operation philosophy zld-1 r-01

01 12/05/12 For Approval AB/DB/KK MA KH

Rev Date Category Prepared Checked Approved

OPERATION PHILOSOPHY

Doc No:

JUSCO/WD/11-153-PRO-A4-001

Lift Pump Along With Associated Assesories And Pipe work For

Installation In Waste Water Collection Catch Pits Tender Enquiry No:- TENV-11-WTS-003/1Q353

OPERATION PHILOSOPHY

Operation Philosophy Page 1

Operation Philosophy – Waste Water Rising Main.

Introduction:

The Scope of work includes design, engineering, manufacture, assembly, packing

supply, storage at site, painting/coating, erection, construction, testing, trial run

and commissioning including performance demonstration at site and handing over

to the purchaser on turnkey basis the complete pump sets, associated accessories,

electrical, structural, instrumentation, ventilation and pipe work but excluding

civil works within the scope.

Brief Description of Waste water Collection and pump out scheme: In Tata Steel Jamshedpur works, there are several nallahs which carry waste water

from production shops mixed with rain water and discharges outside the works

Boundary. Tata Steel is presently implementing zero discharge scheme from the

works under environmental management program. In order to do that, it is

proposed to collect the waste water from various nallahs in separate catch pits

through diversion channel. The catch pits will be constructed adjacent to

the respective nallahs. The waste water collected in the catch pit will be pumped

out through pipeline either to low end consuming points/to a larger catch pit for

subsequent processing.


Process and Mechanical

Operation Principle of Pumps:

Operation of the pumps will be automatic through level switch. When the waste

water in the catch pit reaches a preset level one pump will be started. If the level

goes on increasing the second pump will automatically start, then the third pump

and so on. If the water level in the catch pit falls below a preset low level, the

pump will automatically trip.

The following catchpits are included in the scope of this project:

i) Tuiladungri Catchpit

ii) Jugsalai Catchpit 1

iii) Gharabasa catchpit

iv) Jugsalai catchpit 2.

A brief description of the pumping equipments for each catchpits is shown in

Table1.0

SL

no

.

Location Pump Type

Flow

rate(

m3/

hr)

Head

(m)

No

s. Purpose

1 Tuiladungri

catchpit Dry motor

centrifugal,

submersible

type and fixed

installation,

suitable for non

clog operation

and capable of

handling dirty

waste

including

suspended

particles upto

size 10mm.

150 45 3

To pump waste water

from tuiladungri catchpit

to sunsungaria catchpit

2 Jugsalai pit

1 150 34.5 2

To pump waste water

from jugsalai pit 1 to

jugsalai pit 2

3 Gharabasa

Catch pit 200 59 3

To pump waste water

from gharabasa catchpit

to WRP, LD1&LD2

area.

4 Jugsalai pit

2 150 61 3

To pump waste water

from jugsalai catchpit 2

to Pellet plant and

RMHS zone.

Table 1.0


**The Pumps are to be installed for a minimum Submergence depth. These

are given as follows catchpit wise. A) Tuiladungri catch pit pumps: Minimum submergence depth is 1605mm.

B) Jugsalai catch pit 1 pumps: Minimum submergence depth is 1402mm.

C) Gharabasa catch pit pumps: Minimum submergence depth is 1774mm.

D) Jugsalai Cacth pit 2 Pumps: Minimum submergence depth is 1774mm.

** In addition to the main pumps 1 no. of dewatering pump has been provided in

each catch pit for dewatering purpose.

A brief description of the dewtareing pumps for each catchpits is shown in

Table2.0

SL

no. Location Pump Type

Flow

rate(m

3/hr)

Head

(m) Nos. Purpose

1

Tuiladun

gri

catchpit

Submersible,

type and fixed

installation

10 15 1 Dewatering of pump

catchpit

2 Jugsalai

pit 1

Mobile trolley

mounted

submerged

and potable

type.


catchpit

3

Gharabas

a Catch

pit

Submersible,

type and fixed

installation


catchpit

4 Jugsalai

pit 2

Submersible,

type and fixed

installation


catchpit

Table 2.0


**In each catch pit Bar screens have been provided in each chamber of the

diversion channel between isolation sluice gates for arresting oversized suspended

materials and preventing them from flowing into catch pits.

A brief description of the Bar screens for each catchpits is shown in

Table3.0

Sl no. Location Type Specs. Nos. Purpose

1

Tuiladun

gri

catchpit

Bar Screen

with

motorized

scrapper

mechanism

1700X3900,

with 10mm

clear

opening

installed at

75° to

horizontal.

