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KSB SRA, Installation & Operating Manual

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2 Safety

10 of 62

SRA

2334.810/03-EN

2.7 Safety information for maintenance, inspection and installation

▪

Modifications or alterations of the system require 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 resulting damage.

▪

The operator ensures that maintenance, inspection and installation are
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.

▪

Carry out work on the system during standstill only.

▪

The pump casing must have cooled down to ambient temperature.

▪

Pump pressure must have been released and the pump must have been drained.

▪

When taking the system out of service always adhere to the procedure described
in the manual.

▪

Decontaminate systems which handle fluids posing a health hazard.

▪

As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning.

▪

Make sure the system cannot be accessed by unauthorised persons (e.g. children).

2.8 Safety instructions for entering collecting tanks

 DANGER

Sparking

Explosion hazard!

▷

Remove combustible gases from the collecting tank.

 DANGER

Formation of life-threatening gases

Danger to life!

▷

Observe the following safety regulations and safety information
(

ð

 Section 7.4, Page 45)  .

 DANGER

Failure to observe the safety instructions for work in the collecting tank

Risk to persons!

▷

Always observe the health and safety regulations as per BGR 117-1.

Excerpt from the accident prevention regulations:

▪

Secure the access opening and close off the working area.

▪

Free the collecting tank from any gases which are injurious to health or
combustible (e.g. with a blower).

▪

Only enter the collecting tank while another person is supervising from outside
the collecting tank.

▪

When entering the collecting tank, use a safety harness, safety ropes and a
breathing apparatus.

▪

Make sure that all tools (e.g. lifting equipment) are in good and reliable working
condition.

Summary of Contents for SRA

Page 1: ...Pump Station SRA Installation Operating Manual ...

Page 2: ...ed The contents provided herein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without the manufacturer s express written consent Subject to technical modification without prior notice 01 03 2022 ...

Page 3: ...urn to supplier 14 3 5 Disposal 14 4 Description 15 4 1 General description 15 4 2 Product information as per Regulation No 1907 2006 REACH 15 4 3 Designation 15 4 4 Name plate 17 4 5 Design details 18 4 6 Configuration and function 19 4 7 Scope of supply 20 4 8 Dimensions and weights 20 4 9 Accessories 20 5 Installation at Site 21 5 1 General 21 5 2 Preparing the construction pit 21 5 3 Installin...

Page 4: ...ecting tank 45 8 Trouble shooting 47 9 Related Documents 49 9 1 General drawings with list of components 49 9 1 1 Collecting tank 49 9 1 2 Valve pit optional 50 9 1 3 Piping collecting tank 51 9 1 4 Piping valve pit 52 9 2 Dimensions and connections 54 9 2 1 Drainage without valves 54 9 2 2 Drainage with integrated valves 55 9 2 3 Drainage with valves in a valve pit 55 9 3 Installation examples 56...

Page 5: ...ng of drainage systems in buildings and on premises Flood level Maximum backflow level of waste water in a drainage system Frost line Dimension to be determined from the upper edge of the surrounding surface to the soffit of the pipe or sewer In most cases a cover of 800 mm is sufficient Grey water Faecal free waste water Separator Device for physically separating the two phases of a two phase flo...

Page 6: ...ed at the target group of trained and qualified specialist technical personnel ð Section 2 3 Page 9 1 3 Other applicable documents Table 1 Overview of other applicable documents Document Contents Sub supplier product literature Operating manuals and other product literature of accessories and integrated machinery components operating manual of submersible motor pump and control unit For accessorie...

Page 7: ...Explosion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with the Equipment and Protective Systems Intended for use in Potentially Explosive Atmospheres Regulations 2016 Explosion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with Technical Regula...

Page 8: ...tion at all times This applies to for example Arrow indicating the direction of rotation Markings for connections Name plate The operator is responsible for ensuring compliance with all local regulations not taken into account 2 2 Intended use The system must only be operated within the operating limits described in the other applicable documents Only operate systems which are in perfect technical...

