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
Flygt 3153 Installation, Operation, and Maintenance Manual 1
Sewage Pump Station Townsend St SPS SP058 Installation, Operation and Maintenance Manual
QP Id: VM174
Active: 26/08/2013
Page 5 of 136

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
2 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 6 of 136

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
Flygt 3153 Installation, Operation, and Maintenance Manual 3
Sewage Pump Station Townsend St SPS SP058 Installation, Operation and Maintenance Manual
QP Id: VM174
Active: 26/08/2013
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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
4 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
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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
Flygt 3153 Installation, Operation, and Maintenance Manual 5
Sewage Pump Station Townsend St SPS SP058 Installation, Operation and Maintenance Manual
QP Id: VM174
Active: 26/08/2013
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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
6 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 10 of 136