Start-up & Field Check-Out
Procedures Manual

Table of Contents

Warnings, Cautions, and Symbols

Introduction

Procedure A1: Start-Up and Check-Out Procedures Using a Multimeter

Procedure A2: Start-Up and Check-Out Procedures Using a Multimeter and a Clamp-On Ammeter

Procedures A3: Start-Up and Check-Out Procedures Using a Voltmeter, a Clamp-On Ammeter, and a Megohmmeter

Procedure B1: Flow Evaluation Using a Watch Displaying Seconds

Procedure B2: Performance (Flow and Head) Evaluation Using a Watch Displaying Seconds and a Pressure Gauge

Periodic Station Checks and Inspections

Notes on Operation and Maintenance

Start-Up Report Form

Station Log Book and Log Book Forms

SWPA's Common Terminology for the Components of a Typical Submersible Lift Station

Glossary of Terms

Standards Setting Organizations

Introduction

The Technical Committee of the Submersible Wastewater Pump Association (SWPA) began developing a formalized Start-Up and Field Check-Out Procedure document for use in the field during 1995. Committee members did not feel that a simple form was necessary because pump manufacturers represented on the committee already had their own checkoff documents. What they did feel was needed in the field was a "how to" training guide with an explanation of "here's why you're doing it" for use when starting up a lift station.

The committee's intent was to establish a procedure, not to publish a fill-in-the-blank form. The goal was to develop different levels of procedures, based on equipment available, to be used in conjunction with the manufacturers start-up check-out document and Pump Instruction and Operation Manual (IOM), not in place of it.

As the initial phase in the project, a basic outline of the step-by-step procedures to put a lift station into service was developed. That outline was then expanded into this book which lists start-up and check-out procedures at three separate levels, based on test equipment available.

In addition, procedures for flow and performance (flow and head) evaluations were developed and are included in this publication:

This Manual also includes a listing of periodic station checks and inspections, notes on operation and maintenance, a sample Start-Up Report Form, simple guidelines concerning a Station Log Book and Log Book Forms, information about standards setting organizations and a glossary of commonly used terms.

Finally as reference tool, this Manual includes a drawing and SWPA's Common Terminology for the Components of a Typical Submersible Pump Station.

Notes on Operation and Maintenance

Regular inspection and preventive maintenance will insure continued, reliable operation of the entire submersible pump station. All stations, pumps, and operating equipment should be inspected at least once a year, and more frequently under severe operating conditions. All equipment in the station should be backed by manufacturers' service manuals. This material should be carefully read and filed and should be consulted whenever servicing is required.

In conducting regular inspections and preventative maintenance, be sure to follow the manufacturer's recommendations (pump, control panels, valves, etc.) as well as appropriate safety precautions to minimize the risk of accidents.

Before starting work, make sure the pump and the control panel are isolated from the power supply and that neither can be energized.

For additional information on Operation and Maintenance, including a "Trouble Checklist" of common problems and their probable causes, consult Submersible Sewage Pumping Systems (SWPA) Handbook -- 2nd Edition © 1997 by the Submersible Wastewater Pump Association (See Inside Back Cover).

Start-Up Report Form

Most pump and panel manufacturers have special forms that can be used during the start-up of a lift station.

A sample pump manufacturer's Start-Up Report is shown on the following pages*.

Some manufacturers require that these forms be filled out and returned to ensure warranty on the pumps, control panel, and station components. This type of form provides a detailed description of the procedures and tests to be performed.

*Submersible Sewage Pumping Systems (SWPA) Handbook 2nd Edition (©1997), Submersible Wastewater Pump Association, Glenview, IL 60025.

Start-Up Report Form

This report is designed to insure the customer that customer service and a quality product are the number one priority.

