109.02 - Seo - Pumping Station - Sewage Storage & Lifting

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LAHMEYER INTERNATIONAL
GOVERNMENT OF THE REPUBLIC OF THE SUDAN

MINISTRY OF IRRIGATION AND WATER RESOURCES
MEROWE DAM PROJECT IMPLEMENTATION UNIT
MEROWE DAM PROJECT

10 x 140MVA
CONTRACTS 3A, 3B, 3C, 3E
ENGINEER:
CONTRACTOR:
OPERATING & MAINTENANCE MANUAL
PUMPING STATION EQUIPMENT SEWAGE STORAGE & LIFTING

-SEO(92SEO001DG, 92SEO003PO/004PO, 92SEO001ZE, + CHAIN BLOCK)
SCALE
1/1
Subcontractor:
Power Environment
Hydro
REV
AHS MRW00SEO.OM.109.02
SH/SH END N of SH
1/
INTERNAL USE
Ce document proprit de ALSTOM ne doit pas tre utilis, copi ou communiqu des tiers sans son autorisation
This document is the exclusive property of ALSTOM and shall not be used copied or communicated to third parties without their prior authorization
AHS-MRW00SEO.OM.109.02
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OPERATION & MAINTENANCE MANUAL
PAGE
CHAPTER
B)
List of Illustrations
C)
Introduction:
C1)
General Description of Equipment
C2)
Brief Description of Equipment Use
C3)
Definitions and Technical Terms Used
C4)
List of items used
19
20
D)
E)
F)
G)
Detailed Description of Equipment

Operating Principles and Characteristics
Operating Instructions
Testing and Adjustment
FLOWDIAGRAMS
21
24
LIFTINGDAVIT
41
60
CHAINBLOCK
69
Maintenance Instructions:
72
73
11
77
SEWAGETRANSFERPUMPS(92SEO003PO/004PO)
MECHANICALMIXER(92SEO001ZE)
H)
H1)
Preventive Maintenance
H2)
Repair and Adjustment
H3)
MAINTENANCEINSTRUCTIONS:MOTORIZEDBARSCREEN
78
MAINTENANCEINSTRUCTIONS:SEWAGETRANSFERPUMPS(92SEO003PO/004PO)
84
MAINTENANCEINSTRUCTIONS:MECHANICALMIXER(92SEO001ZE)
90
MAINTENANCEINSTRUCTIONS:CHAINBLOCK
94
Spare Parts Lists
SPAREPARTSCATALOGUE:SEWAGETRANSFERPUMPS(92SEO003PO/004PO)
H4)
H5)
J)
Special Tools Lists

List of Suppliers
As Built Drawings
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99
101
115
116
117
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B) LIST OF ILLUSTRATIONS
SITE TEST REPORTS
SEO DOMESTIC SEWAGE SANITARY

WASTEWATER TREATMENT SYSTEM
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C) INTRODUCTION
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C1) BRIEF DESCRIPTION OF EQUIPMENT

SEWAGE STORAGE AND LIFTING - PUMPING STATION
LIST OF MAIN EQUIPMENT AND ACTUATORS:
REFERENCE
DESCRIPTION
MODEL
SUPPLIER
92SEO001DG
MECHANIZED BAR SCREEN
SERTEL
9/256/10
92SEO007BA
WASTE TANK
---
92SEO002BA
SEWAGE TANK
---
MANUF:
SERINOL
SUPPLIER:
HYTEC
MANUF:
FKYGT
SUPPLIER:
HYTEC
MANUF:
FKYGT
SUPPLIER:
HYTEC
92SEO003PO/004PO
SEWAGE TRANSFER PUMPS
DP3057 MT
92SEO001ZE
MECHANICAL MIXER (FLYGT)
4620-410
---
LIFTING DAVIT
HYTEC
---
CHAIN BLOCK
HYTEC
92SEO004SN
LEVEL DETECTOR (LL EL)
*)
92SEO005SN
LEVEL DETECTOR (L EL)
*)
92SEO006SN
LEVEL DETECTOR (H EL)
*)
92SEO007SN
LEVEL DETECTOR (HH EL)
*)
*)
The level detectors are
described in the OMM of Valves and
Instruments (ITY system)
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C2) DESCRIPTION OF USE OF EQUIPMENT
SUBMERSIBLE PUMP:
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MECHANICAL MIXER:
MECHANIZED BAR SCREEN, LIFTING DAVIT AND CHAIN BLOCK:

-
REFER TO DETAILS IN CHAPTERS DEFG) AND H2) OF THIS MANUAL.
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C3) DEFINITION OF TECHNICAL TERMS

