KSB Amarex N Operating And Maintenance Instructions Manual
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KSB Amarex N Operating And Maintenance Instructions Manual

Submersible motor pump
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Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual
Cust. Doc. No.:GDSTP-24090-MAN-0006-P1
Client
Project
P.O. No.
Equipment / Tag No. :
Sales and Service
Phone
Fax
Email
Spares
Q-Pulse Id VM372
K S B A u s t r a l i a P t y L t d
A B N 2 9 0 0 6 4 1 4 6 4 2
A Q u a l i t y E n d o r s e d C o m p a n y A S / N Z I S O 9 0 0 1 : 2 0 0 8
OPERATING AND
MAINTENANCE
INSTRUCTIONS
KSB Doc. No.:KSB-88980-084
KSB REF No: 88980/ 48
:
Thiess Pty Ltd
:
Goodna Sewerage Treatment Plant Upgrage [Stage 4A]
:
GDSTP-24090-CON-0000
Amenities Pump Station
:
(07) 3436 8600
:
(07) 3436 8699
:
ksbqldsales@ksb.com.au
:
1300 KSB SPARES ( 1300 572 772 )
Active 29/10/2013
Issue Date: 8/02/2012
Page 1 of 94

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  • Page 1 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual K S B A u s t r a l i a P t y L t d A B N 2 9 0 0 6 4 1 4 6 4 2...
  • Page 2 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual I N D E X Pump • Amarex N Pumps Installation/ Operating Manual • Package Pump Station IOM - Fibreglass Wetwell Instructions - Package Pump Station Product Literature Drawings •...
  • Page 3 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Submersible Motor Pump Amarex® N Pump sizes DN 50 to DN 100 Motor sizes: 2-pole: 002 to 042 4-pole: 004 to 044 Installation/Operating Manual Page 3 of 94...
  • Page 4 Original operating manual KSB Aktiengesellschaft Pegnitz All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, processed for any other purpose, nor otherwise transmitted to a third party without KSB´s express written consent. Subject to technical modification without prior notice.

  • Page 5: Table Of Contents

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Contents Contents Glossary ....................5 General ....................6 Principles ......................6 Installation of partly completed machinery ..........6 Target group ....................6 Other applicable documents ................6 Symbols ......................
  • Page 6 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Contents Commissioning/Start-up/Shutdown ..........32 Commissioning/start-up ................32 Operating limits .................... 33 Shutdown/storage/preservation ..............35 Returning to service ..................35 Servicing/Maintenance ..............37 Safety regulations ..................37 Maintenance/Inspection ................38 Drainage/disposal ..................

  • Page 7: Glossary

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Glossary Glossary Certificate of decontamination Monobloc pump set A certificate of decontamination certifies that Motor housing and pump casing form a single the pump (set) has been properly drained to component.

  • Page 8: General

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 1 General 1 General 1.1 Principles This manual is supplied as an integral part of the type series and variants indicated on the front cover (for details, please refer to the table below).

  • Page 9: Symbols

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 1 General 1.5 Symbols Table 3: Symbols used in this manual Symbol Description ✓ Conditions which need to be fulfilled before proceeding with the step-by-step instructions ⊳...

  • Page 10: Safety

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER 2.1 Key to safety symbols/markings Table 4: Definition of safety symbols/markings...
  • Page 11 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 2 Safety ▪ Only use the pump to handle the fluids described in the data sheet or product literature of the pump model. ▪ Never operate the system without the fluid to be handled.

  • Page 12: Personnel Qualification And Training

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 2 Safety 2.4 Personnel qualification and training All personnel involved must be fully qualified to install, operate, maintain and inspect the machinery this manual refers to. The responsibilities, competence and supervision of all personnel involved in installation, operation, maintenance and inspection must be clearly defined by the operator.

  • Page 13: Safety Information For Maintenance, Inspection And Installation Work

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 2 Safety 2.8 Safety information for maintenance, inspection and installation work ▪ Modifications or alterations of the pump are only permitted with the manufacturer's prior consent. ▪ Use only original spare parts or parts authorised by the manufacturer. The use of other parts can invalidate any liability of the manufacturer for consequential damage.

  • Page 14: Transport/Temporary Storage/Disposal

    ▷ Use the attachment point (pump handle) provided for attaching lifting tackle. ▷ Never suspend the pump set by its power cable. ▷ Never use the chains or lifting ropes included in KSB's scope of supply for lifting loads other than the KSB product supplied.

  • Page 15: Return To Supplier

    4. Always complete and enclose a certificate of decontamination when returning the pump (set). (⇨ Section 11 Page 64) It is imperative to indicate any safety and decontamination measures taken. NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination 3.4 Disposal...