Page 9: ...cal effects and explosions Failure of important product functions Failure of prescribed maintenance and servicing practices Hazard to the environment due to leakage of hazardous substances 2 5 Safety awareness In addition to the safety information contained in this operating manual and the intended use the following safety regulations shall be complied with Accident prevention health regulations a...

Page 10: ...y safety relevant and protective devices Before returning the product to service observe all instructions on commissioning Make sure the system cannot be accessed by unauthorised persons e g children 2 8 Safety instructions for entering collecting tanks DANGER Sparking Explosion hazard Remove combustible gases from the collecting tank DANGER Formation of life threatening gases Danger to life Obser...

Page 11: ...n Hazardous substances which can be absorbed via the skin or inhaled Electrical equipment Moving parts or fixed internal parts Psychological strain confined space 2 9 Unauthorised modes of operation Always observe the limits stated in the product literature The warranty relating to the operating reliability and safety of the system supplied is only valid if the system is used in accordance with it...

Page 12: ...proper transport Damage to the collecting tank Prevent impermissible loads when transporting the collecting tank Never use chains or steel ropes for transport Watch the nozzles and any protruding parts Do not roll or drag the collecting tank along the floor NOTE A sufficiently firm all weather access to the unloading area and a turning facility for trucks must be provided Should the truck become s...

Page 13: ... at the place of installation Protect it against damage and secure it against rolling off 3 3 Storage preservation CAUTION Damage during storage due to frost humidity dirt UV radiation or vermin Corrosion contamination of the collecting tank Store the collecting tank in a dry dark frost proof room not exposed to sunlight where the atmospheric humidity is as constant as possible Only remove caps co...

Page 14: ...blown through the collecting tank to ensure drying 4 Complete and enclose a certificate of decontamination when returning the collecting tank and its internal parts Indicate any safety measures and decontamination measures taken ð Section 10 Page 58 3 5 Disposal WARNING Fluids handled consumables and supplies which are hot and or pose a health hazard Hazard to persons and the environment Collect a...

Page 15: ...ble 5 Designation key Position Code Description 1 3 Type series SRA SRA Pump Station 4 7 Size diameter of the collecting tank 1000 1400 1800 9 10 Height of the collecting tank 25 2 5 m 60 6 0 m 12 Design B Pro E Expert P Premium 13 Collecting tank cover S None M Single piece C Manhole cover ring D Double safety 14 Pump station type L Drainage without valves D Drainage with integrated valves R Drai...

Page 16: ...valves made of grey cast iron EN GJL 250 with epoxy resin paint RAL 5002 22 23 Size diameter of the valve pit R1 1000 mm R2 1400 mm 25 26 Height of the valve pit 10 1 m 60 6 m 28 30 Nominal size of piping and valves mm 31 Valve pit cover S None M Single piece C Ring D Double safety 33 34 Scope of function of the valve pit F0 Without module standard F1 Drain module F2 Air vessel module and drain mo...

Page 17: ...he collecting tank example 1 Type series 3 Production number 2 Type series code size and version ð Section 4 3 Page 15 4 Year of construction Valve pit SRA VALVE PIT 9974XXXXXX 000100 R1 10 150M F2 09 12 2020 KSB SAS 10 rue de la gare 76250 Déville lès Rouen FRANCE 1 2 3 4 Fig 5 Name plate of the valve pit example 1 Type series 3 Production number 2 Type series code size and version ð Section 4 3 ...

Page 18: ...coating Collecting tank made of glass fibre reinforced polyester Tank cover single piece or two piece Integrated piping with or without valves Integrated ball check valve with connection for flushing option and ball valve Gate valve to UNI EN 1171 optional Check valve optional Valve pit optional Installation Underfloor buried installation Automation Automation options Sensor system Control unit ...