2

To arrest oversized

suspended particles

and preventing them

from flowing into

catch pit

2 Jugsalai

pit 1

Bar Screen

with manual

cleaning

facility.

1000x1000,

with 10mm

clear

opening

installed at

90° to

horizontal.

1

To arrest oversized

suspended particles

and preventing them

from flowing into

catch pit. Due to

space constraint here

manual bar screen

will be installed.

3

Gharabas

a Catch

pit

Bar Screen

with

motorized

scrapper

mechanism

1400x2100,

with 10mm

clear

opening

installed at

75° to

horizontal.

2

To arrest oversized

suspended particles

and preventing them

from flowing into

catch pit

4 Jugsalai

pit 2

Bar Screen

with

motorized

scrapper

mechanism

1700X2300,

with 10mm

clear

opening

installed at

75° to

horizontal.

2

To arrest oversized

suspended particles

and preventing them

from flowing into

catch pit

Table 3.0


**Isolation Sluice gates shall be supplied in diversion channel for isolation

purpose. The gates shall be manually gear operated type with rising spindle type

and Cast Iron material of construction confirming to IS:13349 code.

A brief description of the Sluice gates for each catchpits is shown in

Table4.0

Sl

no. Location Type Size MOC Nos. Purpose

1

Tuiladungri

catchpit

Manually

gear operated

and rising

spindle type

600x600 CI 4 For

isolation

of the

catch pit

2

Jugsalai pit

1

Manually

gear operated

and rising

spindle type

500x500 CI 4 For

isolation

of the

catch pit

3

Gharabasa

Catch pit

Manually

gear operated

and rising

spindle type

600x600 CI 1 For

isolation

of the

catch pit

4

Jugsalai pit

2

Manually

gear operated

and rising

spindle type

600x600 CI 4 For

isolation

of the

catch pit

Table 4.0

** In addition to the above equipments one no. chain pulley block and one no.

Monorail, manually operated type of 1.5 ton capacity shall be provided in each

catch pit for maintenance purpose of pumps, screens and sluice gates.


Electrical Operation & Control Philosophy

Introduction:

In Tata Steel Jamshedpur works, there are several nallahs which carry waste

water from production shops mixed with rain water and discharges outside the

works boundary. Tata Steel is presently implementing zero discharge scheme

from the works under environmental management programme. In order to do

that, it is proposed to collect the waste water from various nallahs in separate

catch pits through diversion channel. The catch pits will be constructed

adjacent to the respective nallahs. The diversion channel will have two

compartments; each compartment will be fitted with barscreen to eliminate

oversize material, debris, silt etc. Each compartment will have isolation gates at

inlet and outlet to facilitate cleaning and maintenance. The waste water

collected in the catch pit will be pumped out through pipeline either to low end

consuming points/to a larger catch pit for subsequent processing. In case of

heavy rainfall, if the water pumping out capacity exceeds the pumps combined

rated capacity, the excess water will be allowed to overflow against a weir to

be installed in the nallah, to discharge outside of the works boundary.

Operation of the pumps will be automatic through level switch. When the

waste water in the catch pit reaches a preset level one pump will be started. If

the level goes on increasing the second pump will automatically start, then the

third pump and so on. If the water level in the catch pit falls below a preset low

level, the pump will automatically trip.

The following catch pits included:

(i)Tuiladungri Catch Pit ii) Gharabasa Catch Pit iii) Jugsalai Catch Pit-1 iv)

Jugsalai Catch Pit-2

Considerations:

1) TSL shall locate required capacity of 415V source for proposed Catch pit

MCC Room. The laying & supply of cable from TSL switchgear to proposed

Catch pit MCC Room and all down steam ---- JUSCO scope.

2) The power cable from TSL switchgear shall be terminated to Catch pit

PMCC. The PMCC shall have feeder for intended requirements and relay

logic for pump operation on Auto & manual mode depending upon the

Ultrasonic level controller of catchpit.


3) Each catch pit shall have one wall mounting Kiosk panel to fed supply to

Ultrasonic level transmitter(ULT) and accommodate Bar graph level indicator

cum controller to fed intended requirement to PMCC.

4) Local Control Station(LCS) shall be provided for local operation of all Pump

motors and process equipments. LCS shall have One (1) Start, One (1) Stop,

One (1) Mushroom Head- Lockable type Emergency Stop pushbuttons. All

push buttons shall have 2 NO + 2 NC potential free contacts. The Local

remote selector switch shall be on PMCC only. The Emergency stop shall be

active on all modes.

