New Cargo Lift No-03,SGS Inspection Report (as on 12-08-2011)
LIFT STATION INSPECTION & ASSESSMENT Presentation Outline
Transcript of LIFT STATION INSPECTION & ASSESSMENT Presentation Outline
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David E. Koberlein, PE, GISPBurgess & Niple, Inc.
LIFT STATION INSPECTION & ASSESSMENT
Why Perform Lift Station Assessments
System Components and What to Look For
What to do with Your Findings
Questions
Presentation Outline
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Wide Range of Design and Construction Methods Nothing is Standard – Even the Standards Lots of Moving Parts
Lift Station Location At the lowest point in the gravity system At the highest point in the pressure system Critical point in the conveyance pathway to the WWTP
Determine Station Performance Characteristics Normal Operation and Wet Weather
Regulatory Compliance
Why Perform Lift Station Assessments
Asset Management Programs Expensive, Non Standard Assets Require the Most Attention
Force Main Condition
Safety Issues Workers
Public
Elimination or Combination
Why Perform Lift Station Assessments
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Lift Stations are the Final Resting Place (FRP) for ALL of the Interesting Things People put in sewers
Why Perform Lift Station Assessments
Lift Station Site Access, Security, Signs, Operational Alarms
Structural Systems Wet Well, Concrete Pads, Entryways, Equipment Access
Electrical Systems Controls, Conduits, Power, SCADA, Monitoring
Hydraulic Systems Pumps, Force Mains, Gravity Systems
System Inspections
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What to Inspect Access Road, Fencing, Controlled Access, and Site Security Adequate Parking for Equipment and Vehicles External Station Operation Alarms and Lights Signage – Warnings, Station Identification, Emergency Contacts Station Protected from 100 Year Flood Station Accessible During 25 Year Flood Station Shelter or Housing Note Type of Lift Station Odor Control/Chemical Feed Systems Others
Lift Station Site
What to Look For General Condition of: Access Road Site Fencing, Gates, and Locks Record Type of Fence and Gates
Site Security Features (Cameras, Lighting) Parking Area for Equipment and Vehicles General Overall Appearance of the Station Signage Station Shelter or Housing Record Type of Shelter or Housing
Lift Station Site
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What to Look For Check Operation of: External Station Operation Alarms and Lights
Site Security Features (Cameras, Lighting)
Site Fencing, Gates, and Locks
Site Drainage and Stormwater Control Features
Odor Control/Chemical Feed Systems
Lift Station Site
What to Inspect Wet Well, Dry Well, Valve Pit
All Concrete Flatwork
Anchors, Mounting Bolts, Connections
Hatches/Entryways/Ladders/Stairs/Rails
Sump Pumps
Pump and Motor Fittings, Hardware, Mounting Points, Rails
Pipe and Conduit Penetrations
Pipe/Valve/Motor Stands, Mounting Points, Anchors
Lift Station Structural Systems
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What to Inspect Conduits and Fittings Air Handling Systems and Ventilation Lighting and Illumination Systems Emergency Communications Systems Weather/Freeze Protection Systems Any Installed Liner Systems Electrical and Instrumentation Enclosures and Panels Trash/Solids Handling Systems Hoist/Crane Systems Other
Lift Station Structural Systems
What to Look For General Condition of: Wet Well, Dry Well, Valve Pit Record Dimensions and Construction Material High Resolution Digital Photograph Record Presence of Grease/Debris/Stormwater Accumulation Record Influent and Force Main Elevations
All Concrete Flatwork Anchors, Mounting Bolts, Connections, and Joints Hatches/Entryways/Ladders/Stairs/Rails Sump Pumps Record Nameplate Information
Pump and Motor Hardware, Mounting Points, Rails Pipe and Conduit Penetrations
Lift Station Structural Systems
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What to Look For General Condition of: Conduits and Fittings Air Handling Systems and Ventilation Lighting and Illumination Systems Emergency Communications Systems Weather/Freeze Protection Systems Wet/Dry Well Liner Systems Electrical and Instrumentation Enclosures and Panels Hoist and Pump Removal Systems Screens
Lift Station Structural Systems
What to Look For Rust, Corrosion, Fatigue Noisy Components Unusual Odors Non-Functional Systems Chipped or Missing Paint Discolored Concrete, Spalling, Unsupported Slabs or Walls Cracks, and
Fractures Exposed Piping and Valves Free Movement of Gates, Hatches, Entryways High and Low Water Marks Leakage of Any Fluid Presence of Vandals or Vermin
Lift Station Structural Systems
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What to Look For Noisy Station Components/Unusual Odors Provision for Pipe, Valve, Motor, or Pump Replacement All Joints are Flanged
Non-Functional Ventilation Systems Confined Space Explosion Hazards
Non-Functional Electrical Systems Fans, Lights, Alarms, Controls, SCADA
Cracks, Tears, Delamination of Liner System Exposed Rebar/Reinforcement Components Evidence of Overflows Room for a Spare Pump Operations and Maintenance Manuals
