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WATER INDUSTRY MAINTENANCE WORKING GROUP
PREVENTIVE MAINTENANCE SPECIFICATION (PMS) SUMMARY 06
SUBMERSIBLE PUMPS
ISSUE 1
NOVEMBER 2012
Copyright 2012, ESR Technology. All rights reserved. No part of this document, may be reproduced in any form, electronic or mechanical, including photocopying, recording or any other information storage and
retrieval system, without permission in writing from the Pump Centre.
The Pump Centre is a Centre of Excellence within ESR Technology, one of the UK’s leading engineering, safety and risk consultancies. ESR Technology provides independent technical expertise to help its customers ensure asset integrity, improve machine reliability, manage safety and risk and transfer best practice.
WATER INDUSTRY MAINTENANCE WORKING GROUP
PREVENTIVE MAINTENANCE SPECIFICATION SUMMARY 06
SUBMERSIBLE PUMPS
Prepared by:
M Craven Pump Centre R Marlow Pump Centre
With technical support and co-operation from the Water Industry Maintenance Working Group (WIMWG) consisting of:
K Martin Affinity Water C Hampshire M Phipps
Bristol Water
N Garnett Dwr Cymru K Solts Environment Agency A Cross A Hastie
Essex & Suffolk Water
A Atkinson T Quinn
NI Water
P Richardson Northumbrian Water R White Scottish Water M Ison South West Water D Olatunde Southern Water R Edwards D White
Thames Water
S Crouchley United Utilities D Appleyard K Plumb
Yorkshire Water
Please Note This document may be reviewed and re-issued periodically to take account of changes to maintenance practices.
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
CONTENTS
INTRODUCTION
ENVIRONMENT AGENCY
ESSEX & SUFFOLK WATER
NORTHERN IRELAND WATER
NORTHUMBRIAN WATER
SCOTTISH WATER
SOUTH WEST WATER
SOUTHERN WATER
THAMES WATER
UNITED UTILITIES
YORKSHIRE WATER
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
INTRODUCTION This preventive maintenance specification (PMS) summary comprises a collection of preventive maintenance specifications from the following WIMWG members: a) Environment Agency; b) Essex and Suffolk Water; c) Northern Ireland Water, d) Northumbrian Water; e) Scottish Water; f) South West Water; g) Southern Water; h) Thames Water; i) United Utilities; and j) Yorkshire Water. Where a WIMWG member has not contributed PMSs to this summary, it should generally be inferred that the member: a) Does not operate/maintain a significant number of assets of this type; b) Has contracted-out preventive maintenance for this asset; or c) Does not implement a preventive maintenance regime for this asset. It should be noted that some of the PMSs include routine preventive maintenance (RPM) tasks (typically performed by operations staff), while others do not. Where RPM tasks are not included in a given specification, it does not necessarily mean that these tasks are not performed on the asset. In some cases, RPM tasks are not detailed in a specific document relating to the asset, but are included in a higher level, more generic maintenance specification. Any queries regarding RPM should be addressed to the WIMWG member in question.
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
ENVIRONMENT AGENCY
ENVIRONMENT AGENCY GENERIC MEICA PLANNED MAINTENANCE SCHEDULE
Created by j barlow Page 1 of 2S_PE00_12E_01A - Electric submersible pump annual maintenance
Task Pump electric submersible annual maintenance Frequency 12M Asset Types Pump Electric submersible All sizes
Doc.ref. S_PE&00_12E_01 Rev A Date 05/10/09 PLANNING FOR SAFETY
Competence Electrical craftsman Resources Live functional testing prevents lone working Task Hazards (generic SSOW apply) N_GGSSW_H_ 03C SSoW Part 1 Electrical isolation before work takes place revC N_GGSSW_H_ 10C SSoW Part 1 Mechanical isolation before work takes place revC N_GGSSW_H_ 05C SSoW Part 1 General environmental considerations during works revC N_GGSSW_H_ 09C SSoW Part 1 Low voltage electrical systems live functional testing revC N_GGGRA_H_02C GRA Part 3 Electrical isolation before work takes place revC N_GGGRA_H_07C GRA Part 3 Mechanical isolation before work takes place revC N_GGGRA_H_01C GRA Part 3 Low voltage electrical systems live functional testing revC
ENVIRONMENTAL HAZARDS Activity Potential environmental damage Control measure
Manual operation of the pump
Fish kills, Water quality in low flow conditions, Sediment disturbance Water levels - destruction of habitat
Consult with site responsible officer and obtain permission prior to operation of the pump.
JOB PLANNING
To obtain more information or in the absence of specific site information, refer to site Operation and Maintenance manuals, site drawings and site safety file information or seek advice from the Regional MEICA Engineer. Notify the site responsible officer prior to site access and agree with them any limitations of access or equipment operation. This is a generic schedule of maintenance and it identifies typical hazards. Your on site technical and risk assessment must determine if this PPM and the hazards it identifies are relevant, if not you should seek advice from the Regional MEICA Engineer.
WORK SCHEDULE 1. Identify and isolate the pump 2. Check continuity and resistance of instrumentation (refer to the pump manufacturer's O&M manual for
correct testing methods).
♦ water in motor casing ♦ water in seal
♦ water in terminal box
♦ motor temperature thermistors:
3. Check the motor and cable continuity and insulation resistance
♦ between phases ♦ between phases and earth
4. Open sump (dewater sump if possible) and without entering the space visually inspect:
lifting chains or ropes
♦ guide rails
♦ discharge pipework ♦ power and instrumentation cables
♦ junction boxes 5. Visually inspect supporting steelwork, access ladders, steps, platforms and edge protection for
ENVIRONMENT AGENCY GENERIC MEICA PLANNED MAINTENANCE SCHEDULE
Created by j barlow Page 2 of 2S_PE00_12E_01A - Electric submersible pump annual maintenance
corrosion, soundness and security. Close sump
6. Turn pump isolator back on, if permitted operationally run pump
7. Measure motor running current using test equipment and compare with the panel mounted ammeter 8. While the pump is running, check the casing and associate pipe work for excessive vibration/noise
9. Visually inspect and where possible functionally test control and protection equipment
♦ low level protection
♦ overload settings ♦ restart timers
♦ discharge inhibit timers 10. Visually inspect discharge pipe system, siphon breakers, NRVs and associated pumping system
components 11. Visually inspect weed screen
♦ mechanically secure. ♦ complete
♦ bars are evenly spaced and straight 12. Visually inspect main and supplementary bonding to the pump system
REPORTING DOCUMENTS DOC REF D_PE&00_12E_01 Rev A date 01/04/06 DOC REF Rev date END
ENVIRONMENT AGENCY GENERIC MEICA PLANNED MAINTENANCE SCHEDULE
Created by j barlow Page 1 of 3
Task Pump electric submersible 5yr major maintenance Frequency 60M Asset Types Pump Electric submersible All sizes
Doc.ref. S_PE&00_60E_01 Rev A Date 05/10/09 PLANNING FOR SAFETY
Competence Electrical craftsman and a mechanical craftsman trained for lifting operations Resources Live functional testing prevents lone working
Requires selection and use of lifting equipment Task Hazards (generic SSOW apply) N_GGSSW_H_ 10C NA SSoW Part 1 Mechanical isolation before work takes place revC N_GGSSW_H_ 03C NA SSoW Part 1 Electrical isolation before work takes place revC N_GGSSW_H_ 05C NA SSoW Part 1 General environmental considerations during works revC N_GGSSW_H_ 06C NA SSoW Part 1 General fitting works revC. N_GGGRA_H_02C NA GRA Part 3 Electrical isolation before work takes place revC N_GGGRA_H_06C NA GRA Part 3 General fitting work revC N_GGGRA_H_07C NA GRA Part 3 Mechanical isolation before work takes place revC
ENVIRONMENTAL HAZARDS Activity Potential environmental damage Control measure
Draining and refilling seal cavity with oil
Spillage of oil into watercourse
Site storage/ disposal of waste oil
Use absorbent mats and have spill containment kit to hand. Identify route for disposal and containment for transport
Manual operation of the pump
Fish kills Water quality in low flow conditions, Sediment disturbance Water levels - destruction of habitat
Consult with site responsible officer and obtain permission prior to operation of the pump.
