Sewage Pumping Station Code of

Supplementary Manual to the

WSAA Sewerage Pumping Station Code

(WSA 04-2005:2.1)

Version 2.5

Supplementary Manual WSA 04-2005:2.1

UNCONTROLLED IF PRINTED OR DOWNLOADED

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CONTENTS

CONTENTS ............................................................................................................... 2

Document Details ....................................................................................................... 6

Document History ...................................................................................................... 6

ACKNOWLEDGMENTS ............................................................................................ 8

DISCLAIMER ............................................................................................................. 8

INFORMATION .......................................................................................................... 8

INTENDED AUDIENCE ............................................................................................. 8

PREFACE TO CWW SUPPLEMENT ........................................................................ 8

Part 0 ......................................................................................................................... 9

Glossary of Terms ...................................................................................................... 9

Part 1 ....................................................................................................................... 11

Planning and Design ................................................................................................ 11

1GENERAL .............................................................................................................. 12

1.1 Scope ......................................................................................................... 12

2CONCEPT DESIGN ............................................................................................... 12

2.2 Functionality ............................................................................................... 12 2.5 Due Diligence Requirements ..................................................................... 12 2.9 Odour Control............................................................................................. 12 2.14 Signage ...................................................................................................... 12 2.15 Supporting Systems ................................................................................... 13 2.17 Commissioning Plan .................................................................................. 13

2.17.3 Commissioning .................................................................................. 13

3General Design ...................................................................................................... 14

3.1 General ...................................................................................................... 14

4MATERIALS DESIGN ............................................................................................ 14

4.2 Corrosion Protection .................................................................................. 14 4.2.2 Concrete Surfaces ................................................................................. 14 4.2.3 Metallic Materials ................................................................................... 14

5PUMPING STATION DESIGN ............................................................................... 14

5.2 Site Selection, Location and Layout ........................................................... 14 5.2.1 Site Selection ........................................................................................ 14 5.2.3 Location and Layout .............................................................................. 15 5.2.5 Site Layout and Access ......................................................................... 15

5.3 Inlet MH ...................................................................................................... 15 5.3.3 Pumping Station Wet Well Isolating Valve ............................................ 15

5.4 Wet Well Design ......................................................................................... 16 5.4.1 General .................................................................................................. 16 5.4.2 Sizing ..................................................................................................... 16 5.4.4 Control Levels........................................................................................ 16 5.4.7 Washers ................................................................................................ 17

5.5 Wet-Well Ventilation ................................................................................... 17 5.5.3 Educt Vent Shaft ................................................................................... 17

5.6 Overflow Containment ................................................................................ 17



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5.6.2 Emergency Storage ............................................................................... 17 5.6.2.2 Configurations ......................................................................... 17 5.6.2.3 Design ..................................................................................... 17 5.6.2.4 Access and Cover Arrangements ........................................... 17

5.6.4 Emergency Relief System ..................................................................... 18 5.7 Ladders and Platforms ............................................................................... 18 5.8 Wet-Well Access Covers ............................................................................ 19 5.9 Safety Systems .......................................................................................... 19 5.10 Grit Collection ............................................................................................. 20 5.11 Screens ...................................................................................................... 20 5.12 Mixers......................................................................................................... 20

6PUMPING SYSTEM .............................................................................................. 21

6.2 Hydraulic Design ........................................................................................ 21 6.4 Pump Selection .......................................................................................... 21 6.6 Submersible Pumps ................................................................................... 21

6.6.1 General .................................................................................................. 21 6.7 Ancillary Equipment ................................................................................... 22 6.8 Pump Starters and Variable Speed Drives ................................................ 22

6.8.1 General .................................................................................................. 22 6.8.3 Soft Starters .......................................................................................... 22 6.8.4 Variable Speed Drives ........................................................................... 22

6.10 Emergency Stop ......................................................................................... 22

7POWER SYSTEM .................................................................................................. 22

7.2 Power Supplies .......................................................................................... 22 7.2.3 Primary Supply ...................................................................................... 22 7.2.5 Emergency Power ................................................................................. 22

7.3 Power and Control Cubicle ........................................................................ 22 7.3.1 Design ................................................................................................... 22 7.3.2 Low Voltage Switchboards .................................................................... 23 7.3.3 Meter Requirements .............................................................................. 23 7.3.4 Lighting .................................................................................................. 23

8CONTROL AND TELEMETRY SYSTEM............................................................... 24

8.1 General ...................................................................................................... 24 8.3 Pumping Control ........................................................................................ 24

8.3.1 Control Design ....................................................................................... 24 8.3.3 Control Systems .................................................................................... 24

8.4 Alarms ........................................................................................................ 24 8.4.2 Locally Displayed Alarms ...................................................................... 24

8.5 Alarm, Status Monitoring and Control Telemetry ....................................... 24 8.5.3 Alarm Creation Function ............................................................................ 25

8.5.4 Status Monitoring Function .................................................................... 26 8.6 Telemetry Hardware ................................................................................... 26

8.6.1 General .................................................................................................. 26 8.6.3 Inputs and Outputs ................................................................................ 26

8.8 Equipment and Devices ............................................................................. 27 8.8.2 Flow Measurement ................................................................................ 27 8.8.5 Level Sensors ........................................................................................ 27 8.8.6 Float-Switch ........................................................................................... 27 8.8.8 Protection Devices ................................................................................ 27

8.8.8.5 Thermal-Overload Relays ....................................................... 28

9WET-WELL PIPEWORK ........................................................................................ 28

9.1 Pump Discharge Pipe Work ....................................................................... 28



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9.1.1 General .................................................................................................. 28 9.1.2 Sizing ..................................................................................................... 28 9.1.3 Type ...................................................................................................... 28

9.2 Valve Applications ...................................................................................... 29 9.2.1 Isolating valves ...................................................................................... 29 9.2.3 Scour/ Emergency By-Pass Connection ............................................... 29 9.2.4 Sewerage air release valves ................................................................. 29

9.3 Valve Chamber .......................................................................................... 29 9.3.1 General .................................................................................................. 29 9.3.2 Design ................................................................................................... 29 9.3.3 Dismantling Joints ................................................................................. 30 9.3.6 Access Covers ...................................................................................... 30

10PRESSURE MAIN ............................................................................................... 31

10.2 Location of Pressure Mains ........................................................................ 31 10.2.1 General ............................................................................................. 31

10.3 Hydraulic Design ........................................................................................ 31 10.3.5 Velocity in Pressure Mains ................................................................ 31

10.9 Pressure Main Valves ................................................................................ 31 10.10 Odour and Septicity Control ....................................................................... 32

11Structural Design ................................................................................................. 33

11.1 Difficult Ground Conditions ........................................................................ 33 11.3 Pressure Mains .......................................................................................... 33

11.3.2 Products and Materials ..................................................................... 33

12SUPPORT SYSTEM ............................................................................................ 33

12.1 Services ..................................................................................................... 33 12.1.2 Water ................................................................................................. 33

12.2 Materials Handling ..................................................................................... 34 12.2.1 Lifting Equipment ............................................................................. 34

12.3 Site Security ............................................................................................... 34

13DESIGN DOCUMENTATION AND DRAWINGS ................................................. 35

15.2 Design Drawings ........................................................................................ 35 15.2.1 General ............................................................................................ 35 15.2.4 Structures .......................................................................................... 35 15.2.5 Pressure Mains and Sewers ............................................................. 35 15.2.6 Longitudinal Sections Profiles ........................................................... 36

Part 2 ....................................................................................................................... 37

Products and Materials ............................................................................................ 37

Part 3 ....................................................................................................................... 39

Construction ............................................................................................................. 39

37 Commissioning ................................................................................................... 40

37.2.3 Commissioning ................................................................................. 40

Part 4 ....................................................................................................................... 41

Standard Drawings .................................................................................................. 41

4.1 SPS-STD-001 - Pump Pedestal and Chain Bracket Details ......................... 44 4.2 SPS-STD-002 - Float / Motor Cable Assembly Details ................................. 45 4.3 SPS-STD-003 - Inlet Valve Mounting Flange Details .................................... 46 4.4 SPS-STD-004 - Pump Guide Rail Intermediate Support Details ................... 47 4.5 SPS-STD-005 - Lateral Support Brackets for Rising Main ............................ 48



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4.6 SPS-STD-006 - Valve Spindle Details .......................................................... 49 4.7 SPS-STD-007 - Spindle Guide Assembly Details ......................................... 50 4.8 SPS-STD-008 - Retractable Handgrip Stanchions Ladder ........................... 51 4.9 SPS-TYP-006 - Typical Drawing Cabinet Plinth and Cable Entry ................. 52 4.10 SPS-TYP-007 - Typical Drawing System Diagram ..................................... 53 4.11 SPS-TYP-008-A - Typical Drawing Pump Starter (small pump) ................. 54 4.12 SPS-TYP-008-B-Rev 1 - Typical Drawing Pump Starter (large pump) ....... 55 4.13 SPS-TYP-009 - Typical Drawing RTU Digital I/O ........................................ 56 4.14 SPS-TYP-010 - Typical Drawing Electrical Control Cabinet ....................... 57 4.15 SPS-TYP-011 - Typical Drawing Electrical Notes and Details .................... 58 4.16 SPS-TYP-012-R1 - Typical Drawing Light Pole Details .............................. 59 4.17 SPS-TYP-013-R1 - Typical Drawing Canopy Details (Revised) ................. 60 4.18 SPS-TYP-015 - Typical Drawing Level Sensor Installation ......................... 61