Wastewater Glossary
Acidic: the condition of water or soil that contains a sufficient amount of acid substances to
lower the pH below 7.0.
Activated Sludge:
Sludge that has undergone flocculation forming a bacterial culture typically carried out in
tanks. Can be extended with aeration. See Extended Aeration.
Advanced Primary Treatment:
The use of special additives to raw wastewater to cause flocculation or clumping to help
settling before the primary treatment such as screening.
Advanced Wastewater Treatment
Any advanced process used above and beyond the defacto typical minimum primary and
secondary wastewater treatment.
Aeration
the mixing or turbulent exposure of water to air and oxygen to dissipate volatile contaminants
and other pollutants into the air.
Aeration tank
a chamber used to inject air into water.
Aerobic Wastewater Treatment
Oxygen dependent wastewater treatment requiring the presence of oxygen for aerobic
bacterial breakdown of waste.
Algicide
substance or chemical used specifically to kill or control algae.
Alkaline
the condition of water or soil that contains a sufficient amount of alkali substance to raise the
pH above 7.0.
Alkalinity
the measurement of constituents in a water supply which determine alkaline conditions. The
alkalinity of water is a measure of its capacity to neutralize acids. See pH.
Alkalinity
A measure of a substances ability to neutralize acid. Water containing carbonates,
bicarbonates, hydroxides, and occasionally borates, silicates, and phosphates can be
alkaline. Alkaline substances have a pH value over 7
Anaerobic: Wastewater treatment in which bacteria breakdown waste without using oxygen.
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Anaerobic Wastewater Treatment

