Title

12 RAS Pump Start Up

Three 30 HP, variable speed, non-clog type pumps each with a capacity of 3750 gpm make up the RAS Pumping System. Two pumps provide sufficient capacity with a third provided for redundancy. The Lead/Lag/Standby status of the pumps is manually changed by the operator each month.  During normal operation, RAS pumps are automatically controlled by VFDs from SCADA. Pump status, however, can be monitored at the HMI.

SOP Identification Number
SOP Identification Number:
1202 - RAS Pump Start Up
Purpose and scope
Purpose and scope:

The primary function of the RAS Pumps is to transfer Return Activated Sludge from the Secondary Clarifiers to the Aeration Tanks. 

Definitions
Definitions:
  • RAS: Return Activated Sludge
Health & Safety Warnings
Health & Safety Warnings:

Watch for open tanks, vaults and channels.  If working on or near equipment, watch for rotating parts. 

Cautions
Cautions:
  • Verify that suction valve(s) are open. Verify that discharge valve(s) are open.
  • Ensure that valves are completely open or closed.  Valves are gear operated and take multiple turns to open or close.
Potential Interferences
Potential Interferences:
  • The selected RAS ratio setpoint must be accurate in order for SCADA to assign correct pumping flow rates. 
Personnel Qualifications
Personnel Qualifications:

Operator 1, knowledge of secondary treatment process and equipment controls.

Quality Control/Quality Assurance Activities for the Procedure
Quality Control/Quality Assurance Activities for the Procedure:
  • Record activity to log book.
  • Compare flow rates with the SCADA target rate.
Procedure
Procedure:


1.     Check Valve Status :

a.     Locate the Suction Valve {tag nos. 1204VLV2100, 1204VLV2200 & 1204VLV2300}.  Open the valve if it is not already open.   The suction valves are located between the pump and the building wall. The valves are gear operated and will take multiple turns to open.

b.     Locate the Discharge Valve {tag nos. 120VLV2100A, 1204VLV2200A & 1204VLV2300A}.  Open the valve if is it not already open. The discharge valves are located above the check valve. The valves are gear operated and will take multiple turns to open.

2.     Prepare Pumps for Start Up at Control Panel:

a.     Locate the stantion with the local and Lockout Switch {tag nos. 1204HS2100A, 1204HS2200A & 1204HS2300A} and HOA Switch {tag nos. 1204HS2100, 1204HS2200 & 1204HS2300}.  Verify that the Lockout Switch is in the ON position and the HOA Switch  is in the AUTO position.

b.     At the Control Panel, locate the Main Breaker {tag nos. 1204FBK2100, 1204FBK2200 & 1204FBK2300}.  Flip the switch to the ON position.

c.     At the Control Panel, locate the VFD Breaker {tag nos. 1204FBK2100A, 1204FBK2200A & 1204FBK2300A}.  Flip the switch to the ON position.

d.     At the Control Panel, locate the HOA Switch {tag nos. 1204HS2100, 1204HS2200 & 1204HS2300}.  Flip the switch to the AUTO position.

e.     Verify that the Pump On Indicator Light {tag nos. 1204YL2100, 1204YL2200 & 1204YL2300} is on.

3.     Start Up Pumps from SCADA (Automatic Operation):

a.     At the SCADA Workstation, verify that the pumps are in AUTO mode.  If the VFD HOA switches are in the AUTO position and the Lockout Switch is in the ON position, the RAS Pumps can be controlled and monitored at the SCADA workstation.

b.     From the SCADA screen, select the lead pump at the HOA control.  SCADA will automatically assign the lag and standby pumps. The lead pump graphic will appear green on the display.

c.     Select the RAS ratio setpoint.  This setpoint is determined by the supervisor.  SCADA will automatically correct pumped flow rates to stay within a predetermined minimum and maximum range of flows.

d.     Compare the flow rate displayed by the magnetic flowmeter with the target rate set by SCADA.  The calculation used to determine this rate is: influent flow to plant minus recycled flows that occur upstream of the secondary process.  