  • Page 16: Description Of The Pump (Set)

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 4 Description of the Pump (Set) 4 Description of the Pump (Set) 4.1 General description Pump for handling untreated waste water containing long fibres and solid substances, fluids containing gas and air as well as raw, activated and digested sludge.

  • Page 17: Design Details

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 4 Description of the Pump (Set) 4.4 Design details D e s i g n ▪ Fully floodable submersible motor pump ▪ Not self-priming ▪ Close-coupled unit I m p e l l e r t y p e ▪...

  • Page 18: Configuration And Function

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 4 Description of the Pump (Set) 4.6 Configuration and function Shaft Bearing bracket Discharge cover Suction cover Suction nozzle Discharge nozzle Impeller Shaft seal Bearing, pump end...

  • Page 19: Dimensions And Weights

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 4 Description of the Pump (Set) ▪ Foot pad or pump stool with mounting elements ▪ Lifting rope or chain NOTE A separate name plate is included in KSB's scope of supply.

  • Page 20: Installation At Site

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Improper installation in potentially explosive atmospheres Explosion hazard! Damage to the pump set! ▷ Comply with the applicable local explosion protection regulations.
  • Page 21 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site 1. Check the structural requirements. All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing/general arrangement drawing.

  • Page 22: Installing The Pump Set

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site 2. Check the direction of rotation. Impeller rotation must be anti-clockwise, seen from the pump mouth. (The direction of rotation is marked by an arrow on the pump casing.) Fig.
  • Page 23 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site Table 8: Anchor bolt dimensions Size Hex. Torque requ [mm] [mm] head [mm] [mm] [mm] instal [Nm] [mm] M 10x130 M 16x190 Table 9: Curing times of mortar cartridge...
  • Page 24 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site 5.3.1.3 Fitting the guide wire arrangement The pump set is guided into the sump or tank along two parallel, tightly stretched guide wires made of stainless steel. It attaches itself automatically to the duckfoot bend which has been fitted to the floor.
  • Page 25 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site NOTE The guide rails are not included in KSB's scope of supply. Select guide rail materials which are suitable for the fluid handled or as specified by the operator.
  • Page 26 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site F i t t i n g t h e g u i d e r a i l s ( a r r a n g e m e n t w i t h 1 g u i d e r a i l ) 1.
  • Page 27 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site F a s t e n i n g t h e c l a w f o r g u i d e r a i l a r r a n g e m e n t s w i t h 2 g u i d e r a i l s 1.
  • Page 28 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site 5.3.1.7 Installing the pump set NOTE For pumping water containing sludge and suspended solids pump sets with impeller type S (cutter) are preferable. In such cases it is recommended to use an inclined claw.

  • Page 29: Electrical Connection

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site 5.4 Electrical connection 5.4.1 Information for planning the control system For the electrical connection of the pump set observe the wiring diagrams contained in the Annex.
  • Page 30 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site ▪ Data provided by the manufacturer ▪ Electrical data of the pump set, particularly the rated current ▪ Ensure short start ramps (max. 5 s) Start-up ▪...
  • Page 31 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site 5.4.1.5 Motor temperature DANGER Insufficient cooling Explosion hazard! Winding damage! ▷ Never operate an explosion-proof pump set without operational temperature monitoring. S t a n d a r d p u m p s e t s ( v a r i a n t s U L a n d W L ) : Two bimetal switches (terminals 21 and 22, max.
  • Page 32 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site Every time the relay trips the pump, the pump needs to be inspected and its insulation resistance measured. The electrode relay (K1) must meet the following requirements: ▪...
  • Page 33 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 5 Installation at Site CAUTION Flow-induced motion Damage to the power cable! ▷ Run the power cable upwards without slack. 1. Run the power cables upwards without slack and fasten them.

  • Page 34: Commissioning/Start-Up/Shutdown

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/start-up 6.1.1 Preconditions for commissioning/startup DANGER Fluid level too low Explosion hazard! Damage to the pump set! ▷ Completely prime the pump set with the fluid to be handled to reliably prevent the formation of a potentially explosive atmosphere.

  • Page 35: Operating Limits

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown 6.2 Operating limits DANGER Non-compliance with operating limits Damage to the pump set! ▷ Comply with the operating data indicated in the data sheet. ▷ Avoid operation against a closed shut-off element.
  • Page 36 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown The pump set is ready for operation when the fluid level has reached dimension "R3" as a minimum (see general arrangement drawing/outline drawing). Fig. 19: Minimum fluid level...

