Lift Pump Along With Associated Assesories And Pipe work For

Installation In Waste Water Collection Catch Pits

Tender Enquiry No:- TENV-11-WTS-003/1Q353

OPERATION PHILOSOPHY

01
Rev

12/05/12
Date

For Approval
Category

AB/DB/KK
Prepared

MA
Checked

KH
Approved

Doc No:
OPERATION PHILOSOPHY

JUSCO/WD/11-153-PRO-A4001

Operation Philosophy Waste Water Rising Main.

Introduction:
The Scope of work includes design, engineering, manufacture, assembly, packing
supply, storage at site, painting/coating, erection, construction, testing, trial run
and commissioning including performance demonstration at site and handing over
to the purchaser on turnkey basis the complete pump sets, associated accessories,
electrical, structural, instrumentation, ventilation and pipe work but excluding
civil works within the scope.
Brief Description of Waste water Collection and pump out scheme:
In Tata Steel Jamshedpur works, there are several nallahs which carry waste water
from production shops mixed with rain water and discharges outside the works
Boundary. Tata Steel is presently implementing zero discharge scheme from the
works under environmental management program. In order to do that, it is
proposed to collect the waste water from various nallahs in separate catch pits
through diversion channel. The catch pits will be constructed adjacent to
the respective nallahs. The waste water collected in the catch pit will be pumped
out through pipeline either to low end consuming points/to a larger catch pit for
subsequent processing.

Operation Philosophy

Page 1

Process and Mechanical

Operation Principle of Pumps:
Operation of the pumps will be automatic through level switch. When the waste
water in the catch pit reaches a preset level one pump will be started. If the level
goes on increasing the second pump will automatically start, then the third pump
and so on. If the water level in the catch pit falls below a preset low level, the
pump will automatically trip.
The following catchpits are included in the scope of this project:
i) Tuiladungri Catchpit
ii) Jugsalai Catchpit 1
iii) Gharabasa catchpit
iv) Jugsalai catchpit 2.
A brief description of the pumping equipments for each catchpits is shown in
Table1.0
Flow
SL
rate( Head No
no Location
Pump Type
Purpose
m3/
(m)
s.
.
hr)
1

Tuiladungri
catchpit

Jugsalai pit
1

Gharabasa
Catch pit

Jugsalai pit
2

Dry motor
centrifugal,
submersible
type and fixed
installation,
suitable for non
clog operation
and capable of
handling dirty
waste
including
suspended
particles upto
size 10mm.

150

150

45

34.5

200

59

150

61

To pump waste water

from tuiladungri catchpit
to sunsungaria catchpit
To pump waste water
from jugsalai pit 1 to
jugsalai pit 2
To pump waste water
from gharabasa catchpit
to WRP, LD1&LD2
area.
To pump waste water
from jugsalai catchpit 2
to Pellet plant and
RMHS zone.

Table 1.0

Operation Philosophy

Page 2

**The Pumps are to be installed for a minimum Submergence depth. These

are given as follows catchpit wise.
A) Tuiladungri catch pit pumps: Minimum submergence depth is 1605mm.
B) Jugsalai catch pit 1 pumps: Minimum submergence depth is 1402mm.
C) Gharabasa catch pit pumps: Minimum submergence depth is 1774mm.
D) Jugsalai Cacth pit 2 Pumps: Minimum submergence depth is 1774mm.

** In addition to the main pumps 1 no. of dewatering pump has been provided in
each catch pit for dewatering purpose.
A brief description of the dewtareing pumps for each catchpits is shown in
Table2.0
Flow
SL
Head
Location Pump Type
rate(m
Nos.
Purpose
no.
(m)
3/hr)
Tuiladun Submersible,
Dewatering of pump
1
gri
type and fixed
10
15
1
catchpit
catchpit
installation
Mobile trolley
mounted
Jugsalai
Dewatering of pump
2
submerged
10
15
1
pit 1
catchpit
and potable
type.
Gharabas Submersible,
Dewatering of pump
3
a Catch type and fixed
10
15
1
catchpit
pit
installation
Submersible,
Jugsalai
Dewatering of pump
4
type and fixed
10
15
1
pit 2
catchpit
installation
Table 2.0