Part 5 ....................................................................................................................... 62

Annexures ................................................................................................................ 62

APPENDIX A – CWW STANDARD COMMISSIONING PROCEDURE .............. 63 APPENDIX B – FLOW METER INSTALLATION REQUIREMENTS .................. 76 APPENDIX C – MECHANICAL AND ELECTRICAL SPARE PARTS ................. 77 APPENDIX D – FORMAT FOR OPERATIONS & MAINTENANCE MANUAL .... 78 APPENDIX E – DOCUMENT IMPROVEMENT REQUEST ................................ 79



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DOCUMENT CONTROL INFORMATION

DOCUMENT DETAILS

Document Name CWW Supplementary Manual to the WSAA Sewerage Pumping Station Code

Document Issue 2

Document Revision No 4

Document Owner Manager, Standards and Design

Prepared by Manager, Standards

Date Approved 26th October 2009

Approved by General Manager, Engineering

Next Scheduled Review Date December 2017

DOCUMENT HISTORY

Issue Revision Date

Approved Changes Reasons for change Comments

2 1

5.9 Safety Systems, address of Kennedy’s Aluminium as: 103–109 Holloway Street, Bairnsdale 3875

Reflect amendments to the Products Catalogue for Sewerage Pumping Station

2 1

6.8.3 Soft starters,

f. be either: Allen-Bradley, Schneider, Danfoss, ABB, Sprecher Schuh PCS Ver 2.07 (supplied by NHP) or AuCom IMS2 (supplied by NHP)


2 1

8.8.2 Flow measurement, 3

rd paragraph:

The flow meter shall be an ABB Magmaster/SITRANS Magflow Tube and Mag 6000 Transmitter having…


2 1

8.8.5 Level Sensors, 2nd

and 3

rd paragraph:

A configurable range Vegawell 72 with HART PROTOCOL hydrostatic level sensor…

A configurable range Vegawell 72 with HART PROTOCOL hydrostatic level sensor…


2 1

8.8.6 Float-switch

Additional requirement:

The digital float-switch shall have both NO and NC Contacts.


2 1 15.2.8 delete this section

2 1

Part 4 Standard Drawings

Drawing Number SPS – TYP – 012 has been added to the list of drawings provided as a guide for designers only and should not be used for construction.



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Issue Revision Date

Approved Changes Reasons for change Comments

2 2

Drawing Number SPS-TYP-007 – Typical Drawing System Diagram amended

Drawing Number SPS-TYP-008 – Typical Drawing Pump Starter amended

Drawing Number SPS-TYP-009– Typical Drawing RTU Digital I/O

Drawing Number SPS-TYP-010 – Typical Drawing Electrical Control Cabinet

2 3 29.05.2009

Wet Well Level Sensor Model VEGAWELL 52 with HART protocol, 4 -20 mA output

2 4 26.10.2009

5.6.4 Emergency Relief System

1st

paragraph replaced with: Unless the designer can satisfactorily demonstrate to City West Water……

2nd

Paragraph: added the designer shall also make....

3rd

Paragraph: added Where required by City West Water……..

2 5 01.09.2015 General revision General Revision Latest Version 2.5



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ACKNOWLEDGMENTS

City West Water acknowledges the following source of documents in the preparation of this standard:

Sewerage Pumping Station Code of Australia WSA 04-2005:2.1

DISCLAIMER

City West Water excludes all liability to all persons and all conditions and warranties, which are expressed or implied at law (including under statute).

Where liability and conditions and warranties cannot be excluded at law, the liability of City West Water is limited at their choice, to resupplying the Supplementary Manual or paying the cost of resupplying the Supplementary Manual.”

Please note that the Supplementary Manual or information contained within the Supplementary Manual must only be used in conjunction with the Sewerage Pumping Station Code of Australia WSA 04-2005, of the Water Services Association of Australia.

Further, the Supplementary Manual may be periodically updated.

INFORMATION

For information and advice and to advise of possible errors, omissions and changes required for future revisions, please fill out a Document Improvement Request Form and submit to [email protected].

INTENDED AUDIENCE

This City West Water Supplementary Manual is intended for CWW personnel, consultant engineers and contractors engaged in the design, construction and maintenance of CWW’s pressure sewerage system.

PREFACE TO CWW SUPPLEMENT

This Supplement complements the Sewage Pumping Station Code of Australia, WSA 04-2005 (the Code) and contains additional (supplementary) information to cover:

CWW detailed requirements for specific matters which the Code anticipates individual water agencies will address.

Variations to the Code where its requirements are not compatible with CWW current requirements.

mailto:[email protected]



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Part 0

Glossary of Terms



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Refer to WSAA Sewerage Pumping Station Code WSA 04-2005:2.1



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Part 1

Planning and Design



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1 GENERAL

1.1 Scope

Additional Paragraph:

This Code of Practice does not apply to low pressure pumping systems.

2 CONCEPT DESIGN

2.2 Functionality

Replace item (f) with the following:

f. Provide safe working conditions for operation and maintenance personnel including a hard standing area adjacent to the pump station, fall protection grids and facilities to accommodate City West Water’s portable safety railings.

2.5 Due Diligence Requirements

Replace paragraph two with the following:

Adequate provisions shall be included to eliminate any likelihood of discharges of raw sewage to the environment under normal operating conditions. All occurrences of dry weather surcharge shall be capable of containment on site and/or within the sewerage system for the minimum time as determined by risk assessment. Adequate pumping and storage capacity for attenuation of incoming flows during wet weather shall be provided to ensure containment of a 1 in 5 year Average Recurrence Interval (ARI) rainfall event coinciding with peak dry weather flow. Provision of an emergency storage to contain peak dry weather flow for the periods required in section 5.6.2.2 herein in the event of a pump station failure. Emergency relief shall comply with any sewer system overflow licence requirements established by the environmental regulator.

2.9 Odour Control

Additional Paragraphs:

The designer shall provide evidence that odour generation and control has been considered. This will include calculations that demonstrate odour generating potential and how any odours generated will be treated.

The designer will need to liaise closely with City West Water on proposed ventilation and odour control. The aluminium access covers for the wet well and valve pit shall be provided with rubber seals and shall be water and gastight.

2.14 Signage

Additional requirements:

Signs identifying confined spaces shall be provided. The signs shall display the classification of the confined space and shall be located in a prominent position adjacent to the entry of the confined space.



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City West Water will classify the pump-station wet well and valve pit as a confined space.

In some instances, “No Parking” signs will also be required. City West Water will advise when these are necessary.

City West Water will provide a station identification sign to be installed at the Pump Station.

2.15 Supporting Systems

Additional supporting systems:

f. Alternative power sources (e.g. Generator) g. Dosing and Odour services

2.17 Commissioning Plan

2.17.3 Commissioning


Refer to Appendix A in the Annexure for the CWW Standard Commissioning Procedure.

On completion of all civil, mechanical and electrical works and prior to commissioning the contactor shall arrange for an OHS inspection with CWW Compliance Team to identify any Occupational Health & Safety risks at the pump station site. Any defects identified as part of the OHS inspection shall be rectified prior to commissioning.

City West Water representatives must attend the commissioning.

The pre-commissioning record sheets shall be completed and lodged with City West Water five working days prior to the planned commissioning date. CWW will review the pre-commissioning report and any defects / faults identified during the review process will be rectified prior to the commissioning.

Notification of the upcoming commissioning must be made to City West Water’s SCADA Manager 14 days in advance, to ensure that SCADA is set up, and the SCADA must be pre-commissioned in consultation with him to ensure that all alarms are being received at City West Water’s Communications Centre.

The pump station will not be commissioned / deemed operational until all documentation has been provided together with:

a) Plant data sheets (two hard copies, one digital copy)

b) As constructed drawings for Civil, Mechanical & Electrical (SPS & RM) (two hard copies, one digital)

c) SCADA program (two hard copies, one digital)

d) Job Safety analysis for all routine maintenance tasks to be performed at the SPS

e) Two copies of the operational and maintenance manuals inclusive of pump and system curves



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f) Copy of concrete compressive strength and slump test results.

g) Contingency Plan

h) Factory pump test results

i) Switchboard factory and site acceptance test certificates completed and signed

Digital drawings shall be in AutoCAD format.

3 GENERAL DESIGN

3.1 General

Add

Backfilling around all structures and pipelines shall be in accordance with MRWA Backfill Specification 04-03.2

4 MATERIALS DESIGN

4.2 Corrosion Protection

4.2.2 Concrete Surfaces

Additional paragraph:

Exposed concrete surfaces in the wet well and valve chamber shall be coated with an epoxy lining system conforming to the requirements of APAS Specification 0214 – “Coatings for Concrete Used in Sewage Works”.