Wastewater treatment in the absence of oxygen, anaerobic bacteria breakdown waste.
Aqueous solubility
the maximum concentration of a chemical that will dissolve in pure water at a reference
temperature.
Backwashing
reversing the flow of water through a home treatment device filter or membrane to clean and
remove deposits.
Bar screen
in wastewater treatment, a device used to remove large solids from the incoming wastewater
stream.
Bacteria
Single cell Microscopic living organisms lacking chlorophyll that digest many organic and
inorganic substances. An essential part of the ecosystem including within human beings.
Bioengineering
The use of living plants as part of the system, be it wastewater treatment, erosion control,
water polishing, habitat repair and on.
Biological treatment / Bioreactor
The biological treatment in the fixed bed bioreactor is the main treatment in the waste water
plant. The process consists of decomposing soluble organic compounds in the waster water
into carbon dioxide, nitrogen compounds and water. This decomposition is principally done
by a bacteria population in aerobic conditions.
Biological oxidation
decomposition of complex organic materials by microorganisms. Occurs in self-purification of
water bodies and in activated sludge wastewater treatment.
Biosolids
Rich organic material leftover from aerobic wastewater treatment, essentially dewatered
sludge that can be re-used.
BOD - Biochemical Oxygen Demand
Since oxygen is required in the breakdown or decomposition process of wastewater, its
"demand" or BOD, is a measure of the concentration of organics in the wastewater.
Blowdown
the water drawn from boiler systems and cold water basins of cooling towers to prevent the
buildup of solids.
Breakpoint chlorination
addition of chlorine to the point where all organic matter and ammonia compounds have
been destroyed and any additional chlorine becomes a free chlorine residual available for
disinfection.
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Clarifier
A piece of wastewater treatment equipment used to "clarify" the wastewater, usually some
sort of holding tank that allows settling. Used when solids have a specific gravity greater than
1.
COD - Chemical Oxygen Demand
The amount of chemical oxidant required to breakdown the wastes, also an indicator of the
concentration of organics.
Chlorination
the adding of chlorine to water or sewage for the purpose of disinfection or other biological or
chemical results.
Clarification
the clearing action that occurs during wastewater treatment when solids settle out.
Clarification is often aided by centrifugal action or chemically induced coagulation.
Clarifier
a tank in which solids settle to the bottom and are subsequently removed as sludge.
Coagulation
in water treatment, the use of chemicals to make suspended solids gather or group together
into small flocs.
Combined Sewer
Combining the municipal sewer systems with storm drainage. Risks overpowering the
system in large rain events. The benefit is that pollutants from storm drainage get treated,
Combined Sewer Overflow (CSO)
When a combined sewer system is overpowered by storm drainage and overflows.
Constructed Wetland
An artificially created wetland usually with a waterproof lining for wastewater purification.
Detention, flow rates, types of plants and other parameters are controlled to improve BOD,
SS and N removal. Typical riparian plants like cattails and reeds are used to provide bacteria
with an oxygenating root zone.
Deionized water
water free of inorganic chemicals.
Detention Time - Retention Time, Residence Time
How long on average wastewater undergoes the wastewater treatment process. Time vary
greatly across various types of wastewater treatment, from minutes to weeks.
Dewatered Sludge
The sludge after it's been dewatered, also know as sludge cake.
Dewatered Sludge Cake
The sludge after dewatering that is cake like, compressed. The lower the water content the
better for wastewater treatment purposes.
Dewatering
Removing water from sludge or other solids.
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Dewater
remove or separate a portion of the water in a sludge or slurry to dry the sludge so it can be
handled and disposed; remove or drain the water from a tank, trench, or aquifer.
Digestion
The breaking down of sludge and other waste biologically by microorganisms. Results in
byproducts such as methane gas, carbon dioxide, sludge solids and water. Aerobic digestion
requires oxygen, anaerobic digestion the absence of oxygen.
Denitrification
Biologically removing nitrate converting it to nitrogen gas.
Dilution ratio
the critical low flow of the receiving water at the point of recycled water discharge divided by
the flow of the discharge. Is used in the biomonitoring test to simulate in-stream conditions
that organisms will be exposed to during critical low-flow times.
Discharge
the volume of water that passes a given point within a given period of time. It is an allinclusive outflow term, describing a variety of flows such as from a pipe to a stream, or from
a stream to a lake or ocean.
Disinfectant
a chemical or physical process that kills or inactivates pathogenic organisms in water.
Chlorine is the most commonly used disinfectant for recycled water, potable water supplies,
wells, and swimming pools. Other disinfectants include ozone, bromine, iodine, chlorine
dioxide, heat, and ultraviolet light.
Disinfection
The use of chemicals to kill any disease causing organisms in the polished wastewater. UV
light can also be used.
Dissolved Oxygen (DO)
The amount of oxygen dissolved in the water. Measured in milligrams per liter.
Effluent
The final output flow of a wastewater treatment plant.
Extended Aeration
An aeration system that adds aerobic sludge digestion to the activated sludge process.
Facultative Ponds
Wastewater ponds with some form of aeration for oxygen replenishment. Can also use algae
and other plants for oxygen replenishment.
Filter
a device used to remove solids from a mixture or to separate materials. Materials are
frequently separated from water using filters.
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Filtration
the mechanical process which removes particulate matter by separating water from solid
material, usually by passing it through sand.
Floc
Particulate and or bacterial clumps forming wooly looking clusters in wastewater. In
biological processes such as extended aeration or activated sludge and others the floc
contains aerobic or anaerobic microorganisms. For industrial applications flocculants are
used.
Flocculation
The process whereby a chemical or other substance is added to wastewater to trap or attract
the particulate suspended solids into clusters or clumps of floc or flocculent, wooly looking
masses.
Flocculating Agent
The flocculant or chemical used to cause flocculation.
Flocculant
Same as flocculating agent, the catalyst substance that causes the chemical reaction with
TSS to form flocculent many times encapsulating the solids.
Flocculent
The "floc" or wooly mass of clusters that is formed in flocculation. Many times used
interchangeably with "flocculant" however truly refers to the floc mass and not the catalyst
flocculating agent.
Free Water Surface Wetland (FWS)
A constructed wetland or other shallow wastewater treatment pond where the shallow water
is exposed directly to the air.
Grease
Fats, soaps, oils, waxes and etc. in wastewater.
Grit Chamber
Usually in municipal wastewater treatment, a chamber or tank in which primary influent is
slowed down so heavy typically inorganic solids can drop out, such as metals and plastics.
Head
the pressure of a fluid owing to its elevation, usually expressed in feet of head or in pounds
per square inch, since a measure of fluid pressure is the height of a fluid column above a
given or known point.
Headworks
The beginning of the treatment plant where the influent begins treatment.
Hydrometer
an instrument used to measure the density of a liquid.
Impermeable
material that does not permit fluids to pass through.
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Impervious
the quality or state of being impermeable; resisting penetration by water or plant roots.
Impervious ground cover like concrete and asphalt affects quantity and quality of runoff.
Industrial Ecology
Industrial Ecology (IE) focuses on combining perpetually desirable outcomes in environment,
economy and technology sustainably. The primary tenet is that all systems mimic nature and
are thus closed loop, continuous, circular. In wastewater treatment industrial ecology would
mean that all so called "waste" is re-input into the same or other process. For example,
biosolids as fertilizer can be considered a use of sludge consistent with industrial ecology.
Recycling wastewater into the treatment plant, manufacturing or other process is another
example.
Industrial Wastewater Treatment
Wastewater treatment for industries such as manufacturing, food processing, corrugators,
printing and so on. Paper and pulp mills' treatment of wastewater is an example of industrial
wastewater treatment. Municipal wastewater treatment would be an example not considered
to be industrial.
Influent
The untreated wastewater or raw sewage coming into a wastewater treatment plant.
Influent Screens
Sreens used to remove large inorganic solids from the wastestream.
Innovative and Alternative (I&A)
An EPA term for wastewater treatment systems that reuse all or part of the wastewater.
Jar test
a laboratory procedure that simulates a water treatment plant's coagulation/flocculation units
with differing chemical doses, mix speeds, and settling times to estimate the minimum or
ideal coagulant dose required to achieve certain water quality goals.
Liquid Solids Separation
The process of separating the liquids and solids in a given wastewater. Liquid/solids
separation comes in one of 3 processes:
1. If the solids sink (specific gravity greater than 1) use a clarifier
2. If the solids float (specific gravity less than 1) use a floatation unit (DAF)
3. If neither sink or float (specific gravity is 1) try using a screen (rotary or parabolic)
Mechanized Bar Screen located at the inlet of sewage tank remove bigger
solids from wastewater to prevent clogging
MGD
Million Gallons per Day - 694.4 gallons per minute.
Mixing zone
a limited volume of receiving water that is allocated for diluting a wastewater discharge
without causing adverse effects to the overall water body.
Modified Permit, Waiver
EPA variances or waivers granted.
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Nitrate
a compound containing nitrogen that can exist in water as a dissolved gas. It can have
harmful effects on humans and animals. Nitrates in water can cause severe illness in infants
and domestic animals. A plant nutrient and inorganic fertilizer, nitrate is found in septic
systems, animal feed lots, agricultural fertilizers, manure, industrial wastewaters, sanitary
landfills, and garbage dumps.
N: Nitrogen (N - NH4)
The measure of nitrogen usually as ammonia and nitrate present in various wastewaters.
NO2: Emissions from immersed biofilters during nitrogen removal in tertiary treatments. An
aerobic process to convert ammonium in to nitrate
Nonpotable
not suitable for drinking. Compare potable.
Natural Systems
Wastewater treatment systems usually biological with a minimum of mechanical components
or processes, for example, constructed wetlands.
Onsite
Wastewater treatment at the point of production typically associated with residential systems
such as septic tanks. Onsite treatment plants are also common in hotels, schools, small
communities and manufacturing plants. Onsite treatment can reduce the costs of
concentrating wastewaters into one huge treatment plant.
On-site sewage treatment
any individual residential sewage treatment and wastewater dispersal system, such as a
septic system.
Organic chemicals
chemicals containing carbon.
Osmosis
the passage of a liquid from a weak solution to a more concentrated solution across a semipermeable membrane that allows passage of the solvent (water) but not the dissolved solids.
Overland Flow Land Treatment
Grassy slopes used to treat wastewater. Leftover water is captured at the bottom.
Oxygen demanding waste
organic water pollutants that are usually degraded by bacteria if there is sufficient dissolved
oxygen (DO) in the water
Permeability
the ability of a water bearing material to transmit water. It is measured by the quantity of
water passing through a unit cross section, in a unit time, under 100 percent hydraulic
gradient.
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PH
A measure of acidity or alkalinity of water, or any given substance. The scale is 1 to 14 with
7 being neutral. Over 7 is alkaline or caustic, under 7 is acid or base.
Phenols
organic compounds that are byproducts of petroleum refining; tanning; and textile, dye, and
resin manufacturing. Low concentrations cause taste and odor problems in water; higher
concentrations can kill aquatic life and humans.
Phosphorous
a plant nutrient that can cause an overabundance of bacteria and algae when high amounts
are present, leading to a depletion of oxygen and fish kills. High levels of phosphorous in
water are usually caused by agricultural runoff or improperly operating wastewater treatment
plants. Also see nitrogen.
P: Phosphorus
The measure of Phosphorus present in wastewater, causes algae blooms.
Polychlorinated biphenyls (PCBs)
toxic industrial chemical compound substances that were used in the manufacture of plastics
and as insulating fluids in electrical transformers and capacitors. Banned since 1979, PCBs
continue to be found in fish/animals.
PPM - parts per million
number of parts of a chemical found in one million parts of a solid, liquid, or gaseous mixture.
Equivalent to milligrams per liter (mg/L).
Primary Wastewater Treatment
The first process usually associated with municipal wastewater treatment to remove the
large inorganic solids and settle out sand and grit.
Primary settling tank Here the wastewater is going to be clarified so that only soluble
organic matters are sent to the fixed bed bioreactor.
Raw Sewage
Untreated sanitary wastewater.
Reclaimed Water
Reusable wastewater from wastewater treatment such as tertiary treatment of wastewater in
biological and other systems.
Remediation
methods used to remove or contain a toxic spill or hazardous materials from a Superfund
site; a generic term used to describe cleanup activities.
Run Off
Storm flows that aren't absorbed and flow off the land and streets.
Sand filters
devices that remove suspended solids from a wastewater treatment plant effluent or water
treatment plant product.
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Sanitary Wastewater (domestic)

