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Common Wastewater Pumping Issues

For Troubleshooting
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Lily Feng
Application Engineer
GC Transport
Common wastewater pump issues

Clogging

Corrosion
Waterhammer

Vibration &
Cavitation
Noise

Physical Motor
Damages Overheating

Abnormal Abnormal
Flow Current
Adverse
hydraulic
Wear
phenomena
Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Clogging

Clogging is the most common operational issue in wastewater pumping.

Result in:
 Reduced pump efficiency
 Pump tripping—more
emergency calls
 Increased operational and
maintenance cost
 Environmental issues from
overflow.

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Soft clogging
A gradual build-up of solids and fibers in the hydraulic end, when the pump
stops the buildups can be flushed back to the sump, and when the pump
restarts it works normally.

Result in
 Decreasing/unstable flow
 Increasing/unstable current
 Vibration and noise

Verification
Start/run/stop the pump at least three cycles and write down water level, flow, current or
power for analysis.
Soft clogging
Case study—Guangzhou Lijiao STP, China.
4 units C3602

Flow

1 2 3

Water level

Time
Pump stop
Hard clogging

A large piece existing in the pump hydraulics


stops the pump.

Soft clogging

Hard clogging

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Clogging Actions

Item First assessment of causes Remedial Action

1 Long running cycle without alternation Alternate the pumps every certain hours
Clogging Actions

Item First assessment of causes Remedial Action

1 Long running cycle without alternation Alternate the pumps every certain hours

Increase min. speed setting and run the pump at


2 Pump runs at very low speed (VFD)
full speed regularly
Clogging Actions

Item First assessment of causes Remedial Action

1 Long running cycle without alternation Alternate the pumps every certain hours

Increase min. speed setting and run the pump at


2 Pump runs at very low speed (VFD)
full speed regularly

3 Pump always runs at high water level Stop the pump at snoring level regularly
Clogging Actions
Cleaning cycle

Stop the pump at the snoring water


level regularly to remove
 Sediments
 Floating debris
Clogging Actions

First assessment of causes


Item Remedial Action

1 Long running cycle without alternation Alternate the pumps every certain hours

Increase min. speed setting and run the pump at full


2 Pump runs at very low speed (VFD)
speed regularly

3 Pump always runs at high water level Stop the pump at snorning level regularly

1)Install flush valve or APF if possible


2)Stop the pump at snorning level regularly
4 Pump sump is badly designed/too big 3)Clean the pump sump regularly
4)Optimize the sump design, add walls and slope to
minimize dead area if possible
Clogging Actions

First assessment of causes


Item Remedial Action

1 Long running cycle without alternation Alternate the pumps every certain hours

Increase min. speed setting and run the pump at full


2 Pump runs at very low speed (VFD)
speed regularly

3 Pump always runs at high water level Stop the pump at snoring level regularly

1)Install flush valve or APF if possible


2)Stop the pump at snorning level regularly
4 Pump sump is badly designed/too big 3)Clean the pump sump regularly
4)Optimize the sump design, add walls and slope to
minimize dead area if possible
Pump hydraulics design is not suitable
5 Modify/upgrade the pump hydraulics
for the application
Clogging Actions
Modify/upgrade hydraulics

Modified leading edge N-technology


Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Vibration & noise
Vibration is a mechanical phenomenon whereby
oscillations occur around an equilibrium point.
Vibration also creates pressure waves– noise.
Vibration and noise are closely related.
Flygt vibration standard: 7.1mm/s
Flygt vibration sensor’s settings:
 15mm/s---alarm
 25mm/s—stop the pump

Result in:
 Mechanical seals failure
 Decreased bearing life
 Damaged pipe/accessories
Vibration & noise Actions
Item First assessment of causes Remedial Action
1 Unqualified installation/support Enhance the fixing
Vibration & noise Actions
Installation considerations
Vibration & noise Actions
First assessment of causes
Item Remedial Action

1 Unqualified installation/support Enhance the fixing


Change impeller or system so that the pump duty point is
2 Pump duty point is far from BEP
close to BEP
Vibration & noise Actions
First assessment of causes
Item Remedial Action

1 Unqualified installation/support Enhance the fixing


Change impeller or system so that the pump duty point is
2 Pump duty point is far from BEP
close to BEP
3 Pump clogging Check ’clogging’ Actions
4 Pump cavitation Check ’cavitation’ Actions
Vibration & noise Actions
First assessment of causes
Item Remedial Action

