OM - Sewerage Pumping Station

MMC-GAMUDA KVMRT (PDP) SDN BHD
PROJEK MASS RAPID TRANSIT LEMBAH KELANG JAJARAN SUNGAI BULOH

KAJANG
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
Document No. : KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
WPC Ref. No. : N/A
Revision : 00
Date Issued : 30/09/2016
Prepared by Reviewed by Approved by
NOORIDAYU DAVID KHOO

Name Name CHIN MIN NGEE Name
MAT RIPIN TAT WAI
SR.
QAQC PROJECT
Position Position CONSTRUCTION Position
MANAGER MANAGER
MANAGER
MMC-GAMUDA KVMRT (PDP) SDN BHD Page 1 of 35

KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023
SEWERAGE PUMPING STATION Revision: 00
REVISION HISTORY
REVISION NO. ISSUE DATE DETAILS OF REVISION

00 23/03/2016 Initial Submission
Page 2 of 35
TABLE OF CONTENTS
Page 3 of 35
1 INTRODUCTION 5
1.1 PURPOSE 5
1.2 SCOPE 5
2 ABBREVIATIONS & DEFINITIONS 5
2.1 ABBREVIATIONS 5
2.2 DEFINITIONS 5
3 REFERENCES 6
3.1 PROJECT DOCUMENTS 6
3.2 STANDARDS 6
4 O&M DOCUMENT STRUCTURE 6
5 O&M MANUAL CONTENT 7
5.1 VOLUME 1: GENERAL INFORMATION 7
5.1.1 INTRODUCTION 7
5.1.2 DESIGN CONCEPT 7
5.1.3 FEATURES & PERFORMANCE 7
5.1.3.1 PRIMARY SCREEN CHAMBER 7
Page 4 of 35
5.1.3.2 PUMP SUMP 7
5.2 VOLUME 2: OPERATION MANUAL 8
5.3 VOLUME 3: MAINTENANCE MANUAL 8
5.3.2 SAFETY INFORMATION 8
5.3.3 MAINTENANCE PLANNING DATA 9
5.3.3.1 LUBRICATION 9
5.3.3.2 PENSTOCKS 9
5.3.3.3 PUMPS AND ANCILLARY 9
5.3.3.4 VALVE AND PIPEWORKS 9
5.3.3.5 LEVEL CONTROL 9
5.3.4 PREVENTIVE MAINTENANCE 10
5.3.4.1 MAINTENANCE WORKS 10
5.3.5 CORRECTIVE MAINTENANCE 11
5.3.6 WORKSHOP MAINTENANCE & OVERHAUL 11
5.4 VOLUME 4: ILLUSTRATED PART CATALOGUE 11
5.4.2 SAFETY INFORMATION 12
Page 5 of 35
5.4.3 CLASSIFICATION OF SPARE PARTS 12
5.4.4 PARTS CATALOGUE 12
5.4.5 STORAGE REQUIREMENTS 12
5.4.6 DISPOSAL 12
5.5 VOLUME 5: DIAGNOSTIC TEST EQUIPMENT & SPECIAL TOOLS MANUAL 12
APPENDIX 1 PRODUCT CATALOGUE

APPENDIX 2 SEWERAGE PUMP TROUBLESHOOTING & INSTRUCTION MANUAL
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
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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.
2 ABBREVIATIONS & DEFINITIONS

The following table lists out the abbreviation and acronyms used in this document.
1.3 Abbreviations
Abbreviation Definition
KVMRT Klang Valley Mass Rapid Transit
MRT Corp Mass Rapid Transit Corporation Sdn Bhd
PDP Project Delivery Partner
IPC Illustrated Part Catalogue
Table 2-1: Table of Abbreviations
1.4 Definitions
Terms Definition
Project Projek Mass Rapid Transit Lembah Klang ~ Sungai Buloh-
Kajang
Table 2-2: Table of Definitions
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3 REFERENCES
1.5 Project Documents
Document Number Document Title
KVMRT-PDP1-SBK-SC08A-
Operation and Maintenance Manual Specification
SYSW-SPC-OPM-000001
As-Built Drawings Sewerage Pump Station
Table 3-3: List of References ~ Contractual Documents
1.6 Standards
Document Number Document Title
Guidelines for Developers Sewer Networks and Pump Station