  • Page 37: Shutdown/Storage/Preservation

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown CAUTION Pumping solids-laden fluids at reduced speed Increased wear and clogging! ▷ Never operate the pump set with flow velocities below 0.7 m/s in horizontal pipes and 1.2 m/s in vertical pipes.
  • Page 38 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 6 Commissioning/Start-up/Shutdown WARNING Failure to re-install or re-activate protective devices Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is completed, re-install and/or re-activate any safety- relevant and protective devices.

  • Page 39: Servicing/Maintenance

    (set) with a minimum of maintenance expenditure and work. NOTE All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/ contact".

  • Page 40: Maintenance/Inspection

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance 7.2 Maintenance/Inspection Table 15: Overview of maintenance work Maintenance interval Maintenance work For details see ... Insulation resistance test (⇨ Section 7.2.1.3 Page 38) After 4,000 operating hours Check the power cables (⇨...
  • Page 41 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance NOTE If the insulation resistance for one of the power supply cables is less than 1 MΩ, the cable is defective and must be replaced.
  • Page 42 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance WARNING Contamination of fluid handled by lubricant Hazardous to persons and the environment! ▷ Using machine oil is only permitted if the oil is disposed of properly.
  • Page 43 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance 2563:109 Fig. 21: Topping up the lubricant a) Variants YL and WL; B) Variants YL, WL for pump sizes 50-170... and 65-220 2. Fill lubricant through the lubricant filler opening until the lubricant in the lubricant reservoir reaches the required level M (see the following table).

  • Page 44: Drainage/Disposal

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance 7.3 Drainage/disposal WARNING Fluids posing a health hazard Hazardous to persons and the environment! ▷ Collect and properly dispose of flushing liquid and any fluid residues.
  • Page 45 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance 7.4.3 Dismantling the pump section Dismantle the pump section in accordance with the relevant general assembly drawing. 1. Remove suction cover 162. 2. Undo and remove the M8 impeller fastening screw.

  • Page 46: Reassembling The Pump Set

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance 11. Remove bearing bracket housing 355. 12. Pull out rotor 818. 13. Remove circlip 932.01. 14. Remove circlip 932.02. 15. Pull off the two rolling element bearings 321.
  • Page 47 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance 7.5.2 Reassembling the pump section 7.5.2.1 Installing the mechanical seal Observe the following points to ensure trouble-free operation of the mechanical seal: ▪ Make sure the surface of the shaft is absolutely clean and undamaged.
  • Page 48 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance CAUTION Incorrect installation Clearance gap inaccurate! ▷ Pull the rotor assembly right up to the suction cover until it will not go any further. Maintain this position until dimensions x and y have been measured.
  • Page 49 Slide impeller 230 onto the shaft end and fasten it with impeller screw 914.04. Then, remove the impeller screw again. Screw in an M8 x 100 eyebolt (not included in KSB's scope of supply) instead of the impeller screw. Push on suction cover 162 until it rest against the impeller.

  • Page 50: Tightening Torques

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance 2563:115 Fig. 29: Screwing in the testing device 1. Unscrew and remove the screwed plug and joint ring of the lubricant reservoir. 2. Screw the testing device tightly into the lubricant filler opening.
  • Page 51 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 7 Servicing/Maintenance 7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 Table 22: Quantity of spare parts for recommended spare parts stock Part No.

  • Page 52: Trouble-Shooting

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 8 Trouble-shooting 8 Trouble-shooting Pump is running but does not deliver Pump delivers insufficient flow rate Excessive current/power consumption Insufficient discharge head Vibrations and noise during pump operation...

  • Page 53: Related Documents

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components 9.1.1 Amarex N — variant ULG Size of hydraulic system D 50 ... 100 Motor sizes 002...042...
  • Page 54 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents 9.1.2 Amarex N — variant YLG/WLG Size of hydraulic system DN 50...100 Motor sizes 002...042 004...044 2563:121/2 General assembly drawing of explosion-proof pump set (YLG)/non-explosionproof pump...
  • Page 55 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents 9.1.3 Exploded views A m a r e x N - S 5 0 YLG - - WLG 321.01 412.01 932.02 321.02 932.04 932.01 412.04...
  • Page 56 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents A m a r e x N - F 5 0 - 1 0 0 YLG - - WLG 321.01 412.01 932.02 321.02 932.04 932.01...
  • Page 57 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents A m a r e x N - D 8 0 - 1 0 0 YLG - - WLG 321.01 412.01 932.02 321.02 914.01 932.04...
  • Page 58 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents Table 27: List of components Part No. Description Part No. Description Casing Ring Intermediate casing Disc Suction cover Grooved pin Feet 69-6 Temperature sensor...