JOB PLANNING
To obtain more information or in the absence of specific site information, refer to site Operation and Maintenance manuals, site drawings and site safety file information or seek advice from the Regional MEICA Engineer. Notify the site responsible officer prior to site access and agree with them any limitations of access or equipment operation. Identify pump lifting requirements and prepare (or check existing) lifting plan. You are required to submit a lifting plan before commencing work. If lifting equipment is fixed inspect to check if it is in date, otherwise arrange for it to be inspected Identify and obtain correct oil for inter seal cavity and replacement terminal cover seal This is a generic schedule of maintenance and it identifies typical hazards. Your on site technical and risk assessment must determine if this PPM and the hazards it identifies are relevant, if not you should seek advice from the Regional MEICA Engineer.
WORK SCHEDULE
1. Refer to standard PPM schedule S_PS&00_12E_A1. Carry out annual service checks and complete record sheet D_PE&00_12E_A1. It is my belief that the full text be inserted KF
2. Lift the pump. Use a SSOW for the removal that recognises that the lifting chain and connection to the pump may be unsafe:
♦ lift to floor level with all personnel clear of the lift area, if the pump lift fails the pump will fall into the sump but no persons will be at risk.
♦ when the pump is at floor level, support it, then visually inspect the lifting point on the pump and change the lifting chains for an inspected set
♦ continue the lift above floor level using the new chains
ENVIRONMENT AGENCY GENERIC MEICA PLANNED MAINTENANCE SCHEDULE
Created by j barlow Page 2 of 3
3. With the pump at ground level,
♦ remove the inter seal drain plug and drain the oil from the seal cavity. If the cavity is full of oil with no indication of water ingress or oil loss, refill the cavity and fit the drain plug. Send a sample of oil for analysis
♦ remove the pump power and instrumentation terminal cover and inspect the terminal area and cable glands for any deterioration or water ingress. Check terminations for tightness and signs of overheating. If there is no deterioration, refit the terminal cover with a new terminal housing joint.
♦ visually inspect the power and instrumentation cabling for chafing cracking and wear to the insulation sheath
♦ inspect the external body of the pump for corrosion, holes etc
4. With the pump supported to allow access visually inspect:
♦ obstructions to intake
♦ the impellor for abnormal wear
♦ damage to the leading edge of impellor blades ♦ integrity of impeller lock nut
♦ integrity of impeller nose cone
5. If possible, rotate impellor by hand and listen for low frequency noise, observe impellor clearances for eccentricity, measure and record blade clearances to pump body
6. Secure the area around the pump and secure pump to prevent rotation and movement.
♦ remove isolation and start then stop the pump very quickly ♦ check for the correct direction of rotation
♦ the pump rotates free from noise and excessive vibration
♦ If none of the above inspections indicate a problem, rebuild the pump and continue work from step 9
below
7. On completion of the above tasks report all concerns immediately.
If directed to refurbish the pump then isolate the pump, disconnect the pump power and instrumentation cables at the most convenient junction position. Ensure that the cable cores are labelled on removal or a labelled sketch is made to assist refitting. Remove the pump from site to a workshop for full strip down and report. On completion of repair works and approval of the works by the Regional MEICA Engineer, return the pump to site for installation Otherwise continue to step 9
8. Refitting a refurbished pump only
♦ obtain approval to refit the pump.
♦ check the electrical isolation at the pump power and instrumentation junction connection
♦ remove any transit packaging or protection form the pump and prove it turns freely. ♦ reconnect the power and instrumentation cables and test the connections. (where additional
protection is required to prevent mechanical damage to cables in the flow stream, sleeves etc
ENVIRONMENT AGENCY GENERIC MEICA PLANNED MAINTENANCE SCHEDULE
Created by j barlow Page 3 of 3
should be fitted )
♦ secure the area around the pump, secure the pump to prevent rotation and movement, remove isolation and check for the correct direction of rotation and that the pump operates in free air.
♦ functionally isolate the pump and refit the pump into the sump. 9. Refit the pump into the sump 10. Secure power and instrument cables ensuring manufacturers recommendations are followed with
regard to tensioning power and control cables. Refit any covers to discharge pipework 11. If permitted operationally, test run the pump and record pump run hours REPORTING DOCUMENTS DOC REF D_PE&00_12E_01 Rev A date 01/04/06 DOC REF Rev date END
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
ESSEX & SUFFOLK WATER
Essex & Suffolk Water
Work Instruction Details
Page 375 of 794
FLYGT PUMP INSPECTIONLAY0074
Estimated Time (Hrs) 4Task Classification: MAINTENANCE TASK
Activity Type: SERVICE Default Interval (Weeks) 52
Equipment Class: PSET Equipment Model: FLYGT
General Competency 1: MO3
General Competency 2: ET3
Specialist Competency 1 TM09
Specialist Competency 2
Task Competency Requirements
Work Instruction
Flygt submersible pump - inspection of ingress at seals and motor
insulation test.
For full ITT flygt maintenance instructions see their installation,
care and maintenance manual, pages 11-20. This manual is located in
vol x section x of the site manual for layer boby's upgrade 2005.
Before removal check that the other two pumps are operational. if not
obtain permissions from site manager to proceed.
Arrange for pump duty selection to be changed to able isolation of
this pump.
Refitting of the pump unit into the stilling tube requires care as the
pump must sit fully home and locate between lugs.
The pumps cables must be hung according to flygt's instructions, see
manual.
Refer to site operational manual instruction No. LAY00010
Task Records
To be confirmed
Instruction Status: VERIFIED
Last Updated: 08-OCT-2010
Instruction Owner: ENGINEER
LAY0074Date
Work Instructions
Originator of this document is ESW Production Maintenance Strategy
03 September 2012
Essex & Suffolk Water
Work Instruction Details
Page 537 of 794
FLYGT PUMPS SPIN/ROTATIONPSET5038
Estimated Time (Hrs)Task Classification: OPERATIONAL TASK
Activity Type: TEST Default Interval (Weeks) 4
Equipment Class: PSET Equipment Model:
General Competency 1: PC
General Competency 2: MO4
Specialist Competency 1 .
Specialist Competency 2
Task Competency Requirements
Work Instruction
ALL THE SUBMERSIBLE PUMPS ARE TO BE SPUN FOR 10-15 SECONDS. THIS WILL
ENSURE THAT SEALS DO NOT STICK AND TEAR. IF PROCESS ALLOWS RUN FOR 5
MINUTES, TO PROVE THE PUMP SET.
FOR THOSE PUMP SETS WHICH HAVE DUTY/STANDBY, ROTATE THE DUTY SO THAT
PUMPING DUTY IS SHARED AND HOURS RUN ARE EQUAL (WITHIN 336HRS).
ANY UNITS WHICH FAIL NEED TO BE REPORTED AND INVESTIGATED WITHIN 72
HOURS. FAILED UNITS TO BE REPORTED TO TEAM LEADER.
Task Records
To be confirmed
Instruction Status: UNVERIFIED
Last Updated: 17-DEC-2008
Instruction Owner: OPERATIONS
PSET5038Date
Work Instructions
Originator of this document is ESW Production Maintenance Strategy
03 September 2012
Essex & Suffolk Water
Work Instruction Details
Page 538 of 794
CONDITION BASED MONITORING - FLYGT MAS711PSET5039
Estimated Time (Hrs) .5Task Classification: OPERATIONAL TASK
Activity Type: INSPECTION Default Interval (Weeks) 12
Equipment Class: AUX Equipment Model: Flygt MAS711
General Competency 1: ET2
General Competency 2: MO3
Specialist Competency 1 TM01
Specialist Competency 2
Task Competency Requirements
Work Instruction
[] RA TO BE COMPLETED FOR TASK. TO INCLUDE WORKING BY OPEN WATER AND
USE OF LIFTING EQUIPMENT.
[] ISOLATION AND PERMITS TO WORK FORMS TO BE COMPLETED AS NECESSARY.
IF UN-FAMILIAR WITH THIS PPM, SEEK ADVISE FROM ICA TECHNICIAN AS WELL
AS THE FLYGTS INSTALLATION, CARE AND MAINTENANCE MANUAL.
NOTE: THE PUMP UNIT REQUIRES INSPECTION EVERY 5000 HOURS AND A FULL
OVERHAUL (BY FLYGT) EVERY 25000 HOURS.