4.2.3 Metallic Materials


Metal work within all pumping station structures shall be grade 316 stainless steel (grade 316L for fabricated items).

5 PUMPING STATION DESIGN

5.2 Site Selection, Location and Layout

5.2.1 Site Selection


The designer shall consult with City West Water if the proposed pump station site is not within City West Water land or council land.

In all instances the designer shall prepare a plan for City West Water that addresses environmental impacts and buoyancy effects.

In most instances the designer will need to arrange for a borehole or a number of boreholes to be drilled at the proposed site.



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5.2.3 Location and Layout


The pumping station shall be located such that cranes operating on site are clear of overhead electrical cables in accordance with the “No Go Zones” requirement of Work Cover.

5.2.5 Site Layout and Access


The design of the access road to a pumping station shall reflect the size and operating requirements of the largest maintenance vehicle specified by City West Water required to access the site. . CWW shall be consulted in the design phase to determine the type of access road that is required, i.e. bitumen or crushed rock.

The minimum turning radii around the station and access roads shall however be at least suitable for an 8.8 metre service vehicle as per Austroads Standards Australia – AS HB72. The vehicle must be able to be parked with the rear or side of the vehicle next to the well.

Access road grades steeper than 2% shall be cement stabilised, and roads steeper than 5% must be sealed. In areas where the station is at the end of a dead-end access, the hardstand must allow for the truck to be turned around within the pavement area.

The average grade of roads must be no more than 1 in 7 (14.4%) with a maximum of no more than 1 in 5 (20%) for more than 50 metres. Dips must have no more than a 1 in 8 (12.5%) entry and exit angle.

5.3 Inlet MH

5.3.3 Pumping Station Wet Well Isolating Valve


The incoming sewer-isolating valve shall preferably be housed in an appropriate upstream MH or if this is not practicable on the inside of the pump well provided there is easy access for maintenance. A knife gate isolating valve shall be used. This isolating valve shall have a non-rising spindle, a mounting flange, an extension spindle and a valve key that allows the operation of the valve from the top of the MH or pumping station.

The knife gate valve must have an epoxy coated ductile iron body with Grade 316 stainless steel blade and a resilient seat or the entire knife gate valve unit must be stainless Steel.

The mounting flange must be ductile iron or fabricated from grade 316L stainless steel and attached to the pump well with Grade 316 stainless steel studs using chemical anchors.



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A valve spindle of 25 mm shall be used for valves of 150 to 300 NS. A valve spindle of 38 mm shall be used for valves of 375 NS. If the spindle length is greater than 6 metres, an intermediate spindle must also be used.

The extension spindle must be adequately supported from the pump well wall. Bolts or anchors of Grade 316 stainless steel must be used for securing the spindle guide assembly to the pump well wall. The valve spindle shall be accessible without the need to remove any covers and shall be housed at ground level within a valve-winding box as detailed on City West Water standard drawing SPS-STD-007.

All valves shall be clockwise closing.

Any knife gate valve > 400mm diameter shall be electrically actuated.

5.4 Wet Well Design

5.4.1 General

Replace sixth paragraph i.e.:

The design shall incorporate a 316 stainless steel baffle from the inlet isolating valve or drop pipe as agreed with City West Water. Any drop pipe shall be open-ended at the top to allow jetting and shall end at least one pipe diameter above the normal pump cut-out level to allow the inlet pipe to drain completely on every pump cycle.

5.4.2 Sizing

Replace criteria (b) with the following:

b. Where person-entry is required, there shall be sufficient room to work safely and effectively and evacuate / rescue personnel if necessary.


d. The wet-well shall be large enough to accommodate future pumps sized for the ultimate development.

5.4.4 Control Levels

Replace Table 5.1 with the following:

TABLE 5.1 DEFAULT CONTROL LEVELS

Level Description

duty pump cut-in for ultimate development

set at 150 mm below the incoming sewer invert level

duty pump cut-out for initial and ultimate development

the cut-in/cut-out volume height for ultimate development determines the cut-out level. The minimum submergence level of the pumps shall be set at this point.

duty pump cut-in for initial development

set at the initial cut-in/cut-out volume height above the cut-out level

standby cut-in set at 600 mm above the duty cut-in level



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5.4.7 Washers


When required by City West Water pump wells shall be fitted with a guide rail mounted MultiTrode wet well washer. The washer shall be controlled by the MultiTrode MultiSmart pump controller.

5.5 Wet-Well Ventilation

5.5.3 Educt Vent Shaft

Additional paragraphs:

Dependant on the level of H2S generation, it may be necessary to carry out odour modelling of any dispersion proposed to determine the impact of the discharge on neighbouring properties.

The height of any vent shaft shall be designed to perform to its maximum. Plume calculations shall comply with the requirements set out in the State Environmental Protection Policy (Air Quality Management) Schedule C.

All pumping stations with forced ventilation shall have plume modelling carried out.

5.6 Overflow Containment

5.6.2 Emergency Storage

5.6.2.2 Configurations

Insert after paragraph 1:

City West Water requires the emergency storage to retain the maximum dry weather sewage inflow from the ultimate development for a minimum response time of two hours.

5.6.2.3 Design


The emergency storage shall be constructed from a non-corrosive material.

For a separate storage system the designer will need to consider and discuss with City West Water:

• the installation of a storage cleaning system;

• Ventilation requirements; and

• level monitoring requirements (refer to City West Water’s SCADA Installation Requirements)

5.6.2.4 Access and Cover Arrangements

City West Water requires ladders in emergency storages subject to section 5.7 herein.



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5.6.4 Emergency Relief System


Unless the designer can satisfactorily demonstrate to City West Water an ERS is not required, an ERS shall be designed and constructed for all Sewerage Pumping Station.

Whilst the minimum design requirement is for the storage to retain two hours peak dry weather flow to provide an adequate response time to a pump station failure, the designer shall also make an assessment of the likely impact upon the environment of any spillage from the ERS or whether the capacity of the sewerage system in the catchment is sufficient to contain all sewage flows associated with a 1 in 5 year ARI storm event.

CWW generally requires a minimum of 2 hours emergency storage before the system can spill in the event of a SPS failure. In more remote areas CWW may require in excess of 2 hours. The designer shall confirm minimum hours storage with CWW at design stage.

The designer shall also investigate and report on any alternative means that might be available to avert or reduce the risk of emergency spillage from the sewerage system from a I in 5 year ARI event coinciding with a pump station failure.

After completing all relevant investigations, the designer should forward to City West Water a complete set of computations, drawings and all other relevant materials together with a summary document detailing the investigations and findings. Where required by City West Water this summary document shall be forwarded by the designer to the EPA for information and comments, if appropriate.

City West Water will refer any recommendations of the EPA back to the designer for consideration in the final detail designs.

The ERS shall be designed in accordance with the provisions of the Sewerage Code of Australia WSA 02-2002-2.3 Melbourne Retail Water Agencies Edition.

A flap gate shall be installed at the emergency relief overflow pipe to ensure that a positive and effective water and gas seal is achieved.

Where the emergency overflow relief pipe discharges into an unformed drain, creek or water course then the designer will be required to indicate the impact of 1 in 10, 1 in 20 and 1 in 100 year ARI storm events on the emergency relief operation.

An approved hydrostatic level sensor shall be installed in the ERS (Emergency Relief Structure) in a stilling tube.

5.7 Ladders and Platforms

5.7 (a) Add: Ladders shall include sufficient room to safely access the structure. There must be sufficient space to safely get on and off the ladder without having to climb on or straddle any pipework, pumps, valves or other fittings.




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Ladders shall be included in all wet wells, valve chambers and separate emergency storages, unless otherwise specified by City West Water. Ladders shall be in accordance with SPS-STD-008. The ladders shall be fitted with extendable stanchions and shall be fabricated from annealed stainless steel grade 316 L.

5.8 Wet-Well Access Covers


Covers shall be aluminium 6061-T6 alloy and temper, unless otherwise specified by City West Water.

The covers should not be heavy for maintenance personnel to lift them and drop them back into seat. The cover area should not be more than 1.2 Sqm to prevent them being too heavy for manual handling.

Covers shall finish flush with the slab.

Covers including bracings and hinges should comply with the photos and requirements set out in this supplementary manual.

Covers shall be sized to suit any future pumps.

Bollards shall be placed to prevent vehicle loading on the wet well and valve chamber covers.

5.9 Safety Systems


No tripping hazards shall be within the vicinity of well or pit openings.

Provide fall protection grids and facilities to accommodate City West Water’s portable safety railings of 50mm diameter as manufactured and supplied by:

Kennedy’s Aluminium Pty Ltd,

103 – 109 Holloway Street, Bairnsdale 3875,

Telephone: 03 5152 3633.

Fall protection grids for the wet well shall be provided with cut-out section to access floats, junction box, and lifting chains without the need for lifting the fall protection arrangements.

Details of City West Water’s portable safety railings will be provided upon request. Refer also to Figures 1 and 2.



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Pump well with safety hand rail system in place Note: Pumps to be removed whilst hand rails are in place.