Wastewater from human domestic water use.
Saturation
the condition of a liquid when it has taken into solution the maximum possible quantity of a
given substance at a given temperature and pressure.
Scum
Usually fatty material in wastewater that floats.
Secondary Wastewater Treatment
Second biological process of digestion with bacteria.
Secondary settling tank After biological treatment the secondary tank receives the effluent
by gravity. Here the treated effluent is going to be clarified. Then the clarified water of the
secondary settling tank is directed by gravity across the UV disinfection treatment (U.V
sterilizer to the discharge tank
Sedimentation
a large scale water treatment process where heavy solids settle out to the bottom of the
treatment tank after flocculation.
Seep
a spot where water contained in the ground oozes slowly to the surface and often forms a
pool; a small spring.
Seepage
percolation of water through the soil from unlined canals, ditches, laterals, watercourses, or
water storage facilities.
Segment
a water body or portion of a water body that is individually defined and classified. A segment
is intended to have relatively homogenous chemical, physical, and hydrological
characteristics.
Sewage (or wastewater)
The used water and added waste of a community which is carried away by drains and
sewers.
Sewerage
A system of sewers; the removal of waste materials by means of a sewer system.
Skimming
using a machine to remove oil or scum from the surface of the water.
Sludge
The solid waste material which settles out in the wastewater treatment process, sometimes
biosolids. Can be dewatered and reused or disposed.
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Sludge digester
tank in which complex organic substances like sewage sludge are biologically dredged.
Energy is released and much of the sewage is converted to methane, carbon dioxide, and
water.
Sludge Dewatering
Removing the remaining water from sludge for reuse and to lighten the sludge for reuse or
disposal.
Solubility
the amount of mass of a compound that will dissolve in a unit volume of solution.
Solute
any substance derived from the atmosphere, vegetation, soil, or rock that is dissolved in
water.
Soft water
any water that does not contain a significant amount of dissolved minerals such as salts of
calcium or magnesium.
Storm Water Run-Off (SRO)