[] OBTAIN PERMISSION FROM CONTROLLER THAT A UNIT AT A TIME CAN BE
STOPPED AND THE MAS711 (PUMP CONDITION MONITORING DEVISE) BE
INTERROGATED FOR LATEST DATA TO BE REVIEWED.
[] FOLLOWING THE TRAINING AND FLYGT'S MANUAL AND CHECK THE OUTPUTS
FROM THE MAS711, ALARMS B,A AND THE GO SIGNAL.
[] FOLLOW THE MANUAL AND INTERROGATE THE SOFTWARE FOR ALARMS AND
TRENDS FROM THE ONBOARD PUMPS SENSORS.
[] COMPARE THE TRENDS WITH LAST MONTHS AND CONTACT TEAM LEADER AND/OR
M&P DEPT. TO ADVISE OF ANY DETERIORATION IN THE SENSOR READINGS.
SHOULD THE B ALARM BE ACTIVE - ENSURE THAT TEAM LEADER IS AWARE AND
THAT INSPECTION OF PUMP IS PROGRAMMED IN FOR WITHIN THE NEXT 14 DAYS.
IF THE A ALARM IS ACTIVE THE PUMP MUST BE STOPPED AND ISOLATED.
[] DOWNLOAD THE DATA AND SEND IT ONTO THE RELIABILITY ENGINEER WITHIN
M&P DEPT.
[] COMPLETE DOCUMENTATION AS NECESSARY.
[] RETURN PUMP UNIT TO SERVICE AND ARRANGE FOR CONTROLLER TO MONITOR
THE PUMP DAILY.
Task Records
To be confirmed
PSET5039Date
Work Instructions
Originator of this document is ESW Production Maintenance Strategy
03 September 2012
Essex & Suffolk Water
Work Instruction Details
Page 539 of 794
Instruction Status: UNVERIFIED
Last Updated: 17-DEC-2008
Instruction Owner: ENGINEER
PSET5039Date
Work Instructions
Originator of this document is ESW Production Maintenance Strategy
03 September 2012
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
NORTHERN IRELAND WATER
- 19 -
PLANNED MAINTENANCE
STANDARD JOB MEP015 - MEP081
SERVICE A Sheet 1/3
Complete
Task PM Description Y N N/A Range
This maintenance sheet covers multiple items of plant and is intended to be
used for general reference and the collection of work order completion
information only. It is not prescriptive, does not cover every area of work and
requires the craftsmen to use their knowledge, skills and training to ensure
that all work activity is carried out in compliance with NIW's H&S Policies,
Procedures and Risk Assessments. Any concerns, errors or omissions should
be notified to your Field Manager to facilitate continuous improvement of the
information
Site Establishment
10 On manned site, sign visitors book and inform site staff of proposed work
20 Inform telemetry centre
30 On unmanned site, ensure site supervisor has been informed if there is any threat to
the continued operation of the process from planned work
LIVE SYSTEM CHECKS
40 Check starter/local control panel indicator lamps, voltmeter, ammeter, switches
and Simocode type units where applicable
50 Check starter timer operation where applicable
60 Check keypad operation, control systems and displays and ensure pot control is
operating correctly where applicable
70 Check emergency stop button is working correctly (latched reset)and release after
test
80 Check fault log where applicable
90 Check system parameters are correct and download parameters to laptop where
applicable
100 Test run motor and check for abnormal noise/heat
110 Check for abnormal starting/running current
120 Where appropriate and safe to do so, check that the auto controls are functioning
130 Carry out safe isolation of equipment
140 Please complete the section for the type of starter fitted only
150 If Starter go to Starter section
160 If Soft Start selected go to Soft Start section
170 If Variable Speed Drive selected go to Variable Speed Drive section
180 Ensure panel is isolated and capacitors and cables are discharged
190 Remove debris and dust from control panel interior
200 Check all internal and external labels are fitted and correctly identify components
210 Carry out general inspection of contactors and examine for signs of overheating,
check pole continuity and mechanical interlocks
220 Ensure overloads are undamaged and note overload settings (Amps)
230 Check terminals for tightness and examine cables for any damage or signs of
hydrogen sulphide contamination
240 Examine fuse carrier for heat distress and check fuse continuity/ratings
250 Check all cable trunking lids are fitted properly
260 Check auto transformer settings / resistance bank connections where applicable
SOFT START
270 Ensure Soft Start unit is isolated and where appropriate, capacitors and
cables are discharged
280 Visually inspect for Defects
290 Remove debris and dust from the control panel interior
300 Check / clean ventilation cooling fans / grills
310 Check cable connections are tight and check for signs of overheating
320 Check any associated contactors for damage or overheating / check pole continuity
330 Examine all fuse carriers/mcbs for heat distress and check fuses for continuity and
appropriate ratings
VARIABLE SPEED DRIVE
340 Ensure VSD panel is isolated and where appropriate, capacitors and cables
are discharged
350 Visually inspect for Defects
360 Remove debris and dust from the control panel interior
- 20 -
MEP015 – MEP081
SERVICE A Sheet 2/3
Complete
Task PM Description Y N N/A Range
370 Check / clean ventilation cooling fans / grills
380 Check cable connections are tight and check for signs of overheating
390 Check any associated contactors for damage or overheating / check pole continuity
400 Examine all fuse carriers/mcbs for heat distress and check fuses for continuity and
appropriate ratings
410 Complete the next section if there is a local control panel
LOCAL CONTROL PANEL
420 Ensure panel is isolated
430 Visually inspect exterior of control panel for defects
440 Check operation of all isolators/interlocks
450 Remove debris and dust from control panel interior
460 Carry out general inspection of contactors and examine for signs of overheating
and check pole continuity
470 Check all fuse ratings / MCB ratings are correct
480 Examine fuse carriers for heat distress and check fuse continuity
490 Ensure overloads are undamaged and note overload settings (Amps)
500 Check terminals for tightness and examine cables for any damage
510 Check all cable trunking lids are fitted properly
520 Complete the next section if there is a remote start/stop and e-stop station
REMOTE START/STOP, E-STOP STATION
530 Ensure the starter panel is isolated and locked off
540 Check for signs of water ingress, condensation, or corrosion and replace seals if
necessary
550 Visually inspect components for defects
560 Check operation of start/stop switches
570 Check operation of E-Stop (latched reset)
MOTOR
580 Ensure motor has been correctly isolated
590 Check condition of motor casing and cooling fan grill and clean if necessary.
600 Check and clean brush gear and slip rings, replace brushes if necessary (wound
rotor only)
610 Check condition of cabling, glands and sheaths.
620 Remove motor terminal box cover, check main connections for tightness and signs
of overheating
630 Check motor heater for continuity where applicable
640 Check Earth Continuity Conductor connections and continuity from motor to
starter
650 Is the motor above 2Kw rating? If Yes go to Motor Test Script, If No go to
Sensors / Switches question
MOTOR TEST SCRIPT
660 WARNING:- WHERE THE MOTOR IS CONNECTED TO A SOFT START
OR VARIBALE SPEED DRIVE THESE MUST BE DISCONNECTED
BEFORE CARRYING OUT THE FOLLOWING TESTS
670 Measure winding resistance between L1 phase to L2 phase (ohms)
680 Measure winding resistance between L1 phase to L3 phase (ohms)
690 Measure winding resistance between L3 phase to L2 phase (ohms)
700 Carry out motor IR test using appropriate instrument L1 phase to earth (Mohms)
710 Carry out motor IR test using appropriate instrument L2 phase to earth (Mohms)
720 Carry out motor IR test using appropriate instrument L3 phase to earth (Mohms)
730 Are there Sensors / Switches? If yes go to the Sensors / Switches script, if no
go to next script
SENSORS / SWITCHES
740 Clean switches/sensors
750 Calibrate sensors if applicable
760 Check correct operation of switch/sensor
770 Check feedback signal for correct operation if applicable
Site Disestablishment
780 Remove all equipment and material associated with task/s from site
- 21 -
MEP015 – MEP081
SERVICE A Sheet 3/3
Complete
Task PM Description Y N N/A Range
790 Return all plant to normal operation
800 Inform site staff or site supervisor of job status and sign out where appropriate
810 Inform telemetry centre
820 Did you complete any other tasks not on the list? Answer - If Y, Please enter
additional tasks in text box below If N close script
Total Time - 60 mins
Action by Supervisor
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
Additional Comments
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
- 82 -
PLANNED MAINTENANCE
STANDARD JOB MMP084 - MMP090
SERVICE A Sheet 1/2
Complete
Task PM Description Y N N/A Range
This maintenance sheet covers multiple items of plant and is intended to be
used for general reference and the collection of work order completion
information only. It is not prescriptive, does not cover every area of work and
requires the craftsmen to use their knowledge, skills and training to ensure that
