LIFT STATION INSPECTION & ASSESSMENT

Transcription

1 David E. Koberlein, PE, GISP Burgess & Niple, Inc. LIFT STATION INSPECTION & ASSESSMENT Presentation Outline Why Perform Lift Station Assessments System Components and What to Look For What to do with Your Findings Questions 1

2 Why Perform Lift Station Assessments 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 2

3 Why Perform Lift Station Assessments Lift Stations are the Final Resting Place (FRP) for ALL of the Interesting Things People put in sewers System Inspections 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 3

4 Lift Station Site 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 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 4

5 Lift Station Site 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 Structural Systems 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 5

6 Lift Station Structural Systems 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 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 6

7 Lift Station Structural Systems 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 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 7

8 Lift Station Structural Systems 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 8

9 Lift Station Electrical Systems 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 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 9

10 Lift Station Electrical Systems 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 10

11 Lift Station Hydraulic Systems What to Inspect Pumps Motors Screens Upstream and Downstream Gravity Manholes Lift Station Performance Pump and Motor Documentation Lift Station Hydraulic Systems 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 11

12 Lift Station Hydraulic Systems 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 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 12

13 Lift Station Hydraulic Systems 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 Assessment Advice 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 13

14 Lift Station Assessment Advice 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 Findings 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 14

15 Questions/Comments? Contact Information David E. Koberlein, PE, GISP Burgess & Niple, Inc. Phone (512) x