1 Unqualified installation/support Enhance the fixing


Change impeller or system so that the pump duty point is
2 Pump duty point is far from BEP
close to BEP
3 Pump clogging Check ’clogging’ Actions
4 Pump cavitation Check ’cavitation’ Actions

5 Adverse hydraulic phenomena Optimize sump design, add walls, splitters or slope etc.
Adverse hydraulic phenomena
 Excessive pre-swirl

 Uneven velocity at the pump intake

 Entrained air

 Vortices

Result in:
 Vibration and noise

 Cavitation

 Reduced pump efficiency

 Physical damages of the pump


Vibration & noise Actions
First assessment of causes
Item Remedial Action

1 Unqualified installation/support Enhance the fixing


Change impeller or system so that the pump duty point is
2 Pump duty point is far from BEP
close to BEP
3 Pump clogging Check ’clogging’ Actions

4 Pump cavitation Check ’cavitation’ Actions

5 Adverse hydraulic phenomena Optimize sump design, add walls, splitters or slope etc.

6 Unbalanced hydraulic parts Change/repair hydraulic parts


Vibration & noise
Unbalance
Vibration & noise Actions
First assessment of causes
Item Remedial Action

1 Unqualified installation/support Enhance the fixing

Change impeller or system so that the pump duty point is


2 Pump duty point is far from BEP
close to BEP
3 Pump clogging Check ’clogging’ Actions

4 Pump cavitation Check ’cavitation’ Actions

5 Adverse hydraulic phenomena Optimize sump design, add walls, splitters or slope etc.

6 Unbalanced hydraulic parts Change/repair hydraulic parts


Change part of the pumping system so that natural
7 Resonance
frequency and source frequency are not equal.
Vibration & noise
Resonance

Resonance is the tendency of a system to oscillate with greater amplitude at


some frequencies than at others.

Natural frequency

Resonance
Source frequency
Vibration & noise Actions
First assessment of causes
Item Remedial Action

1 Unqualified installation/support Enhance the fixing


Change impeller or system so that the pump duty point is
2 Pump duty point is far from BEP
close to BEP

3 Pump clogging Check ’clogging’ Actions

4 Pump cavitation Check ’cavitation’ Actions

5 Adverse hydraulic phenomena Optimized sump design, add walls, splitters or slope etc.

6 Unbalanced hydraulic parts Change/repair hydraulic parts


Change part of the pumping system so that natural
7 Resonance
frequency and souce frequency are not equal.
Some pumps have higher vibration and
8 Check with product engineer if it’s acceptable
noise than others
Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Cavitation
When the impeller/propeller's blades accelerate the fluid to pass the blades,
low-pressure areas are formed. If it reaches vapor pressure, the fluid
vaporizes and forms small bubbles of gas. When the bubbles implode later,
they cause very strong local shock waves in the fluid.

Result in:
 Noise--crackling sound

 Vibration

 Damage of hydraulic parts

 Reduced pump efficiency

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Cavitation Actions

First assessment of causes


Item Remedial Action

1) Increase submergence
1 NPSHav < NPSHre 2) Use VFD to reduce speed
3) Optimize inlet pipe if possible (dry installations)
Net Positive Suction Head (NPSH)
NPSHav ≥ NPSHre
NPSHav = Hatm + Hsub – Hev – Hloss

Hsub

Hloss  

Hatm – Atmospheric pressure—Elevation of the pump sump


Hsub – Submergence—Water level
Hev – Evaporation pressure –Liquid temperature
Hloss – Dynamic head loss in inlet/inlet pipe—Inlet/inlet pipe dimension/geometry

Application Engineering Conference Dordrecht 2014


Cavitation Actions

First assessment of causes


Item Remedial Action

1) Increase submergence
1 NPSHav < NPSHre 2) Use VFD to reduce speed
3) Optimize inlet pipe if possible (dry installations)

1) Build guide walls and splitters in the sump


2 Bottom or backwall vortex
2) Use formed suction inlet for P-pump
Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Wear

Wear means the loss of material from a surface due to abrasive particles in the
media.
When velocity increase by 50%, wear increases
2.64 times per pumped volume.