all work activity is carried out in compliance with NIW's H&S Policies,
Procedures and Risk Assessments. Any concerns, errors or omissions should be
notified to your Field Manager to facilitate continuous improvement of the
information
SITE ESTABLISHMENT
10 On manned site, sign visitors book and inform site staff of proposed work
20 Inform telemetry centre
30 On unmanned site, ensure site supervisor has been informed if there is any threat to
the continued operation of the process from planned work
RUNNING CHECKS
40 Record running hrs
50 Check for noise/ vibration/ unnatural movement
60 Perform visual check of entire plant
70 Perform safe isolation of equipment
SUBMERSIBLE PUMP
80 Check condition of lifting chains, guide rails and brackets
90 Remove pump to a suitable stable base
100 Check inlet and outlet for blockages and clear as necessary
110 Check condition of all seals and gaskets
120 Check oil condition and level and top up as required
130 Check condition of impellor & wear ring
140 Check shaft for play
150 Remove isolation and test run on hand to ensure proper direction and operation
160 Ensure safe isolation
170 Insert back into well
MACERATOR
180 Check oil condition and level and top up as required
190 Check condition of cutters and shear plates.
VALVE
200 If safe to do so close and open valve over full travel to confirm isolation and
freedom of operation
210 Repack valve or replace O ring / gasket as necessary
220 Grease hand wheel operated valves with lithium base grease/ food grade grease as
applicable
230 Check valve gland for leaks
240 Check lever operation or NRV if applicable
250 Confirm NRV is holding and pump is not running backwards when stopped if
possible
SITE DISESTABLISHMENT
260 Remove all equipment and material associated with task/s from site
270 Return all plant to normal operation
280 Inform site staff or site supervisor of job status and sign out where appropriate
290 Inform telemetry centre
300 Did you complete any other tasks not on the list? Answer - If Y, Please enter
additional tasks in text box below
Total Time - 120 mins
- 83 -
MMP084 - MMP090
SERVICE A Sheet 2/2
Action by Supervisor
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
Additional Comments
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
- 84 -
PLANNED MAINTENANCE
STANDARD JOB MMP084 - MMP090
SERVICE B Sheet 1/2
Complete
Task PM Description Y N N/A Range
This maintenance sheet covers multiple items of plant and is intended to be
used for general reference and the collection of work order completion
information only. It is not prescriptive, does not cover every area of work and
requires the craftsmen to use their knowledge, skills and training to ensure that
all work activity is carried out in compliance with NIW's H&S Policies,
Procedures and Risk Assessments. Any concerns, errors or omissions should be
notified to your Field Manager to facilitate continuous improvement of the
information
SITE ESTABLISHMENT
10 On manned site, sign visitors book and inform site staff of proposed work
20 Inform telemetry centre
30 On unmanned site, ensure site supervisor has been informed if there is any threat to
the continued operation of the process from planned work
RUNNING CHECKS
40 Record running hrs
50 Check for noise/ vibration/ unnatural movement
60 Perform visual check of entire plant
70 Ensure safe isolation
SUBMERSIBLE PUMP
80 Check condition of lifting chains, guide rails and brackets
90 Remove pump to a suitable stable base
100 Check inlet and outlet for blockages and clear as necessary
110 Check condition of all seals and gaskets
120 Drain oil and replace with new
130 Check condition of impellor & wear ring
140 Check shaft for play
150 Remove isolation and test run on hand to ensure proper direction and operation
160 Ensure safe isolation
170 Insert back into well
MACERATOR
180 Drain oil and replace with new
190 Check condition of cutters and shear plates.
VALVE
200 If safe to do so close and open valve over full travel to confirm isolation and
freedom of operation
210 Repack valve or replace O ring / gasket as necessary
220 Grease hand wheel operated valves with lithium base grease/ food grade grease as
applicable
230 Check valve gland for leaks
240 Check lever operation or NRV if applicable
250 Confirm NRV is holding and pump is not running backwards when stopped if
possible
SITE DISESTABLISHMENT
260 Remove all equipment and material associated with task/s from site
270 Return all plant to normal operation
280 Inform site staff or site supervisor of job status and sign out where appropriate
290 Inform telemetry centre
300 Did you complete any other tasks not on the list? Answer - If Y, Please enter
additional tasks in text box below
Total Time - 140 mins
- 85 -
MMP084 - MMP090
SERVICE B Sheet 2/2
Action by Supervisor
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
Additional Comments
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
NORTHUMBRIAN WATER
CATEGORY [SEWSUBMERS] Pump-Sewage-Submersible Failure Modes 1. Bearing failure 2. Seal failure 3. Blockage 4. Pump seat failure 5. Loose impeller 6. Impeller ring wear 7. Performance 8. Bearing failure 9. Burn out 10. Insulation deterioration 11. O/L klaxon fail 12. Seal failure 13. Cable damage
Procedures 2 Yearly Electrical Examination-E024044 Carry out IR test. If possible test run and check starting for undue noise, vibration and excessive current. Check cable glands and earth connections for security and condition. Check the motor cable is correctly supported. Six Yearly Electrical Examination-E025044 Test for protection against indirect contact. Annual Mechanical Examination-M034044 Remove pump, check for impeller wear, adjust clearance and wear plate/cutter where fitted. Check oil level and quality. Check lifting chain/eyebolt/shackles for corrosion, check seating arrangement of duck foot. Condition of pump set, external inspection of NRV, report any defects Run if possible and check for any abnormal noise or vibration. 4 Yearly Mechanical Examination-M035044 Remove pump, check for impeller wear, adjust clearance and wear plate/cutter where fitted. Check oil level and quality. Check lifting chain/eyebolt/shackles for corrosion, check seating arrangement of duck foot. Condition of pump set, Internal inspection of NRV, report any defects Run if possible and check for any abnormal noise or vibration.
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
SCOTTISH WATER
MPPS1B
SUBMERSIBLE PUMP SERVICE
Page 1 of 1 Ver1.1
Before starting work, ensure that you have risk assessed the work and put in place any required safety procedures. Visual Checks
♦ Check the unit for signs of excessive or unusual vibration, noise and temperature and / or loose guards.
♦ Inspect chain and shackle before/whilst lifting pump from tank/chamber. If chain is not a stainless steel lifting chain, then it should be replaced. Raise separate work order.
♦ Complete electrical lock off procedure (Electrically isolated)
Service Checks
♦ Complete mechanical lock off procedure and isolate hydraulically.
♦ Check the security of all bolts and fittings. If accessible, check the guide bars and brackets.
♦ Check all hose connections for tightness and tighten as required.
♦ Inspect/ renew the oil in the oil case. If it is milky, then the seals should be inspected and renewed, as well as the oil.
♦ Remove and clean the outer screen and inspect the impeller for wear and damage.
♦ Inspect and adjust the wear plate, if fitted, and restore the manufacturer’s recommended tolerances.
♦ Where fitted, check cutter plate and blades for correct clearance.
♦ Check the operation of all isolation and Non return valves/ duck foot bends/seals.
♦ Test run pump and record the flow.
♦ Inform area personnel task is complete and sign off work order.
♦ Report all or any other defects.
♦ Return unit to service.
MPMP1B
SMALL SUBMERSIBLE PUMPING STATION SERVICE
Page 1 of 2 Ver1.3
Before starting work, ensure that you have risk assessed the work and put in place any required safety procedures. This task covers all of the checks required at a standard small twin pump wet well sewage pumping station. It should not be used for larger pumping stations or for dry well installations. Ensure that the site operator is aware of the work you are about to carry out. If the site has telemetry installed, contact the relevant Control room/ Call centre and advise them that you are working on the site. This task contains both electrical and mechanical checks. Unless the craftsman is fully multiskilled, then this task should be carried out by a two man squad, one electrical and one mechanical. Visual Checks ♦ Check the general access to the site and the condition of any security fencing,
gates, buildings, kiosks etc that they are in good order.
♦ Open the equipment housing/kiosk and lubricate the hinges and the locks.
♦ Inspect the inside for signs of damage or water ingress.