Figure 1: Portable Safety Rail and Grid (City West Water SPS 713, Swan St, Richmond)

Hand rail corner brackets fitted with structural “true” bolts Aluminium grate designed to sit on corner brackets.

Figure 2: Brackets for Hand Rail and Fall Prevention Grid Also provide an opening For Level Sensor Maintenance

(City West Water SPS 713, Swan St, Richmond)

5.10 Grit Collection

City West Water does not require grit collection chambers.

5.11 Screens

City West Water does not require screens.

5.12 Mixers


The designer shall determine from City West Water whether mixing is required; if mixing is required and the pump is unable to be fitted with an approved flushing valve,



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or if the well is too large for a flushing valve to operate efficiently (> 4m diameter or depth), an approved electric mixer must be installed in the pump well.

Placement and orientation of mixers is critical to ensure efficient mixing of the well contents.

Mixers shall be sized to ensure that they draw only 85% of full load current under the most adverse well conditions.

The mixer is to be configured to commence just prior to pump start and to run a minimum of two minutes to enable sufficient mixing for solids to be placed in suspension.

The mixer is to be controlled by the MultiTrode MultiSmart pump controller to run at appropriate intervals to achieve sufficient mixing to enable all suspended and floating solids to be pumped out of the wet well.

6 PUMPING SYSTEM

6.2 Hydraulic Design


The pressure main shall be designed to accommodate flow for the next 50 years.

The designer shall plot the hydraulic grade line of the initial and ultimate pump station duties on the pressure main longitudinal section and provide these to City West Water for review.

6.4 Pump Selection


The preferred pumps are Flygt, Amarex, ABS, or Grundfos, however, other pumps may be considered on a case by case basis.

Final selection of the pump model and size is subject to approval from City West Water.

Sphere clearance shall be a minimum of 75 mm.

6.6 Submersible Pumps

6.6.1 General


An identical spare pump shall be provided as part of the due diligence requirements detailed in Clause 2.5.

Any proposal that varies from a two pump, 100% standby configuration, (i.e. one pump duty, one pump standby) must be approved in writing by City West Water.



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6.7 Ancillary Equipment

6.8 Pump Starters and Variable Speed Drives

6.8.1 General

Replace clause with the following:

All submersible sewage pumps larger than 5.5 kW shall use soft starters and Variable Speed Drives. Direct on line (DOL), auto transformer or soft starters may be used on pumps less than 5.5 kW.

6.8.3 Soft Starters

The soft starters shall comply with CWW approved products as specified in MRWA Products Web Portal.

6.8.4 Variable Speed Drives

The Variable Speed Drive shall comply with CWW approved products as specified in MRWA Products Web Portal.

6.10 Emergency Stop

This clause applies only to dry well pumping stations.

7 POWER SYSTEM

7.2 Power Supplies

7.2.3 Primary Supply


To limit electrical interference with adjoining households; for larger pump stations which utilise VSD or Soft Starters it is advisable that the station incoming power supply be fed from its own dedicated transformer.

7.2.5 Emergency Power

Replace second sentence of last paragraph with:

The backup capacity shall be sufficient to sustain at least six hours of full load operation.

7.3 Power and Control Cubicle

7.3.1 Design

Replace the first sentence in paragraph five with:

The cubicle shall be located so that the doors can be opened safely whilst providing a safe working area clear of the wet well and valve chamber openings. A minimum of



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900mm clearance will be required to walkthrough the gap between the open wet well access covers and cabinet doors.


• All external electrical control cabinets shall be Marine Grade Aluminium 3 mm thick painted internally “White” and externally equivalent to Colorbond® “Wilderness®”.

• Entry or exit of all cables shall be through the bottom of the electrical control cabinet.

• The electrical control cabinet shall not be installed directly over the wet well.

• City West Water will not allow power, control and communication cables to be run in the same conduit.

• A minimum of three conduits shall enter the wet well: One conduit for pump power cables, one conduit for control cables and wet well lighting, and one conduit for communication / instrumentation cables.

• The minimum conduit size for the power control and communication shall be sufficient enough to allow the cable to be pulled through easily without any restrictions.

• Conduits shall be sealed to prevent gases from the wet well entering the control cabinet.

• A canopy shall be provided over the electrical cabinet as per the standard drawing SPS-TYP-013(A)

• The drop down pipe from the roof of the canopy shall be connected to the existing or proposed storm water system as appropriate.

7.3.2 Low Voltage Switchboards

Refer to additional requirements under Clause 7.3.1.

7.3.3 Meter Requirements


External electrical control cabinets shall be designed such that the incoming supply-metering cubicle is integrated within the cabinet. Separate metering cubicles shall not be permitted.

The meter compartment shall be fitted with a Power Industry master keyed Lockwood Pi201 Series Nightlatch Cylinder lock with a PI 874 key – available from:

Aus Lock & Safe Co. Pty Ltd

Factory 16, 47-51 Little Boundary Road

Laverton North 3026

7.3.4 Lighting

Replace the first sentence in paragraph one with:

External electrical control cabinets shall have separate fluorescent lighting tubes inside each compartment.



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Motion sensor operated security lighting shall be provided to illuminate the site. The light shall be positioned in such a way that it maximises security and illumination for operations; and minimises the impact on surrounding properties. The light pole shall be pivot type to enable easy change of Globes as required.

8 CONTROL AND TELEMETRY SYSTEM

8.1 General

Insert new paragraph:

Provide SCADA equipment in accordance with City West Water’s SCADA Installation Specification current at the time of installation; a copy of which will be provided upon request.

8.3 Pumping Control

8.3.1 Control Design


If the low level alarm remains on for longer than the time specified by the designer, then the running pump shall stop.

8.3.3 Control Systems

Replace (a) with:

Telemetry shall be via a separate Kingfisher RTU. The overall operation and control of the pumping station shall normally be effected through an onsite local intelligent control system. The sewage level in the wet-well(s) shall control automatic operation of the pumps. The sewage level in each wet-well shall be monitored by a level sensor.


Pumping control shall be by a MultiTrode MultiSmart pump controller.

8.4 Alarms

8.4.2 Locally Displayed Alarms


The local alarms shall be derived in the Kingfisher RTU. No separate annunciator is required.

The globe covers for the display lamp in the control cabinet shall be in red or amber colour for clear visibility.

8.5 Alarm, Status Monitoring and Control Telemetry



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8.5.3 Alarm Creation Function


TABLE 8.1: DEFAULT ALARM LEVELS

Parameter Description

low level alarm set at the snort level of the pumps

high level alarm set at 300 mm above stand-by cut-in level but never above the inflow emergency alarm level

overflow alarm set at the ERS weir spill level

inflow emergency alarm* set at the obvert (soffit) of the outlet to the wet well in the collecting chamber

NOTE: *Required where emergency storage is not provided.


Table 8.2: TYPICAL LOCAL AND REMOTE ALARMS (Informative)

Alarm–

Operation Digital Signal

Description

Telemetry OVERRIDE Local switch provided to stop the RTU sending alarms to SCADA master station when the site is attended.

Mains power supply FAILURE Main power failure determined by phase failure relay

Control power supply FAILURE Control power failure determined by phase failure relay

Wet well level LOW Level below pump snort level, derived from analog level signal

Stand-by level REACHED Duty-pump failed to pump efficiently. Stand-by cut-in set at 600 mm above duty cut-in

Wet well level HIGH High-level device has operated. Set at 300 mm above the stand-by cut-in level

No pumps available Both pumps have failed or are unavailable

Pump 1 motor FAULT Pump 1 thermal O/L or thermistor trip or failed to start

Pump 2 motor FAULT Pump 2 thermal O/L or thermistor trip or failed to start

Vent fan FAULT Alarm activated by digital signal

PLC FAILURE Alarm activated by digital signal

Enunciator FAILURE Alarm activated by digital signal

Telemetry communications FAILURE

Communication failure between pump station and base

Intruder Alarm ACTIVATED Station access door opened

Wet well level loop FAILURE Analogue signal open circuited

Station on OVERFLOW Sewage has reached overflow level

Inflow emergency level REACHED

Inlet valve is shut and sewage is backed up into the collection system – Optional

High-level mode ON Emergency controller is in control of the pumps

Wet well level high limit REACHED

Alarm activated by analogue signal

RTU/PLC Status (Heartbeat) Monitors operation of RTU/PLC

PLC / Telemetry Back Up BATTERY LOW

Alarm activated by analogue signal



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8.5.4 Status Monitoring Function

Replace Table 8.3 with:

TABLE 8.3: TYPICAL REMOTE MONITORED CONDITIONS (Informative)

Analogue Signal Type

Wet-well level Display and trend

Station in flow Display and trend

Station outflow Display and trend

VSD pump No.1 speed Display and trend

VSD pump No.2 speed Display and trend

Pump 1 power usage in kW Display and trend

Pump 2 power usage in kW Display and trend

Data age Display

RTU temperature Display and trend

Motor current Motor current and voltage

Mode of operation of the pumping unit Display

Number of starts Display

Overflow rate Display and trend

Time to overflow Display

Running time Display

Telemetry battery voltage Display

Operation Digital Signal Type

Stand-by pump operated Alarm

Pump 1 available State

Pump 2 available State

Pump 1 in auto State

Pump 2 in auto State

Pump 1 running State

Pump 2 running State

8.6 Telemetry Hardware

8.6.1 General


The design and installation of the SCADA system shall comply with City West Water’s SCADA Installation Specification current at the time of tendering; a copy of which will be provided upon request.