4.     Start Up Pumps from SCADA (Manual Operation):

a.     Locate the VFD HMI {tag nos. 1204HMI2100, 1204HMI2200 & 1204HMI2300}.

b.     Start the pump and adjust the pump speed.

c.     Locate the Pump Run Indicator Light {tag nos. 1204YL2100A, 1204YL2200A & 1204YL2300A} and verify that it is ON.

5.     Observe RAS  Pump Operation:

a.     Check that the lead pump is operating and check for proper rotation.

b.     If the pump is running at a high rate, the check valve should be in a “non-horizontal position”.

c.     Listen for excessive noise or vibration.

d.     Check for oil or process fluid leaks.

6.     Record Data to Operator’s Log Book:  Record RAS Pump Activities to the log book with other entries for the day.  Include the following in the entry:

·         Operator(s) that performed the RAS Pump Start Up SOP.

·         Note condition of equipment, piping, valves, etc.

·         Note any unusual conditions with flows, levels, odors or other process issues.

·         Note any damage, wear, or required maintenance on equipment.

 

Data & Records Management, Calculations, Forms, Reports
Data & Records Management, Calculations, Forms, Reports:
  • Update log book.
  • Update maintenance records (if applicable).
  • Report any maintenance or attention that is required.
Equipment
Equipment:

EQUIPMENT NAME

TAG NUMBER

RAS Transfer Pump No. 1

1204PMP2100

RAS Transfer Pump No. 1 Motor

1204MTR2100

RAS Transfer Pump No. 1 VFD

1204VFD2100

RAS Transfer Pump No. 1 – Suction Valve

1204VLV2100

RAS Transfer Pump No. 1 - Discharge Valve

1204VLV2100A

RAS Transfer Pump No. 1- Local HOA Switch

1204HS2100

RAS Transfer Pump No. 1 - Local Start Switch

1204HS2100A

RAS Transfer Pump No. 1- Main Breaker

1204FBK2100

RAS Transfer Pump No. 1- VFD Breaker

1204FBK2100A

RAS Transfer Pump No. 1- Bucket

1204BKT2100

RAS Transfer Pump No. 1- HMI Interface

1204HMI2100

RAS Transfer Pump No. 1- Indicator Light

1204YL2100

RAS Transfer Pump No. 1- Run Light

1204YL2100A

RAS Transfer Pump No. 2

1204PMP2200

RAS Transfer Pump No. 2 Motor

1204MTR2200

RAS Transfer Pump No. 2 VFD

1204VFD2200

RAS Transfer Pump No. 2 – Suction Valve

1204VLV2200

RAS Transfer Pump No. 2 - Discharge Valve

1204VLV2200A

RAS Transfer Pump No. 2- Local HOA Switch

1204HS2200

RAS Transfer Pump No. 2 - Local Start Switch

1204HS2200A

RAS Transfer Pump No. 2- Main Breaker

1204FBK2200

RAS Transfer Pump No. 2- VFD Breaker

1204FBK2200A

RAS Transfer Pump No. 2- Bucket

1204BKT2200

RAS Transfer Pump No. 2- HMI Interface

1204HMI2200

RAS Transfer Pump No. 2- Indicator Light

1204YL2200

RAS Transfer Pump No. 2- Run Light

1204YL2200A

RAS Transfer Pump No. 3

1204PMP2300

RAS Transfer Pump No. 3 Motor

1204MTR2300

RAS Transfer Pump No. 3 VFD

1204VFD2300

RAS Transfer Pump No. 3 – Suction Valve

1204VLV2300

RAS Transfer Pump No. 3 - Discharge Valve

1204VLV2300A

RAS Transfer Pump No. 3- Local HOA Switch

1204HS2300

RAS Transfer Pump No. 3 - Local Start Switch

1204HS2300A

RAS Transfer Pump No. 3- Main Breaker

1204FBK2300

RAS Transfer Pump No. 3- VFD Breaker

1204FBK2300A

RAS Transfer Pump No. 3- Bucket

1204BKT2300

RAS Transfer Pump No. 3 - HMI Interface

1204HMI2300

RAS Transfer Pump No. 3- Indicator Light

1204YL2300

RAS Transfer Pump No. 3- Run Light

1204YL2300A

ID
Maintenance Connect