Electrical Panel Checks ♦ Test the lamps for operation, replace those not operating.
♦ Check that the panel is clearly labelled and matches the equipment at the site.
♦ Isolate and open each panel and check for signs of overheating, burning or water ingress and corrosion.
♦ Check that the anti-condensation heater is operating correctly.
♦ Check the insulation resistance between the main power terminals and earth in each panel cubicle where appropriate. If reading is below 0.5Meg, then investigate and rectify.
♦ Check the operation of the level control system, using task IILU1C for Ultrasonic level instruments and EILP1A for probes.
♦ Remove and check condition and operation of float control (If applicable). If faulty or damaged replace if necessary.
♦ Contact the local Control room/ Call Centre and check the well level, electrical supply, and intruder and pump status alarms back through telemetry to ensure it is operating correctly.
MPMP1B
SMALL SUBMERSIBLE PUMPING STATION SERVICE
Page 2 of 2 Ver1.3
Electrical Motor Checks
♦ Operate the pump for approx. 5 to 10 mins prior to checking the insulation resistance.
♦ Isolate the starter and open the cubicle.
♦ Check the insulation values between each outgoing power cable and the motor earth, and phase to phase. If all values are within +/- 5%, and above 0.5Meg, then it can be assumed that all cables are in good order. If the insulation is below 0.5Meg, operate the pump for a further 5 minutes and re-check. If it still fails, it will be necessary to check the pump terminal box enclosure, plugs and the cables for signs of damage or water ingress.
♦ When the pump is withdrawn for mechanical inspection, visually check the cables, plug connections and terminal box for signs of damage.
♦ Any covers, plugs or lids removed from the pumpset itself MUST have a new seal used when it is re-fitted.
Mechanical Checks
♦ Complete mechanical lock off procedure and isolate hydraulically.
♦ Inspect chain and shackle before/ whilst lifting pump from tank/chamber. If chain is not a stainless steel lifting chain, then it should be replaced. Raise separate work order.
♦ Complete any visual inspection report where requested.
♦ Check the security of all bolts and fittings. If accessible, check the guide bars and brackets.
♦ Check all hose connections for tightness and tighten as required.
♦ Inspect the oil in the oil case. If it is milky, then the oil should be renewed. Always replace the O ring seals.
♦ Remove and clean the outer screen and inspect the impeller for wear and damage.
♦ Inspect and adjust the wear plate, if fitted, to restore the manufacturer’s recommended tolerances.
♦ Confirm and record the pump plate details on the workorder.
♦ Reinstate pump after inspection.
♦ Check the operation of all isolation and Non return valves. Isolation valves should be turned at least 10 turns in each direction to ensure they are kept free to operate.
♦ Test run the pump and record the flow and the hours run meter reading.
♦ Check the operation of any solenoid operated backflush valves installed in the pipework.
♦ Allow pump to drain down chamber and check seal at claw bend for leakage.
♦ Inform area personnel task is complete and sign off work order.
♦ Report all or any other defects.
♦ Return unit to service.
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
SOUTH WEST WATER
SWW – MEC 036
IF INTERLOCKS ARE FITTED, CHECK THEY ARE FUNCTIONING
CORRECTLY*
****************************************************
SAFE SYSTEMS OF WORK MUST BE ADHERED TO AT ALL TIMES
****************************************************
ISOLATE UNIT BEFORE COMMENCING WORK
ARRANGE WITH SITE MANAGER FOR OPERATOR ASSISTANCE
Liaise with Site Operator / Manager & Company Control
Centre.
ELECTRICAL; check the following:-
Check float switches or rod gear (full operation).
Insulation / resistance etc.
Power supply, cable and glands.
MECHANICAL; check the following:-
Check lifting gear is in date and safe to use where
applicable.
Lift pump.
Change oil.
- guide rails , suspension chains and associated fixings.
- pump casing, securing bolts, seals, etc.
- volute casing, mating flanges (or joint rings if fitted).
- wear ring clearance and suction cover adjustment.
Record details of pump (serial no., model etc.)on job card.
Report defects not corrected.
SITE OPERATOR:-
Clean sump with hose where possible.
Lubricate gate valves where necessary.
Replace pump, carry out running checks, leave in operating
condition as found.
Inform Site Operator / Manager & Company Control Centre when
maintenance is completed.
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
SOUTHERN WATER
CONTROLLED DOCUMENT MTM MF0511Date: July 2012 Page 1 of 2 Issue No: 3
SOUTHERN WATER
MAINTENANCE TASK MANUAL
SUBMERSIBLE PUMP (TIER 2)
Southern Water employees shall undertake work in accordance with Southern Water procedures and safety instructions. Non Southern Water employees shall undertake work in accordance with the general contract conditions and safety requirements.
1. Confirm asset details correspond to available information and submit an Asset Revision Form where asset details are incorrect
2. Prior to commencing maintenance test run and check for correct operation and excessive noise, heat and vibration
3. Confirm operation of all emergency stops and trips 4. Carry out necessary isolation 5. Carry out external visual inspection of electrical equipment and enclosures 6. Visually check for leaks, corrosion, damage, condition and security of mechanical
components, fittings and structure 7. Where the cleanliness of the wet well is likely to affect pump reliability submit a
Maintenance Revision Form requesting an increase of frequency of well cleaning 8. Carry out a visual inspection of the wet well structure and benching 9. Confirm satisfactory operation of valve chamber drain 10. Check mechanical condition of:
a) guide rails / wires and lifting equipment and security of fixings b) pipework and fittings c) delivery valves
11. Lift pump and check mechanical condition of:
a) pump and motor casing b) impeller and wear ring c) rotate the impeller and check for excess play/damage/wear or noise in the
motor bearings and free rotation d) cable, cable gland, support brackets, fixings and security of cables e) pump lifting handle/ lifting point of attachment f) flushing valve where applicable
12. Check clearance between impeller and wear ring/pump wear plate. Adjust where necessary
13. Check condition of buffer chamber fluid and undertake the appropriate action detailed in Table 1 – Buffer Chamber below. Ensure fluid type used and level complies with pump specification
14. Check for fluid ingress in the motor chamber and undertake the appropriate action detailed in Table 2 – Motor Chamber below
15. Clean cooling fins and flush cooling jacket where necessary 16. Check operation of Non-return valve and remove any debris 17. Operate delivery valve(s) 18. Enter/ record operational statistics for hours run
MTM MF0511 CONTROLLED DOCUMENT
Issue No: 3 Page 2 of 2 Date: July 2012
19. Ensure all guarding, identification labels and covers are present, secure and in good condition
20. Reinstate asset, test run and check for correct operation and excessive noise, heat and vibration. Visually confirm pump/ ducks foot seal is effective
21. Where air release pipework is fitted, strip down, clean and check operation 22. Check Voltage & Amperage running values for correct pump rotation 23. Confirm the pumps work in hand and auto operational modes. Where possible,
confirm the pump flow is as per the operational requirements of the station 24. Where fitted check the operation of swinging arm non-return valves 25. Return plant to required operational mode 26. Raise a reactive work order for all remedial actions identified
Submit a MTM 401 Form where maintenance provision is incorrect.
TABLE 1 – BUFFER CHAMBER
7.5 kW or less Greater than 7.5 kW without motor chamber moisture
detector
Greater than 7.5 kW with motor
chamber moisture detector
Minor contamination/ emulsification
Top up as required and reinstate
Top up as required and reinstate
Top up as required and reinstate
Considerable contamination/ emulsification
Flush chamber, change fluid, reinstate and raise a follow on reactive work order to check in 1 month
Flush chamber, change fluid, reinstate and raise a follow on reactive work order to check in 1 month
Change fluid, reinstate and confirm detector wiring is connected and not linked out
TABLE 2 – MOTOR CHAMBER
7.5 kW or less Greater than 7.5 kW without motor chamber moisture
detector
Greater than 7.5 kW with motor
chamber moisture detector
Minor ingress Drain fluid and reinstate
Drain fluid and reinstate. Check in 1 months
Drain fluid and reinstate
Considerable ingress Drain fluid and reinstate raise a follow on reactive work order to check in 1 Month
Refurbish or replace Drain fluid, reinstate, confirm detector wiring is connected and not linked out and undertake an Insulation Resistance Test If the Insulation Resistance Test measures less than 0.5M Ω/kV Refurbish or replace
CONTROLLED DOCUMENT MTM MF0603Date: January 2011 Page 1 of 4 Issue No: 2
SOUTHERN WATER
MAINTENANCE TASK MANUAL
SUBMERSIBLE PUMP (TIER UNKNOWN)
Southern Water employees shall undertake work in accordance with Southern Water procedures and safety instructions. Non Southern Water employees shall undertake work in accordance with the general contract conditions and safety requirements.