8.6.3 Inputs and Outputs

Replace paragraph one with:



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The telemetry unit shall have provision for an Analog input for the wet-well, ERS and detention levels, discharge flow, pump input power for each pump and digital control outputs.

8.8 Equipment and Devices

8.8.2 Flow Measurement


A magnetic flow meter is required on the pressure main, following the valve chamber.

The flow meter shall be an ABB MagMaster / SITRANS Magflow Tube and Mag 6000 Transmitter having a 4-20mA flow analogue output and a pulse output proportional to volume.

The flow meter location to be marked with a marker post or a buried detectable electronic device.

The flow meter shall be installed as per the installation requirements as shown in Appendix B in the Annexure.

8.8.5 Level Sensors

Level Sensors shall comply with the CWW approved product catalogue.

Level transmitter Stilling Tube shall comply with the following requirements

- To be located in an accessible position for easy removal of the sensor without the need to enter the wet well.

- 100mm ABS minimum diameter - Avoid placing slots over cut-in, cut out levels where the fat builds up, potentially

blocking the tube. - One or two sets of slots shall be located below the cut in level and 4 sets located

above the stand by cut in level. - Shall rest on a 45º cut/bevel on the floor of the wet well. - Refer Standard Drawings SPS-TP-015.

8.8.6 Float-Switch


The digital float-switch shall have both NO and NC contacts.

A high level backup pump control via a float set 50 mm below the high level alarm shall be installed, using Omron Zen programmable relays ZEN-10C1DR-D-V1 for critical pump stations nominated by City West Water.

8.8.8 Protection Devices




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Provide protection to radio mast from vandalism and theft to City West Water’s satisfaction. Refer to City West Water’s SCADA Installation Specification current at the time of installation; a copy of which will be provided upon request.

Assess the need for and provide lightning protection as required.

8.8.8.5 Thermal-Overload Relays

Replace clause with:

If soft starters are provided in accordance with the requirement of clause 6.8.3 herein, these shall be used as prevention of motor overload.

Alternatively three element bi-metallic type or electronic type thermal-overload relays shall be provided in all motor starting circuits for three-phase electric motor protection. The thermal overload relays specified shall comply with AS 1023.2. The current setting shall be adjustable to suit the full-load current of the protected motor. Thermal-overload relays shall be the manual-reset type with ambient-temperature compensation and located external to the unit.

Thermal-overload relays shall be set to the motor full load current.

9 WET-WELL PIPEWORK

9.1 Pump Discharge Pipe Work

9.1.1 General


Vertical Pipework shall be supported at maximum 3 m intervals using supports as shown on City West Water standard drawing SPS-STD-005.

The discharge pipe work shall include a scour line to enable the pressure main to be drained back to the wet-well or into an adjoining sewer reticulation system.

9.1.2 Sizing


The minimum diameter shall be DN 100 or as otherwise specified by City West Water.

9.1.3 Type


Grouting of penetrations through block outs shall be carried out using high quality non-shrink grout with at least the same strength as the parent concrete.

Discharge pipe work in the wet well and valve chamber shall be PE100 or calcium aluminate DICL unless otherwise approved by City West Water.

All exposed pipe work within the station is to be coated with products approved under APAS Specification 0213.



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9.2 Valve Applications

9.2.1 Isolating valves

City West Water’s requirements are:

Gate valves shall have non-rising stems, be resilient seated and clockwise closing with the direction of closing to be stamped on the valve spindle or handwheel as appropriate. Valves operated from the surface shall have the direction of closing indicated on an engraved sign, mounted adjacent to, or on the cover of the valve winding box.

9.2.3 Scour/ Emergency By-Pass Connection


The pressure main shall scour back to the wet well.

Facilities for emergency by-pass pumping shall be provided within close vicinity outside the valve chamber.

The by-pass facility shall be provided with a valve and shall be located within a surface box (EZIpit) with a 600mm clear opening and terminate with a vertical 150 mm flanged Bauer Type B Female Coupling within 100 mm of the top of the surface box.

9.2.4 Sewerage air release valves

Add the following paragraph:

Air valve locations shall take customer and environmental impacts into consideration, i.e. noise and odour. (Not too close to walkways, houses, etc.)

9.3 Valve Chamber

9.3.1 General

Additional provision:

The depth of the valve chamber must be ≤ 1.5m.

The valve chamber will include a non-return valve upstream of the stop valve. CWW currently specify an AVK non-return Ball valve. Permanent bleed valve/ pressure test point shall be mounted downstream of isolation valve for pressure testing.

9.3.2 Design


Operation of the isolation valves and the scour valve is not required from the surface.

The wet-well roof slab shall incorporate the covers of the valve chamber unless otherwise approved. The valve chamber covers shall be large enough to enable crane access to remove valves for maintenance purposes. For valves greater than DN150, removal must be able to be carried out as a “direct lift” operation.



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The valve chamber drain back to the pump-well shall be fitted with a Hume-King Flood gate or approved equivalent.

The depth of the valve chamber shall be the minimum necessary to accommodate the valves while providing the minimum cover to the rising main exiting the chamber.

A retractable handgrip stanchions ladder as per Standard drawing SPS-STD-008 shall be provided in the valve chamber.

9.3.3 Dismantling Joints


City West Water requires restrained flange-socket connectors or Uni-Flanges to be provided in the valve chamber. Uni-Flanges supplied by Metaval Consolidated Pty Ltd or approved equivalent are to be used and installed according to the manufacturer’s instructions, using only stainless steel grade AISI 4100 set screws. The set screw torque shall be tightened to the recommended level as shown below:

DN 50 - 100 95 Nm

DN 150 - 375 125 Nm

DN 400 - 600 160 Nm

In vertical pipe work the Uni-Flange joint shall be at the top of the pipe.

No Gibault joints shall be used as dismantling joints. Dismantling joints shall be provided with sufficient clearance to dismantle fittings as required.

9.3.6 Access Covers

Fall protection arrangements and facilities to accommodate City West Water’s portable safety railings of 50mm diameter are required under valve chamber covers regardless of the depth of valve chambers.



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10 PRESSURE MAIN

10.2 Location of Pressure Mains

10.2.1 General

Replace clause with:

Pressure mains are not permitted in private property. Pressure mains shall be located in road reserves. Any other location is to be agreed with City West Water prior to completing the final design.

Pressure main location is to be identified with relevant posted signs. Signs are to be erected at:

• change of direction;

• at fittings along the pipeline; and

• maximum 500 m spacing

Posts shall be green recycled plastic and comply with standard drawing SEW-1450-M.

City West Water will provide 90 mm x 160 mm signs for fixing to the posts using self-tapping stainless steel screws.

10.3 Hydraulic Design

10.3.5 Velocity in Pressure Mains

Replace the second last paragraph with the following:

Velocities for initial and ultimate flows shall be less than 3 m/s. The velocity shall be reduced to a maximum of 2 m/s before discharge to receiving sewer.

10.4.3 Surge


The designer shall provide City West Water with a surge analysis for all pressure mains supporting pipe selection.

10.6.2 Fatigue Design for Thermoplastics Pipes


The designer shall provide the results of the fatigue analysis supporting pipe selection.

10.9 Pressure Main Valves

10.9.2 Isolation Valves




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Provide two isolation valves in the pressure main, one upstream and one downstream of scour valves or eduction points, when the system volume between scour points exceeds 9m3.

10.9.3 Gas Release Valves


The designer shall submit plans of proposed air release valve locations for City West Water’s approval prior to completing design plans.

The air release valve shall comply with WSAA standard WSA112-2002 “Sewage Air Release and Vacuum Break Valves”.

In determining the location of the air release valve the following factors are to be considered:

• proximity to properties;

• venting requirements and subsequent odour issues; and

• aesthetics of vent.

10.9.5 Scours


Scour points shall be provided on all low points on rising mains with crests. They shall include a branch line from the pressure main incorporating a resilient seated sluice valve. Where possible the scour points shall drain to a separate sewer. Otherwise they shall include a 900 bend and a flanged riser to terminate with a blank flange within 100 mm of the top of the pit. The minimum diameter of scour lines shall be DN 100.

Provide two isolation valves in the pressure main, one upstream and one downstream of scour valves or eduction points, when the system volume between scour points exceed 9m3.

10.10 Odour and Septicity Control


The designer shall provide calculated detention times and design adequate odour and septicity controls. The designer shall ensure that the sulphide generation potential in rising mains that discharge to standard manholes is kept to a level that is not likely to cause nuisance odour.

10.11.2 Discharge MHs


Where the receiving sewer is substantially deeper than the normal depth of the pressure main, a vertical bend should be provided on the pressure main adjacent to the receiving MH. This enables the obvert of the pressure sewer at the MH to be placed at the same level as, or slightly higher than, the obvert of the outlet in the MH.