Page 19: ...1 27 26 25 24 23 22 Fig 7 Illustration of the valve pit example 20 Tank cover 24 Leakage return connection 21 Valve pit 25 Inlet line connection 22 Air vessel 26 Drain line connection 23 Cross beam 27 Discharge connection Design Via a crane mounted in the socket for lifting equipment 3 the submersible motor pumps 7 are lowered into the collecting tank or removed for maintenance work The guide rail...

Page 20: ...level is reached the sensor system 13 sends a signal to the control unit 19 and the submersible motor pumps 7 are started up The submersible motor pumps transport the fluid handled out of the collecting tank through the discharge connection 11 To distribute the load evenly between the pump sets used pumps are automatically alternated after each drain cycle by the control unit 4 7 Scope of supply S...

Page 21: ...at the height of the discharge connection of the valve pit is equal to or above the height of the discharge nozzle of the collecting tank See ð Section 5 4 Page 24 ü Keep the construction pit dry for the entire construction time 1 Excavate the construction pit to DIN 4124 DIN 18300 and VOB Observe the slopes of the respective soil class slope angle planking strutting requirements etc 1 Fig 8 Prepa...

Page 22: ...e slopes of the respective soil class slope angle planking strutting requirements etc 1 Fig 10 Preparing the construction pit 2 Provide a minimum working space of 50 cm on the pit floor in every direction 3 Level the pit floor 4 Place a horizontal layer of approximately 100 mm of sand or fine gravel 1 on the level pit floor 5 Pour construction concrete 2 onto the sand layer fine gravel layer to co...

Page 23: ...ment lifting equipment suitable for the corresponding weight see data sheet has been selected and is available ü The data sheet scope of supply is available 1 Lower the collecting tank into the construction pit with suitable transport equipment lifting equipment e g digger or crane 2 Position the collecting tank making sure it is level and at equal distances to the construction pit walls Verify th...

Page 24: ...Section 5 3 Page 23 ü Transport equipment lifting equipment suitable for the corresponding weight see data sheet has been selected and is on hand ü The data sheet scope of supply is available 1 Lower the valve pit into the construction pit with suitable transport equipment lifting equipment e g digger or crane 2 Position and level the valve pit and verify the permissible height difference against ...

Page 25: ...e 1 Overflow connection optional 3 Cable entry 2 Inlet line connection 4 Discharge connection ü The collecting tank has been positioned levelled and installed properly ð Section 5 3 Page 23 ü The product literature provided by the manufacturer of the flexible low pressure pipe couplings and high pressure pipe coupling is available 1 Connect the discharge line to the discharge connection 4 with the...

Page 26: ...ure provided by the manufacturer of the flexible low pressure pipe couplings and high pressure pipe coupling is available 1 Connect the discharge line to the discharge connection 4 with the flexible high pressure pipe coupling as per the coupling manufacturer s product literature Lay the discharge line in accordance with the applicable local regulations regarding backflow prevention 2 Carry out a ...

Page 27: ...gh pressure pipe coupling as per the coupling manufacturer s product literature Connect the discharge line of the collecting tank to the inlet connection 8 of the valve pit with a flexible low pressure pipe coupling as per the coupling manufacturer s product literature 2 Carry out a pressure test 3 Clean the inlet line 4 Connect the inlet line to the inlet connection 2 of the collecting tank with ...

Page 28: ...f the collecting tank and to the leakage return connection 4 of the valve pit with two hose clips2 9 Connect the discharge line to the discharge connection 10 of the valve pit with a flexible high pressure pipe coupling as per the coupling manufacturer s product literature 2 Scope of supply of the valve pit ...

Page 29: ...Fig 18 Back filling and compacting the construction pit 1 Filling material 3 Reinforced concrete foundation reinforced concrete plate 2 Concrete base 4 Anti lift grouting collar Table 6 Filling height depending on the size Size Filling height Hmin mm 1000 720 1400 943 1800 1228 ü The piping has been properly connected ð Section 5 5 Page 25 1 Fill the collecting tank with water 2 Pour concrete with...