1. Confirm asset details correspond to available information and submit an Asset Revision Form where asset details are incorrect
2. Prior to commencing maintenance test run and check for correct operation and excessive noise, heat and vibration
3. Confirm operation of all emergency stops and trips 4. Carry out necessary isolation 5. Carry out external visual inspection of electrical equipment and enclosures 6. Visually check for leaks, corrosion, damage, condition and security of mechanical
components, fittings and structure 7. Where the cleanliness of the wet well is likely to affect pump reliability submit a
Maintenance Revision Form requesting an increase of well cleaning frequency 8. Carry out a visual inspection of the wet well structure and benching 9. Confirm satisfactory operation of valve chamber drain 10. Check mechanical condition of:
a) guide rails / wires and lifting equipment and security of fixings b) pipework and fittings c) delivery valves
11. Lift pump and check mechanical condition of:
a) pump and motor casing b) impeller and wear ring c) cable, gland and supports d) pump lifting handle/ lifting point of attachment e) flushing valve where applicable
12. Check clearance between impeller and wear ring/pump casing. Adjust where necessary
13. Check condition of buffer chamber fluid and undertake the appropriate action detailed in Table 1 – Buffer Chamber below. Ensure fluid type used and level complies with pump specification
14. Check for fluid ingress in the motor chamber and undertake the appropriate action detailed in Table 2 – Motor Chamber below
15. Clean cooling fins and flush cooling jacket 16. Check operation of Non-return valve and remove any debris
MTM MF0603 CONTROLLED DOCUMENT
Issue No: 2 Page 2 of 4 Date: January 2011
17. Complete and return an Asset Revision Sheet with the following information:
a) manufacturer b) type/model c) serial number d) kW rating e) RPM f) lifting method (if lifting chain state material and chain asset number) g) weight kg h) situation (wet well/drywell) i) leak detection fitted (Yes/No)
18. Enter/ record operational statistics for hours run 19. Ensure all guarding, identification labels and covers are present, secure and in good
condition 20. Replace rope used with the SW hook system where fitted 21. Reinstate asset, test run and check for correct operation and excessive noise, heat and
vibration. Visually confirm pump/ ducks foot seal is effective 22. Return plant to required operational mode 23. Raise a reactive work order for all remedial actions identified
Submit a Maintenance Revision Form where maintenance provision is incorrect.
TABLE 1 – BUFFER CHAMBER
7.5 kW or less
Greater than 7.5 kW without motor chamber
moisture detector
Greater than 7.5 kW with motor chamber moisture
detector Minor
contamination/ emulsification
Top up as required and
reinstate
Top up as required and reinstate
Top up as required and reinstate
Significant contamination/ emulsification
Top up as required and
reinstate
Change fluid and reinstate
Change fluid and reinstate
Considerable contamination/ emulsification
Top up as required and
reinstate
Change fluid, reinstate and raise a Follow On Reactive Work Order to check
in 6 months
Change fluid, reinstate and confirm
detector wiring is connected and not
linked out
CONTROLLED DOCUMENT MTM MF0603Date: January 2011 Page 3 of 4 Issue No: 2
TABLE 2 – MOTOR CHAMBER
7.5 kW or less
Greater than 7.5 kW without motor chamber
moisture detector
Greater than 7.5 kW with motor chamber moisture
detector Minor ingress Drain fluid and
reinstate Drain fluid and
reinstate Drain fluid and
reinstate Significant ingress Drain fluid and
reinstate Drain fluid, reinstate and raise a Follow On Reactive Work Order to check in 6
months
Drain fluid and reinstate
Considerable ingress
Drain fluid and reinstate
Refurbish or replace Drain fluid, reinstate, confirm detector
wiring is connected and not linked out and undertake an
Insulation Resistance Test
MTM MF0603 CONTROLLED DOCUMENT
Issue No: 2 Page 4 of 4 Date: January 2011
This page intentionally left blank.
CONTROLLED DOCUMENT MTM MF0608Date: January 2011 Page 1 of 2 Issue No: 2
SOUTHERN WATER
MAINTENANCE TASK MANUAL
SUBMERSIBLE PUMP (TIER 3)
Southern Water employees shall undertake work in accordance with Southern Water procedures and safety instructions. Non Southern Water employees shall undertake work in accordance with the general contract conditions and safety requirements.
1. Confirm asset details correspond to available information and submit an Asset Revision Form where asset details are incorrect
2. Prior to commencing maintenance test run and check for correct operation and excessive noise, heat and vibration
3. Confirm operation of all emergency stops and trips 4. Carry out necessary isolation 5. Carry out external visual inspection of electrical equipment and enclosures 6. Visually check for leaks, corrosion, damage, condition and security of mechanical
components, fittings and structure 7. Where the cleanliness of the wet well is likely to affect pump reliability submit a
Maintenance Revision Form requesting an increase of frequency of well cleaning 8. Carry out a visual inspection of the wet well structure and benching 9. Confirm satisfactory operation of valve chamber drain 10. Check mechanical condition of:
a) guide rails / wires and lifting equipment and security of fixings b) pipework and fittings c) delivery valves
11. Lift pump and check mechanical condition of:
a) pump and motor casing b) impeller and wear ring c) cable, gland and supports d) pump lifting handle/ lifting point of attachment e) flushing valve where applicable
12. Check clearance between impeller and wear ring/pump casing. Adjust where necessary
13. Check condition of buffer chamber fluid and undertake the appropriate action detailed in Table 1 – Buffer Chamber below. Ensure fluid type used and level complies with pump specification
14. Check for fluid ingress in the motor chamber and undertake the appropriate action detailed in Table 2 – Motor Chamber below
15. Clean cooling fins and flush cooling jacket 16. Check operation of Non-return valve and remove any debris 17. Operate delivery valve(s) 18. Enter/ record operational statistics for hours run 19. Replace rope used with the SW hook system where fitted 20. Ensure all guarding, identification labels and covers are present, secure and in good
condition 21. Reinstate asset, test run and check for correct operation and excessive noise, heat and
vibration. Visually confirm pump/ ducks foot seal is effective
MTM MF0608 CONTROLLED DOCUMENT
Issue No: 2 Page 2 of 2 Date: January 2011
22. Carry out drop down test; assess pump performance by comparing with standard pump data and energy consumption
23. Return plant to required operational mode 24. Raise a reactive work order for all remedial actions identified
Submit a Maintenance Revision Form where maintenance provision is incorrect.
TABLE 1 – BUFFER CHAMBER
7.5 kW or less
Greater than 7.5 kW without motor chamber
moisture detector
Greater than 7.5 kW with motor chamber moisture
detector Minor
contamination/ emulsification
Top up as required and reinstate
Top up as required and reinstate
Top up as required and reinstate
Significant contamination/ emulsification
Top up as required and reinstate
Change fluid and reinstate
Change fluid and reinstate
Considerable contamination/ emulsification
Top up as required and reinstate
Change fluid, reinstate and raise a Follow On Reactive Work Order to check
in 6 months
Change fluid, reinstate and confirm
detector wiring is connected and not
linked out
TABLE 2 – MOTOR CHAMBER
7.5 kW or less
Greater than 7.5 kW without motor chamber
moisture detector
Greater than 7.5 kW with motor chamber moisture
detector Minor ingress Drain fluid and
reinstate Drain fluid and
reinstate Drain fluid and
reinstate Significant ingress Drain fluid and
reinstate Drain fluid, reinstate and raise a Follow On Reactive Work Order to check in 6
months
Drain fluid and reinstate
Considerable ingress
Drain fluid and reinstate
Refurbish or replace Drain fluid, reinstate, confirm detector
wiring is connected and not linked out and undertake an
Insulation Resistance Test
CONTROLLED DOCUMENT MTM MF0721Date: July 2012 Page 1 of 4 Issue No: 2
SOUTHERN WATER
MAINTENANCE TASK MANUAL
ITT FLYGT N TYPE SUBMERSIBLE PUMP (TIER 1 AND 2)
Southern Water employees shall undertake work in accordance with Southern Water procedures and safety instructions. Non Southern Water employees shall undertake work in accordance with the general contract conditions and safety requirements.