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Where required by City West Water, venting shall be provided to the receiving sewer MH.

Internal exposed surfaces of the receiving structure shall be coated with epoxy lining systems conforming to the requirements of APAS Specification 0213 – “Coatings for Steel Used in Sewage Works” and APAS Specification 0214 – “Coatings for Concrete Used in Sewage Works”, as applicable.

The receiving structure shall be as far as possible from residential properties.

Properties connected to the receiving sewer shall be protected by a water seal. (BT or Gas Check MH)

11 STRUCTURAL DESIGN

11.1 Difficult Ground Conditions


The word “Difficult” shall be ignored in the title of section 11.1.

That is the designer shall arrange for a geotechnical assessment and address the requirements of Sections 11.1.1 and Section 11.1.2 regardless of ground conditions.

11.3 Pressure Mains

11.3.2 Products and Materials


Only pipes and fittings specified in City West Water’s Approved Products Catalogue in the MRWA Products Web Portal and the associated WSAA Product Specification shall be used. Pressure mains must comply with colour and marking requirements of the Product Specification to differentiate pressure sewerage mains from potable water and recycled water pressure mains. (These colours are currently PVC pipe coloured cream; PE pipe coloured black.)

Pipe type, size, class and series (PVC pipe) shall be clearly notated on design and as-constructed drawings.

12 SUPPORT SYSTEM

12.1 Services

12.1.2 Water

Replace paragraph two with:

The water service shall terminate with an Atlas claw coupling compatible with a DN25PE service within a surface box cast in the slab adjacent to the wet well located within hose length of wet well for wash down purposes. As part of service connection a RPZD (backflow prevention device) is to be provided with the meter assembly. The meter & RPZD assembly will be located above ground, clear of traffic in a lockable



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cage. The registered back flow prevention device shall be tested after commissioning and a test report to be provided.


The designer shall confirm the required diameter of the water service taking into account the minimum service pressure in the area, the length of service from the water main to the pump station and the flow rates required by well washers and other fittings requiring a water supply in the pump station.

12.2 Materials Handling

12.2.1 Lifting Equipment


The pumps lifting chains shall be 316 Stainless steel and in accordance with AS 4797. The following information shall be marked at intervals of not more than 20 links.

Manufacturer identification,

Material grade (e.g, 316),

Quality grade (i.e.,5 or 50)

The lifting chains shall be tested and tagged with ratings as appropriate.

The minimum chain size shall be 10 mm for small pumps, but larger pumps will require 12 mm or 16 mm, particularly where a lower bridle is used to attach to two eyebolts.

The Dee shackles used shall be 316 stainless steel, manufactured to comply with AS 2741.

Eyebolts provided by the manufacturer as part of the lifting arrangement to equipment shall be manufactured to comply with AS 2317.

The lifting chain shall be located within arm’s reach and supported and retained as shown on City West Water standard drawing SPS-STD-001; by a 3.2 mm 1/19 stainless steel wire rope with a SS snap hook on one end and a SS Dee shackle on other end.

12.3 Site Security


City West Water will nominate if security fencing is required. Security fencing shall not impede access to pump station equipment. Fencing and gates shall be in accordance with Melbourne Water Drawing Nos. 7251/8/205 Rev. A, 7251/8/209 Rev. A & 7251/8/210 Rev. A.

This is based on the standard for ‘chain link fabric fencing’ part 1: Security fences and gates – general requirements (AS 1725.1 – 2010). The standard of fence CWW requires at any of our fenced remote sites should be Type 2-B-R/B-T (Bottom rail only, 3 barbed top security fencing (vertical or cranked top). This is detailed in Section 1.7 Types of Security Fencing Design Options.



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All cabinet compartments shall be fitted with a City West Water master Keyed Nightlatch Cylinder lock with an O.SMK.A.1 key. Padlocks used on wet well and valve chamber access covers shall have an O.SMK.A.1 series key. Full length cabinet doors will also require Dead Bolts. All doors shall be independently operable without any interlocking arrangements.

All padlocks used on entrance gates and other wire enclosures such as non-return valves etc. shall be with an O.A.1 series key.

The above locks and padlocks are available from:

Aus Lock & Safe Co. Pty Ltd

Factory 16, 47-51 Little Boundary Road

Laverton North 3026

Motion sensor operated security lighting shall be provided to illuminate the site.

13 DESIGN DOCUMENTATION AND DRAWINGS

15.2 Design Drawings

15.2.1 General

Design Drawings and Work As Constructed (WAC) drawings shall be prepared in accordance with City West Water’s requirements.

Except where otherwise notified, the requirements are as set out in this Section. The information to be shown in the Design Drawings and WAC drawings shall include, but not be limited to, that detailed in clause 15.2 of the code and the following.

WAC drawings shall include Design Drawings suitably amended to show final as-constructed details. Any differences between designed information and as-constructed information shall be shown in a different colour or some other method acceptable to CWW. WAC drawings shall be submitted in AutoCAD and pdf.

15.2.4 Structures

Add the following requirements:

i. Details of all inlets and property connection sewers. j. Water seal requirements

15.2.5 Pressure Mains and Sewers

Add the following additional requirements:

n. Position of sewers relative to property boundaries. o. Insets and diagrams (amend as constructed drawings). p. Notations and standard labels indicating current status of facilities, e.g. “Existing

end to be extended” (to be edited to “Existing end extended” in WAC drawings and as Constructed documentation).



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q. Ties and downstream distance. r. Drainage limits - full or partial. s. Design assumptions for ancillary structures. t. Method and type of construction if boring to be undertaken. u. If a sewer is amended in position and/ or depth, redefined drainage limits on

WAC drawings.

15.2.6 Longitudinal Sections Profiles

Add the following:

m. Design type of structures e.g. single collection chamber, double collection chamber, etc.

n. Special features of structures e.g. bolt down DI Class B watertight cover.

Part 2 Products and Materials

Supplementary Manual WSA 04-2005: 2.1


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Additional Requirement:

Refer to products referred in Part 1 of this Supplement.



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Part 3

Construction



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37 Commissioning

37.2.3 Commissioning

Additional Requirement:

Comply with City West Water’s requirements in section 2.17.3 of this supplement.



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Part 4

Standard Drawings



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Add the following City West Water Standard Drawings.

DRAWING

NUMBER ACTIVITY TITLE

SPS-STD-001 Wet Well Details

Sewerage Pump Station

Pump Pedestal and Chain Bracket Details.

SPS-STD-001



Float / Motor Cable Assembly Details.

SPS-STD-002



Inlet Valve Mounting Flange Details.

SPS-STD-003



Pump Guide Rail Intermediate Support Details

SPS-STD-004



Lateral Support Brackets for Rising Main.

SPS-STD-005



Valve spindle Details.

SPS-STD-006



Spindle Guide Assembly Details.

SPS-STD-007



Retractable Handgrip Stanchions Ladder.

SPS-STD-008

Add the following:

The following City West Water typical drawings are provided as a guide for designers only and should not be used for construction.

DRAWING


SPS-TYP-006 Electrical Controls

Sewerage Pumping Station, Typical Drawings

Cabinet Plinth and Cable Entry.

SPS-TYP-006



System Diagram.

SPS-TYP-007

SPS-TYP-008-A Electrical Controls


SPS-TYP-008-A Pump Starter (Small pump)

SPS-TYP-008-B-Rev 1 Electrical Controls


SPS-TYP-008-B-rev1 Pump Starter (large pump).



Version 2.5 of 79

DRAWING




RTU Digital I/O.

SPS-TYP-009



Electrical Control Cabinet.

SPS-TYP-010


Sewerage Pumping Station, Typical Drawings Electrical Notes and Details

SPS-TYP-011

SPS-TYP-012-R1 Lighting (Revised)

Sewerage Pumping Station, Typical Drawings Light Pole Details

SPS-TYP-012-R1

SPS-TYP-013-R1 Canopy Detail (Revised)

Sewerage Pumping Station, Typical Drawings Typical canopy Details

SPS-TYP-013-R1

SPS-TYP-015 Level Sensor

Sewerage Pumping Station, Typical Drawings Level Sensor Installation

SPS-TYP-015

4.1 SPS-STD-001 - Pump Pedestal and Chain Bracket Details



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4.2 SPS-STD-002 - Float / Motor Cable Assembly Details



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4.3 SPS-STD-003 - Inlet Valve Mounting Flange Details



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4.4 SPS-STD-004 - Pump Guide Rail Intermediate Support Details



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4.5 SPS-STD-005 - Lateral Support Brackets for Rising Main



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4.6 SPS-STD-006 - Valve Spindle Details



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4.7 SPS-STD-007 - Spindle Guide Assembly Details



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4.8 SPS-STD-008 - Retractable Handgrip Stanchions Ladder



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4.9 SPS-TYP-006 - Typical Drawing Cabinet Plinth and Cable Entry



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4.10 SPS-TYP-007 - Typical Drawing System Diagram



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4.11 SPS-TYP-008-A - Typical Drawing Pump Starter (small pump)



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4.12 SPS-TYP-008-B-Rev 1 - Typical Drawing Pump Starter (large pump)



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4.13 SPS-TYP-009 - Typical Drawing RTU Digital I/O



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4.14 SPS-TYP-010 - Typical Drawing Electrical Control Cabinet



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4.15 SPS-TYP-011 - Typical Drawing Electrical Notes and Details



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4.16 SPS-TYP-012-R1 - Typical Drawing Light Pole Details



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4.17 SPS-TYP-013-R1 - Typical Drawing Canopy Details (Revised)



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4.18 SPS-TYP-015 - Typical Drawing Level Sensor Installation

Part 5

Annexures



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APPENDIX A – CWW STANDARD COMMISSIONING PROCEDURE

SEWERAGE PUMPING STATION

Ref: SPS XXX

Location:

COMMISSIONING CHECK LIST

Supervision by: City West Water Witnessed by:

DEFECTS LIST

Wet Well Structure

Whom When

Electrical

Whom When

Other

Whom When

Item Description Remarks Accept

Yes No

Testing of pressure pipe lines

Testing of Pump Well for Water tightness

Visual inspection of incoming sewer for ovality

Access track, turning space & free standing area - acceptable?