Page 30: ...943 1500 0 5 160 1800 1228 2000 1 5 475 ü The piping has been properly connected ð Section 5 5 Page 25 ü The system for lowering the groundwater level if available has been started up 1 Fill the collecting tank with water 2 Pour concrete with a cement content of 300 kg m3 into the pit in layers until filling height Hmin has been reached see table above The upper edge of the concrete base 2 has to ...

Page 31: ... fill any cavities at the valve pit with a suitable tool e g spade and compact the back fill by hand ð Place sidefill sand with a particle size 8 mm in layers of up to 300 mm around the collecting tank until a height of 500 mm has been reached ð Backfill the remaining pit with material corresponding to soil quality G1 particle size 16 mm in layers of up to 300 mm 3 Evenly compact the filling mater...

Page 32: ...formations other signs of uneven load and installation errors 6 If a system for lowering the groundwater has been used switch it off Valve pit size R2 ü The piping has been properly connected ð Section 5 5 Page 25 ü The system for lowering the groundwater level if available has been started up 1 Pour concrete with a cement content of 300 kg m3 into the pit in layers until the concrete base 2b has ...

Page 33: ...n plate must not be in contact with the walls of the collecting tank Collecting tank 1 Fig 21 Fitting the load distribution plate example 1 Load distribution plate Fitting the manhole cover ring for buried installation under traffic areas L W Fig 22 Access opening in manhole cover ring Table 8 Access opening dimensions collecting tank Size L W mm mm 1000 750 750 1400 900 750 1800 1500 750 ü The co...

Page 34: ...areas L W Fig 24 Access opening in manhole cover ring Table 9 Access opening dimensions valve pit Size L W mm mm R1 750 750 R2 900 750 ü The construction pit has been properly filled and compacted ð Section 5 6 Page 29 1 Make a load distribution plate out of reinforced concrete Make sure the access opening of the valve pit remains accessible 2 Fit the load distribution plate without contact to the...

Page 35: ...able to the attachment rail at the height of the marking Piezoelectric sensor ü The operating manual of the piezoelectric sensor is available and complied with ü Information on the required switching points is available and observed ð Section 9 4 Page 57 1 Mark the length of the power cable of the piezoelectric sensor required for the switching points 2 Allow the piezoelectric sensor to hang down ...

Page 36: ...hand ü Transport equipment lifting equipment suitable for the corresponding weight see operating manual of the pump set has been selected and is on hand 1 If applicable fasten the crane3 to the fastener for lifting equipment of the collecting tank 2 Fasten the chain lifting rope to the pump set in accordance with the operating manual of the pump set 3 Guide the pump set over the suspension bracket...

Page 37: ...chain suitable for the corresponding weight see data sheet have been selected and are available ü If applicable the crane4 has been fastened to the fastener for lifting equipment at the collecting tank 1 Attach the chain to the bail 3 2 Guide the screen basket 4 into the collecting tank 3 Slowly lower the screen basket 4 threading the lower guide rail holders 1 on the guide rails 5 4 Lower the scr...

Page 38: ...A2 2015 modified Whenever modifications are made to existing installations retrofitting a surge protective device SPD in accordance with VDE is mandatory A maximum cable length of 10 metres should not be exceeded between the surge protective device usually type 1 internal lightning protection installed at the service entrance and the equipment to be protected For longer cables additional surge pro...

Page 39: ...GER Sparking Explosion of the system Provide potential equalisation 1 Fig 28 Connecting the potential equalisation conductor to the cross beam of the collecting tank ü The pump station is to be used for handling domestic waste water containing faeces 1 Connect the potential equalisation conductor to DIN VDE 0165 solid copper conductor 6 mm2 to the cross beam 1 2 Connect the potential equalisation ...

Page 40: ...ncludes this feature check its response to a fault Cause a pretend failure at the first pump set and check that the second pump set starts up 7 Check the pump station incl piping and valves for any leakage 8 If the control unit includes this feature check its response to a fault Cause a pretend failure at the second pump set and check that the first pump set starts up 9 Check that the first pump s...