Lift Station Structural Systems
Check Operation of: Ventilation Systems Lighting and Illumination Systems Gates, Hatches, Locks, Entryways Sump Pumps Emergency Communications Systems Conduits and Fittings Weatherproof and Watertight
Piping and Valve Systems Watertight Vibration
Lift Station Structural Systems
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What to Inspect Motor/Pump Controls Wet Well Level Control Systems Record Pump On/Off Levels for Various Combinations of Pumps
Instrumentation/Recoding Systems SCADA and Telemetry Systems Emergency Communication Systems Site and Interior Lighting and Illumination Humidity Control Systems Enclosures and Panels Conduit/Fittings/Wiring Schematics Emergency Power/Generator/Connections Main Power Disconnect Switch
Lift Station Electrical Systems
What to Look For Presence of “Hot Spots” in Enclosures and Panels Frequently Tripped Breakers Smoke/Ozone Odor/Evidence of Sparks Frayed/Exposed Wiring Extensive Repairs to Electrical System Open Conduits/Broken Fittings/Liquid in Conduit Actual Electrical Schematics Accuracy
Terminal Block Connections with Printed Labels Accuracy
Lift Station Electrical Systems
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What to Look For Emergency Generator and Connections Compatibility
Humidity Control/Ventilation System Operational
Instrumentation/Recording System Functional Gages Operational
Wet Well Level Control System Functional
Rust/Corrosion Spare Parts Inventory
Lift Station Electrical Systems
Check Operation of: Everything
Individual Systems/Components All Systems Functioning at Once
Lighting and Illumination Systems Emergency Generator and Connection to Station All Motor Control Center Functions
Instrumentation Gauges Power Usage Motor Stop/Start Records Pump On/Off Runtime Records Wet Well Level Controls
Emergency Communications Systems External Station Alarms and Lights Spare Parts
Lift Station Electrical Systems
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What to Inspect Pumps
Motors
Screens
Upstream and Downstream Gravity Manholes
Lift Station Performance
Pump and Motor Documentation
Lift Station Hydraulic Systems
What to Look For General Condition of: Pumps/Motors Missing Paint/Coatings Rust/Corrosion/Scaling Excessive Vibration Bent Drive Shafts Excessive Start/Stop Cycles Excessive Noise During Operation Hard to Start/Slow to Start Leaking Fluids Start/Stop Cycles are Properly Recorded by Instrumentation Installed Priming Systems
Lift Station Hydraulic Systems
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What to Look For General Condition of: Electrical Connections Conduits and Fittings Weather/Freeze Protection Systems Hoist and Pump Removal Systems Functional and Properly Lubricated
Screening Devices Functioning as Intended
Coating and Liner Systems Cracks/Tears/Delamination/Scaling
Debris/Grease Buildup in Wet Well
Lift Station Hydraulic Systems
What to Look For General Condition of: Station Piping and Valves Peeling Paint, Scaling, Rust, Corrosion Loose Flanges/Connections Displaced Piping/Valves Leakage External Lever on Check Valves Gate Valve Operation
Force Main Piping Corrosion/Rust/Deterioration in Connecting Manholes Pump/Motor Mounting Pads Cracks/Spalling/Loose Hardware
Spare Parts for Pumps and Motors
Lift Station Hydraulic Systems
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Performance Testing Draw Down Testing Basically a Bucket and a Stopwatch
Record Wet Well Fill and Empty Times for: Individual Pump Operating Alone
Various Pumps Operating in Combination
Use with Wet Well Dimensions to Determine Pump Performance
Pump Performance Degrades over Time
Lift Station Hydraulic Systems
Take Pictures of Everything with a GPS Enabled Camera Start and end the assessment with a photo of the station identification
sign Consider the amount of light when taking photos of the interior of
structures and appurtenances Have a predefined format for collecting data and use it. Flexible enough to record the presence and condition of assets Rigid enough to utilize standard methods for assessment
Always set up temporary safety equipment (traffic control, fall protection, etc.) and gas detectors first
The electrical equipment in a lift station is “intrinsically safe” for a reason – Don’t bypass this feature
Lift Station Assessment Advice
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Someone somewhere has the Operations Manual for the Lift Station – Find it and keep it at the Station
Make sure the backup generator works and can be quickly connected to the station to provide power in an emergency
Unless you are a Qualified Lift Station Operator/Electrician/Pump Mechanic – Don’t try to Fix Something
Lift Station Assessment Advice
Improve Station Operation
Make Recommendations for Improvements
Determine the Monetary Value of the Station
Extend the Life of the Station Through Proactive Maintenance
Asset Management Program Data
Lift Station Findings
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Questions/Comments?
Contact InformationDavid E. Koberlein, PE, GISP
Burgess & Niple, Inc.Phone (512) 306-9266x6270
Email: [email protected]