1. Confirm asset details correspond to available information and submit an Asset Revision Form where asset details are incorrect
2. Prior to commencing maintenance test run and check for correct operation and excessive noise, heat and vibration
3. Confirm operation of all emergency stops and trips 4. Carry out necessary isolation 5. Carry out external visual inspection of electrical equipment and enclosures 6. Visually check for leaks, corrosion, damage, condition and security of mechanical
components, fittings and structure 7. Where the cleanliness of the wet well is likely to affect pump reliability submit a
Maintenance Revision Form requesting an increase of well cleaning frequency 8. Carry out a visual inspection of the wet well structure and benching 9. Confirm satisfactory operation of valve chamber drain 10. Check mechanical condition of:
a) guide rails / wires and lifting equipment and security of fixings b) pipework and fittings c) delivery valves
11. Lift pump and check mechanical condition of:
a) pump and motor casing bolts tightness b) impeller condition c) rotate the impeller and check for excess play/damage/wear or noise in the
motor bearings d) check impeller torque measurement (torque to 187 Nm (140 ft lb) + 1/8 turn
(45°) e) cable, cable gland, support brackets, fixings and security of cables f) pump lifting handle/ lifting point of attachment g) flushing valve where applicable
12. Check the clearance between the impeller and the wear plate. Adjust where necessary
13. Check condition of buffer chamber fluid and undertake the appropriate action detailed in Table 1 – Buffer Chamber below. Ensure fluid type used and level complies with pump specification
14. Check for fluid ingress in the motor chamber and undertake the appropriate action detailed in Table 2 – Motor Chamber below
15. Replace O-Rings and ensure that are properly greased 16. Check operation of Non-return valve and remove any debris 17. Operate delivery valve(s)
MTM MF0721 CONTROLLED DOCUMENT
Issue No: 2 Page 2 of 4 Date: July 2012
18. Enter / record operational statistics for hours run 19. Ensure all guarding, identification labels and covers are present, secure and in
good condition 20. Reinstate asset, test run and check for correct operation and excessive noise, heat
and vibration. Visually confirm pump/ ducks foot seal is effective 21. Where air release pipework is fitted, strip down, clean and check operation 22. Check Voltage & Amperage running values for correct pump rotation 23. Return plant to required operational mode 24. Raise a reactive work order for all remedial actions identified 25. Confirm the pumps work in hand and auto operational modes. Where possible,
confirm the pump flow is as per the operational requirements of the station 26. Where fitted check the operation of swinging arm non-return valves 27. Return plant to required operational mode 28. Raise a reactive work order for all remedial actions identified
Submit a MTM 401 Form where maintenance provision is incorrect.
CONTROLLED DOCUMENT MTM MF0721Date: July 2012 Page 3 of 4 Issue No: 2
TABLE 1 – BUFFER CHAMBER
7.5 kW or less Greater than 7.5 kW without motor chamber moisture
detector
Greater than 7.5 kW with motor
chamber moisture detector
Minor contamination/ emulsification
Top up as required and
reinstate
Top up as required and reinstate
Top up as required and reinstate
Considerable contamination/ emulsification
Flush chamber, change fluid, reinstate and
raise a follow on reactive work
order to check in 1 month
Flush chamber, change fluid,
reinstate and raise a follow on reactive
work order to check in 1 month
Drain fluid, reinstate, confirm detector
wiring is connected and not linked out
TABLE 2 – MOTOR CHAMBER
7.5 kW or less Greater than 7.5 kW without motor
chamber moisture detector
Greater than 7.5 kW with motor
chamber moisture detector
Minor ingress Drain fluid and reinstate
Drain fluid and reinstate. Check in 1
months
Drain fluid and reinstate
Considerable ingress Drain fluid and reinstate raise a
Follow On Reactive Work
Order to check in 1 Month
Refurbish or replace Drain fluid, reinstate, confirm detector
wiring is connected and not linked out and undertake an
Insulation Resistance Test If the Insulation
Resistance Test measures less than
0.5M Ω/kV Refurbish or replace
MTM MF0721 CONTROLLED DOCUMENT
Issue No: 2 Page 4 of 4 Date: July 2012
This page intentionally left blank.
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
THAMES WATER
Thames Water Task Specification WS/WWS Common MTS Section 28. Pumps WWO 13. Pump - Submersible Wet & Dry - Task Specification - PMSSUBC Version 1.6
No. A B Tasks
1.0 X Comply with Standard Instructions IEMT000 as applicable.
2.0 ASSESSMENT 2.1 X Visually check unit and its associated equipment for security and free from excessive
noise, vibration or overheating and there is no external damage, leaks, missing fixings and all guards are secure and in good condition.
2.2 Record the following when assessing the equipment: 2.3 X • Record Condition of Equipment (DG Asset Condition: Excellent – Unsatisfactory) 2.4 X • Assess frequency of service is correct 2.5 X • Collect hours run information on all relevant equipment whether running or not. 2.6 X If additional work is required then please raise a Planned Follow Up Workorder (PFU) and
ensure that any detailed requirements are specified (i.e. Specialist Equipment, Confined Space Entry, Materials, etc).
2.7 X Visually check the pump chain and report if condition poor or unsafe. Condition ID: Chain good (no action); Chain poor (use and report) Chain unsafe (Do not use and report)
3.0 PUMP - REPAIR/ADJUST 3.1 X For wet well installation:- Lift pump from wet well. 3.2 X For dry & wet well installation:- Lift pump from bowl, check condition of bowl gasket, renew
as applicable. 3.3 X Remove any restrictions/blockages from pump bowl, impeller or pipework. 3.4 X Remove oil level/filler plug and check condition of oil. Replace as necessary. (Refer to
manufacturers recommendations). 3.5 X Remove upper seal inspection plug and check for signs of water/oil. 3.6 X Rotate impeller and check for any excess play/damage/wear or noise in motor bearings. 3.7 X Check impeller and pump bowl for wear and damage. Pay special attention to the
clearance and condition of the wear rings. Generally if the clearance exceeds 2mm (check Manufacturers recommendations) a work order should be raised to replace/adjust the wear rings.
3.8 X Check for external leaks on water jacket (if applicable). 3.9 X Clear all debris/grease from motor case (to ensure cooling). 3.10 X Inspect cables and sealing gland, report if worn or damaged. 3.11 X Check and inspect the flushing valve for condition and correct operation (if fitted). 3.12 X Check condition of lifting handle - report by exception. 3.13 X Check the condition of the nylon guide rope and replace as necessary. Pumps should not
be fitted with chains unless they have a valid test certificate and have been inspected. 4.0 INSTALLATION & TEST 4.1 X Refit the Pump bowl. 4.2 X Check that pump still rotates freely. 4.3 X Install pump back into DRY/WET well, (as applicable). 4.4 X Run pump, check direction of rotation and operation of all controls. 4.5 X Check for secure seating and adequate seal between pump and base. 4.6 X Record hours run and current (Amps) meter reading in site log book. 5.0 ANCILLARY EQUIPMENT - CHECK/REPAIR 5.1 X Check ALL associated valves for correct operation. 5.2 X Check Non return valves for correct operation. 5.3 X Check security/condition of guide rails. 5.4 X Check & Clear all debris/grease from level controls. 6.0 COMPLETION OF PPM JOB 6.1 X Complete a Thames Standard Maintenance Label with this Task Spec Reference, your
Name and the Date. Affix this label to the Starter Panel of the Pump you have just serviced.
7.0 X Ensure compliance with all Standard Instructions IEMT000 as applicable.
document1 Page 1
Task Specification - Reactive and Preventative Maintenance
WS/WWS Common MTS Section 28. Pumps WWO 27. Pump - Submersible Wet & Dry - RPM Task Specification - PSUBRPMCB Version 1.1
No. B Tasks
1.0 X Comply with Standard Instructions IEMT000 as applicable.
2.0 ASSESSMENT 2.1 X Visually check unit and its associated equipment for security and free from excessive
noise, vibration or overheating and there is no external damage, leaks, missing fixings and all guards are secure and in good condition.
