LIFT PUMP AT WASTEWATER TREATMENT PLANT

2022-02-24

Report by Victor Banerjee

Troubleshooting by John Long and Derrick Mahoney

INITIAL PROBLEM
Out of wastewater lift pumps A,B, and C, only B remained functional. Without a working lift pump, the plant would
have to shutdown. Having a backup is deemed critical by utilities.

HISTORY
Pump A was thought to be removed and currently in the maintenance shop.

Pump B remained functional. Figure 1

Pump C had power but was not functional.

PRE-INVESTIGATION ACTIONS
Utilities organized confirmed space for entry.

Maintenance Lead recommended pre-entry investigation.

FIGURE 1 PUMPS FUNCTION
There is no safe way to isolate wastewater discharge from the plant currently and entry was canceled.

INVESTIGATION PROCESS
ATTEMPT TO START PUMP C
To assist the pump, lift station tank was filled to 70% of capacity to reduce
head pressure and remove any air lock. Production assisted by dumping
rinse water tank from goat line 2. This did not appear to have made any
changes.

ELECTRICIAN DIAGNOSTICS
Electrician began troubleshooting from the control panel (Figure 2) to fuses.
All components were traced from breakers, following lines and at power
isolation switches. This only led to confusion as the power signals were not
logical. Motor had power but sensor errors were present. The motor was
not giving any load indications.
FIGURE 2 UTILITY PUMP PANEL

1
 CONTINUITY OF LINES TO PLUG
The entry covers to the lift station pumps were lifted and the disconnected plug from pump was accessed.
At the outside distribution panel, power from the power isolation switches were tested against the plug.
This found that pump A was removed instead of pump C. Moreso the wires were mismatched between
the pumps. The power to each pump was correct however the feedback sensors were entirely opposite.

SOLUTION AND REPAIRS

The electrician diagnosed which wire is supposed to connect to the correct
location. Power to pumps A and C remained as they were and all sensor
connections switched. The wires were disorganized (Figure 3) but they
were rectified and resolved the issue.

Covers of panels and access hatches were replaced. The pumps were
tested and only Pump C remained out of service. They were set back to
auto with the parameters set to start when the tank reaches 30% capacity.

CONCLUSION
Wastewater lift pump issue was resolved without having to enter confined
space. It saved significant time and costs as well as done in a much safer
manner with proper investigation.

FIGURE 3 WIRING ISSUES

Victor Banerjee, Mech Eng

Mechanical Reliability Engineering
Canada Royal Milk ULC
1680 Venture Drive
Kingston ON K7P 0E9
T: 613-817-1228 x 9566
M: 613-484-3280
banerjee@canadaroyalmilk.com