FRAMEWORK FOR EVALUATION OF PUMP STATION OPERATIONAL ISSUES

1) Introduction to Assessment Framework Efficient and Effective operation of pump stations are dependent on three main factors. Operator; capability and skills, knowledge and access to required information in a language understandable Right equipment in right order and availability of tools and spares to attend to the repairs promptly Design: pump system design, hydraulics, architecture, layout plan, etc

These factors need to work together to achieve effective pump station operation. The following sections assess each of these aspects to understand present operational problems. Thereby making the necessary adjustments to the design and rehabilitation works planned under this project.

2) Implementation Procedure Pump Station by pump station assessment by three teams [Two weeks] o o o Team 1: CMC (Mechanical Engineer) + DSC (Support Engineer) [4 stations] Team 2: PMU (Mechanical Engineer) + DSC (Support Engineer) [4 stations] Team 3: PMU (Electrical Engineer) + DSC (Mechanical Engineer) [2 stations]

Half day Workshop to present the findings to CMC and PMU staff. Proposed date for the Workshop 22nd August 2011. The objectives of the workshop are:

o o o

To reach a general agreement on operational problems and their causes To reach an understanding on Scope of Work for rehabilitation from operational point of view To determine solutions possible for operational problems for implementation under the proposed rehabilitation work

PUMP STATION GENERAL DETAILS

3) Name of the assessor: .......... Date: ................

4) Pump Station Name: .

5) How many operators working: 6) Shift arrangement: 7) Is Standby Generator Available: Yes/No; If yes is it in working order:
8) Is septage disposal allowed: Yes/No 9) Does the station go under floods? Yes/No; If so what are the impacts: ..

OPERATOR / INSTITUION RELATED ISSUES

10) What is the general educational qualifications of operators: . 11) Do the operators have understanding of pump station components and operation: Yes/No 12) Has operators trained in PS operation: Yes/No Comments: .

13) Do the operators have sufficient skills to read the instruments and made operational decision? Yes/No; If not how do they attend to the operations:

14) 15)

Has operators trained in minor repairs: Yes/No Comments: . Comments:

Has operators trained in routine maintenance work: Yes/No .

16) Can the operators read and understand operation and maintenance manuals? Yes/No

17) 18)

Do spare parts available for repair work? Yes/No: Comments: . Comments:

Do necessary tools available for maintenance work: Yes/No .

19) Document availability at site:

Pump station drawings

Civil Mechanical Electrical Instrumentation

Yes/No Yes/No Yes/No Yes/No

Manuals

Operational Yes/No Maintenance routines Yes/No Maintenance check lists Yes/No Equipment Copy of Survey Plan Layout Map Yes/No Yes/No Yes/No

Catalogues Maps

20) Do operators carry out regular maintenance work? Yes/No; if not why .. 21) Do the operators educated in health and safety issues: Yes/No; If not why? . 22) Do the safety equipment provided? Yes/No; If not why? .........................................................

23)

If available do the operators wear safety gear? Yes/No; if not why? ..

24) Does satisfactory facilities are provided for operators for work and rest? Yes/No: If inadequate what are the missing elements: . 25) Is there a satisfactory fault reporting mechanism? Yes/No; If not why?

26) If the response to faults is satisfactory in terms of timeliness? .. 27) How often the Engineer visits the PS: 28) Does discharge of unacceptable/not approved waste take place in the PS: Yes/No; If yes why and how it is happening:

PUMP STATION LAYOUT ARRANGEMENT

29) Sketch of Pump Station Layout and Components

OPERATIONAL PROBLEMS ANALYSIS 30) Deterioration of wet well due to weakening of structural concrete as a result of corrosion:

Are there visible signs such as peeling off of concrete, appearance of cracks of deterioration of wet well concrete structure? Yes/No If yes, describe the signs: . Age of the structure: . Does epoxy coating applied to wet well at acceptable intervals? Yes/No

31) Corrosion of items such as piping, pump guide rails, supports, grating, handrails, stairs, bar screens, bolts, weirs, ladders, slide gates and other steel/metal items.