Page 41: ...zardous to persons and the environment Only discharge permissible fluids into the public sewer system Check the suitability of pump system materials NOTE When pumping faeces observe the local explosion protection regulations The following fluids are permissible to DIN 1986 3 Waste water with without faeces5 Grey water Rainwater not containing abrasive substances Fluids without solids content e g f...

Page 42: ... 1 Perform shutdown in accordance with the operating manuals of the pump set and control unit 6 4 Returning to service ü The pump set has been taken out of service in accordance with the instructions ð Section 6 3 Page 42 ü The measures for servicing maintenance have been carried out ü The measures for servicing maintenance of the pump set and control unit have been carried out in accordance with ...

Page 43: ...maintenance inspection and installation are performed by authorised qualified specialist personnel who are thoroughly familiar with the manual Maintain one log book per pump station Enter the results of servicing and inspection work in the log book Servicing and maintaining drainage systems to DIN 1986 3 Any waste water has to be discharged properly Any changes have to be detected and remedied in ...

Page 44: ...n it if necessary At least once a month 3 Check drain and clean the screen basket At least once a month 4 Switch the pump sets to manual mode and check that they function properly Check the pump sets for smooth running noise emissions in accordance with the operating manual of the pump sets At least once a month 5 If an ammeter has been fitted check the current input At least once a month 6 If an ...

Page 45: ...secured with a harness and ropes the relevant local accident prevention regulations must be complied with and suitable means for entering the tank must be used DANGER Formation of life threatening gases Danger to life Always observe the following safety instructions Observe the general instructions ð Section 2 8 Page 10 DANGER The pressure has not been released from pipe parts valves or they have ...

Page 46: ...evacuate gases from the collecting tank Fig 29 Evacuating gases from the collecting tank 4 Take suitable measures to decontaminate the collecting tank 5 Observe the applicable local accident prevention regulations and use suitable safety equipment e g safety harness suitable means for entering the tank when entering the collecting tank Fig 30 Entering the collecting tank ...

Page 47: ...larm Table 12 Trouble shooting A B C D E F G H I Possible cause Remedy Pump delivers against an excessively high pressure Open the valves until the duty point has been reached Valve in the discharge line is not fully open Fully open the valve Pump running in off design conditions part load overload Check the pump s operating data Pump intake clogged by deposits Clean the intake pump components and...

Page 48: ... been tripped by an excessive winding temperature Let the pump set cool down Observe the operating manual of the pump set Manual 0 automatic selector switch of the control unit set to 0 Briefly set the manual 0 automatic selector switch to manual and then to automatic Sensor system defective or blocked Check that the sensor system can move freely Replace it if necessary Motor contactor defective R...

Page 49: ...sembly drawing of the collecting tank example Table 13 List of components Part No Description Part No Description 14 1 Fall protection 71 20 1 Guide rail arrangement 145 3 4 Adapter 718 5 6 7 Pipe connection 160 2 Cover tank cover 72 1 Flanged bend 180 1 Holder socket for lifting equipment 732 Claw 184 Clamping ring 733 1 4 Pipe clamp 400 1 Gasket 758 Screen screen basket 41 1 Sealing washer 790 S...

Page 50: ... 1 550 14 920 14 180 2 733 2 550 17 920 17 901 9 920 9 550 9 Fig 32 General assembly drawing of the optional valve pit Table 14 List of components Part No Description Part No Description 160 1 2 Cover tank cover 57 31 4 Cross beam 145 3 4 Adapter 59 38 3 Sump valve pit 180 2 Holder 591 Air vessel 184 Clamping ring 733 2 4 Pipe clamp 400 1 97 98 Gasket 900 14 Bolt screw 45 3 2 Wall stuffing box 901...

Page 51: ...903 60 400 60 901 61 920 61 550 61 400 61 901 62 920 62 550 62 400 62 901 63 920 63 550 63 81 17 60 744 60 742 60 700 62 901 64 920 64 550 64 400 64 718 43 731 40 718 44 718 45 Fig 34 General assembly drawing of the piping drainage with integrated valves Table 15 List of components Part No Description Part No Description 13 18 20 41 42 51 52 Pipe bend 742 40 50 60 Lift check valve 400 20 40 51 52 ...

