/ SOUTH COAST WATER DISTRICT
Providing Quality Water and Wastewater Services to the Coastal Communities

LIFT STATION

DAILY/WEEKLY MAINTENANCE PROCEDURES

1)Enter the station through Ritz Cove. To open gate, push key symbol twice then enter the security code.* Drive down to the station.

2)Open the double gate with the Schlage key and park next to the lift Station.

3)Check the outer perimeter of the lift station for security breaches.

4)Notify West Street office (control). Inform them that you will be entering the lift station and will call back after you have completed your work. They will then know that you have tripped any entry alarms they receive.

5)Unlock the door with the key stamped “LS #6” or Main Office” and enter the lift station.

6)Flip the switch on the right to turn on the lights.

7)Take immediate note of any generator, pump or fan running, alarms, open doors, unusual noises or odors.

8)Lift the handset to check the phone line. If there is no dial tone, contact the support services communication technician.

9)Check the HAND/OFF/AUTO switch on all pumps. They must be set to AUTO.

10)Enter pump readings from the hour meters in the “Monthly Pump Run Time Log”.

11)Check the wet well level and enter it in the “Monthly Pump Run Time Log”. Average level should be about 3.5’. High level (~4.5’) will automatically activate a second pump.

12)Alternate the lead pump selection. (Every Monday)

13)Push the PURGE button to purge the TESCO panel manually. The system is set to purge every 8 hours automatically. Manual purge verifies that the system is working.

14)One at a time, run test each pump by setting the HAND/OFF/AUTO switch to the OFF position. Then switch from the VFD setting to constant speed andlet the pump run at full speed for 20 seconds. Observe the wet well level dropping to verify that the pump is working and return the VFD switch to the AUTO setting.

15)Note any alarms on the TESCO panel.

16)Wipe down the TESCO panel.

17)Check the lower and upper motor temperature by holding a temperature gun approximately 12” away from the heat source. (Every Monday) Record the temperature on the daily checklist. The motor temperature will normally be from 10°F to 60°F above the surrounding air. A higher temperature may indicate incorrect pump alignment, over-greasing or bearing failure.

18)Note any unusual vibrations that might indicate a balance problem.

19)Check emergency generator (Every Monday):

  • Check diesel fuel level in both tanks. (Note: at 500 gal. notify fleet mechanic to purchase diesel fuel.)
  • Check oil level.
  • Check water level.
  • Check battery cell level.
  • Check power ready mode.
  • Check day tank.

20)Invert the float to start the small dry well sump pump and verify that it is operating.

21)Visually inspect all pumps. Look for signs of leaks around valves and piping that might indicate wear, failure or excessive vibration.

22)Remove the packing shield. Adjust the packing to a slight drip as needed. Over-tightening may cause excessive wear or over-heat the stuffing box. Change the packing if necessary. After the packing is removed, check the shaft sleeve for wear before placing the new packing.

23)Hose down the packing area with potable water if necessary.

24)Inspect the valve positions. The suction and discharge valves should be completely open and the bleeder valves should be completely closed.

25)Hose down the floor of the lift station.

26)Notify West Street office (control) that you have completed your work and are leaving the station. They will then know that they should return to normal response for alarm calls.

/ SOUTH COAST WATER DISTRICT
Providing Quality Water and Wastewater Services to the Coastal Communities

LIFT STATION

MONTHLY MAINTENANCE PROCEDURES

1)Check that exhaust fan is running and make sure all safety guards are in place.

2)Run test air compressor:

  • Check oil level.
  • Check belts for cracks.
  • Manually drain air tank.
  • Make sure all safety guards are in place.

3)Push and release the lever to test the diesel day tank.

4)Push in the black TEST button to test the diesel alarm. Hold for 5 seconds, then release. Push the red RESET button to reset the alarm system.

5)Check condition of fire extinguishers.

6)Check condition and availability of personal safety equipment. Wear proper gloves and safety glasses when working on any equipment. Do not proceed if any piece of equipment is missing or in questionable condition. Wear hearing protection. Exposure to high decibel levels for a long period of time may cause hearing damage.

