Top ten hassles in wastewater pumping -- and how to avoid them
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Transcript of Top ten hassles in wastewater pumping -- and how to avoid them
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TOP TEN HASSLES INWASTEWATER PUMPING
Brian GongolDJ Gongol & Associates, Inc.
July 2014
Heartland Ops ConferenceKearney, Nebraska
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You're probably a hands-on person
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You need the help of numbers people
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Appeal to their way of thinking, not your own
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Your inconveniences mean little to them
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Learn to quantify your troubles
Make pumping hasslesa matter of dollars and cents
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Ten common problems in no particular order
Your troubles will vary
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Problem #1: Clogging
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There's no such thing as "non-clog"
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Is this real life? Or is this just fantasy?
Anyone who insists that a pump is "non-clog"clearly hasn't seen the kinds of things
real people dump down the drain
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ANY pump can clog. Period.
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What matters
Resistance to clogging How quickly the pump can be unclogged How quickly the pump can return to service
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Trash baskets
People don't use them because they clog ...but then the pumps clog
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Low pump speeds can reduce inlet velocities
Which may lead to clogging
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VFDs are not a magic pill
They can be helpful in some cases,but they risk running too slowly
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Use caution with shredders and grinders
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Solids passage beats solids decimation
It is often better to passa large solid intact
than in many small bits
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Pass the whole baseball...
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...or all of the string and bits inside it?
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Small solids plus high FOG
A recipe for disgusting trouble
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Solids with neutral buoyancy
May be invisible from surface inspectionbut still cause clogs
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You can't prevent every clog
(Not as long as idiots can still flush mop heads)
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Half-filled basketballs
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Waterlogged wood
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Sheets of liner material
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Storms will always bombard wetwells
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Backflushing/jetting doesn't always solve it
If the debris is still there, the problem is too
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Clogged suction piping may require cutters
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Wetwells may require vacuum trucks
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Replacement pumps may clog when old ones didn't
Better suction pulls settled material from the wetwell
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Prevent clogs
Make sure you have true 3" clearances Keep the wetwell clear Run pumps at appropriate speeds
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But when clogs happen...
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Ask: How quickly can you return to service?
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How much does downtime really cost?
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Total cost of a clog
Cost of pump downtime Cost of extraction Cost of labor (service charges or your own time) Cost of transit Cost of unclogging Cost of parts Cost of bypass pumping if required Cost of sewer backup risk Cost of reinstallation
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And one very important cost
Opportunity cost of your time
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Opportunity cost
You might be a pump specialist You might be a jack of all trades Either way...
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You have to place a value on your time
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Opportunity cost
The cost of doing one thingwhen you could be doing something else
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Real total costs
Real total cost =
out-of-pocket cost + labor cost+ opportunity cost
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Don't overlook other potential clogging sites
Lines to air release valves Drain lines Cooling jackets Gauge taps
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Little clogs, big headaches
Rubber center of a golf ball Springs
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Problem #2: Cavitation
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Cavitation can occur on suction or discharge
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Any centrifugal pump is at risk
Submersible Flooded-suction Suction-lift
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Cavitation cause #1
Poor system design
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Cavitation cause #2
Pump clearances open up over time due to wear
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Cavitation cause #3: Valve changes
Even when seemingly innocuous
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Cavitation cause #4
Broken, damaged or closed ARVs on a forcemain
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Cavitation cause #5
Sedimentation or air pockets
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Cavitation cause #6: Broken mains and valves
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Listen closely: Suction cavitation
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Listen closely: Discharge cavitation
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Document performance with all of your senses
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Or maybe all but one.
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We use sight as a crutch
Sounds, smells, and temperatures all matter
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If you're at risk for cavitation
Hardened parts can reduce wear Delays the pump from falling out of tolerance
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Ask this
How easily can the tolerances and clearances be maintained?