Please answer the following questions completely and as accurately as possible. Please mail this form to:

Manufacturer's Name
Manufacturer's Address

1) Pump Owner's Name _____________________________________
Address_________________________________________
Location of Installation ________________________________________
Person in Charge____________________________ Phone_______________
Purchased From___________________________________________________

2) Model____________________________ Serial No._____________________
Voltage ______Phase_________Hertz____________Horsepower_________
Rotation: Direction of Impeller Rotation (Use C/W for clockwise,
CC/W for counterclockwise) _____________________________________
Method Used to Check Rotation (viewed from bottom)______________
Does Impeller Turn Freely by Hand _____Yes _____No

3) Condition of Equipment _____Good _____Fair _____Poor
Condition of Cable Jacket _____Good _____Fair _____Poor
Resistance of Cable and Pump Motor (measured at pump control)
Red-Black______Ohms Red-White______Ohms White-Black______Ohms
Resistance of Ground Circuit Between Control Panel and
Outside of Pump______Ohms
Resistance of moisture sensor ______Ohms
Motor Heat Sensor connected and circuit enclosed ____Yes ____No
MEG Ohm Check of Insulation:
Winding temperature _____ o F or ______ o C.
Red to Ground_____Ohms White to Ground_____Ohms
Black to Ground_____Ohms

4) Condition of Equipment at Start-Up: Dry_______ Wet_______
Muddy________
Was Equipment Stored: ___ Yes ___ No.
If YES, length of Storage: _______________
Describe Station Layout______________________________________

5) Liquid Being Pumped___________________________________
Debris in Bottom of Station? ___ Yes ___ No
Was Debris Removed in Your Presence? ___ Yes ___ No
Are Guide Rails Exactly Vertical (plumb)? ___ Yes ___ No
Is Base Elbow Installed Level? ___ Yes ___ No

6) Liquid Level Controls: Model ___________________________________
Is Control Installed Away from Turbulence? ___ Yes ___ No
Operation Check:
Tip lowest float (stop float), all pumps should remain off.
Tip second float (and stop float), one pump comes on.
Tip third float (and stop float), both pumps on
(alarm on simplex).
Tip fourth float (and stop float), high level alarm
on (omit on simplex).
If not our level controls, describe type
of controls _________________________
Does liquid level ever drop below volute top? ___ Yes ___No

7) Control Panel Model No. ________________________
Number of Pumps Operated by Control Panel _______
NOTE: At no time should hole be made in top of
control panel, unless proper sealing
devices are utilized.
Control Panel Manufactured By Others:
____ Yes ____ No
Company Name_________________________________________________
Model No.____________________________________________________
Short Circuit Protection_________________________________
Type ____________
Number and Size of Short Circuit Device(s)_________________
Amp Rating _________
Overload Type _____________________ Size____________
Amp Rating _________
Do Protective Devices Comply With Pump Motor Amp Rating?
____ Yes ___ No
Are All Connections Tight? ___ Yes ___ No
Is the Interior of the Panel Dry? ___ Yes ___ No. lf "No,"
correct the moisture problem.

8) Electrical Readings:
Single Phase:
Voltage Supply at Panel Line Connection, Pump Off, Ll, L2
__________________
Voltage Supply at Panel Line Connection, Pump On, Ll, L2
__________________
Amperage: Load Connection, Pump On,
Ll __________ L2 __________
Three Phase:
Voltage Supply at Panel Line Connection, Pump Off,
Ll-L2 __ L2-L3 __ L3-Ll __
Voltage Supply at Panel Line Connection, Pump On,
Ll-L2 __ L2-L3 __ L3-Ll __
Amperage, Load Connection, Pump On,
Ll_____ L2 _____ L3 _____

9) Final Check:
Is Pump Seated on Discharge Properly? ___ Yes ___ No
Was Pump Checked for Leaks? ___ Yes ___No
Do Check Valves Operate Properly? ___ Yes ___ No
Flow: Does Station Appear to Operate at Proper Rate?
___ Yes ___ No
Noise Level: ___ Acceptable ___ Unacceptable
Comments: ____________________________________________

10) Describe any Equipment Difficulties During Start-Up:
______________________________________________________
______________________________________________________
______________________________________________________