Is corrosion of these items a major problem: Yes/No Does corrosion protection coatings applied regularly? Yes/No Does the location of Pumps Station Close to the sea? Yes/No Does the pump station is properly ventilated? Yes/No

32)

Sewerage Leaking to the Pumping Station Structure How do these leaks occur? Through cracks and joints in the structure: Yes/No Through pipe lines: Yes/No Through pumps: Yes/No

What are the causes for such leaks? ..

33) Odour Is ventilation system in good order? Yes/No Does the wastewater stay long period in the wet well? Yes/No If so why: .. Is significant agitation of flow taking place at the entry to the wet well or in the channel? Yes/No Does grit deposition is high? Yes/No

34) Surcharge of Upstream Lines

Does upstream lines allowed to surcharge? Yes/No If Yes; is it to allow pumps to be primed? Yes/No, and/or Is it because of excessive flow? Yes/No, and/or Is it due to lack of pumping capacity? Yes/No, and/or Is it due to poor operational practice? Yes/No

35) Overflows

Does PS is allowed to overflow? Yes/No If Yes; Is it due to lack of pumping capacity? Yes/No, and/or Is it because of excessive flow? Yes/No, and/or Is it due to poor operational practice? Yes/No

36) Deposition of Grit in Wet Well

Is there a grit removal device? Yes/No If yes, is it working effectively? Yes/No How the grit deposition does affect the operations? ..

37) Energy Cost What is the energy consumption/cost per unit volume of pumping: .. Do the pumps working close to the best efficiency point: Yes/No If not what are the reasons: . Does the pump design/selection considered the energy efficiency? Yes/No

38) Pumps

Does ware/damage to impellers and casings by grit and solids significant? Yes/No Is removal of solids through screening insufficient? Yes/No Is removal of grit through grit chamber insufficient? Yes/No If the pumps are not submersible or +ive suction do the priming of pumps difficult? Yes/No If yes, what are the reasons for priming difficulties Do the pumps fail frequently? Yes/No

If yes, what are the reasons: . Do the pump motors fail frequently? Yes/No If yes, what are the reasons: . Is the pump operation noisy? Yes/No

39) Plumbing Arrangement Are the pipes in good condition? Yes/No If not what are the most affected sections of pipe work? . Are the valves in good condition? Yes/No If no, what are the most problematic vales? Does the plumbing arrangement hinder easy operation and repair work? Yes/No Any suggestions for improvement of plumbing arrangement: ..

40)

Main Penstock Operation: How often that penstock opening is altered: . If frequent changes are needed, why that is: Is penstock opening and closing difficult: Yes/No; If yes why: Isolation Penstocks (Write separately for each penstock if necessary) How often that penstock opening is altered: . If frequent changes are needed, why that is: . Is penstock opening and closing difficult: Yes/No; If yes why: .

41)

42) Impact of Power Failures

Do long duration power failures common in the area: Yes/No: As a result are there significant problems with (a) overflows: Yes/No (b) Surcharging Yes/No

Does power failures affects pumps and valves due to surge: Yes/No If yes does it due absence of surge protection or non working surge protection system: Yes/No

43) Coarse Screen Is coarse screen (together with screen removal mechanism) working? Yes/No If not working why is that? .

Is there a proper and easy to handle mechanism for removing screen matter from the screen: Yes/No What are the operational problems associated with the screen and screen matter removal device? Is it easy to remove the collected screen mater for disposal: Yes/No; if not what are the difficulties..

44) Grit Removal

What is the type of grit removal unit? .. What is the grit removal mechanism? Grit pump/chain and bucket/ air lift etc Is the grit removal mechanism working? Yes/No If it stops working what was the reasons? If it is working does it give frequent operational problems? Yes/No If yes specify the type of problems: Does the collected grit washed before disposal? Yes/No Does the operators have easy access to grit removal unit for removal of grit material, routine maintenance, etc Can the collected grit be disposed easily? Yes/No; If no what are the issues: .

