by the level transmitter LT-2002, at
the sump level of 45%.
Step 12.1. PLC reduces speed of both motors down to minimum speed.
Step 12.2. When both pumps are running at minimum speed, PLC closes discharge valve of
motor required to stop (both pumps running at minimum speed).
Step 12.3. When discharge valve reaches 10% of open position, PLC stops motor (remaining
pump runs at minimum speed).
Step 12.4. When discharge valve closed and motor stopped, PLC increases speed of remaining
motor to required set point (set point determined by Level transmitter).
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3.1.1.3.1 Purpose
To operate the RAS Pumps in remote manual mode from the SCADA.
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3.1.1.5 Shut-Down
3.1.1.5.1 Shut-down and Operation Checks
Step 1. Close all front doors of the MCC on all starter panels and instrument panels, as well as the
main door of the main switch as this door is interlocked with the main switch or warning
alarms.
Step 2. Stop all equipment from Upstream until downstream. Please note the Process flow needs to
be studied and understood before doing this.
Step 3. Ensure all manual or isolation valves relevant for operation are opened/closed.
3.1.1.6 Isolation
The below procedure defines the isolation points on events of maintenance, troubleshooting, and or
re-outing checks deemed by the process or operations requirements.
Step 1. Senior operator is to identify the need of isolation of a specific pump line. To maintain the
load, only one pump line should be isolated at a time, generally the standby pump.
Step 2. The operator should set the relevant pump into local mode, as illustrated in Error! Reference
source not found..
Step 3. The pump should be slowed down incrementally using the speed control dial, as illustrated
in Figure 3-1, and eventually stopped.
Step 4. The senior operator is to then close valves KGV-2062A/2062B/2062C and KGV-
2056A/2056B/2056C depending on the pump line that is being isolated.
Step 5. Let out excess sludge between the isolation valves by opening the gate valves GV-
2001/2002/2003 to the drain, depending on the pump line.
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3.1.1.7 Troubleshooting
Table 3-1 Troubleshooting of RAS Pump
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Step 1. The operator must ensure the bilge pump, is switched into PLC mode, as illustrated in Figure
3-8, and select AUTO on the SCADA.
Step 2. Check the alarm status of the pump by clicking on the pump, as illustrate in Figure 3-9.
Step 3. Reset any present alarm conditions, as illustrate in Figure 3-10.
Step 4. The PLC will confirm sump level using LSH-2004, when reached high level i.e. level > 60%,
the Bilge pump will start automatically
Step 5. Bilge pump continues to run, until low level is reached, this will be confirmed by LSL-2004 at
level < 30%
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Step 1. The operator must ensure the bilge pump, is switched into PLC mode, as illustrated in Figure
3-8, and select manual on the SCADA.
Step 2. Check the alarm status of the pump by clicking on the pump, as illustrated inFigure 3-9.
Step 3. Reset any present alarm conditions, as illustrated in Figure 3-10.
Step 4. Confirm sump level using LSH-2004, when high level, i.e. level > 60%, is reached, start Bilge
pump on SCADA.
Step 5. Monitor Bilge pump running until low level is reached, i.e. level > 30%, confirming the level
using the LSL-2004 displayed on SCADA.
Step 6. Stop Bilge pump.
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Step 1. The operator must ensure Bilge pump, are switched into Local mode, as illustrated in Figure
3-8.
Step 2. The operator must ensure level is above low set point.
Step 3. Using the Local Control panel, as illustrated in Figure 3-11, located next to the bilge pump
start the pump
Step 4. Start/stop Bilge pump as corresponding to high and low volume in the sump.
Step 1. Close all front doors of the MCC on all starter panels and instrument panels, as well as the
main door of the main switch as this door is interlocked with the main switch or warning
alarms.
Step 2. Stop all equipment from Upstream until downstream. Please note the Process flow needs to
be studied and understood before doing this.
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3.1.2.6 Troubleshooting
Table 3-2 Troubleshooting of the Bilge Pump
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The Ventilation system can be operated in the aforementioned modes of operation. For equipment
general maintenance and fault finding, refer to Operation and Maintenance Manual, RAS Pump Station,
Volume 2.
Step 1. Before operating the units ensure that the fans are clear of any obstacles
Step 2. Check for any loose or damaged electrical wiring, repair or replace if needed
Step 3. Check the water supply line into the individual water tanks by motoring the pressure gauge.
2
Outstanding documentation from Gauche Air
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3.3.2 Calibration
Flow meters and pressure indicators to be calibrated as per Operation and Maintenance Manual,
Return Activated Sludge Pump Station Area, Volume 2. For specific control philosophy refer to the
Functional Design Specification, Volume 2.
4 Handover documentation
To be included on completion.
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