The pulse of surface water following a rainstorm. The water carries sediment, gas, oil, animal
feces, glass and other waste from the watershed to receiving waters creating a difficult
urban/suburban wastewater problem.
Storm Drain
A pipeline or channel system that carries surface water and/or runoff to public waters, but
does not feed into sewer system.
Subsurface Flow Wetland (SF)
A type of constructed wetland in which primarily treated waste flows through deep gravel or
other porous substrate planted with wetland vegetation. The water is not exposed to the air,
avoiding problems with odor and direct contact.
Suspended solids
the small solid particles in water that cause turbidity. Particles of suspended sediment tend
to settle at the channel bottom, but upward currents in turbulent flow counteract gravitational
settling.
TDS - Total Dissolved Solids
Total Dissolved Solids (TDS) is a the combined total of all dissolved solids in wastewater,
both organic and inorganic and very fine, such as colloidal minerals. Generally particles must
be smaller than two micrometers to be considered a dissolved solid. For example, salt
dissolved in water is a dissolved solid. Therefore TDS will "survive" screening or other
coarse filtration.
Tertiary Wastewater Treatment (Advanced)
Biological or chemical polishing of wastewater to remove organics, solids and nutrients.
Tertiary wastewater effluent limits are generally 10 mg/1 BOD5 and 10 mg/1 TSS.
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Tertiary Treatment
The use of filtration to remove microscopic particles from wastewater that has already been
treated to a Secondary Level. Anthracite coal is the filter medium used by the MWWD.
Toxic pollutant
those pollutants or combinations of pollutants, including disease-causing agents, which after
discharge and upon exposure, ingestion, inhalation or assimilation into any organism can, on
the basis of information available, cause death, disease, behavioral abnormalities, cancer,
genetic mutations, physiological malfunctions or physical deformation in such organism or
their offspring. The quantities and exposures necessary to cause these effects can vary
widely.
Treatability
How treatable a water sample is with a given substance. The "treatability" of Floccin is
very high with a wide array of wastewater types. The more treatable wastewater is, the
better, obviously. All wastewater is treatable, how easy it is varies. The treatability can be
tested using samples in a "jar test". A small water sample is taken and placed in a jar. Then
the flocculant or other treatment additive mixed in and the results observed. Treatability tests
are an important part of wastewater optimization.
Total Coliforms
include bacteria that are found in the soil, in water that has been influenced by surface water,
and in human or animal waste.
TSS - Total Suspended Solids
As the name implies, the total solid particles that are suspended (as opposed to dissolved) in
the wastewater. TSS must be filtered out, flocculated, digested and so on for removal in the
treatment of wastewater. Though not necessarily pollutants TSS is considered to be a
measure of pollutants in water by the EPA in the US.
Turbid
thick or opaque with matter in suspension. Rivers and lakes may become turbid after a
rainfall.
Turbidity
A measure of how clear water is in ntu, invisible to the average naked eye until readings in
excess of 100 are reached, typically determined by shining light through a sample placed in
a turbidimeter.
Ultraviolet Disinfection (UV) / UV Sterilizer
The use of ultraviolet light to kills bacteria and other microorganisms in water and
wastewater. Typically a final treatment step.
Wastewater
Wastewater is "used" water, the water leftover after its use in numerous application such as
industrial, agricultural, municipal, domestic and on
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C4) List of Items Used
UNIT SYS. NUM TYPE
DESIGNATION
SUPP. ROOM
92
SEO 001
DG
AHS
STP
92
SEO 003
PO
SEWAGE TRANSFER PUMP
AHS
STP
92
SEO 004
PO
SEWAGE TRANSFER PUMP
AHS
STP
92
SEO 001
ZE
MECHANICAL MIXER
AHS
STP
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D) DETAILED DESCRIPTION
&
E) OPERATING PRINCIPLES AND
CHARACTERISTICS
&
F) OPERATING INSTRUCTIONS
&
G) TESTING AND ADJUSTMENT
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FLOW DIAGRAMS
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92SEO003PO/004PO
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1.2. Sewage transfer pump (92SEO003PO &92SEO004PO)
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MECHANICAL MIXER
92SEO0031ZE
REVISION: B
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1.3. Mechanical mixer (92SEO001ZE)
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LIFTING DAVIT
REVISION: B
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1.4. Sewage transfer pump and mixer Lifting Davit
REVISION: B
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REVISION: B
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CHAIN BLOCK
REVISION: B
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1.5. Sewage transfer pump and mixer - Chain block
REVISION: B
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Before use
After use
To inspect the hook
REVISION: B
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H) MAINTENANCE INSTRUCTIONS
REVISION: B
Rev. Date: 18.04.2011
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H1) PREVENTIVE MAINTENANCE
REVISION: B
Rev. Date: 18.04.2011
page: 73 of 117
OPERATION AND MAINTENANCE MANUAL
92SE0001DG,
92SEO003PO/004PO,
92SEO001ZE, + CHAIN
BLOCK
MECHANIZEDBARSCREEN:
1.1
Checkforchainscrapperwear
1.2
Replaceplasticscrapperasrequiredifscrappingis
insufficientorifscrapperisinwrongposition
X*
1.3
Cleanthescrapperwithpressuredwaterifthereis
pluggingofthegrid&scraper,asrequired.
plugging
of the grid & scraper as required
X*
1.4
Checkforbottomplasticsprocketwear
1.5
Replacetheplasticsprocketifderailed.
1.6
Checkchaintensioning(correctclearanceis23cm)
X*
1.7
Checkstudbolts
X*
X
1.8
Replacechainsifstudboltsarecompletelytightened.
1.9
Checkifallscrewsandnutsofscrapperandscrapper
holderareinplace.
1.10
Replacescrewsandnutsandplasticsprocketsif
necessary
1.11
Greaseallbearingstoavoidjamming.
s Specified
As
As
s Required
5Y
Years
2Y
Years
Yea
early
6M
Months
3M
Months
Da
aily
SEO
PUMPING
STATION SEWAGE
SORAGE &
LIFTING
Mo
onthly
System /Equipment
Nr.
We
eekly
PREVENTIVE MAINTENANCE SCHEDULE
X*
X*
X*
X*
X*
X*
X*
MIXER:
2.1
Checkifthereisoilintheoilcasing
X*
2.2
Checkifcableentryissecurelytightened
X*
2.3
g y
g
Checkthatthemixeristightlyfixedtotheguidebar
X*
2.4
Checkthedirectionofrotation
X*
2.5
Checkallelectricalconnectionscables.
X*
2.6
Checkmotorfuses
X*
2.7
Checkcontactorconnections
X*
X*Note:TheseMaintenancefrequenciesareaguidelineandshouldbecrosscheckedwiththemanufacturesrecommendationsintheir
respectivemanualsconsideringoperationalconditionsandrunninghours.Thesearesuggestedintervalsasthemanufacturersdoesnotspecify
maintenancefrequencies.Thefrequencycanbemodifiedtosuiteaccordingly.
REVISION: B
Rev. Date: 18.04.2011
page: 74 of 117
PUMPING
STATION SEWAGE
SORAGE &
LIFTING
92SE0001DG,
92SEO003PO/004PO,
92SEO001ZE, + CHAIN
BLOCK
FLYGTPUMPS:
3.1
Inspectpump
3.2
Majoroverhaulofpump(requiresspecialtools,normally
doneinFlygtserviceshop)
3.3
Check oil after one week of operation whenever seals