45)

Fine Screen (if available) Is fine screen (together with screen removal mechanism) working? Yes/No If not working why is that? . Is there a proper and easy to handle mechanism for removing screen matter from the screen: Yes/No What are the operational problems associated with the screen and/or screen matter removal device? Is it easy to remove the collected screen mater for disposal: Yes/No; if not what are the difficulties..

46)

Lighting and Ventilation Does the pump station adequately lit? Yes/No Does the ventilation in pump station is satisfactory: Yes/No Do the inadequate lighting and ventilation threats to operator safety? Yes/No If yes, what improvements are suggested: .

47) Instrumentation Does the pump station hydraulic profile is satisfactory i.e. maintenance of levels at various unit operations are adequate? Yes/No If not satisfactory, what are the issues:

DESIGN PROBLEMS ANALYSIS

48) Main Penstock

Does the penstock opening and closing difficult due to design: Yes/No; If yes why: .. Is access to Penstock difficult? Yes/No; Explain: What are the defects in Penstock that you think should be addressed: Material: . Fixing/Arrangement: .. Size: . Any other: ..

49)

Isolation Penstocks (Write separately for each penstock if necessary) Does the penstock opening and closing difficult due to design: Yes/No; If yes why: .. Is access to Penstock difficult? Yes/No; Explain: What are the defects in Penstock that you think should be addressed: Material: . Fixing/Arrangement: .. Size: . Any other: ..

50) Coarse Screen

Is the coarse screen unit is an appropriate design? Yes/No Comments: .. Is the hydraulics of the screen properly designed? Yes/No Comments: .. If not what are the design failures? . Is access to coarse screen difficult: Yes/No If yes, explain the difficulty: Are there any suggestions for improving the design of coarse screen:

51) Grit Removal

52)

Is the choice of grit removal unit type appropriate? Yes/No; Comments: .. Is the hydraulics properly considered in the design? Is the grit removal system is properly designed? Yes/No If no, what are the design issues: ..

Fine Screen (if available) Is the fine screen unit is an appropriate design? Yes/No Comments: .. Is the hydraulics of the screen properly designed? Yes/No Comments: ..

If not what are the design failures? . Is access to fine screen difficult: Yes/No If yes, explain the difficulty: Are there any suggestions for improving the design of coarse screen:

53) Pump System Design

Does the selection of pumps type appropriate: Yes/No; if no why Does the selection of pump capacities appropriate: Yes/No; if no why Does the selection of pumps is based on hydraulic analysis: Yes/No What type of operational problems are caused by the pump design: Does the choice of pump motor appropriate? Yes/No: if not why Does the choice of pump motor arrangement appropriate? Yes/No; If not why: ..

54) Ventilation System

Is ventilation design/arrangement acceptable? Yes/No Is the ventilation system in good/acceptable working condition? Yes/No If no is it due to corrosion? Yes/No: If no what is the reason for failure What is the material used of fabrication of ventilation ducts: .

55) Building

Does the pump station design allow proper ventilation? Yes/No Does the pump station design allow adequate natural lighting? Yes/No Does the pump station layout plant make the operators work easy? Yes/No Does the steps/ladders are properly design and safe? Yes/No Does the layout create risks/hazards for operators? Yes/No; If yes state the issues: .. Is there a room for resting? Yes/No Does the building layout prevent easy access for repairs? Yes/No What are the suggestions for building improvement: . What are the things to avoid in the pump station design: .

56) Hydraulics Does the pump station hydraulic profile is satisfactory i.e. maintenance of levels at various unit operations are adequate? Yes/No If not satisfactory, what are the issues: What are the other design issues related to hydraulics? Is hydraulic profile leading to surcharging of sewers or overflows from sump? Yes/No Comments..

57) Electrical List the short comings of electrical design a. Earthling: .: b. Station wiring not properly done: c. Safety provisions are not adequate:

d. Material used and installation has not considered the high moisture and corrosive environment in stations ..

e. Is lightning protection provided? Yes/No

f. Is surge protection provided? Yes/No