5) The Mechanical coarse bar screen shall be operated with Geared motor and

manual mode start/stop facility without conveyor arrangeents.

6) The unique floating tube type Oil skimmer shall be motorized with manual

mode start/stop facility.

7) The Cosumer end cold pit shall have wall mounting Kiosk panel to fed supply

to Electromagnetic Flow transmitter (EFT) and accommodate

Electromagnetic Flow indicator.


Instrumentation Operation & Control Philosophy

Ref: P & I Diagram, JUSCO/WD/11-153-PRO-A3-003, Rev: 02

The following Instruments has been used for measurement & interlocks for this

particular project.

List of Instruments & Instrumentation Items:

Pressure Gauge with Diaphragm Seal

Pressure Switch with Diaphragm Seal

Ultrasonic Level Transmitter

Digital Bargraph Indicator

Electromagnetic Flow Meter

Instrumentation Cable

Desription of the Items & Their Applications:

Pressure Gauge: Total 11 no.s of Pressure Gauges will be mounted in at

the discharge end of the submersible pumps. Discharge pressure of pumps

will be measured locally direct in engineering units. For the Waste water

application Diaphragm Seal Type Pressure Gauges has been used. Ranges

of Pressure Gauges will be 0-6 & 0-8 Kg/cm2(Ref: JUSCO/WD/11-153-

INST-A3-001, R00)

Pressure Switch: Total 4 no.s of Pressure Switches will be installed in the

common Discharge delivery of submersible pumps of Different Catch Pits.

Blind Type Pressure Switches has been installed there. For Low pressure at

the common discharge switching alarm can be seen from control room

Kiosk Panel .The low alarm contact will trip all the running pumps. For the

Waste water application Diaphragm Seal Type Pressure Switches has been

used. Ranges of Pressure Switches will be 0-6 & 0-8 Kg/cm2(Ref:

JUSCO/WD/11-153-INST-A3-001, R00)

Ultrasonic Level Transmitter: Total 4 no.s of Ultrasonic Level

Transmitters will be installed in 4 different Catch Pits Ranging 0 to 6 and

0 to 8 mtr(Ref: JUSCO/WD/11-153-INST-A3-001, R00). For 3 different

levels Transmitter will send 3 switching o/ps to control room and from that

signal operation of Pumps will be controlled.The operation and the

interlock of pumps will be as per the following:


The Level Tranmsitters will be set into 3 different levels e.g High/Low/Low

Low. When the level of waste water in the Catch pits are only over than

100 mm of the pump sub merged level the Level Transmitter will produce

Low-Low Alarm in Control Room & produce switching o/p contact. The

o/p contact will be interlocked with the pump MCC and all the Running

Pumps will be tripped immediately.

When the Level of waste water in the Catch pit is over than Low-Low set

point and in between 200 mm less than the maximum level of catch pit Low

Level Indication will be generated through ULT and corresponding contact

will run a round off 50% of total pumps only(e.g if total 5 pumps are there

2 will run in auto mode, if 4 pumps are there 2 pumps will run in auto

mode) .

When the waste water level of the catch pits are less than 500 mm of catch

pit overflow High Indication will be generated and corresponding contact

will start 100% of total pumps & remain ON till the Low signal. Electrical

(Re: Operation & Control Philosophy)

Digital Bargraph Indicator: Level of Catchpits can be seen in Bargraph

format and in Direct Engineering Units from the control room through

Digital Bargraph Indicator. The o/p from Level Transmitter varies from 4 –

20 mA DC for Varying Low to High Level. Bargraph Indicator accepts the

signal and dispays it accordingly at Control room.

Electromagnetic Flow Meter: Total 6 no.s of Magnetic Flow Transmitters

will be installed at the low end consumer ends for measuring the flow

locally as well as from control room. Remote type Magnetic Flow

Transmitters will be used there. Flow Totalization will be done from

Control room. (Ref: JUSCO/WD/11-153-INST-A3-001, R00).

Instrumentation Cable: For 4 to 20 mA signal transmission 2P X 1

Sqmm., For Instrument Power 3C X 2.5 Sqmm. And For Instrument

Control Purpose required core of 1.5 Sqmm. Cable will be used. All the

Cables will be Armoured to Provide protection to Cables. For Signal

protection and to avoid the interference of Signal all the Signal Cable will

be Screened.

operation philosophy zld-1 r-01

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