2.2 Record the following when assessing the equipment: 2.3 X • Record Condition of Equipment (DG Asset Condition: Excellent – Unsatisfactory) 2.4 X • Collect hours run information on all relevant equipment whether running or not. 2.5
X
Check Starter Panel for the Thames Standard Maintenance Label. If there is no Label or the last service was more than 12 months ago complete the Full Service as detailed below.
2.6 X Visually check the pump chain and report if condition poor or unsafe. Condition ID: Chain good (no action); Chain poor (use and report) Chain unsafe (Do not use and report)
3.0 PUMP - REPAIR/ADJUST 3.1 X For wet well installation:- Lift pump from wet well. 3.2 X For dry & wet well installation:- Lift pump from bowl, check condition of bowl gasket, renew
as applicable. 3.3 X Remove any restrictions/blockages from pump bowl, impeller or pipework. 3.4 X Remove oil level/filler plug and check condition of oil. Replace as necessary. (Refer to
manufacturers recommendations). 3.5 X Remove upper seal inspection plug and check for signs of water/oil. 3.6 X Rotate impeller and check for any excess play/damage/wear or noise in motor bearings. 3.7 X Check impeller and pump bowl for wear and damage. Pay special attention to the
clearance and condition of the wear rings. Generally if the clearance exceeds 2mm (check Manufacturers recommendations) a work order should be raised to replace/adjust the wear rings.
3.8 X Check for external leaks on water jacket (if applicable). 3.9 X Clear all debris/grease from motor case (to ensure cooling). 3.10 X Inspect cables and sealing gland, report if worn or damaged. 3.11 X Check and inspect the flushing valve for condition and correct operation (if fitted). 3.12 X Check condition of lifting handle - report by exception. 3.13 X Check the condition of the nylon guide rope and replace as necessary. Pumps should not
be fitted with chains unless they have a valid test certificate and have been inspected.
4.0 INSTALLATION & TEST 4.1 X Refit the Pump bowl. 4.2 X Check that pump still rotates freely. 4.3 X Install pump back into DRY/WET well, (as applicable). 4.4 X Check security/condition of guide rails. 4.5 X Run pump, check direction of rotation and operation of all controls. 4.6 X Check for secure seating and adequate seal between pump and base. 4.7 X Record current (Amps) meter reading in site log book. 5.0 COMPLETION OF RPM JOB 5.1 X Complete a Thames Standard Maintenance Label with this Task Spec Reference, your
Name and the Date. Affix this label to the Starter Panel of the Pump you have just serviced.
5.2 X When closing the Maximo DM Work Order ensure that in the Failure Report Remarks field the first letters added are: RPM. Further details or comments may be added after.
5.3 X Continue to close the Work Order in the normal way including the Fault, Cause & Remedy codes
6.0 X Ensure compliance with all Standard Instructions IEMT000 as applicable.
document1 Page 1
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
UNITED UTILITIES
Business Area Simple EGI EGI Description Component Failure Type * For Optional
Component
Strategy
Skill
Frequency Cyclic Task Description Task ID
(MAMS
Use
only)
Stat,
Man,
Reg
Type
Inverter FAILURE Inverter Drive 3 E 364 If applicable, clean starter panel filter, change as required. 944
STARTER PROGRAMMABLE
RELAY FAILURE
7 0 No scheduled maintenance. 583
STARTER DETERIORATION Starter 1 E 364 Carry out a visual check &/or thermal image starter, contactor, relays and
connections/terminations for signs of overheating or deterioration. If faulty, raise
proactive work-order for remedial work.
1122
STARTER CONTACTOR
FAILURE
7 0 No scheduled maintenance. 583
STARTER ISOLATOR
FAILURE
7 0 No scheduled maintenance. 583
DUCK FOOT EXCESSIVE WEAR 7 0 No scheduled maintenance. 583
DUCK FOOT MIS-ALIGNMENT 7 0 No scheduled maintenance. 583
DUCK FOOT CORRODED 7 0 No scheduled maintenance. 583
EX Enclosure LOSS OF
INTEGRITY
1 O 364 Carryout visual inspection in accordance with UU DSEAR COP1 and Site Hazardous
Area Documentation.
Record assets/equipment inspected on work order; report any actions, by
exception.
If faulty raise work order for Close inspection.
1107 DSEAR
EX Enclosure LOSS OF
INTEGRITY
1 E 1092 Carryout detailed inspection in accordance with UU DSEAR COP1 and Site
Hazardous Area Documentation.
Record assets/equipment inspected on work order; report any actions, by
exception.
If faulty raise work order for repair/replacement.
1108 DSEAR
GUIDES CORROSION 7 0 No scheduled maintenance. 583
GUIDES FAILURE OTHER 7 0 No scheduled maintenance. 583
GUIDES MIS-ALIGNMENT 7 0 No scheduled maintenance. 583
IMPELLER EXCESSIVE WEAR 1 O 182 Monitor performance of pump. If performance is outside acceptable limits, raise a
work order for refurbishment.
573
IMPELLER DETACHED 7 0 No scheduled maintenance. 583
IMPELLER FAILURE OTHER 7 0 No scheduled maintenance. 583
LIFTING CHAIN CORROSION 1 M 364 If fitted check lifting chain/wire rope for excessive corrosion. If faulty, raise a work
order for refurbishment/replacement.
235 MAN
LIFTING CHAIN FAILURE 1 M 364 If fitted check lifting chain/wire rope for excessive corrosion. If faulty, raise a work
order for refurbishment/replacement.
235 MAN
MECHANICAL
SEAL
FAILURE 7 0 No scheduled maintenance. 583
MOTOR LOSS OF
EFFICIENCY
7 0 No scheduled maintenance. 583
MOTOR TRIP 7 0 No scheduled maintenance. 583
MOTOR FAILURE 7 0 No scheduled maintenance. 583
NRV EXCESSIVE WEAR 7 0 No scheduled maintenance. 583
PUMP BUILD UP 3 O 91 Flush all excessive rags/fat/silt from level controls, channels, chamber walls & wet
well benching Function test level system. If faulty, raise a work order for
replacement.
431 EP
PUMP MIS-ALIGNMENT 7 0 No scheduled maintenance. 583
PUMP BLOCKAGE 7 0 No scheduled maintenance. 583
STANDBY FAILS TO START 5 O 182 Function test of Standby system & flow. If faulty, raise a work order for
refurbishment.
446
Waste PU-SU-SSP Pump-Submersible-
Sewage/Sludge
PMS SUMMARY 06
ISSUE 1 NOVEMBER 2012
YORKSHIRE WATER
YORKSHIRE WATER PMS
SUBMERSIBLE PUMP SERVICE-1Y 360009 8 1)CHECK WITH LOCAL OPS RE;AVAILABILITY & SAFETY PROCEDURES. 2)ISOLATE,LOCK OFF AND TEST IN ACCORDANCE WITH YW CODE OF
PRACTICE 3)CARRY OUT A POINT OF WORK RISK ASSESSMENT 4) Observe all Health and safety instructions 5) Check condition of delivery and reflux valve, adjust &
repack gland seal as necessary. 6) Close delivery valve and lift pump from well 7) Check external cooling system if fitted for correct
operation
8) Drain seal leak chamber where fitted 9) Examine oil housing for oil loss or water ingress, change
oil and seal as necessary 10)Check and clean strainer if fitted 11)Check volute, wear rings and impeller for wear, replace as
necessary & or adjust wear cone 12)Check stator housing for water ingress 13)Assess condition of bearings 14)ORGANISE OVERHAUL IF NEEDED IN AGREEMENT WITH PLANT MANAGER
15)Examine chain and shackles for corrosion, replace as
necessary 16)Organise lifting chain examination and test as required 17)Examine cables for damage 18)Check condition of pipework and guide rails 19)Check all guards and covers are in place, effective and
secure 20)REPORT ANY DEFECTS AND OR REMEDIAL WORK 21)Check and record: Model ref. _________________________ Serial No. _________________________ Manufactured/installed date ___________ for AI and report
any discrepancies 22)AFTER OBTAINING PERMISSION FROM OPERATIONS, REMOVE LOCKS
AND SWITCH ON 23)Ensure stool connection if fitted has sealed 24)ENSURE CORRECT FUNCTION BEFORE LEAVING SITE 25)If available record Hours Run _________
HIDROSTAL PUMP SERVICE - 1Q 360009 79 AS PER MANUFACTURERS INSTRUCTIONS, TO BE CARRIED OUT BY
HIDROSTAL