Concrete plinths

Water supply - connected and operational

RPZD - Backflow prevention device, has it been installed?

Valve spindles - type and length

Ladders - position, length and fixing

Pump pedestals - type and fixing

Pump guide rails – installation and fixing

Level transmitter - stilling tube

Location and installation satisfactory?

100mm ABS minimum diameter (WITS)

Slotting acceptable as per WITS manual.

Chain safety cable and anchors satisfactory?

Lifting chains, shackles and any other lifting equipment provided.

Load rating required – …01… Tonne

Stamping or other proof of acceptable load rating provided?

Type, size and lengths satisfactory?



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Yes No

Lift each pump in turn

Check for satisfactory movement on guide rails

With Pump lifted – No 01

Check that CWW ID # Label has been fitted to pump.

Energise pump motor momentarily to check direction of rotation.

Record nameplate details.

When the pumps have been restored - check seating on the pedestals.

Pump identification numbers – correct locations?

Lift each pump in turn

Check for satisfactory movement on guide rails

With pump lifted – No 02

Check that CWW ID # Label has been fitted to pumps.

Energise pump motor momentarily to check direction of rotation.

Record nameplate details on form(s) supplied.

1.1.1.1.1.1

When the pumps have been restored - check seating on the pedestals.

Pump identification numbers – correct locations?

All cubicle and building doors - fit properly and adequately stayed?

Bypass overflow

Flap gate fitted and operation satisfactory.

During water tests - check for outflow.

ERS level sensor



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Yes No

Rising Main

Identify location of Final Discharge Point.

Check that Bleed Valves are installed on the rising mains for each pump. (Before the reflux valve and the isolating valve).

Temporarily install gauges on pump to measure discharge pressures

Flow meter

Check that flow meter is connected and local indication available in switchboard

Check pit access

Check pit drainage

Flow meter specifications

Discharge valves to be exercised over their full range.

As part of water tests check for sealing. Run both pumps with shut valves

Blockouts - check that sealing is acceptable (ie. non-porous and no cracking).

Electrical conduits and gas-tight compartments suitably sealed?

All Gatic covers are to be measured up width x length and depth such that weight can be calculated.

Clear Opening:

Wet Well

Actual Lid

Valve Pit

Actual Lid



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Description of Test Accept

Yes No

Pump # 1 - Control Switch Operation

'Man' - Pump # 1 starts and runs (Control Only)

'Off' - Pump # 1 stops (Control Only)

'Auto' – pump operates under Multitrode Controller

Pump # 2 - Control Switch Operation

'Man' - Pump # 2 starts and runs (Control Only)

'Off' - Pump # 2 stops (Control Only)

'Auto' – pump operates under Multitrode Controller

(Controlled by MT2PC Controller)

Pump # 1 - Motor Protection

Pump isolated

Set both pump control switches to 'Auto' with Pump 1 as Duty – Active Pump 1 Overload Protection:

Duty selection should alternate. Before the tests.

Pump 1 - Protection Operated Alarms - SCADA and Local Indicator Alarm active.

Control Switch to 'Man' - Pump should NOT RUN.

Reset Overload Protection – Pump should not 'Run' and Alarms should be able to be reset.

Return Control Switch to 'Auto'.

Pump # 2 - Motor Protection

Two manual switch

Set both Pump Control Switches to 'Auto' with Pump 2 as Duty – Active Pump 2 Overload Protection:

Duty Selection should alternate.

Pump 2 – Protection Operated Alarms - SCADA & Local Ind. - Alarms active.

Control Switch to 'Man' - Pump should NOT run.

Reset Overload Protection – Pump should not 'Run' & Alarms should be Resettable.

Return Control Switch to 'Auto'.

Pump # 1 - Initial Operation

Pump isolated

Check that the discharge valve on the rising main is 'Open'.

Bleed valve provided?

Switch the Pump Control Switch to 'Man' – pump runs.

Bleed air from pump.

Failure Both Pumps on Motor Protection Operated. No Pumps available alarm. Scada only no Local Indicator Alarm

Rising Level Bypass Fail Float Activated Scada Operated

Falling Level SCADA and Local Alarm Resettable



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Yes No

Pump # 2 - Initial Operation

Check that the discharge valve on the rising main is 'Open'.

Bleed valve provided?

Switch the Pump Control Switch to 'Man' - pump runs.

Bleed air from pump - run pump until outflow occurs at the final discharge point.

Pump # 1

Pump isolated

Normal Operation Test (Isolating valve 'OPEN')

Switch Pump 1 Control Switch to 'Man'

Record Pump Running Currents: _____Amp

R Ph ___ Amp W Ph ___ Amp B Ph ___ Amp

Starter Ammeter Reading ___ Amp

Voltages:

R Ph - B Ph ___ V R Ph - N ____ V

W Ph - R Ph ___ V W Ph - N ___ V

B Ph - W Ph ___ V B Ph - N ___ __ V

Overload Set at ____ amp

Pump Discharge Rate from the flowmeter______ l/s

Pump Discharge Pressure ___ mWg at Test Point Height correction factor (ave.) ______ M

Total Head _____ M

Switch Pump 1 control Switch to 'Off':

Check that reflux valve operates correctly and stops any backflow.

'Close' isolating valve and check for leakage.

Shut-Head Operation Test (Isolating valve 'CLOSED’)


Record Pump Running Currents:

R Ph __ Amp W Ph __ Amp B Ph ___ Amp

Starter Ammeter Reading ___ Amp

Voltages:

R Ph - B Ph _ ___ V R Ph - N __ __ V

W Ph - R Ph _ ___ V W Ph - N _____ V

B Ph - W Ph _ ___ V B Ph - N _____ V

Pump Discharge Pressure at Gauge__ _ m H2O.

Height correction _____ m

Total Head _____ m H20

Switch Pump 1 Control Switch to "Off'.

'Re-Open' Pump Isolating Valve.



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Yes No

Pump # 2 Normal Operation Test (Isolating valve 'OPEN')



R Ph ___ Amp W Ph ___Amp B Ph ___Amp

Starter Ammeter Reading _ _ Amp

Voltages:

R Ph - B Ph ___ ___ V R Ph - N __ __ V

W Ph - R Ph ___ ___ V W Ph - N __ __ V

B Ph - W Ph ______ V B Ph - N _____ V

Overload Set at ___ amp

Pump Discharge Flow _____ l/s

Pump Discharge Pressure __ mWg at Test Point

Height correction factor (ave.) _____M

Total Head _____M

Switch Pump 2 control Switch to 'Off':

Check that reflux valve operates correctly and stops any backflow.

'Close' isolating valve and check for leakage.

Shut-Head Operation Test (Isolating valve 'CLOSED’)



R Ph __ Amp W Ph __ Amp B Ph __ Amp

Starter Ammeter Reading __ Amp

Voltages:

R Ph - B Ph _ ___ V R Ph – N ___ __ V

W Ph - R Ph _ ___ V W Ph – N ___ _ V

B Ph - W Ph _ ___ V B Ph - N ___ _ V

Pump Discharge Pressure _____ m H2O.

Switch Pump 2 Control Switch to "Off'.

'Re-Open' Pump Isolating Valve.



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Yes No

Inflow - Rising Level P 1

[if there is not enough water in the wet well then undertake the following tests by level signal simulation]

@ Duty C/I point - Duty Pump is to start and run – stop inflow.

P1 Start Level Analogue Level Indicator Reading mm

Measurement below Top of Cover mm

Falling Level

Stop Level

Check pump running status on SCADA

@ C/O point - Duty Pump to Stop

Pump duties to alternate

Analogue Level Indicator Reading mm


Inflow – Rising Level P 2

@ Duty C/I point the new Duty Pump is to start and run – stop inflow.

Falling Level Check pump running status on SCADA

@ C/O point - Duty Pump to Stop

Pump duties to alternate

Inflow - Rising Level

@ Duty C/I point the Duty Pump is to start and run - restrict outflow or inhibit pump operation – increase level to Standby C/I at which point the Duty Pump call should be de-activated and the Standby Pump should start and run - stop inflow and remove any restriction to outflow.