Operation Philosophy

Page 3

**In each catch pit Bar screens have been provided in each chamber of the
diversion channel between isolation sluice gates for arresting oversized suspended
materials and preventing them from flowing into catch pits.
A brief description of the Bar screens for each catchpits is shown in
Table3.0
Sl no. Location
Type
Specs.
Nos.
Purpose
1700X3900,
Bar Screen
with 10mm
To arrest oversized
Tuiladun
with
clear
suspended particles
and preventing them
1
gri
motorized
opening
2
from flowing into
catchpit
scrapper
installed at
catch pit
mechanism
75 to
horizontal.
To arrest oversized
1000x1000,
suspended particles
with 10mm
Bar Screen
and preventing them
clear
Jugsalai with manual
from flowing into
2
opening
1
catch pit. Due to
pit 1
cleaning
installed at
space constraint here
facility.
90 to
manual bar screen
horizontal.
will be installed.
1400x2100,
Bar Screen
with 10mm
To arrest oversized
Gharabas
with
clear
suspended particles
and preventing them
3
a Catch
motorized
opening
2
from flowing into
pit
scrapper
installed at
catch pit
mechanism
75 to
horizontal.
1700X2300,
Bar Screen
with 10mm
To arrest oversized
with
clear
suspended particles
Jugsalai
and
preventing them
4
motorized
opening
2
pit 2
from flowing into
scrapper
installed at
catch pit
mechanism
75 to
horizontal.
Table 3.0

Operation Philosophy

Page 4

**Isolation Sluice gates shall be supplied in diversion channel for isolation

purpose. The gates shall be manually gear operated type with rising spindle type
and Cast Iron material of construction confirming to IS:13349 code.
A brief description of the Sluice gates for each catchpits is shown in
Table4.0
Sl
Location
Type
Size
MOC
Nos.
Purpose
no.
1
Manually
600x600 CI
4
For
Tuiladungri gear operated
isolation
catchpit
and rising
of the
spindle type
catch pit
2
Manually
500x500 CI
4
For
Jugsalai pit gear operated
isolation
1
and rising
of the
spindle type
catch pit
3
Manually
600x600 CI
1
For
Gharabasa gear operated
isolation
Catch pit and rising
of the
spindle type
catch pit
4
Manually
600x600 CI
4
For
Jugsalai pit gear operated
isolation
2
and rising
of the
spindle type
catch pit
Table 4.0
** In addition to the above equipments one no. chain pulley block and one no.
Monorail, manually operated type of 1.5 ton capacity shall be provided in each
catch pit for maintenance purpose of pumps, screens and sluice gates.

Operation Philosophy

Page 5

Electrical Operation & Control Philosophy

Introduction:
In Tata Steel Jamshedpur works, there are several nallahs which carry waste
water from production shops mixed with rain water and discharges outside the
works boundary. Tata Steel is presently implementing zero discharge scheme
from the works under environmental management programme. In order to do
that, it is proposed to collect the waste water from various nallahs in separate
catch pits through diversion channel. The catch pits will be constructed
adjacent to the respective nallahs. The diversion channel will have two
compartments; each compartment will be fitted with barscreen to eliminate
oversize material, debris, silt etc. Each compartment will have isolation gates at
inlet and outlet to facilitate cleaning and maintenance. The waste water
collected in the catch pit will be pumped out through pipeline either to low end
consuming points/to a larger catch pit for subsequent processing. In case of
heavy rainfall, if the water pumping out capacity exceeds the pumps combined
rated capacity, the excess water will be allowed to overflow against a weir to
be installed in the nallah, to discharge outside of the works boundary.
Operation of the pumps will be automatic through level switch. When the
waste water in the catch pit reaches a preset level one pump will be started. If
the level goes on increasing the second pump will automatically start, then the
third pump and so on. If the water level in the catch pit falls below a preset low
level, the pump will automatically trip.
The following catch pits included:
(i)Tuiladungri Catch Pit ii) Gharabasa Catch Pit iii) Jugsalai Catch Pit-1 iv)
Jugsalai Catch Pit-2
Considerations:
1) TSL shall locate required capacity of 415V source for proposed Catch pit
MCC Room. The laying & supply of cable from TSL switchgear to proposed
Catch pit MCC Room and all down steam ---- JUSCO scope.
2) The power cable from TSL switchgear shall be terminated to Catch pit
PMCC. The PMCC shall have feeder for intended requirements and relay
logic for pump operation on Auto & manual mode depending upon the
Ultrasonic level controller of catchpit.