  • Page 59: Wiring Diagrams

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents 9.2 Wiring diagrams 9.2.1 Variant WLG/YLG Fig. 33: Wiring diagram for variant WLG/YLG Amarex® N 57 of 66 Page 59 of 94 Q-Pulse Id VM372...
  • Page 60 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents 9.2.2 Variant ULG Fig. 34: Wiring diagram for variant ULG Amarex® N 58 of 66 Page 60 of 94 Q-Pulse Id VM372 Active 29/10/2013...

  • Page 61: Wiring Diagrams Overload Protection

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents 9.3 Wiring diagrams overload protection Table 28: Examples of wiring diagrams for overload protection Circuit diagram Q: residual current device 3~30 mA e.g. residual current device Merlin Guérin C60 L, trip characteristic K ▪...

  • Page 62: Flamepaths On Explosion-Proof Motors

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents 9.4 Flamepaths on explosion-proof motors Table 29: Overview of flamepaths Motor sizes Pump set DKN 82 F 50-170 S 50-17... F 65-220 Shaft Pump casing...
  • Page 63 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents Motor sizes Pump set DKN 92 F 50-220 S50-22... F65-170 F 80-220 D 80-220 F 100-220 D 100-220 Shaft Pump casing Cable gland Flamepath number ≥...

  • Page 64: Installation Drawings Of The Mechanical Seal

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 9 Related Documents 9.5 Installation drawings of the mechanical seal Table 30: Installation drawings of the mechanical seal Part No. Description Installation drawing 433.01 Mechanical seal (bellows- type mechanical seal) 932.01...

  • Page 65: Ec Declaration Of Conformity

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 10 EC Declaration of Conformity 10 EC Declaration of Conformity Manufacturer: KSB S.A.S. 128, rue Carnot, 59320 Sequedin/Lille (France) The manufacturer herewith declares that the pump/pump set: Amarex®...

  • Page 66: Certificate Of Decontamination

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual 11 Certificate of Decontamination 11 Certificate of Decontamination Type ..........................Order number/ ..........................Order item number Delivery date ..........................Field of application: ....................................................Fluid handled Please tick where applicable ⃞...

  • Page 67: Index

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Index Index Application limits 8 Maintenance work 38 Mechanical seal 62 Minimum fluid level 34 Misuse 9 Certificate of decontamination 64 Commissioning/start-up 32 Operating voltage 34 Order number 6...
  • Page 68 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual ,4# "LUJFOHFTFMMTDIBGU P.O. ‡ 91257 Pegnitz Bahnhofsplatz 1, 91257 Pegnitz Germany 7HO  9241 71 ‡ )D[  9241 711793 ,4# 4"4 B. P. 95 ‡ 59482 Haubourdin-Cedex • 128, rue Carnot ‡ 59320 Sequedin/Lille )UDQFH 7pO  3 20227000 ‡...
  • Page 69 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION FIBREGLASS WETWELL Installation Instructions Including Lift Stations, Vertical Pump Vaults and Basins Publication No. MAN 200 Effective Date: May 2010 www.gebelaquasafe.com.au Page 1 Copyright © 2009 GEBEL Aquasafe. • All Rights Reserved • May 2010 • Pub. No. MAN 200...
  • Page 70 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION INTRODUCTION TABLE OF CONTENTS These instructions, while using the word "wetwell", will pertain to all wetwells, lift stations, vertical pump vaults and basins. A. Handling and Preparation . . . . . . . . . . . . . . . 3 SAFETY B.

  • Page 71: Handling And Preparation

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION BEFORE YOU BEGIN C. ANTI FLOTATION BALLAST FRP WETWELLS • Read, understand and follow these instructions. • Barricade the work area. • Review and prepare to complete the installation checklist as WARNING the installation progresses.

  • Page 72: Bed And Backfill

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION D. BED AND BACKFILL • For stable soils (cohesion ≥ 36 kpa and / or a bearing capacity ≥ 170 kpa a minimum 300mm of backfill must be Proper backfill selection and compaction is required for a placed around the wetwell.

  • Page 73: Piping Penetrations / Fittings

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION F. PIPING PENETRATIONS / FITTINGS G. INVERT Invert specified by Certified Engineer. The invert may be at any CAUTION angle and may project up the wetwell any distance.
  • Page 74 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION NON-TRAFFIC LOAD (Figure H-1) Rebar Reinforcement per Certified Engineer Design Fibreglass Flat Top with 300mm Rectangular Top Opening 250mm max Backfill (per Section D, Page 4)
  • Page 75 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION TABLE 1 Fibreglass Wetwells With External Anti Floatation Ribs: Fibreglass Wetwells With External Anti Floatation Ribs: The wetwell bottom is designed to BS4994 to any resist buckling of the wetwell bottom from external water...
  • Page 76 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION Fast Installation time Saves Time! Page 8 Copyright © 2009 GEBEL Aquasafe. • All Rights Reserved • May 2010 • Pub. No. MAN 200...