Vol. III (Malaysian Sewerage Industry Guidelines)
Table 3-4: List of References ~ Standard
4 O&M DOCUMENT STRUCTURE

The O&M Manual shall consist of four (4) major volumes as described in Table 4-1. This
arrangement will allow different users referring to the relevant volume easily without having
to read whole document. This O&M manual for sewerage pump station does not include the
Volume 5: Diagnostic Test Equipment & Special Tools Manual which is not applicable.
Volume Manual Title Key End User Remarks

1. Operation Staff
1 General Information Manual 2. Maintenance Staff
3. Training Staff
1. Operation Staff
2 Operation Manual
2. Training Staff
1. Maintenance Staff
3 Maintenance Manual
2. Training Staff
1. Maintenance Staff
4 Illustrated Part Catalogue
2. Training Staff
Diagnostic Test Equipment & 1. Maintenance Staff

5 Not Applicable
Special Tools Manual 2. Training Staff
Table 4-1: O&M Manual Structure
Page 10 of 35
5 O&M MANUAL CONTENT

This section describes the details information of material and finishes use at the respective
buildings including typical maintenance action or activities in effective manners.
1.7 Volume 1: General Information Manual

1.7.1 Introduction
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.
1.7.2 Design Concept
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.
1.7.3 Features & Performance
1.7.3.1 Primary Screen Chamber
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.
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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).
1.8 Volume 2: Operation Manual

The sewerage pump station is designed to run in automated mode with change over to
manual mode. The followings are the step-by-step description to start up and shut down the
plant: (Please also refer to the electrical circuit drawing for better understanding)
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.
1.9 Volume 3: Maintenance Manual

1.9.1 Introduction
This section shall cover the maintenance instructions upon first operation of the plant.
1.9.2 Safety Information
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
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Plant and equipment must be maintained by SPAN-licensed contractor at all times.
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).
1.9.3 Maintenance Planning Data
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
Check / Change / Top up lubricant oil

Service / Replace oil filters
Grease Bearing (It is important to grease as per manufacturer instructions. Lack of
greasing is a major cause of breakdowns. Care has to be taken when greasing the
bearings on electric motors as too much grease can be as harmful as lack of
grease).
1.9.3.2 Penstocks
Inspect, clean and grease operating spindles

Inspect and tighten if necessary all connections, joints, bolts, nuts etc
Repaint with approved epoxy paint all expose bare metal of frame and gate
1.9.3.3 Pumps and Ancillary
To lift up the pump and clean the impeller

Check lifting guide rails and to make sure it is in right position
Check condition of the electrical cables and to make sure that there is no cuts or
swellings
To check cable entry into pump for tightness or any faulty sealant
To off the isolator switch button before lifting up the pumps
1.9.3.4 Valve and Pipework
Check for any blockage in pipework

Page 13 of 35
Clean, inspect and lubricate or grease all valves

Check if valves operate correctly after maintenance and no flow passes through
after the valve is closed.
1.9.3.5 Level Control
Remove, clean, and test level regulators / sensors and adjust accordingly
1.9.4 Preventive Maintenance
1.9.4.1 Maintenance Works:
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.
Visual check plant for vandalism and theft

2
3 Operate, lubricate valves and penstocks not in regular use
Check security of grating, sump covers and fencing.

4
5
Clean access roads within site boundary
6
Cut the grass and remove rubbishes
Table 5.1 General
Item Task
1 Clean screen area and dispose of screenings
2 Hose down area and clean out screen bars

Clear rubbishes and large debris from screenings
3
Channel
Page 14 of 35
Table 5.2 Primary Screen Chamber
Item Task
1 Check all equipment for correct operation
2 Clean wet well level control equipment
3 Change duty/ standby rota
Table 5.3 Pump Sump (Wet Well)
Item Task
1 General cleaning
Table 5.4 - Control Panel
1.9.5 Corrective Maintenance
Corrective maintenance shall refer to Appendix 2 Troubleshooting & Instruction Manual for
Sewerage Pump.
1.9.6 Workshop Maintenance & Overhaul
Workshop Maintenance & Overhaul shall refer to Appendix 2 Troubleshooting & Instruction
Manual for Sewerage Pump.
1.10 Volume 4: Illustrated Part Catalogue