Checkoilafteroneweekofoperationwheneverseals
havebeenreplaced.
3.4
Checkconditionofliftinghandleandchain.
3.5
Checkoil(refertoinstructionsinchapterH2)
3.6
Replaceoilifitcontainstoomuchwater(ISSOVG32,
MobileWhiterex309)
3.7
Replaceoringsunderoilhousingscrews(plugs)
wheneveroilischanged.
X
3years
CHAINBLOCK:
4.1
Periodicinspection:dismantleandinspectitin
accordancewithmanualuserinstrutions.(byqualified
person)
4.2
Replacedamagedorwornpartswithgenuinespareparts
4.3
HOOKS:
4.3.1
Hookjawopening
4.3.2
Wearanddamages
433
4.3.3
Top and bottom yokes

Topandbottomyokes
LOADCHAIN:
4.4.1
Deformationsandwearonlinks
4.4.2
Pitchoflinks
4.4.3
Rustanddamages
4.4.4
Endanchor
Endanchor
4.4
As Sp
pecified
As Re
equired
5 Yea
ars
2 Yea
ars
y
Yearly
6 Mon
nths
3 Mon
nths
Daily
SEO
Month
hly
System
y
/Equipment
q p
Nr.
Week
kly
REVISION: B
Rev. Date: 18.04.2011
page: 75 of 117
Lifting,loweringandbraking
BRAKEASSEMBLY:
461
4.6.1
Wear on brake disc

Wearonbrakedisc
4.6.2
Wearonratchetgear
4.6.3
Smoothactionofpawl
4.7
HOISTINGMECHANISM:
4.7.1
Deformationoftheloadsheave
4.7.2
dd
f h
Wearanddamageofthegear.
4.7.3
Wearanddeformationofthemanouvrewheel.
FRAME:
4.8.1
Nuts
4.8.2
Deformationofcovers
4.8.3
Lossenedstayscrew
4.8.4
Deformationinrollerguide
4.8.5
Cracksinstriper
4.5.1
4.6
4.8
As Spec
cified
As Requ
uired
5 Years
92SE0001DG,
92SEO003PO/004PO,
92SEO001ZE, + CHAIN
BLOCK
FUNCTION:
4.5
2 Years
Yearly
s
6 Months
3 Months
s
Daily
SEO
PUMPING
STATION SEWAGE
SORAGE &
LIFTING
Monthly
System /Equipment
Nr.
Weekly
maintenance frequencies. The frequency can be modified to suite accordingly.
REVISION: B
Rev. Date: 18.04.2011
page: 76 of 117
H2) REPAIR AND ADJUSTMENT
REVISION: B
Rev. Date: 18.04.2011
page: 77 of 117
MAINTENANCE INSTRUCTIONS
92SEO001DG
REVISION: B
Rev. Date: 18.04.2011
page: 78 of 117
1. SEWAGE STORAGE AND LIFTING PUMPING STATION