Standby Cut In



'Standby Operated' SCADA alarm should be activated.

Should only stop the running pump (running pump should not be faulted)

Local 'S/By Operated' indicator should be illuminated.

Falling Level 'Standby Operated' SCADA alarm and local indicator should continue to remain active (i.e. not able to be reset at this stage).

@ C/O point - Standby Pump to Stop mm

Pump Duties to Alternate. (i.e. The next pump to run will be the next duty pump)

'Standby Operate' SCADA Alarm and local indicator should be able to be reset.


@ Duty C/I point the new Duty Pump is to start and run – top inflow, inhibit Normal C/O operation



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Yes No

Falling Level

Manually operated

P1

@ Low Level point (just prior to pump being stopped) – check that pump is NOT sucking air.

Is bowl of pump not visible? Visible: not sucking air

Duty Pump to Stop

Pump Duties to alternate Simulation

'Low Level' SCADA Alarm should be active

Local 'Low Level' Indicator should be illuminated




Increase water level to normal C/I level to Initiate operation of other (new duty) pump - inhibit inflow.

'Low Level' SCADA Alarm should be 'resettable'

Local 'Low Level' Indicator should be 'resettable'

Falling Level

P2

@ Low Level point (just prior to pump being stopped) – check that pump is NOT sucking air.

Is bowl of pump not visible? Visible: not sucking air

Running Pump to Stop.

Pump duties to alternate. Stop top of cover mm

'Low Level' SCADA alarm should be active.

Local 'Low Level' indicator should be illuminated.

Restore Normal C/O operation - restore inflow.

Rising Level High Level Float Activated Scada & Local Indicator

Falling Level Float De-Activated Resettable/Clear Scada & Local Indicator



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Emergency Pumping Controls (PLC inoperative / faulted)

Description of Test

Accept

Yes Yes

Rising Level High Level float switch activated - stop inflow – duty (or selected?) pump (Pump # 2) operates for required period min

1.1.1.1.1.2

Level @ Pump switch-off m

Inflow Enabled – High level float switch activated – other pump (Pump # 1 ) operates for required period ___ min

Level @ Pump switch-off _____ m

Main C/B - Switched 'Off'

All supplies isolated

Phase Fall Relay De-Energized - 'Mains Power Fail' alarm - SCADA and local indicator – active.

Multitrode Lockout

'Control Power Fail' Alarm - SCADA and local indicator

'Motor Protection Operated' Alarms - SCADA and local indicator

Portable Generator Main Switch – operable?

Main C/B -Switched 'On' Generator Main Switch MUST be Off)

All Supplies active.

'Mains Power Fail' Alarm - SCADA and local indicator – resettable?

‘Control Power Fail' Alarm - SCADA and local indicator – resettable?

'Motor Protection Operated' Alarms - SCADA and local indicator – resettable?

Portable Generator Main Switch - should NOT be operable. (Manual change over system)

Pump 1 C/B C/B = 'On'

Pump 1 Starter Supply = active

Pump 1 - Protection Operated Alarms - SCADA & Local Ind. = Normal (reset)

C/B switched - 'Off'

Check that Pump 1 Starter Supply is isolated.

Check & record - Motor Insulation Resistance Tests:

Windings - Earth = Ohm R mm

W mm

B mm

Check & record - Overload Protection Setting = A

Pump 1 - Protection Operated Alarms - SCADA & Local Ind. - Alarm active.



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Description of Test

Accept

Yes Yes

C/B = 'On'


Pump 1 - Protection Operated Alarms - SCADA & Local Ind. = Resettable

Pump 2 C/B C/B = 'On'


Pump 2 - Protection Operated Alarms - SCADA & Local Ind. = Normal (reset)

C/B switched - 'Off'

Check that Pump 2 Starter Supply is isolated.

Check & record - Motor Insulation Resistance Tests:

Windings - Earth = Ohm R mm

W mm

B mm

Check & record - Overload Protection Setting = A

Pump 2 - Protection Operated Alarms - SCADA & Local Ind. - Alarm active.

C/B = 'On'


Pump 2 - Protection Operated Alarms - SCADA & Local Ind. = Resettable

Phase Fail

Relay - Operation

C/B Closed - Relay energised (normal)

Trip C/B - Relay De-Energises - Alarm Activated

Disconnect any one (1) Phase from relay - Relay De-Energises - Alarm Activated

Restore C/B & wiring to normal - Relay Energised - Alarm Resettable.



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Other tests and calibrations conducted during commissioning 1. Level sensor calibration Level Units in M H2O Fixed Local Reading mA SCADA Vega Probe Available 4-20mA 0-20mA

2. Emergency Generator testing



of 79 Version 2.5

APPENDIX B – FLOW METER INSTALLATION REQUIREMENTS

The contactor must ensure:

a) The cables are potted on the sensor by the supplier or supplier nominated a competent person

b) The flow sensor should be wrapped with DENSO and then plastic in preparation for buried installation

c) One side of the pipe flange should be a uni-flange or any other dismantling flange for easy removal for maintenance

d) The sensor cable should be drawn in an electrical conduit from the flow sensor to the electrical cabinet

e) The transmitter should be a remote type; panel mounted installed in the electrical cabinet

f) Minimum 5D upstream and 3D downstream straight lengths must be adhered

g) Back filling around the flow sensor must be soft sand

h) Cable protector concrete slab is placed about 300 -400 mm above the flow sensor for protection from future excavations

i) Marker post or a marker slab with clear sign should be placed above the flow sensor. Alternatively a buried detectable electronic device shall be used.

Electrical and SCADA

a) Contactor should arrange the flow meter supplier to configure and commission the system

b) 4-20mA signal from the flow transmitter should be terminated at the RTU at WGS280

c) CWW approved integrator should be engaged to configure and upgrade the SCADA with this new flow signal

Submersible and buriable

WaterMaster sensors have a rugged, robust construction to ensure a long, maintenance- free life under the arduous conditions experienced in the Water and Waste Industry. The sensors are, as standard, inherently submersible (IP68, NEMA 6P), thus ensuring suitability for installation in chambers and metering pits that are susceptible to flooding.

A unique feature of the Water Master sensors is that sizes DN40 to DN2400 (11/2 to 96 in. NB) are buriable; installation simply involves excavating to the underground pipe, fitting the sensor, cabling back to the transmitter and then backfilling the hole. Grounding The flowmeter sensor must be connected to ground potential. For technical reasons, this potential should be identical to the potential of the metering fluid. For plastic or insulated lined pipelines, the fluid is grounded by installing a minimum of one earthing ring. When there are stray potentials present in the pipeline, an earthing ring is recommended on both ends of the meter sensor. Mounting

The installation conditions shown below must be observed to achieve the best operational results. The sensor tube must always be completely full.

The flow direction must correspond to the identification plate. The device measures the flowrate in both directions. Forward flow is the factory setting. The devices must be installed without mechanical tension Sling Angle <90° (torsion, bending). If required support the pipeline, Fluid contact rings.



Version 2.5 of 79

APPENDIX C – MECHANICAL AND ELECTRICAL SPARE PARTS

Make and model of the following spares should be as per City West Water requirements.

01 soft starter

01 MultiSmart pump controller

01 complete RTU with back plane, power supply and I/O cards

01 radio unit

01 GSM modem

01 Vega level sensor

01 loop isolator

01 LCD indicator for level signal

01 power supply/battery charger

02 indicator lamps with globes

01 submersible pump identical to two units installed



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APPENDIX D – FORMAT FOR OPERATIONS & MAINTENANCE MANUAL

The basic format of the Operation & Maintenance Manual should be as per below:

Section 1 - System Description

Contract details

System description

Section 2 - As constructed data

General arrangement drawings (require AutoCAD version and PDF files of all the drawings separated

Electrical drawings – (require AutoCAD version and PDF files of all the drawings separated)

Pump Curves

Technical data – site information

Section 3 - Manufactures Equipment Data & Manuals

Pump installation Manual

Pump Controller Manual

Level control system

Valves

Soft Starters

Flow meter

Electrical Equipment fitted in the cabinet

Section 4 - Maintenance schedule

Routine Maintenance

Maintenance chart

Trouble Shooting

Problem Solving and remedial actions

OH&S requirements

Warranty

Section 5 - Test Results

Calibration Reports

Commissioning Report

Warranty Certificates

SCADA commission Test Plans



Version 2.5 of 79

APPENDIX E – DOCUMENT IMPROVEMENT REQUEST

DOCUMENT IMPROVEMENT REQUEST

Supplementary Manual to WSA 04-2005 Version 2.5 FROM: Name:

Position/Title:

Section/Company:

Address:

Email: Phone: Fax:

Signature Date:

TO: Standards and Design, City West Water

Email: [email protected]

PROPOSED IMPROVEMENT

Part Clause Page No Proposed Improvement

OFFICE USE ONLY

Outcome of Review:

Comment/Decision:

Name and signature of approving authority:

Date:

mailto:[email protected]

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