Urban Utilities SP0958 User manual

Sewage Pump Station Townsend St SPS SP058
Installation, Operation and Maintenance Manual
SP0958
TOWNSEND STREET SEWAGE PUMP STATION
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
PARTS LIST
ENVIRONMENT PRODUCT DECLARATION
Sewage Pump Station Townsend St SPS SP058 Installation, Operation and Maintenance Manual
QP Id: VM174
Active: 26/08/2013
Page 1 of 136

INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Sewage Pump Station Townsend St SPS SP058 Installation, Operation and Maintenance Manual
QP Id: VM174
Active: 26/08/2013
Page 2 of 136

Flygt 3153
Installation,
Operation, and
Maintenance Manual
Sewage Pump Station Townsend St SPS SP058 Installation, Operation and Maintenance Manual
QP Id: VM174
Active: 26/08/2013
Page 3 of 136

Sewage Pump Station Townsend St SPS SP058 Installation, Operation and Maintenance Manual
QP Id: VM174
Active: 26/08/2013
Page 4 of 136

Table of Contents
Introduction and Safety.........................................................................................................................3
Introduction..........................................................................................................................................3
Safety.....................................................................................................................................................3
Safety terminology and symbols....................................................................................................3
Environmental safety........................................................................................................................4
User safety.........................................................................................................................................5
Ex-approved products.....................................................................................................................6
Product warranty...............................................................................................................................7
Transportation and Storage..................................................................................................................9
Inspect the delivery.............................................................................................................................9
Inspect the package.........................................................................................................................9
Inspect the unit..................................................................................................................................9
Transportation guidelines..................................................................................................................9
Precautions........................................................................................................................................9
Position and fastening......................................................................................................................9
Lifting..................................................................................................................................................9
Temperature ranges for transportation, handling and storage..................................................10
Handling at freezing temperature................................................................................................10
Unit in as-delivered condition.......................................................................................................10
Lifting the unit out of liquid...........................................................................................................10
Storage guidelines............................................................................................................................11
Storage location.............................................................................................................................11
Freezing precautions.....................................................................................................................11
Long-term storage..........................................................................................................................11
Product Description.............................................................................................................................12
Pump design......................................................................................................................................12
Parts....................................................................................................................................................13
Monitoring equipment.....................................................................................................................14
Optional sensors.............................................................................................................................14
The data plate....................................................................................................................................14
Approvals...........................................................................................................................................15
Product approvals for hazardous locations.................................................................................15
EN approval plate...........................................................................................................................15
IEC approval plate..........................................................................................................................16
FM approval plate..........................................................................................................................16
Product denomination......................................................................................................................17
Installation.............................................................................................................................................18
Install the pump.................................................................................................................................18
Authority regulation.......................................................................................................................18
Fasteners.........................................................................................................................................18
Install with P-installation.................................................................................................................19
Install with S-installation.................................................................................................................20
Install with T/Z-installation.............................................................................................................21
Make the electrical connections......................................................................................................22
General precautions.......................................................................................................................22
Requirements..................................................................................................................................22
Cables..............................................................................................................................................23
Earthing (Grounding).....................................................................................................................23
Connect the motor cable to the pump........................................................................................23
Table of Contents
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Connect the motor cable to the starter and monitoring equipment.......................................24
Cable charts....................................................................................................................................25
Sensor-connection.........................................................................................................................31
Check the impeller rotation.............................................................................................................33
Operation..............................................................................................................................................35
Precautions.........................................................................................................................................35
Distance to wet areas........................................................................................................................35
Noise level..........................................................................................................................................35
Start the pump...................................................................................................................................35
Maintenance.........................................................................................................................................37
Precautions.........................................................................................................................................37
Maintenance guidelines...................................................................................................................37
Torque values....................................................................................................................................38
Change the coolant..........................................................................................................................39
Empty the coolant..........................................................................................................................39
Fill with coolant...............................................................................................................................41
Service the pump..............................................................................................................................42
Inspection........................................................................................................................................43
Major overhaul................................................................................................................................44
Service in case of alarm.................................................................................................................44
Replace the impeller.........................................................................................................................44
Replace the impeller for wet installation.....................................................................................44
Replace the impeller for dry installation......................................................................................52
Troubleshooting...................................................................................................................................62
Introduction.......................................................................................................................................62
The pump does not start..................................................................................................................62
The pump does not stop when a level sensor is used.................................................................63
The pump starts-stops-starts in rapid sequence...........................................................................63
The pump runs but the motor protection trips.............................................................................64
The pump delivers too little or no water........................................................................................65
Technical Reference............................................................................................................................67
Application limits...............................................................................................................................67
Motor data..........................................................................................................................................67
Table of Contents
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Sewage Pump Station Townsend St SPS SP058 Installation, Operation and Maintenance Manual
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Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is
over-pressurized. Take all necessary measures to avoid over-pressurization.
•Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment. This includes
any modification to the equipment or use of parts not provided by Xylem. If there is a
question regarding the intended use of the equipment, please contact an Xylem
representative before proceeding.
•This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion
and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in
their removal.
•Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in
physical injury, damage, or delays.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Introduction and Safety
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Hazard levels
Hazard level Indication
DANGER: A hazardous situation which, if not avoided, will result in
death or serious injury
WARNING: A hazardous situation which, if not avoided, could result
in death or serious injury
CAUTION: A hazardous situation which, if not avoided, could result
in minor or moderate injury
NOTICE:
• A potential situation which, if not avoided, could
result in undesirable conditions
• A practice not related to personal injury
Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
•Crush hazard
•Cutting hazard
•Arc flash hazard
Magnetic hazard
Magnetic hazards are indicated by a specific symbol that replaces the typical hazard level
symbols:
CAUTION:
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Introduction and Safety
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Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the Xylem manufacturer if it has been contaminated by any
nuclear radiation. Inform Xylem so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always recycle according to these guidelines:
1. Follow local laws and regulations regarding recycling if the unit or parts are
accepted by an authorized recycling company.
2. If the first guideline is not applicable, then return the unit or parts to your Xylem
representative.
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
•Pay attention to the risks presented by gas and vapors in the work area.
•Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.
Introduction and Safety
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Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
Condition Action
Chemicals or hazardous
fluids in eyes 1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Chemicals or hazardous
fluids on skin 1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
Personnel requirements
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
•All work on the product must be carried out by certified electricians and Xylem-
authorized mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas, the vapor, or both present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national
standards (for example, IEC/EN 60079-17).
Xylem disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data.
•You must fully submerge the Ex-approved product during normal operation. Dry
running during service and inspection is only permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control panel
are isolated from the power supply and the control circuit, so they cannot be
energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
•Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product, and that they are in use.
• Intrinsically safe circuits are normally required for the automatic level-control system by
the level regulator if mounted in zone 0.
•The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
Introduction and Safety
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• Do not modify the equipment without approval from an authorized Xylem
representative.
• Only use parts that are provided by an authorized Xylem representative.
Guidelines for compliance
Compliance is fulfilled only when you operate the unit within its intended use. Do not
change the conditions of the service without the approval of an Xylem representative.
When you install or maintain explosion proof products, always comply with the directive
and applicable standards (for example, IEC/EN 60079–14).
Minimum permitted liquid level
See the dimensional drawings of the product for the minimum permitted liquid level
according to the approval for explosion proof products. If the information is missing on the
dimensional drawing, the product must be fully submerged. Level-sensing equipment
must be installed if the product can be operated at less than the minimum submersion
depth.
Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices
include but are not limited to the following:
• Level indicators
• Temperature detectors
Product warranty
Coverage
Xylem undertakes to remedy defects in products from Xylem under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an Xylem representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in
use.
• All service and repair work is done by Xylem-authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by Xylem are used in Ex-
approved products.
Limitations
The warranty does not cover defects caused by these situations:
•Deficient maintenance
• Improper installation
•Modifications or changes to the product and installation made without consulting
Xylem
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
Xylem products are high-quality products with expected reliable operation and long life.
However, should the need arise for a warranty claim, then contact your Xylem
representative.
Introduction and Safety
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Spare parts
Xylem guarantees that spare parts will be available for 15 years after the manufacture of
this product has been discontinued.
Introduction and Safety
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Transportation and Storage
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Transportation guidelines
Precautions
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
Position and fastening
The unit can be transported either horizontally or vertically. Make sure that the unit is
securely fastened during transportation, and cannot roll or fall over.
Lifting
WARNING:
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
• Lift and handle the product carefully, using suitable lifting equipment.
•The product must be securely harnessed for lifting and handling. Use eyebolts or lifting
lugs if available.
• Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the
hose.
• Do not attach sling ropes to shaft ends.
Transportation and Storage
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Lifting equipment
Lifting equipment is always required when handling the unit. It must fulfill the following
requirements:
•The minimum height (contact Xylem for information) between the lifting hook and the
floor must be sufficient to lift the unit.
• The lifting equipment must be able to hoist the unit straight up and down, preferably
without the need for resetting the lifting hook.
• The lifting equipment must be securely anchored and in good condition.
• The lifting equipment must support weight of the entire assembly and must only be
used by authorized personnel.