Result in:
 Worn hydraulic parts
 Mechanical seals failure
 Reduced pump efficiency
 High operation and maintenance cost

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Impeller material relative wear resistance

Accelerated wear test N-impeller hardness

Hardened
Material Impeller leading Flygt Recommendation
edge

WW without abrasives or
Grey iron 13 HRC 47 HRC
chlorides

WW with abrasives
Hard-Iron 37 HRC 60 HRC
and/or chlorides

Stainless Low pH liquids and


10-20
steel ---- projects where stainless
HRC
316/329 steel is a firm requirement

Note: Wear resistance for Hard-Iron is set at 10, the other


choices are normalized relative to this

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Wear Actions

Check if

 Change impeller material to hard iron?

 Special painting for hydraulic parts?

 Add sand trap before the pump?


Item
 Use metal hose to protect cable and

cable entry?

*Please contact application engineers to

get the best Action.


Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Corrosion

Corrosion is the gradual destruction of materials by chemical


reaction with its environment. Usually it happens to metals, but it
could happen to ceramics or polymers.

Result in:
 Damage of pump parts or accessories
 Cable or cable entry failure
 Mechanical seals leakage
 O-ring leakage

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Corrosion
Common metal corrosions in wastewater:
 General corrosion
 Occurs slowly
 Accelerated by pH, temp., oxygen, chlorides

 Erosion-corrosion
 High velocity water remove protective layer of material surface
 Accelerated by gas bubbles or solid particles

 Galvanic corrosion
 Different materials are in contact in the media
 is determined by magnitude of materials electrical
potential difference
 is determined by conductivity of the liquid

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Corrosion Actions
First assessment of causes
Item Remedial Action

1) Hard iron/stainless steel impeller


1 Low pH < 5.5 2) HCR cable or metal hose cable protection
3) RSiC mechanical seals

Item
Corrosion Actions
First assessment of causes
Item Remedial Action

1) Hard iron/stainless steel impeller


1 Low pH < 5.5 2) HCR cable or metal hose cable protection
3) RSiC mechanical seals

1) Hard iron/stainless steel impeller


2 Sea water, high chlorides >500ppm 2) Special coating
3) Zinc anodes
Item
Corrosion Actions
First assessment of causes
Item Remedial Action

1) Stainless steel/hard iron impeller


1 Low pH < 5.5 2) HCR cable or metal hose cable protection
3) RSiC mechanical seals

1) Stainless steel/hard iron impeller


2 Sea water, high chlorides >500ppm 2) Special coating
3) Zinc anodes
Item
3 High temperature media 40-70 deg.C Special coating
Corrosion Actions
First assessment of causes
Item Remedial Action

1) Stainless steel/hard iron impeller


1 Low pH < 5.5 2) HCR cable or metal hose cable protection
3) RSiC mechanical seals

1) Stainless steel/hard iron impeller


2 Sea water, high chlorides >500ppm 2) Special coating
3) Zinc anodes
Item
3 High temperature media 40-70 deg.C Special coating

4 High dissolved oxygen media Hard iron impeller


Corrosion Actions
First assessment of causes
Item Remedial Action

1) Stainless steel/hard iron impeller


1 Low pH < 5.5 2) HCR cable or metal hose cable protection
3) RSiC mechanical seals

1) Stainless steel/hard iron impeller


2 Sea water, high chlorides >500ppm 2) Special coating
3) Zinc anodes
Item
3 High temperature media 40-70 deg.C Special coating

4 High dissolved oxygen media Hard iron impeller

5 Other corrosive ingredients Check CREST or contact application engineer for suggestions
CREST-Version 5.2

CREST helps you determine whether a


selected Flygt or Lowara product is suitable
for a particular liquid.
 
The new version 5.2 includes: 
 Lowara products added
 Updated Flygt products  
 73 new materials added 

http://oasis.xyleminc.com/en-us/Home/our-value-center/is-it/Software/Pages/
CREST.aspx

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Wear & Corrosion — impeller selection
Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Motor Overheating

Motor sensor shows higher temperature than


normal. Motor can alarm, trip, even burn out.

