WATER INDUSTRY MAINTENANCE WORKING GROUP · ENVIRONMENT AGENCY GENERIC MEICA PLANNED MAINTENANCE...

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


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


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


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


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



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



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


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



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


Specialist Competency 1 .



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


03 September 2012



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


Specialist Competency 1 TM01



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


03 September 2012



Page 539 of 794

Instruction Status: UNVERIFIED

Last Updated: 17-DEC-2008

Instruction Owner: ENGINEER

PSET5039Date

Work Instructions


03 September 2012

PMS SUMMARY 06


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


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)



700 Carry out motor IR test using appropriate instrument L1 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


790 Return all plant to normal operation

800 Inform site staff or site supervisor of job status and sign out where appropriate


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





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





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






additional tasks in text box below


- 83 -

MMP084 - MMP090

SERVICE A Sheet 2/2


…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

Additional Comments

…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

- 84 -

PLANNED MAINTENANCE

STANDARD JOB MMP084 - MMP090

SERVICE B Sheet 1/2

Complete





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





RUNNING CHECKS

40 Record running hrs

50 Check for noise/ vibration/ unnatural movement

60 Perform visual check of entire plant


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


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






additional tasks in text box below


- 85 -

MMP084 - MMP090

SERVICE B Sheet 2/2


…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

Additional Comments

…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

PMS SUMMARY 06


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


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


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


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



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


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

http://cww.southernwater.co.uk/bus_proc_02/pdf_02/mtm/mtm401.doc

CONTROLLED DOCUMENT MTM MF0603Date: January 2011 Page 1 of 4 Issue No: 2

SOUTHERN WATER


SUBMERSIBLE PUMP (TIER UNKNOWN)






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) 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



15. Clean cooling fins and flush cooling jacket 16. Check operation of Non-return valve and remove any debris


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.


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



Significant contamination/ emulsification


reinstate

Change fluid and reinstate




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



7.5 kW or less


moisture detector


detector Minor ingress 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


Considerable ingress


Refurbish or replace Drain fluid, reinstate, confirm detector

wiring is connected and not linked out and undertake an

Insulation Resistance Test



This page intentionally left blank.


SOUTHERN WATER


SUBMERSIBLE PUMP (TIER 3)






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) 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



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



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.


7.5 kW or less


moisture detector


detector Minor

contamination/ emulsification




Significant contamination/ emulsification






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


7.5 kW or less


moisture detector


detector Minor ingress 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


Considerable ingress




Insulation Resistance Test


SOUTHERN WATER


ITT FLYGT N TYPE SUBMERSIBLE PUMP (TIER 1 AND 2)






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) 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



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)



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.

http://cww.southernwater.co.uk/bus_proc_02/pdf_02/mtm/mtm401.doc




detector



Minor contamination/ emulsification


reinstate




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


7.5 kW or less Greater than 7.5 kW without motor




Minor ingress Drain fluid and reinstate

Drain fluid and reinstate. Check in 1

months


Considerable ingress Drain fluid and reinstate raise a

Follow On Reactive Work

Order to check in 1 Month



Insulation Resistance Test If the Insulation

Resistance Test measures less than

0.5M Ω/kV Refurbish or replace



This page intentionally left blank.

PMS SUMMARY 06


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


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


STARTER ISOLATOR

FAILURE


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


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


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

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