Operation Philosophy

Page 6

3) Each catch pit shall have one wall mounting Kiosk panel to fed supply to
Ultrasonic level transmitter(ULT) and accommodate Bar graph level indicator
cum controller to fed intended requirement to PMCC.
4) Local Control Station(LCS) shall be provided for local operation of all Pump
motors and process equipments. LCS shall have One (1) Start, One (1) Stop,
One (1) Mushroom Head- Lockable type Emergency Stop pushbuttons. All
push buttons shall have 2 NO + 2 NC potential free contacts. The Local
remote selector switch shall be on PMCC only. The Emergency stop shall be
active on all modes.
5) The Mechanical coarse bar screen shall be operated with Geared motor and
manual mode start/stop facility without conveyor arrangeents.
6) The unique floating tube type Oil skimmer shall be motorized with manual
mode start/stop facility.
7) The Cosumer end cold pit shall have wall mounting Kiosk panel to fed supply
to Electromagnetic Flow transmitter (EFT) and accommodate
Electromagnetic Flow indicator.

Operation Philosophy

Page 7

Instrumentation Operation & Control Philosophy

Ref: P & I Diagram, JUSCO/WD/11-153-PRO-A3-003, Rev: 02
The following Instruments has been used for measurement & interlocks for this
particular project.
List of Instruments & Instrumentation Items:
Pressure Gauge with Diaphragm Seal
Pressure Switch with Diaphragm Seal
Ultrasonic Level Transmitter
Digital Bargraph Indicator
Electromagnetic Flow Meter
Instrumentation Cable
Desription of the Items & Their Applications:
Pressure Gauge: Total 11 no.s of Pressure Gauges will be mounted in at
the discharge end of the submersible pumps. Discharge pressure of pumps
will be measured locally direct in engineering units. For the Waste water
application Diaphragm Seal Type Pressure Gauges has been used. Ranges
of Pressure Gauges will be 0-6 & 0-8 Kg/cm2(Ref: JUSCO/WD/11-153INST-A3-001, R00)
Pressure Switch: Total 4 no.s of Pressure Switches will be installed in the
common Discharge delivery of submersible pumps of Different Catch Pits.
Blind Type Pressure Switches has been installed there. For Low pressure at
the common discharge switching alarm can be seen from control room
Kiosk Panel .The low alarm contact will trip all the running pumps. For the
Waste water application Diaphragm Seal Type Pressure Switches has been
used. Ranges of Pressure Switches will be 0-6 & 0-8 Kg/cm2(Ref:
JUSCO/WD/11-153-INST-A3-001, R00)
Ultrasonic Level Transmitter: Total 4 no.s of Ultrasonic Level
Transmitters will be installed in 4 different Catch Pits Ranging 0 to 6 and
0 to 8 mtr(Ref: JUSCO/WD/11-153-INST-A3-001, R00). For 3 different
levels Transmitter will send 3 switching o/ps to control room and from that
signal operation of Pumps will be controlled.The operation and the
interlock of pumps will be as per the following:

Operation Philosophy

Page 8

The Level Tranmsitters will be set into 3 different levels e.g High/Low/Low
Low. When the level of waste water in the Catch pits are only over than
100 mm of the pump sub merged level the Level Transmitter will produce
Low-Low Alarm in Control Room & produce switching o/p contact. The
o/p contact will be interlocked with the pump MCC and all the Running
Pumps will be tripped immediately.
When the Level of waste water in the Catch pit is over than Low-Low set
point and in between 200 mm less than the maximum level of catch pit Low
Level Indication will be generated through ULT and corresponding contact
will run a round off 50% of total pumps only(e.g if total 5 pumps are there
2 will run in auto mode, if 4 pumps are there 2 pumps will run in auto
mode) .
When the waste water level of the catch pits are less than 500 mm of catch
pit overflow High Indication will be generated and corresponding contact
will start 100% of total pumps & remain ON till the Low signal. Electrical
(Re: Operation & Control Philosophy)
Digital Bargraph Indicator: Level of Catchpits can be seen in Bargraph
format and in Direct Engineering Units from the control room through
Digital Bargraph Indicator. The o/p from Level Transmitter varies from 4
20 mA DC for Varying Low to High Level. Bargraph Indicator accepts the
signal and dispays it accordingly at Control room.
Electromagnetic Flow Meter: Total 6 no.s of Magnetic Flow Transmitters
will be installed at the low end consumer ends for measuring the flow
locally as well as from control room. Remote type Magnetic Flow
Transmitters will be used there. Flow Totalization will be done from
Control room. (Ref: JUSCO/WD/11-153-INST-A3-001, R00).
Instrumentation Cable: For 4 to 20 mA signal transmission 2P X 1
Sqmm., For Instrument Power 3C X 2.5 Sqmm. And For Instrument
Control Purpose required core of 1.5 Sqmm. Cable will be used. All the
Cables will be Armoured to Provide protection to Cables. For Signal
protection and to avoid the interference of Signal all the Signal Cable will
be Screened.

Operation Philosophy

Page 9

Operation Philosophy

Page 10