OM - Sewerage Pumping Station
OM - Sewerage Pumping Station
OM - Sewerage Pumping Station
O&M MANUAL
SEWERAGE PUMPING STATION
PACKAGE DPT 1: CONSTRUCTION AND COMPLETION OF
SUNGAI BULOH MAINTENANCE DEPOT, ADMINISTRATION
BUILDING, EXTERNAL WORKS AND OTHER ASSOSIATED
WORKS
Revision : 00
REVISION HISTORY
Page 2 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
TABLE OF CONTENTS
Page 3 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
1 INTRODUCTION 5
1.1 PURPOSE 5
1.2 SCOPE 5
2.1 ABBREVIATIONS 5
2.2 DEFINITIONS 5
3 REFERENCES 6
3.2 STANDARDS 6
5.1.1 INTRODUCTION 7
Page 4 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
5.3.1 INTRODUCTION 8
5.3.3.1 LUBRICATION 9
5.3.3.2 PENSTOCKS 9
5.4.1 INTRODUCTION 11
Page 5 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
5.4.6 DISPOSAL 12
List of Tables
Table 2-1: Table of Abbreviations............................................................................................5
Table 2-2: Table of Definitions................................................................................................5
Table 3-1: List of References ~ Contractual Documents.........................................................6
Table 3-2: List of References ~ Standards..............................................................................6
Table 4-1: O&M Manual Structure..........................................................................................6
Table 5-1: General................................................................................................................ 10
Table 5-2: Primary Screen Chamber....................................................................................10
Table 5-3: Pump Sump (Wet Well).......................................................................................10
Table 5-4: Control Panel.......................................................................................................11
Table 5-5: Product Material Details 1....................................................................................11
Table 5-6: List of Supplier.....................................................................................................11
Page 6 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
Page 7 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
Page 8 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
1 INTRODUCTION
This sewerage pumping station is designed in compliance to the design guideline
(Guidelines for Developers Vol. III Sewer Networks and Pump Station. This operation and
maintenance (O&M) manual for the sewerage pump station in KVMRT Sg. Buloh Depot.
1.1 Purpose
The purpose of this document is to be used as a guide for proper operation and
maintenance for the sewerage pump station. This is to prevent damages blockage, which
might result in losses. This manual should be read carefully before any operation and
maintenance works. Proper operation instruction and procedure must be adhered to ensure
optimum efficiency and to pro-long the life span of the equipment.
1.2 Scope
This manual shall cover and explains operation and maintenance procedure required for the
sewerage pump station in KVMRT Sungai Buloh Depot.
1.3 Abbreviations
Abbreviation Definition
KVMRT Klang Valley Mass Rapid Transit
1.4 Definitions
Terms Definition
Project Projek Mass Rapid Transit Lembah Klang ~ Sungai Buloh-
Kajang
Page 9 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
3 REFERENCES
KVMRT-PDP1-SBK-SC08A-
Operation and Maintenance Manual Specification
SYSW-SPC-OPM-000001
1.6 Standards
1. Maintenance Staff
3 Maintenance Manual
2. Training Staff
1. Maintenance Staff
4 Illustrated Part Catalogue
2. Training Staff
Page 10 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
This manual shall provide the general information for sewerage pump station in KVMRT
Sungai Buloh Depot including suppliers details, operation and maintenance information for
the installed equipment.
Through gravity, the domestic wastewater collected from all the buildings in KVMRT Sungai
Buloh Depot will end up flowing into the last manhole and subsequently into the primary
screen chamber of the pump station.
This is where the raw wastewater will undergo the primary screening before it is
accumulated in pump sump. The untreated raw wastewater will, when it reaches certain
level, be pumped up, through D.I. force main, into the nearest and approved existing public
sewer manhole, which would lead to an existing public sewage system.
This is often the first stage of treatment in pump station. The screen must be provided
upstream of flow to protect the downstream processes and equipments from rags, woods
and other junky debris as well as to reduce interference with in-plant flow and performance.
All solids must be removed from the collection bin and disposed off regularly by the SPAN
licensed contractor.
1 Pump Sump
Inlet of pumping sump must be preceded by primary screen for protection of pumps from
being damaged or clogged. The inlet pumps of treatment works have to be equipped
with sewage application pumps and not water pumps. This is due to the characteristic of
the sewage flow that is not compatible with normal water pumps. The raw sewage will be
pumped via 2 nos. raw sewage submersible pumps to, in this case, an existing public
sewer manhole at the neighboring housing estate.