1.1. Mechanized bar screen (92SEO001DG)
B
E
A
C
D
REVISION: B
Rev. Date: 18.04.2011
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page: 79 of 117
Mounting of scrapers holders on the chain

Respect the following procedure to get a good working
order
Make sure that the mechanized bar screen is

isolated from the power supply and can not be
energized.
Chains tension has to be released (1)
Mounting of the scrapers holders must be done in
the middle zone of the sieve mechanized bar screen
(cleared area)
Insert the 4 screws M8-25 (2) for each scrapper into
the axis of the chain. The head of the screw being
external as shown on the picture.
Don't fix the scrapers on quick clamp
Put the spacer and install the scraper (4)
Proceed to the tightening of the nylstop nuts (2)
Proceed to the chain tension
2
4
CHAIN
SCREW S M8-65
SCRAPER HOLDER
CASING
NUT
SPACER
LINK
REVISION: B
Rev. Date: 18.04.2011
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page: 80 of 117
Replacement of bottom plastic sprocket

This procedure is suitable for the replacement
of pieces.
Stop the electrical power supply
Release the chain (1)
Unscrew the four nylstop nuts (2)
Take off the sprocket wheel (3)
Install the new plastic sprocket wheel
Screw back again the four nylstop nuts
B
1
Adjustment of polyethylene scrappers

Release the chain
The scrapper must be positioned in the upper part of the sieve, at 200 mm from the upper SS sprockets.
Unscrew the nylstop nuts (1) and adjust the scrapper against the grid
Proceed to the tightening of the nylstop nuts (1)
REVISION: B
Rev. Date: 18.04.2011
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Grid replacement
Stop the bar screen in order to position the scrappers out of the grid as much as possible (1).
Take off the screw (3)
Release the grid (2) and take it off
Install the new grid and proceed to the same thing in reverse.
best spacing : 4 to 5 cm
Chain tensioning
Stop the electrical power supply and take off the sieve cover
Unscrew the four screws maintaining the reduction gear (1)
Unscrew the four screws of the bearing plates (2)
Proceed to the tightening of the chain with the stud bolts (3)
Screw back again the screws and nuts
2
3
REVISION: B
Rev. Date: 18.04.2011
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page: 82 of 117
Minor maintenance work

- Chain scrapper wearing
Inefficient scrapping
Scrapper in wrong position
Replace the plastic scrapper. See title Adjustment of polyethylene scrappers
Plugging of the grid
Plugging of the scrapper
Clean the scrapper with pressure water.
- Bottom plastic sprocket wearing

The chain scrapping derail
replace the plastic sprocket.
- Chain tensioning
If the chain tension is so soft, this can jam the machine and destroy the scrapping system.
The correct clearance is about 2 to 3 cm
If the stud bolts are completely tightened, change the chains
- Needed operations
Have a look to check if all screws and nuts of the scrapper and scrapper holder are in place. Replace it if
necessary; see title "mounting of scrapers holders on the chain"
To replace the plastic sprockets, see the title "Replacement of bottom plastic sprocket"
Greasing of the bearings (to avoid the jamming)
.
REVISION: B
Rev. Date: 18.04.2011
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92SEO003PO/004PO
REVISION: B
Rev. Date: 18.04.2011
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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MECHANICAL MIXER
92SEO001ZE
REVISION: B
Rev. Date: 18.04.2011
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REVISION: B
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REVISION: B
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REVISION: B
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CHAIN BLOCK
REVISION: B
Rev. Date: 18.04.2011
page: 94 of 117
To adjust the brake
Periodic maintenance
No stress !
REVISION: B
No stress !
The chain hoist is now ready to use
Rev. Date: 18.04.2011
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page: 95 of 117
Maintenance and troubleshooting
REVISION: B
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REVISION: B
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REVISION: B
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H3) SPARE PARTS LIST
REVISION: B
Rev. Date: 18.04.2011
page: 99 of 117
OPERATION & MAINTENANCE MANUAL
a) Spare Parts to be supplied under the current contract:
(UNAVAILABLE AT THIS TIME)

List is being prepared by Alstom in Paris, and will be included in this chapter after
finalization and approval.
REVISION: B
Rev. Date: 18.04.2011
page: 100 of 117
SPARE PARTS CATALOGUE