• Two sets of lifting equipment must be used to lift the unit for repair work.
• The lifting equipment must be dimensioned to lift the unit with any remaining pumped
media in it.
• The lifting equipment must not be oversized.
NOTICE:
Oversized lifting equipment could cause damage if the unit should stick when being
lifted.
Temperature ranges for transportation, handling and storage
Handling at freezing temperature
At temperatures below freezing, the product and all installation equipment, including the
lifting gear, must be handled with extreme care.
Make sure that the product is warmed up to a temperature above the freezing point before
starting up. Avoid rotating the impeller/propeller by hand at temperatures below the
freezing point. The recommended method to warm the unit up is to submerge it in the
liquid which will be pumped or mixed.
NOTICE:
Never use a naked flame to thaw the unit.
Unit in as-delivered condition
If the unit is still in the condition in which it left the factory - all packing materials are
undisturbed - then the acceptable temperature range during transportation, handling and
storage is: –50°C (–58ºF) to +60°C (+140ºF).
If the unit has been exposed to freezing temperatures, then allow it to reach the ambient
temperature of the sump before operating.
Lifting the unit out of liquid
The unit is normally protected from freezing while operating or immersed in liquid, but the
impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a
surrounding temperature below freezing.
Units equipped with an internal cooling system are filled with a mixture of water and 30%
glycol. This mixture remains a flowing liquid at temperatures down to –13°C (9°F). Below –
13°C (9°F), the viscosity increases such that the glycol mixture will lose its flow properties.
However, the glycol-water mixture will not solidify completely and thus cannot harm the
product.
Follow these guidelines to avoid freezing damage:
Transportation and Storage
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1. Empty all pumped liquid, if applicable.
2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for
the presence of water. Change if needed.
Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and
vibrations.
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
Freezing precautions
The unit is frost-proof while operating or immersed in liquid, but the impeller/propeller
and the shaft seal may freeze if the unit is lifted out of the liquid into a surrounding
temperature below freezing.
Follow these guidelines to avoid freezing damage:
When Guideline
Before storage • The unit must be allowed to run for a short time after raising it to
discharge remaining pumped liquid.
This does not apply to impeller/propeller units.
• The discharge opening must be covered in a suitable way, or placed
facing down so that any still remaining pumped liquid runs out.
• If present, the cooling jacket must be drained manually by opening the
air vent screws at the top of the cooling jacket.
After storage If the impeller/propeller is frozen, it must be thawed by immersing the unit
in liquid before operating the unit.
NOTICE:
Never use a naked flame to thaw the unit.
Long-term storage
If the unit is stored more than 6 months, the following apply:
• Before operating the unit after storage, it must be inspected with special attention to
the seals and the cable entry.
• The impeller/propeller must be rotated every other month to prevent the seals from
sticking together.
Transportation and Storage
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Product Description
Pump design
The pump is submersible, and driven by an electric motor.
For a list of pump version and corresponding motor type, see Motor data (page 67).
Intended use
The product is intended for moving wastewater, sludge, raw and clean water. Always
follow the limits that are given in Application limits (page 67). If there is a question
regarding the intended use of the equipment, please contact an Xylem representative
before proceeding.
WARNING:
In explosive or flammable environments, only use Ex- or MSHA-approved pumps.
NOTICE:
Do NOT use the pump in highly corrosive liquids.
Spare parts
•Modifications to the unit or installation should only be carried out after consulting with
Xylem.
• Original spare parts and accessories that are authorized by Xylem are essential for
compliance. The use of other parts can invalidate any claims for warranty or
compensation. For more information contact your Xylem representative.
Pressure class
LT Low head
MT Medium head
HT High head
SH Super high head
Product Description
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Parts
1
11
10
9
8
7
2
3
6
12
13 14
WS000850A
Figure 1: Without cooling jacket
4
5
WS006171A
Figure 2: With cooling jacket
Positio
nPart Description
1 Monitoring
sensor Optional sensor. For information about sensors, see Monitoring equipment (page 14).
2 Shaft Stainless steel, with an integrated rotor
3 Cooling without
jacket The pump is cooled by the ambient liquid.
4 Cooling with
jacket The motor is cooled by a closed loop system. An integrated coolant pump circulates the coolant whenever the pump is operated.