1.10.1 Introduction
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.
No Type Brand Model Power Quantity

Page 15 of 35
2 nos
1. Raw Sewerage Pump Ebara 100 DML 511 11.0 kW (1 Duty; 1 Standby)
Table 5-5: Product Material Details 1
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
Table 5-6: List of Supplier
1.10.2 Safety Information
Safety information shall refer to item 5.3.2 Safety Information.
1.10.3 Classification of Spare Parts
This section is not applicable for Sewerage Pumping Station Manual. Any replacement shall
contact the supplier of the material Ebara Pump Malaysia Sdn Bhd.
1.10.4 Parts Catalogue
Please refer to the Ebara Pump Catalogue Appendix 1.
1.10.5 Storage Requirements
This section is not applicable for this manual.
1.10.6 Disposal
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1.11 Volume 5: Diagnostic Test Equipment & Special Tools Manual

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Appendix 1
Product Catalogue
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Appendix 2
Sewerage Pump
Trouble Shooting and Instruction
Manual
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MMC-GAMUDA KVMRT (PDP) SDN BHD

PROJEK MASS RAPID TRANSIT LEMBAH KELANG JAJARAN SUNGAI BULOH

Document No. : KVMRT-TRC-SBK-PKG1-SUBD-MAN-OPM-000023

WPC Ref. No. : N/A

Date Issued : 30/09/2016

Prepared by Reviewed by Approved by

NOORIDAYU DAVID KHOO

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 1 of 35

REVISION NO. ISSUE DATE DETAILS OF REVISION

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 2 of 35

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 3 of 35

2 ABBREVIATIONS & DEFINITIONS 5

3.1 PROJECT DOCUMENTS 6

4 O&M DOCUMENT STRUCTURE 6

5 O&M MANUAL CONTENT 7

5.1 VOLUME 1: GENERAL INFORMATION 7

5.1.2 DESIGN CONCEPT 7

5.1.3 FEATURES & PERFORMANCE 7

5.1.3.1 PRIMARY SCREEN CHAMBER 7

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 4 of 35

5.1.3.2 PUMP SUMP 7

5.2 VOLUME 2: OPERATION MANUAL 8

5.3 VOLUME 3: MAINTENANCE MANUAL 8

5.3.2 SAFETY INFORMATION 8

5.3.3 MAINTENANCE PLANNING DATA 9

5.3.3.3 PUMPS AND ANCILLARY 9

5.3.3.4 VALVE AND PIPEWORKS 9

5.3.3.5 LEVEL CONTROL 9

5.3.4 PREVENTIVE MAINTENANCE 10

5.3.4.1 MAINTENANCE WORKS 10

5.3.5 CORRECTIVE MAINTENANCE 11

5.3.6 WORKSHOP MAINTENANCE & OVERHAUL 11

5.4 VOLUME 4: ILLUSTRATED PART CATALOGUE 11

5.4.2 SAFETY INFORMATION 12

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 5 of 35

5.4.3 CLASSIFICATION OF SPARE PARTS 12

5.4.4 PARTS CATALOGUE 12

5.4.5 STORAGE REQUIREMENTS 12

5.5 VOLUME 5: DIAGNOSTIC TEST EQUIPMENT & SPECIAL TOOLS MANUAL 12

APPENDIX 1 PRODUCT CATALOGUE

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 6 of 35

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 7 of 35

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 8 of 35

2 ABBREVIATIONS & DEFINITIONS

MRT Corp Mass Rapid Transit Corporation Sdn Bhd

PDP Project Delivery Partner

IPC Illustrated Part Catalogue

Table 2-1: Table of Abbreviations

Table 2-2: Table of Definitions

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 9 of 35

1.5 Project Documents

Document Number Document Title

As-Built Drawings Sewerage Pump Station

Table 3-3: List of References ~ Contractual Documents

Document Number Document Title

Guidelines for Developers Sewer Networks and Pump Station

Table 3-4: List of References ~ Standard

4 O&M DOCUMENT STRUCTURE

Volume Manual Title Key End User Remarks

Diagnostic Test Equipment & 1. Maintenance Staff

Table 4-1: O&M Manual Structure

MMC-GAMUDA KVMRT (PDP) SDN BHD Page 10 of 35