REVISION: B
Rev. Date: 18.04.2011
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
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REVISION: B
Rev. Date: 18.04.2011
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H4) SPECIAL TOOLS LIST
- Not applicable
REVISION: B
Rev. Date: 18.04.2011
page: 115 of 117
H5) LIST OF SUPPLIERS
HYTEC Industrie
28 av des Bthunes
BP19060
95071 CergyPontoise
CEDEX
T: +33 1 34 30 84 37
sav@hytecindustrie.com
Flygt pumps
ITT France
Parc de LIle
29, rue du Port
92022 Nanterre CEDEX
Tel: +33-1-46 95 33 33
Fax: +33-1-46 95 33 79
E-mail: contact.france@itt.com
REVISION: B
Rev. Date: 18.04.2011
page: 116 of 117
J) AS BUILT DRAWINGS
REFERENCE
DESCRIPTION
AHS MRW
92 SEO EQ 100
SANITARY WASTE WATER TREATMENT SYSTEM - CONTROL CUBICLE

EQUIPMENT DRAWING
AHS MRW
92 SEO IG
100
SANITARY WASTE WATER TREATMENT SYSTEM - GENERAL ARRANGEMENT

DRAWING
AHS MRW
92 SEO IG
101
SANITARY WASTE WATER TREATMENT SYSTEM - LEVEL 265.000 - GENERAL

ARRANGEMENT DRAWING
AHS MRW
92 SEO IG
102
SANITARY WASTE WATER TREATMENT SYSTEM - SECTION A-A - GENERAL

ARRANGEMENT DRAWING
AHS MRW
92 SEO IG
103
SANITARY WASTE WATER TREATMENT SYSTEM -TECHNICAL BUILDING GENERAL ARRANGEMENT DRAWING
AHS MRW
92 SEO LC
100 SANITARY WASTE TREATMENT SYSTEM - CABLES LIST
AHS MRW
92 SEO LE
100 SANITARY WASTE WATER TREATMENT SYSTEM - EQUIPMENTS LIST
AHS MRW
92 SEO NF
100 SANITARY WASTE WATER TREATMENT SYSTEM -PROCESSING NOTE
AHS MRW
92 SEO RC 100 SANITARY WASTE WATER TREATMENT SYSTEM - CONNECTING DIAGRAM
AHS MRW
92 SEO SD
100 SANITARY WASTE WATER TREATMENT SYSTEM - ELECTRICAL DIAGRAM
AHS MRW
92 SEO SP
101 SANITARY WASTE WATER TREATMENT PLANT - FLOW DIAGRAM
AHS MRW
92 SEO SP
102
SANITARY WASTE WATER TREATMENT PLANT - SEWAGE STORAGE &

PRIMARY SETTLING DIAGRAM
AHS MRW
92 SEO SP
103
SANITARY WASTE WATER TREATMENT PLANT - BIOREACTOR & SLUDGE

STABILIZATION DIAGRAM
AHS MRW
92 SEO SP
104
SANITARY WASTE WATER TREATMENT PLANT - SECONDARY SETTLING &

FINAL TREATMENT SKID DIAGRAM
REVISION: B
Rev. Date: 18.04.2011
page: 117 of 117

109.02 - Seo - Pumping Station - Sewage Storage & Lifting

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GOVERNMENT OF THE REPUBLIC OF THE SUDAN

MEROWE DAM PROJECT

OPERATING & MAINTENANCE MANUAL

PUMPING STATION EQUIPMENT SEWAGE STORAGE & LIFTING

Rev. Date: 18.04.2011

OPERATION & MAINTENANCE MANUAL

General Description of Equipment

Brief Description of Equipment Use

Definitions and Technical Terms Used

List of items used

Detailed Description of Equipment

Repair and Adjustment

Spare Parts Lists

Special Tools Lists

Rev. Date: 18.04.2011

SITE TEST REPORTS

SEO DOMESTIC SEWAGE SANITARY

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

C1) BRIEF DESCRIPTION OF EQUIPMENT

LIST OF MAIN EQUIPMENT AND ACTUATORS:

MECHANIZED BAR SCREEN

SEWAGE TRANSFER PUMPS

MECHANICAL MIXER (FLYGT)

LEVEL DETECTOR (LL EL)

LEVEL DETECTOR (L EL)

LEVEL DETECTOR (H EL)

LEVEL DETECTOR (HH EL)

Rev. Date: 18.04.2011

C2) DESCRIPTION OF USE OF EQUIPMENT

Rev. Date: 18.04.2011

MECHANIZED BAR SCREEN, LIFTING DAVIT AND CHAIN BLOCK:

REFER TO DETAILS IN CHAPTERS DEFG) AND H2) OF THIS MANUAL.

Rev. Date: 18.04.2011

C3) DEFINITION OF TECHNICAL TERMS

Rev. Date: 18.04.2011

Anaerobic Wastewater Treatment

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Sanitary Wastewater (domestic)

Rev. Date: 18.04.2011

Storm Water Run-Off (SRO)

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

C4) List of Items Used

UNIT SYS. NUM TYPE

MECHANIZED BAR SCREEN

SEWAGE TRANSFER PUMP

SEWAGE TRANSFER PUMP

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

SEWAGE TRANSFER PUMPS

Rev. Date: 18.04.2011