5 Flow diffuser Provides heat transfer from the coolant to the pumped fluid.
6 Seal housing Includes a coolant that lubricates and cools the seals; the housing acts as a buffer
between the pumped fluid and the electric motor
7 Impeller N-impeller, a semi-open, two-vane impeller
8 Inspection
chamber Equipped with an FLS10 leakage sensor to prevent damages to the motor
9 FLS10 For information about FLS10, see Monitoring equipment (page 14).
10 Mechanical seals Made of one of the following alternatives:
• Alternative 1
• Inner seal: corrosion-resistant cemented carbide WCCR/WCCR
• Outer seal: corrosion-resistant cemented carbide WCCR/WCCR
• Alternative 2
• Inner seal: corrosion-resistant cemented carbide/Aluminum oxide WCCR/Al2O3
• Outer seal: silicon carbide RSiC/RSiC
11 Main bearings Consisting of a two-row angular contact ball bearing
12 Motor For information about the motor, see Motor data (page 67).
Product Description
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Positio
nPart Description
13 Thermal contact/
Thermistors For information about the thermal contact and thermistors, see Monitoring equipment (page 14).
14 Support bearing Consisting of a two-row ball bearing
Monitoring equipment
The following applies to the monitoring equipment of the pump:
• The stator incorporates three thermal contacts connected in series that activate the
alarm and stops the pump at overtemperature
• The thermal contacts open at 140°C (285°F).
• Ex-approved pumps must have thermal contacts connected to the control panel.
• The sensors must be connected to either the MiniCAS II monitoring equipment or an
equivalent equipment.
• The monitoring equipment must be of a design that makes automatic restart
impossible.
• The pump is supplied with an inspection sensor FLS 10 for sensing the presence of any
liquid in the inspection chamber.
• Information in the junction box shows if the pump is equipped with optional sensors.
Optional sensors
Thermistor Thermistors are optional sensors for measuring the temperature. They are
connected in series in the stator and activate the alarm at overtemperature.
Thermistors are not applicable to Ex-approved pumps.
NOTICE:
Thermistor must never be exposed to voltages higher than 2.5 V. If the
voltage exceeds this value, for example when the control circuit is tested, the
thermistors will be destroyed.
The data plate
The data plate is a metal label located on the main body of the products. The data plate
lists key product specifications. Specially approved products also have an approval plate.
2
1312 14
22
21
20
17 18 1916159 10 11
8
7
6
5
4
31
23
24
WS006257A
1. Curve code/Propeller code
2. Serial number, see Product denomination (page 17)
3. Product number
Product Description
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4. Country of origin
5. Additional information
6. Phase; type of current; frequency
7. Rated voltage
8. Thermal protection
9. Thermal class
10. Rated shaft power
11. International standard
12. Degree of protection
13. Rated current
14. Rated speed
15. Maximum submergence
16. Direction of rotation: L=left, R=right
17. Duty class
18. Duty factor
19. Product weight
20. Locked rotor code letter
21. Power factor
22. Maximum ambient temperature
23. Read installation manual
24. Notified body. Only for EN-approved Ex-products
Figure 3: The data plate
Approvals
Product approvals for hazardous locations
Pump Approval
• 3153.091
• 3153.095
• 3153.390
• 3153.810
• 3153.830
• 3153.850
European Norm (EN)
• ATEX Directive
• EN 60079-0, EN 60079-1, EN 1127-1
•I M2 Ex d I
•II 2 G Ex d IIB T3
EN approval for cable entry:
•Certificate number: INERIS 02ATEX9008 U
•II 2 G Ex d IIC or I M2 Ex d I
IEC
• IECEx scheme
• IEC 60079–0, IEC 60079–1
• Ex d I
• Ex d IIB T3
Factory Mutural (FM)
• Class I. Div 1. Group C and D
• Dust ignition proof for use in Class II. Div 1. Group E, F and G
• Suitable for use in Class III. Div 1. Hazardous Locations
EN approval plate
This illustration describes the EN approval plate and the information contained in its fields.
Product Description
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1 2 3
4
5
6 7 89 10
12
11
13
14
15
WS003972A
1. Approval
2. Approval authority +
approval number
3. Approval for Class I
4. Approved drive unit
5. Stall time
6. Starting current/Rated
current
7. Duty class
8. Duty factor
9. Input power
10. Rated speed
11. Controller
12. Additional information
13. Maximum ambient
temperature
14. Serial number
15. ATEX marking
IEC approval plate
This illustration describes the IEC approval plate and the information contained in its fields.
International Norm; not for EU member countries.
WS001279B
21
876
3
4
5 9
10
11
12
13
1. Approval
2. Approval authority +
approval number
3. Approved for drive unit
4. Stall time
5. Starting current/Rated
current
6. Duty class
7. Duty factor
8. Input power
9. Rated speed
10. Controller
11. Additional information
12. Max. ambient temperature
13. Serial number
FM approval plate
This illustration describes the FM approval plate and the information contained in its fields.
1
2WS003973A
1. Temperature class
2. Maximum ambient
temperature
Product Description
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