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  9. Xylem FLYGT Compit 901 Series User manual

Xylem FLYGT Compit 901 Series User manual

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Installation, Operation, and
Maintenance Manual
90011201_2.0
Flygt Compit 901
Table of Contents
1 Introduction and Safety..............................................................................................................3
1.1 Introduction.......................................................................................................................... 3
1.2 Safety terminology and symbols........................................................................................3
1.3 User safety.............................................................................................................................4
1.4 Special hazards.....................................................................................................................4
1.4.1 Confined spaces........................................................................................................... 4
1.4.2 Biological hazards.........................................................................................................4
1.4.3 Wash the skin and eyes................................................................................................5
1.5 Protecting the environment................................................................................................5
1.6 Spare parts............................................................................................................................5
1.7 Warranty................................................................................................................................5
2 Transportation and Storage...................................................................................................... 6
2.1 Precautions........................................................................................................................... 6
2.2 Position and fastening......................................................................................................... 6
2.3 Examine the delivery........................................................................................................... 6
2.3.1 Examine the package................................................................................................... 6
2.3.2 Examine the unit............................................................................................................6
2.4 Transportation guidelines...................................................................................................7
2.4.1 Lifting..............................................................................................................................7
2.5 Remove from the pallet: Unit delivered right-side up.....................................................7
2.6 Turn the unit to an upright position: Unit with anchoring ring (foot)............................ 8
2.7 Turn the unit to an upright position: Unit without anchoring ring (foot).................... 10
2.8 Long-term storage.............................................................................................................12
3 Product Description................................................................................................................. 13
3.1 Products included..............................................................................................................13
3.2 Design................................................................................................................................. 13
3.2.1 Anchoring ring (foot)..................................................................................................13
3.2.2 Parts..............................................................................................................................13
3.2.3 Intended use............................................................................................................... 14
3.2.4 Application limits........................................................................................................ 14
3.2.5 Dimensions..................................................................................................................15
3.2.6 Weight..........................................................................................................................16
3.2.7 Materials.......................................................................................................................16
3.2.8 External loads..............................................................................................................16
3.2.9 Pumping station identification.................................................................................. 16
3.3 Pump versions....................................................................................................................17
3.4 Monitoring equipment......................................................................................................17
3.5 The data plate.................................................................................................................... 17
4 Installation................................................................................................................................. 18
4.1 Precautions......................................................................................................................... 18
4.1.1 Underground utilities................................................................................................. 18
4.1.2 Excavations.................................................................................................................. 18
4.1.3 Inspect the work area before permit-required hot work....................................... 19
4.2 Installing the unit................................................................................................................19
4.2.1 Prepare the site........................................................................................................... 19
4.2.2 Prepare the pit base................................................................................................... 20
4.2.3 Attach the anchoring ring (foot)................................................................................20
4.2.4 Install the unit.............................................................................................................. 21
Table of Contents
Flygt Compit 901 Installation, Operation, and Maintenance Manual 1
4.2.5 Connect the external piping......................................................................................22
4.2.6 Install the extension: H-installation...........................................................................25
4.2.7 Install the extension: P-installation........................................................................... 25
4.2.8 Make the electrical connections............................................................................... 27
4.2.9 Installing the level sensors.........................................................................................27
4.2.10 Install the control panel........................................................................................... 28
4.2.11 Equipotential bonding.............................................................................................29
4.2.12 Insulate the unit........................................................................................................ 29
4.2.13 Backfill........................................................................................................................30
4.2.14 Installing the access cover.......................................................................................31
4.3 Installing the pump............................................................................................................33
4.3.1 Install with H-installation............................................................................................ 34
4.3.2 Install with P-installation.............................................................................................35
5 Operation.................................................................................................................................. 37
5.1 Precautions......................................................................................................................... 37
5.2 Before commissioning...................................................................................................... 37
5.3 Open and close the shutoff valve.................................................................................... 37
5.4 Start the pump....................................................................................................................38
6 Maintenance..............................................................................................................................39
6.1 Precautions......................................................................................................................... 39
6.1.1 Inspect the work area before permit-required hot work....................................... 40
6.2 Maintenance guidelines....................................................................................................40
6.3 Replace the check valve....................................................................................................40
7 Declaration of Conformity.......................................................................................................41
7.1 Declaration of Conformity................................................................................................ 41
Table of Contents
2 Flygt Compit 901 Installation, Operation, and Maintenance Manual
1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide the necessary information for working with the
unit. Read this manual carefully before starting work.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the location of the
unit.
Intended use
WARNING:
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 and the
surroundings. 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 a Xylem representative before proceeding.
Other manuals
See also the safety requirements and information in the original manufacturer's manuals
for any other equipment furnished separately for use in this system.
1.2 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 and its surroundings
• Product malfunction
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:
Notices are used when there is a risk of equipment
damage or decreased performance, but not personal
injury.
1 Introduction and Safety
Flygt Compit 901 Installation, Operation, and Maintenance Manual 3
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
Electrical Hazard:
CAUTION:
1.3 User safety
All regulations, codes, and health and safety directives must be observed.
The site
•Observe lockout/tagout procedures before starting work on the product, such as
transportation, installation, maintenance, or service.
• Pay attention to the risks presented by gas and vapors in the work area.
• Always be aware of the area surrounding the equipment, and any hazards posed by
the site or nearby equipment.
Qualified personnel
This product must be installed, operated, and maintained by qualified personnel only.
