Mishref Pump Station

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Copyright [insert date set by system] by [CH2M HILL entity] • Company Confidential

Rehabilitation of Mishref Pump Station (MPS)

First CH2M HILL Project with municipal sector since liberation of Kuwait in 1991


Presentation Covers

General Info

Process, site plan and section

Failure of MPS

Root cause

Emergency Action and remedies

Lessons implemented

Photos


General Information

Client - Kuwait Ministry of Public Works (MPW). MPS is located in Kuwait 10 km south of Kuwait City Built 33 m below the ground level. CH2M HILL OMBG provided consultancy services for the

Assessment, Evaluation and Rehabilitation of the MPS and 2 years of O&M oversight

CH2M HILL contract value to date: 4M KWD Total Rehab/O&M contract value: 15.1M KWD

MPS was… Designed by a JV of KEO International Consultants and Metcalf &

Eddy. Constructed by United Gulf Construction Company (UGCC) -2006


Process Diagram

Emrg.Pumps (560KW) – Cornell (46.8 m3/m)

M.Pumps (740 KW) - Cornell (73 m3/m @ 51m H)

Flow 308,202 m3 /day

Vortex Grit System –MASS

Aritma (1.75m3/s)

Conveyor -SPIRAC

Screen-MASS Aritma (3.7m3/s)


Lower Level Floor Plan

Wet well Area

Dry well Area

Emergency Pumps

Gravity Influent Flow


Midlevel – Plan

Odour Control Plant

– 175,000m3/h

r(16 air changes)

ELECTRICAL CONTROL ROOM

11 kv ABB VFD Drive


Plant section


Power Distribution Diagram


Failure of MPS

On 23 August 2009 the MPS stopped operating due to a cascading series of equipment failures.

Resulted in a catastrophic failure and flooding of the MPS. Failure of two critical items: the Main Pump Variable Frequency

Drives (VFD’s) and the Main Isolation Gate resulted in the flooding of the MPS.

In spite of all the efforts by Operator attempting to manually close the gate, chest deep in

sewage and eventually did not succeed. Presence onsite of VFD representatives efforts to restore the

failed VFDs back into operation.


33 m

20 m

Flooded Zone


MPS Failure – Root Cause and Contributing factor

VFDs began failing periodically months in advance of ultimate failure.

Due to chronic overheating (inefficient HVAC), humidity, dust and H2S gases plus poor maintenance - subsequent failure of the VFDs controlling the Main Pumps and Emergency Pumps.

Critical equipment (Electrical, MCC,VFD’s, and emergency pump controls) all located in high risk areas were considered as major contributing factor to the failure of the MPS.

Normal and desirable operating room temperatures are 25ºC to 29ºC. The temperatures recorded range from 41ºC to 44ºC in the VFD and the electrical control room.

Influent channel penstock gate got stuck and failed to close gate.


Emergency Actions and Remedies

A team of local consultants, contractors, and the U.S.Army Corps of Engineers assisted the MPW in identifying options for isolation and repair.

Sewage flow was redirected through the storm drain culvert to the Gulf in order to prevent sewage backing up into streets, commercial, and public housing areas.

Approximately one month after, the influent sewage was eventually blocked at a manhole upstream (sand bag) and was successfully diverted to the Gulf. Some of the sewage was hauled by tankers

Kharafi National (KN), a general contractor, was hired to drain, clean, sanitize and PS of residual raw sewage.

KN started Repair & Rehabilitation works in Feb. 2010.


Losses and after effect

The total financial losses are estimated at 21 M KWD. Dumping 180,000 cubic meters of untreated sewage to Kuwait

Bay. Violation of the international and local regulations on

environmental safety. Fishing and swimming was banned in affected areas. Indirect economic losses to the fishing. The Public Prosecution Department has charged the company

who executed the project, the O&M team AND the engineering consultant.


Capture the Lessons to improve asset performance

Resulted in relocation of all the critical equipment's above ground. Develop more comprehensive O&M procedure and emergency

response plan. O&M personnel require more comprehensive training. Replace the main isolation gate and include hydraulic actuator and

thimble mounting. Modify station access points for removal and replacement of large

equipment. Redesign and improve HVAC System.


Major findings

Thank you

Mishref Pump Station

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Transcript of Mishref Pump Station