Page 11 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
Except during the two designated peak flow moments when two pumps are pumping, only
one pump will be operating in normal flow situation. During normal operations, the pump
is automatically controlled by a high/ low level switches (floating ball).
1. Switch on the MCCB (Moulded Case Circuit Breaker) to give power to the
switchboard.
2. Switch on all the MCB (Miniature Circuit Breaker) on the switchboard.
3. Check if the timer settings for other mechanical equipments that are controlled by
time switch are properly set. Ensure that all valves are opened before pumps are
turned on.
4. Turn on all the selector switches for all equipments to the M (manual) position and
test run the equipment one after another.
5. If all the equipments are in order, then turn on all the selector switches to the A
(auto) position for automated operation. It is advised not to shut down the entire
treatment plant unless under specific circumstances and reason.
This section shall cover the maintenance instructions upon first operation of the plant.
This section shall brief general safety information and advice to be considered during the
maintenance operation.
Fence
Fences must be in good condition covering the whole site boundary. There must be no gaps
in or under the fence of more than 100mm. Fences will be minimum 8 feet high. The fence
will have a method of deterring climbing (barbed wire).
Access
Access shall be sufficient width to allow tankers to enter site without to cause damage to the
vehicle, fence, gates or surrounding property and pavements.
Service Condition
MMC-GAMUDA KVMRT (PDP) SDN BHD Page 12 of 35
Page 12 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
Odour Levels
The contractor will ensure no unpleasant odors due to operational activities are detectable
outside the site boundary. There will not be any persistent smells or hydrogen Sulphide in
tanks, channels, pump wells, open chambers and plant enclosures.
Main Switchboard
This plant is designed to run in automated mode, therefore it is important to make sure all
push-button are turned on and are set on automatic mode. All checking and testing involving
electrical panel must be done by a qualified person as this panel incoming current involve 3
phase. (415v).
This section shall provide sufficient information for the Operators Maintenance Personnel to
define the required maintenance planning data. The following preventive maintenance tasks
shall be conducted at least once every month for the all electrical and mechanical
equipment:-
1.9.3.1 Lubrication
1.9.3.2 Penstocks
Page 13 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
Remove, clean, and test level regulators / sensors and adjust accordingly
Routine Inspection
The frequency of Operation and Maintenance (O&M) visit to the pump station shall
be weekly basis.
Task Description
Item Task
Read and record all designated meters (e.g. hours run, ampere
1 readings etc) attach Form/Checklist.
Item Task
Page 14 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
Item Task
1 Check all equipment for correct operation
Item Task
1 General cleaning
Corrective maintenance shall refer to Appendix 2 Troubleshooting & Instruction Manual for
Sewerage Pump.
Workshop Maintenance & Overhaul shall refer to Appendix 2 Troubleshooting & Instruction
Manual for Sewerage Pump.
The section is prepared for the use of maintainer and contains information relating to the
provisioning, requesting, storing and issuing spare parts required for all levels of
maintenance activities.
Page 15 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
2 nos
1. Raw Sewerage Pump Ebara 100 DML 511 11.0 kW (1 Duty; 1 Standby)
Equipment
Model Supplier/Address Tel/Fax
Description
Ebara Pumps Malaysia Sdn. Bhd. Tel: 03-55691655
Raw Sewerage Ebara
20, Jalan Juruhebah U1/50, Fax: 03-
Pump 100 DML 511
Temasya Industrial Park, 55693766
40150 Shah Alam,
Selangor Darul Ehsan
This section is not applicable for Sewerage Pumping Station Manual. Any replacement shall
contact the supplier of the material Ebara Pump Malaysia Sdn Bhd.
1.10.6 Disposal
Page 16 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
Page 17 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
Appendix 1
Product Catalogue
Page 18 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 19 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 20 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 21 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 22 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
Appendix 2
Sewerage Pump
Trouble Shooting and Instruction
Manual
Page 23 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 24 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 25 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 26 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 27 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 28 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 29 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 30 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 31 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 32 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 33 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 34 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
MMC-GAMUDA KVMRT (PDP) SDN BHD
Page 35 of 35
KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023