  • Page 77: Wetwell Installation Checklist

    Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual FIBREGLASS WETWELL INSTALLATION Wetwell Installation Checklist including Lift Stations, Vertical Pump Vaults, and Basins Complete this checklist and keep it with copies of any written authorizations for variations and/or deviations received from GA.
  • Page 78 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual water and waste water experts Fibre Reinforced Plastic [FRP] Packaged Pump Stations the simple solution Page 78 of 94 Q-Pulse Id VM372 Active 29/10/2013...
  • Page 79 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Why GEBEL Aquasafe? GEBEL Aquasafe has been manufacturing Fibreglass Reinforced Plastic pump stations since 1972. These years of experience and our company’s diversified operations have allowed us to design, engineer and manufacture our range of high quality Pump Stations.
  • Page 80 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Designed in accordance with BS4994 GEBEL Aquasafe’s FRP pump stations are manufactured for many applications and in a wide range of specifications to handle such substance such as Water, Sewage, Farm effluent, petroleum products and chemicals.
  • Page 81 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual the simple solution The need for cost-effective methods of pump station installation has become more and more essential. The development of the GEBEL Aquasafe Underground Pump Well has provided a simple, cost-effective solution.
  • Page 82 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Standard Minimum Standards of Design and Construction shall be Specifications for • BS4994 - 1987 Design & Construction of vessels & tanks in reinforced plastics Gebel Aquasafe •...
  • Page 83 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual PS Series FRP Pumping Station Page 83 of 94 Q-Pulse Id VM372 Active 29/10/2013...
  • Page 84 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Pumping station: available sizes Diameter Nom Capacity@ Nom Capacity@ Nom Capacity@ Nom Capacity@ 2M Deep 4M Deep 6M Deep 8M Deep 1000 1414 2985 4556 6127 1200...
  • Page 85 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual PSV Series FRP Pumping Station w Page 85 of 94 Q-Pulse Id VM372 Active 29/10/2013...
  • Page 86 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual with Valve Pit Valve Pit: available sizes Part Number Length Width Height Opening Size VP666-66 600 x 600 SQ VP699-66 600 x 600 SQ VP699-69 600 x 900 SQ...
  • Page 87 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual PSV Series FRP Pumping Station wi Page 87 of 94 Q-Pulse Id VM372 Active 29/10/2013...
  • Page 88 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual with Valve Pit & Emergency Storage Emergency Storage: available sizes Model Nº Diameter Length 600ø Manway Series 300 - 10000 1850ø 4500 - 15000 1850ø 6500 Series 350 - 20000 2200ø...
  • Page 89 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Options Access Openings Available sizes 600 x 600 SQ 600 x 900 SQ 900 x 900 SQ 1200 x1200 SQ 600mm diameter 900mm diameter 1200mm diameter Custom sizes available upon request...
  • Page 90 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Access Covers Available sizes Cast Iron Gatics in Light, Medium and Heavy Duty 600mm x 600mm Square 600mm x 900mm Square 900mm x 900mm Square 900mm x 1200mm Square...
  • Page 91 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Options Guiderails Available sizes 20mm galvanised single 20mm stainless steel single 20mm galvanised dual 20mm stainless steel dual 20mm galvanised triplex 20mm stainless steel triplex 32mm galvanised...
  • Page 92 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual Pipework Available sizes Polyethylene 2” complete with bronze valves 2” complete with cast iron valves 3” complete with bronze valves 3” complete with cast iron valves 4” complete with bronze valves 4”...
  • Page 93 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual talk to an expert today 02 4722 9696 Manufacturers and wholesalers 02 4722 9696 26 Coombes Drive, Penrith NSW 2750 of composite handling and 02 4722 9506...
  • Page 94 Goodnal STP ST041 Pre Treatment (KSB Amenities Pump Station OM Manual) Vendor Manual KSB AUSTRALIA PTY LTD 27 INDWE STREET TOTTENHAM VIC 3012 KSB DOC No: KSB-88980-076 Client Doc No: IW-GDSTP-4A-VEN-0200-2001_P2 CUSTOMER: Thiess - Goodna STP - Stage 4A Page 94 of 94...

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