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Identifying cavitation by autopsy
Discharge-side cavitation
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Identifying cavitation by autopsy
Suction-side cavitation
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Uniform abrasive wear isn't cavitation
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Problem #3: Animals, vermin, and nature being a jerk
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Warm, protected spaces are attractive
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Seal your gaps with gaskets
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Keep doors closed
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Patch holes
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Keep things off floors
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Containerize with plastic
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Containerize with plastic
Avoid wood, cardboard, and metal
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Sweep and clean up
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A place for everything; everything in its place
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Natural enemy: Muskrats
Swim into warm wetwells Get sucked up into pipes and pumps (they're squishy)
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Natural enemy: Turtles
Swim into warm wetwells
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Natural enemy: Turtles
Block off suction inlets
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Natural enemy: Turtles
Cause pumps to overheat and shut down
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Natural enemy: Turtles
Swim away once the lag pump lowers the wetwell to the off-elevation
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Natural enemy: Turtles
The operator gets the call, runs out to the station and can't find anything wrong
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Natural enemy: Rattlesnakes
Southern and Eastern Iowa
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Natural enemy: Bees, wasps, and hornets
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Natural enemy: Spiders
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Ask: Can we really keep the pump station clean?
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Problem #4: Lubrication
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Seals
Oil-lubricated Grease-lubricated Water-lubricated Lubrication by media
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Bearings
Oil or grease
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Maintenance charts
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Treat it like a bowling scorecard
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Clean up spills
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Use simple checklists
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Rule of 7
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Problem #5: Seal failures
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Cause: Debris like sand and grit
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Cause: Alignment problems
Factory-alignedon base
V-belts areforgiving
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Cause: Mechanical vibration
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Cause: Hydraulic imbalance
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Ask: Can I replace my own seals?
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Keep pump stations clean
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You can only see what's wrongif you know what looks right
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Problem #6: Motor failure
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Power surges and lightning strikes
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Excessive starts per hour
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Mice building nests in motors
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Car accidents can cause pump problems
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Car accidents can cause pump problems
Power line comes down Power company changes transformer Phases get reversed Motor runs backwards, leading to half or zero flow overnight
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VFDs at a distance
VFDs more than 100' from the motor can cause reflected waves
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Use infrared temperature sensors to track
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Know the motor's lubrication requirements
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Ask: Are replacement motors readily available?
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Ask: Are the sensors useful?
Do moisture sensors give you time to react?
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Problem #7: Temperature problems
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Overheating...and freezing
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Proper ventilation for summer and winter
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Heaters are cheap
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Frozen water-line epidemic of 2014
Don't waste a good crisisthat was widely experienced
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Ask: Are we using the right enclosures?
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Problem #8: System changes
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System head curves change over time
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Wear can cause pump performance to change
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Sedimentation adds to friction losses
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Water hammer can break valves and pipes
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Ask: Is the system protected against surges?
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Air buildup where ARVs should be installed
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ARVs can fail, raising discharge heads
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Ask: Do we have ARVs and surge valves?
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Document performance on a pump curve
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Problem #9: Vortexing and air entrainment
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All centrifugal pumps are susceptible
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Pumps are meant to move water
If you need to move air, get a fan
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Air leads to irregular shaft loads
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Inlet main failures
Can explain surprise low-water alarms
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Fix air entrainment with baffles
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Fix vortexing with proper pump spacing
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Fix vortexing with added submergence
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Problem #10: Safety
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Safety isn't the problem - complacency is
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Safety always starts at the top
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Nobody will watch out for your safety like you
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You are not paid enough to risk life and limb
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Ask: Is there a safer way?
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One thread runs through most of these problems
Recordkeeping!
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Take gauge readings and record them
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Document spills and leaks...look for patterns
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Record smells, sounds, temperatures
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Get comfortable with spreadsheets
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Officials and managers need hard evidence
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Engineers need actionable observations
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Equipment suppliers need feedback
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Spare parts
Availability of replacementpumps, motors, and parts
is essential to maintenance
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Spare parts
Your shelf+ supplier's shelf
+ manufacturer's shelf
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Don't put it off
Deferred maintenance costsaren't any less real
just because we defer them
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Compounding interest can make you rich
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Deferred maintenance costs compound, too
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Compounding costs can ruin a great system
Decide what you need Measure the total costs Document Quantify, quantify, quantify Make the case to get what you need to serve the public
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References
All images are original work by and copyright reserved to Brian Gongol