Check:
 Motor submergence
 Power consumption
 Changes of flow or power during operation
 Voltage and current balance
 Coolant and cooling jacket
 MAS setting about alarming temperature, compensation, disturbance
Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
3 Faulty signal due to wrong Pt 100 setting Change the setting
Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
3 Faulty signal due to wrong Pt 100 setting Change the setting
Faulty signal due to long control cable
4 Compensate in MAS
between the pump and MAS
Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
3 Faulty signal due to wrong Pt 100 setting Change the setting
Faulty signal due to long control cable
4 Compensate in MAS
between the pump and MAS
Faulty signal due to unscreened cable Change to screened cable and keep at least 500mm between
5
between the pump and VFD power cable and control cable
Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
3 Faulty signal due to wrong Pt 100 setting Change the setting
Faulty signal due to long control cable
4 Compensate in MAS
between the pump and MAS
Faulty signal due to unscreened cable Change to screened cable and keep at least 500mm between
5
between the pump and VFD power cable and control cable
6 Clogging in the pump Check ''clogging Action''
Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
3 Faulty signal due to wrong Pt 100 setting Change the setting
Faulty signal due to long control cable
4 Compensate in MAS
between the pump and MAS
Faulty signal due to unscreened cable Change to screened cable and keep at least 500mm between
5
between the pump and VFD power cable and control cable
6 Clogging in the pump Check ''clogging Action''

7 Clogging in the cooling jacket Clean inside of the cooling jacket


Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
3 Faulty signal due to wrong Pt 100 setting Change the setting
Faulty signal due to long control cable
4 Compensate in MAS
between the pump and MAS
Faulty signal due to unscreened cable Change to screened cable and keep at least 500mm between
5
between the pump and VFD power cable and control cable
6 Clogging in the pump Check ''clogging Action''

7 Clogging in the cooling jacket Clean inside of the cooling jacket

8 Leakage of coolant (New midrange) Add enough coolant


Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
3 Faulty signal due to wrong Pt 100 setting Change the setting
Faulty signal due to long control cable
4 Compensate in MAS
between the pump and MAS
Faulty signal due to unscreened cable Change to screened cable and keep at least 500mm between
5
between the pump and VFD power cable and control cable
6 Clogging in the pump Check ''clogging Action''

7 Clogging in the cooling jacket Clean inside of the cooling jacket

8 Leakage of coolant (New midrange) Add enough coolant


Damaged propeller in mechanical seals
9 Replace mechanical seals
(New midrange, Slimline)
Motor Overheating Actions
First assessment of causes
Item Remedial Action
1 The motor is not submerged enough Top up the level
1)Change to smaller impeller so that the pump will not overload
2 Higher ambient temperature than expected
2)Add an external cooling system for the pump
3 Faulty signal due to wrong Pt 100 setting Change the setting
Faulty signal due to long control cable
4 Compensate in MAS
between the pump and MAS
Faulty signal due to unscreened cable Change to screened cable and keep at least 500mm between
5
between the pump and VFD power cable and control cable
6 Clogging in the pump Check ''clogging Action''

7 Clogging in the cooling jacket Clean inside of the cooling jacket

8 Leakage of coolant (New midrange) Add enough coolant


Damaged propeller in mechanical seals
9 Replace mechanical seals
(New midrange, Slimline)
Uneven voltage balance in the stator due to
10 Replace the stator
fauty stator windings
Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Wrong impeller rotation direction

Result in:
 Less/no flow
 Less current/power consumption
 Low efficiency

Reason:
Wrong connection between electrical phases

Action:
Invert two phases
Other common issues

 The pump doesn’t start

 The pump doesn’t stop when a level sensor is used

 The pump start-stops-starts in rapid sequence

 The pump runs but motor protection trips

 The pump delivers too little or no water

Actions
Check ’’Installation, Operation and Maintenance’’
brochure
Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Pipe Issue- Waterhammer
Waterhammer is a pressure surge or wave
propagating in the pipe when the pump stops or a
valve closes suddenly in a long pipeline system and
the fluid in motion is forced to stop or change
direction suddenly.