Protective equipment and safety devices
• Use personal protective equipment as needed. Examples of personal protective
equipment include, but are not limited to, hard hats, safety goggles, protective gloves
and shoes, and breathing equipment.
• Make sure that all safety features on the product are functioning and in use at all times
when the unit is being operated.
1.4 Special hazards
1.4.1 Confined spaces
DANGER: Inhalation Hazard
The chamber or tank where the equipment is installed should be treated as a confined
space. Always follow the applicable safety laws, regulations and guidelines for confined
spaces.
Never work alone in a confined space. Before entering the space, check that the following
requirements are complied with:
•The atmosphere contains sufficient oxygen
• The atmosphere contains no explosive or toxic gases
• If there is a risk of insufficient oxygen or toxic or hazardous gases, then use an airline
respirator or self-contained breathing apparatus.
• All energy sources are locked out and tagged out
• Adequate ventilation is in place
• There is a clear path of retreat
• Monitoring is in place for hazards which can develop after entering the confined space
• The applicable safety laws, regulations, and guidelines for confined spaces are
understood and followed.
1.4.2 Biological hazards
The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
1 Introduction and Safety
4 Flygt Compit 901 Installation, Operation, and Maintenance Manual
• Make sure that all personnel who may come into contact with biological hazards are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
WARNING: Biological Hazard
Infection risk. Rinse the unit thoroughly with clean water before working on it.
1.4.3 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.
1.5 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
•Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless
Xylem has been informed and appropriate actions have been agreed upon.
1.6 Spare parts
CAUTION:
Only use the manufacturer’s original spare parts to replace any worn or faulty
components. The use of unsuitable spare parts may cause malfunctions, damage, and
injuries as well as void the warranty.
1.7 Warranty
For information about warranty, see the sales contract.
1 Introduction and Safety
Flygt Compit 901 Installation, Operation, and Maintenance Manual 5
2 Transportation and Storage
2.1 Precautions
DANGER: Electrical Hazard
Before starting work on the unit, make sure that the unit and the control panel are isolated
from the power supply and cannot be energized. This applies to the control circuit as well.
CAUTION:
The operator must be aware of safety precautions to prevent physical injury.
Tip risk if pallet straps are removed
If the straps securing the unit to its pallet have been removed, then the unit must be
secured from tipping or falling.
CAUTION: Crush Hazard
Make sure that the unit cannot roll or fall over and injure people or damage property.
2.2 Position and fastening
Units with a concrete access cover are delivered in a vertical position, standing upside
down on the delivery pallet. Regardless of the type of access cover, the unit must be
stored in an upright position.
2.3 Examine the delivery
2.3.1 Examine the package
1. Examine the package for damaged or missing items upon delivery.
2. Record any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, then file a claim with the shipping company.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
2.3.2 Examine the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the
product.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
Use care around nails and straps.
4. If there is any issue, then contact a sales representative.
2 Transportation and Storage
6 Flygt Compit 901 Installation, Operation, and Maintenance Manual
2.4 Transportation guidelines
2.4.1 Lifting
Always inspect the lifting equipment and tackle before starting any work.
WARNING: Crush Hazard
Always lift the unit by its designated lifting points.
Use suitable lifting equipment and ensure that the product is properly harnessed.
Wear personal protective equipment.
Stay clear of cables and suspended loads.
NOTICE:
Never lift the unit by its cables or hose.
Lifting equipment
Lifting equipment is always required when handling the unit. It must fulfill the following
requirements:
• The minimum height (contact your local sales and service representative 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 not be oversized.
CAUTION: Crush Hazard
Over-dimensioned lifting equipment can lead to injury. A site-specific
risk analysis must be done.
Separate handling of pump and unit
The unit and the pump are delivered separately. Never install a pump prior to lifting the
unit.
Empty the unit before lifting
The unit must be emptied of liquid before lifting.
2.5 Remove from the pallet: Unit delivered right-side up
This section is applicable for units that are delivered with a plastic access cover. Units with
a plastic access cover are delivered in a vertical position, standing right-side up on the
delivery pallet.
1. Unload the unit from the truck and put it carefully on a rigid, horizontal surface.
2. Attach a sling to the lifting eye.
2 Transportation and Storage
Flygt Compit 901 Installation, Operation, and Maintenance Manual 7
WS011555A
Figure 1: Lifting eyes
3. Connect the other end of the lifting strap to the lifting equipment.
4. Raise the lifting hook until the lifting sling is taut.
5. Cut the straps which secure the pump station to the pallet.
6. Lift the unit straight up.
The unit may jolt or sway near the end of the lifting operation.
WARNING: Crush Hazard
Always lift the unit by its designated lifting points.
Use suitable lifting equipment and ensure that the product is
properly harnessed.
Wear personal protective equipment.
Stay clear of cables and suspended loads.
7. Lower the unit into position.
CAUTION: Crush Hazard
Make sure that the unit cannot roll or fall over and injure people or
damage property.
2.6 Turn the unit to an upright position: Unit with anchoring ring
(foot)
This section is applicable for pump units that are delivered with a concrete access cover.
The unit is delivered with the foot attached.
Units with a concrete access cover are delivered in a vertical position, standing upside
down on the delivery pallet.
1. Unload the unit from the truck and put it carefully on a rigid, horizontal surface.
2. Attach a sling around the foot.
2 Transportation and Storage
8 Flygt Compit 901 Installation, Operation, and Maintenance Manual