Page 52: ...y drawing of the piping material variant PP 700 8 180 3 733 3 550 18 920 18 901 10 920 10 550 10 718 84 81 17 81 718 81 718 82 718 83 718 85 723 84 400 84 901 84 550 84 920 84 744 81 742 80 73 1 80 13 18 81 901 81 550 81 920 81 400 81 901 82 550 82 920 82 400 82 901 83 550 83 920 83 13 18 82 723 81 71 2 81 723 82 71 2 82 400 85 901 85 550 85 920 85 744 82 901 86 550 86 920 86 81 17 82 718 86 Fig 3...

Page 53: ...sembly drawing of the piping material variant CG A Figure 0 C Figure 2 B Figure 1 D Figure 3 Table 16 List of components Part No Description Part No Description 13 18 71 72 73 81 82 Pipe bend 731 71 Pipe union 180 3 Holder 733 3 Pipe clamp 400 81 82 84 85 91 92 93 94 96 Gasket 740 71 72 Valve 550 10 18 81 82 83 8 4 85 86 91 92 93 94 95 96 Disc 742 70 80 90 Lift check valve 700 7 8 9 91 Piping 744 ...

Page 54: ... EN 9 2 Dimensions and connections 9 2 1 Drainage without valves 615 615 400 Ø1126 1250 1043 2360 400 800 ND 50 ND 65 PVC Ø63 Ø75 out d1 613 ND 200 PVC Ø204 out Ø 1000 in Fig 38 Drainage without valves d1 Leakage return connection diameter 32 mm ...

Page 55: ...5 out 613 615 615 Ø1126 in Fig 39 Drainage with integrated valves 9 2 3 Drainage with valves in a valve pit Valve pit only in connection with a collecting tank without valves ð Section 9 2 1 Page 54 d2 800 1120 400 ND 50 ND 65 PVC Ø63 Ø75 out 600 600 Ø 1012 1180 Ø 1000 in Fig 40 Drainage with valves in a valve pit d1 Leakage return connection diameter 32 mm ...

Page 56: ...valves A Buried installation B Buried installation under traffic areas A B Fig 42 Collecting tank without integrated valves A Buried installation B Buried installation under traffic areas A B Fig 43 Valve pit for collecting tanks without integrated valves A Buried installation B Buried installation under traffic areas ...

Page 57: ... A Fig 44 Setting the switching points A Alarm level L2 Fill level 2 L1 Fill level 1 cut out level L3 Fill level 3 ü The operating manual of the pump set is on hand ü The data sheet scope of supply is available 1 Set the alarm level A The alarm signal must be triggered at a level below the lower edge of the inlet 2 Set the fill level 1 cut out level L1 in accordance with operating manual of the pu...

Page 58: ... bearing ring carrier plain bearing inner rotor has been removed from the pump and cleaned In cases of containment shroud leakage the outer rotor bearing bracket lantern leakage barrier and bearing bracket or intermediate piece have also been cleaned For canned motor pumps the rotor and plain bearing have been removed from the pump for cleaning In cases of leakage at the stator can the stator spac...

Page 59: ...pplication 8 I Installation 18 Intended use 8 K Key to safety symbols markings 7 M Maintenance work 44 Maintenance inspection 43 N Name plate 17 O Other applicable documents 6 P Personnel 9 Piping 25 Potential equalisation 39 Preservation 13 Product code 15 Q Qualification 9 R Return to supplier 14 Returning to service 42 S Safety 8 Safety awareness 9 Safety instructions for entering the tank 10 S...

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Page 62: ...KSB S A S 4 allée des Barbanniers 92635 Gennevilliers Cedex France Tél 09 69 39 29 79 www ksb com fr fr 2334 810 03 EN ...

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