Result in:
 Pipe can rupture or collapse
 Pipe movement and noise
 Seals leakage
 Check valve damage

64
FET –Flygt Engineering Tool
Waterhammer calculation
Waterhammer Actions

 Air Chamber
 Surge Tower
 Air inlet/release valve
 Slow closing valve
 By pass pipe
 VFD (not for power failure)
 Soft stopper (not for power failure)
Common wastewater pump issues
Many pumps issues are related with each other

Clogging
Corrosion
Waterhammer

Vibration &
Cavitation
Noise

Physical Motor
Damages Overheating

Ad Abnormal Abnormal
ver Flow Current
se
hyd
rau
lic Wear
phe
no
me
na
Agenda
 Wastewater pump issues
 Clogging

 Vibration & noise

 Cavitation

 Wear

 Corrosion

 Motor Overheating

 Wrong impeller rotation direction

 Pipe issue--Waterhammer
 Troubleshooting Guide
Troubleshooting Guide
Troubleshooting Guide can be used to define
your hypothesis for the most likely causes for a low
performing pumping system.
The goal is to solve customer’s issues quickly.

Follow steps:
1) Collect the information
2) Find the customer's problem
3) Make the first assessment
4) Verify the hypothesis
5) Propose remedial actions
6) Feedback the result
Troubleshooting guide
Step 1: Information Collection
Item Basic Information for Troubleshooting

1 Detailed description of customer's problem, provide photos and/or movies if possible


2 Pump application, pumping media
3 Performance curve with duty point
4 Serial number, product number
5 Test report from the factory
6 Start/stop/operation method, w or w/o VFD
7 Date of operation, date of failure or problem
8 Power supply information, voltage, frequency
9 Historical record of current, power, running hours, water levels, MAS export.
10 Pump station drawing
11 Piping system drawing
12 If there were some changes in the system, please clarify what was changed and the date
Any other information that may be useful for the specific installation (retrofit, old pump info, repair,
13
etc)
Troubleshooting guide
Step 2: Find the problem
Item Customer's problem Description
1.1--No flow or reduced flow and the flow is stable
1 Abnormal flow
1.2--Decreasing flow and the flow is unstable
2.1--Increasing current and the current is unstable
2 Abnormal current 2.2--High current and the current is stable
2.3--Low current and the current is stable
3.1--High vibration & noise when pump starts
3 Vibration & noise 3.2--High vibration & noise when pump runs
3.3--High vibration & noise when pump stops
4.1--A or B alarm on high temperature motor PT100 or tripping of thermo-switch
4.2--A or B alarm on high temperature bearing PT100
Monitoring alarm
4 4.3--A or B alarm on leakage sensor FLS
(MAS)
4.4--A or B alarm on leakage sensor CLS
4.5--A or B alarm on vibration sensor
5.1--Corrosion of pump material
5.2--Damaged coating
5 Corrosion & wear
5.3--Excessive consumption of zinc anodes
5.4--Wear of pump material
6.1--Motor stator damage
6 Others
6.2--Pump start & control problems
Troubleshooting guide

Step 3: First assessment of causes--example

Customer’s Problem First assessment of causes


Unstable flow--- Soft clogging in the pump
When the pump starts the flow is normal, but
later the flow is fluctuant with deceasing trend Wrong VFD settings. Pump runs at very low RPM
even the head doesn't change much. When the Item which is easy to cause clogging
pump restarts the flow becomes normal again.
Troubleshooting guide

Step 4: Verification of causes--example

Customer’s Problem First assessment of causes Verificiation


Unstable flow---
When the pump starts the flow
Start/run/stop the pump at least
is normal, but later the flow is
three cycles, write down water
fluctuant with deceasing trend Soft clogging in the pump
levels, power, current, flow for
even the head doesn't change
analysis.
much. When the pump restarts
the flow becomes normal again.
Troubleshooting guide
Step 5: Remedial Action--example
First
Customer’s Problem Verification Remedial Action
assessment
1)Start/stop the pump more often.
2)Stop the pump at snoring water level regularly.
Unstable flow---
3)Install flush valve or APF if possible.
When the pump starts the Start/run/stop the
4)Modify the leading edge of the impeller/
flow is normal, but later pump at least
propeller
the flow is fluctuant with three cycles,
Soft clogging in 5)Cut relief grooves on the wear ring (PL-pump)
deceasing trend even the write down water
the pump 6)Upgrade the impeller/propeller to anti-clogging
head doesn't change levels, power,
one
much. When the pump current, flow for
7)Install a chopper pump in the pump sump
restarts the flow becomes analysis.
8)Install a better screen in the sump
normal again.
**Please contact application engineer to get the
best Action in your case.
Troubleshooting guide

Step 6: Feedback and documentation

Best Practice!
Questions?

77
Thanks!

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