7)Follow SCWD’s hazardous energy control program lockout/tagout procedure to isolate pump #1 from the system and set the HAND/OFF/AUTO switch to the OFF position.

8)Exercise the isolation valves on the large dry well pump, the small sump pump and the force main. One at a time, close each valve all the way to form a tight seal. Open the valve all the way again and back it off 1/4 turn.

9)Inspect the pump:

  • Close the suction valve by turning it clockwise all the way to form a tight seal. Close the discharge valve in the same way.
  • Loosen inspection plate on the elbow without removing it and drain off water.
  • Remove both inspection plates completely.
  • Inspect for rags and other debris inside the impeller and the pump volute. If debris is found, carefully try to dislodge it. Beware of sharp objects.
  • Check the impeller clearance to be sure that the impeller is not grinding against the housing at any point.

  • If an object is too large to remove through the inspection plate opening, derag the pump by disconnecting the driveline from the pump. Raise the pump head to remove the object. After the object is removed, lower the pump head and reconnect the driveline.
  • After inspection and/or deragging are complete, replace the inspection plates.

10)Inspect the check valves for rags, debris or any other objects that would hinder smooth operation of the valve.

11)Turn the suction valve slightly counterclockwise to open it and vent air from the pump through the bleeder valve. Open the discharge valve all the way and back it off 1/4 turn. After all the air is out of the pump, open the suction valve completely. Make sure both valves are open (back off 1/4 turn).

12)One at a time, run test each pump by setting the HAND/OFF/AUTO switch to the OFF position. Then switch from the VFD setting to constant speed and let the pump run at full speed for 20 seconds. Observe the wet well level dropping to verify that the pump is working and return the VFD switch to the AUTO setting.

13)If everything is okay, set the HAND/OFF/AUTO switch to the AUTO position.

14)Reverse the lockout/tagout procedure to bring the pump back on line.

Isolate each pump in turn to inspect and derag each one.

15)After all of the pumps have been deragged, return the station to normal operation.

/ SOUTH COAST WATER DISTRICT
Providing Quality Water and Wastewater Services to the Coastal Communities

LIFT STATION

QUARTERLY MAINTENANCE PROCEDURES

IMPORTANT NOTE: The proper confined space entry procedures must be followed and a Confined Space Entry Permit must be filled out before entering the wet well. All necessary safety equipment must be in place and used correctly. Proper ventilation must be established and maintained and three people must be present whenever a worker is in the wet well, an entrant, an observer and a supervisor.

1)Check grease lubricated bearings. If the grease is whitish in color, water or some other fluid is leaking past the bearing shaft seal causing saponification. When saponification occurs, wash out the bearings with kerosene and replace the grease with the proper type as recommended by the pump manufacturer.

2)Grease the pumps and drivelines.

3)Remove and replace odor pellets in manhole next to lift station at south side of building.

WET WELL CLEANING

Wet well cleaning is to be done under low peak flow conditions, i.e. midnight. (No exceptions.)

4)Enter the station through Ritz Cove. To open gate, push key symbol twice then enter the security code.* Drive down to the station.

5)Open the double gate with the Schlage key and park next to the lift Station.

6)Check the outer perimeter of the lift station for security breaches.

7)Notify the answering service that you will be entering the lift station and will call back after you have completed your work. They will then know that you have tripped any entry alarms they receive.

8)Unlock the door with the key stamped “Lift Station 6” and enter the lift station.

9)Flip the switch on the right to turn on the lights.

10)Do not proceed without a Confined Space Entry Permit sheet. Two people must be present, the worker that will enter the wet well and an attendant.

  • Write the location, date and time on the Confined Space Entry Permit.
  • Remove the hatch cover and test the atmosphere of the wet well for oxygen (O2), methane (CH4), hydrogen sulfide (H2S) and carbon monoxide (CO) and enter the readings on the Confined Space Entry Permit.
  • After you have established that it is safe to enter the wet well, set up the ladder. The entrant will wear a harness with lifeline.
  • Climb down the ladder into the wet well.
  • Take atmospheric readings in the wet well every 15 minutes.