11) Manuals:
Has Operator Received Pump Instruction and Operations
Manual? ___ Yes ___ No
Has Operator Received Electrical Control Panel Diagram?
___ Yes ___ No
Has Operator Been Briefed On Warranty? ___ Yes ___ No
Name/Address of Local Representative/Distributor
_______________________________________________________
_______________________________________________________
_______________________________________________________

I Certify This Report To Be Accurate.
Signed By (Start-Up Person) __________________________________
Employed By: ________________________________________________
Date: _____________
Date and Time of Start-Up___________________________
Present at Start-Up:
( ) Engineer's Name________________________
( ) Operator's Name ______________________
( ) Contractor's Name______________________
( ) Others _______________________________

Station Log Book and Log Book Forms

It is recommended that a Station Log Book be created based on the needs and specifics of the individual station. There is no universally accepted format for a Station Log Book and no pre-formatted forms for recording station data.

Whatever format is used, it is recommended that the Station Log Book be kept at the station in the control panel.

A daily planner type book, available in most office supply stores, offers an ideal format for a Station Log Book. For most stations, a standard, wirebound book, 4-7/8"" x 8" page size, dated for a full year, with one weekday per page, Saturday and Sunday combined.

This format and size is ideal to use for recording station information and maintaining a record of periodic maintenance done on the station. The lined format allows space for comments about the station's operation which need to be noted. This might not be easily accomplished on a pre-formatted form.

The value of the Station Log is in consistently utilizing the book and noting all important information so it can be used for analysis and comparison.

Glossary of Terms

Following are definitions of some of the more common systems and electrical terms used when referring to submersible sewage lift stations.

For a more complete glossary of systems and electrical terms, consult Submersible Sewage Pumping Systems (SWPA) Handbook -- 2nd Edition © 1997 by the Submersible Wastewater Pump Association.
CLICK HERE TO VIEW THOSE GLOSSARIES

Standards Setting Organizations

Listed below are the major standards setting organizations whose work impacts on submersible sewage lift stations and their components. For additional information on applicable standards, contact these organizations directly.

ANSI -- AMERICAN NATIONAL STANDARDS INSTITUTE
11 W. 42nd Street, 13th Floor
New York, NY 10036-9002
Phone: 212/642-4900
FAX: 212/398-0023
Web Site: www.ansi.org

CSA -- CANADIAN STANDARDS ASSOCIATION
178 Rexdale Boulevard
Rexdale, Ontario, Canada M9W 1R3
Phone: 416/747-4000
FAX: 416/747-4149
Web Site: www.csa.ca

FM -- FACTORY MUTUAL RESEARCH CORPORATION
1151 Boston-Providence Turnpike
P. 0. Box 9102
Norwood, MA 02062
Phone: 781/762-4300
FAX: 781/762-9375
Web Site: www.factorymutual.com

HI -- HYDRAULIC INSTITUTE
9 Sylvan Way
Parsippany, NJ 07054-3802
Phone: 973/267-9700
FAX: 973/267-9055

IEEE -- INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS
345 East 47TH Street
New York, NY 10017-2394
Phone: 212/705-7900 FAX: 212/752-4929

NEMA -- NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION
2101 L Street, NW
Washington, DC 20037
Phone: 202/457-8400
FAX: 202/457-8411

NEC -- NATIONAL ELECTRICAL CODE NFPA -- NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
P. 0. Box 9101
1 Batterymarch Park
Qunicy, MA 02269-9101
Phone: 617/770-3000
FAX: 617/770-0700
Subscription Department:
Phone: 800/344-3555
FAX: 800/593-6372 or 508/895-8301
Web Site: www.nfpa.org

NSF INTERNATIONAL
P. O. Box 130140
NSF Building
3475 Plymouth Road
Ann Arbor, MI 48113-0140
Phone: 313/769-8010
FAX: 313/769-0109
Web Site: www.nfs.org

UL -- UNDERWRITERS LABORATORIES
333 Pfingsten Road
Northbrook, IL 60062
Phone: 847/272-8800
FAX: 847/272-8129
Web Site: www.ul.com