11)Remove the railing and covers from the wet well.

12)Pump the wet well all the way down to the floor.

13)Isolate all three pumps by turning the HAND/OFF/AUTO switch to the HAND setting.

14)Use two 12-inch plugs to stop flow into the wet well.

15)Monitor the upstream manhole with standby vacuum truck.

16)Set up the vacuum truck and start vacuuming.

17)Wash down the entire wet well and scrape the walls as necessary.

18)Inspect the bubbler system to be sure that pipes and hoses are secured and not cracked or broken.

19)Flush the inlet piping to the pump room and visually inspect the piping for foreign matter or debris.

20)Remove all tools and equipment from the wet well.

21)Remove the plugs that isolate the wet well.

22)Allow the water level to rise high enough to bleed all the pumps.

23)One at a time, run test each pump by setting the HAND/OFF/AUTO switch to the OFF position. Then switch from the VFD setting to constant speed and let the pump run at full speed for 20 seconds. Observe the wet well level dropping to verify that the pump is working and return the VFD switch to the AUTO setting.

24)If everything is ok, set the HAND/OFF/AUTO switch on all three pumps back to the AUTO setting.

25)Reset all alarms.

26)Return wet well covers and railings to their proper places.

27)Contact the answering service to let them know you are finished with the maintenance.

28)Remember to turn off the lights and lock the gates as you leave the station.

/ SOUTH COAST WATER DISTRICT
Providing Quality Water and Wastewater Services to the Coastal Communities

LIFT STATION

SEMI-ANNUAL MAINTENANCE PROCEDURES

IMPORTANT NOTE: The proper confined space entry procedures must be followed and a C-5 form must be filled out before entering the air vac manhole. All necessary safety equipment must be in place and used correctly. Proper ventilation must be established and maintained and an observer must be present whenever a worker is in the manhole.

1)Check the packing and replace it if necessary with the grade recommended by the manufacturer. Be sure that the seal cages are centered at the entrance of the stuffing box piping connection.

2)If the packing is being replaced, check the shaft and shaft sleeve for scoring while the packing is out of the stuffing box. Scores on the shaft or sleeve can accelerate packing wear.

3)Replace the air-vac located in a manhole at the South East corner of the building with the rebuilt air-vac from the shelf in the lift station. Do not proceed without a C-5 form. Two people must be present, the worker that will enter the manhole and an attendant.

  • Write the location, date and time on the C-5 sheet.
  • Test the atmosphere of the manhole for oxygen (O2), methane (CH4), hydrogen sulfide (H2S) and carbon monoxide (CO) and enter the readings on the C-5 form.
  • After you have established that it is safe to enter the manhole, remove the lid with a manhole cover remover or popper.
  • Set up the tripod. The entrant will wear a harness with lifeline and approved SCBA.
  • Lower the entrant into themanhole.
  • Take atmospheric readings in the manhole every 15 minutes.
  • Close the 2" gate valve below the air-vac to isolate it and release excess pressure in the air-vac.
  • Remove the air-vac using two 24" pipe wrenches; one for backup and the other for removal.
  • Install rebuilt air-vac and make sure all plumbing is in good working order. Replace worn pipe and fittings as necessary.

/ SOUTH COAST WATER DISTRICT
Providing Quality Water and Wastewater Services to the Coastal Communities

LIFT STATION

ANNUAL MAINTENANCE PROCEDURES

1)Push in the red TEST button to test the hydrostatic alarm. Hold for 5 seconds, then release. Push the black RESET button to reset the alarm system. The hydrostatic alarm indicates water intrusion. Note the seasonal level.

2)Remove the rotating element and inspect it thoroughly for wear. Order replacement parts if necessary. Check wearing clearances. Remove any deposits or scaling. Clean out the stuffing box piping.

3)Measure total dynamic suction head and discharge head as a test. This is especially important where the fluid being pumped tends to form a deposit on internal surfaces.

4)Inspect the check valves. The check valves safeguard against reverse flow when the pump stops. A faulty check valve will also cause poor operational pump performance.