Manaual Lazy River

2016

CONTROLLED COPY ARIHANT INDUSTRIAL COROPERAT COROPERATION ION LTD 1/1/2016

ARIHANT INDUSTRIAL CORPORATION LIMITED

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Document name: LAZY RIVER MANUAL ----------------------------------------------------------------------------------------------------------------------------------

Table of Contents TECHNICAL SPECIFICATION ......................... ............ .......................... .......................... ................ ... 1 A.) B.) C.)

Area Machine room layout Equipment

INSTALLATION ............................................................................ 14 D.) E.) F.) G.) H.)

The types of pump room. Pump placement. Pump room plumbing assembly. Grating assembly. Electrical Assembly.

MAINTENANCE ............................................................................ 36 A.) B.) C.)

Pump maintenance. Plumbing maintenance. Electrical panel maintenance.

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WARNING Safety First! When installing, operating, or servicing the equipment, always use proper safety procedures in accordance with State and Local laws and regulations. To avoid injury to yourself, others, or damage to the equipment, adhere to the following safety practices. PERFORM ALL COMBINED CHECKS MENTIONED IN THE BOOKLET DURING COMMISIONING! 1. Always use qualified personnel and technicians for installation, maintenance, and servicing of Electrical control panels, Pneumatic system, pumps and motors. Electrical connections, servicing and maintenance should be performed only by properly trained, certified technician. 2. Always disconnect the electrical power at the main line before working on the motor and / or pump assembly. Take special precautions to ensure that the power cannot be turned “ON” while you are working on the motor or pump assembly. Observe proper Lockout / tag out procedures. 3. Do not operate the pump assembly without the inlet cover installed, or with the pump inlet unprotected by a proper filter element assembly. Inlet Failure to operate blowers without proper guarding could result in personal injury or death. 4. Do not operate the pump with the discharge outlet open. Failure to operate pump under a working load could c ould result in high current draw, damaging the motor and electrical systems. 5. Always keep hands, tools, long hair, loose clothing, neckties, jewelry or similar loose items away from all moving or rotating parts. 6. Always check the three phase availability & ensure the Power supply voltage is 380 volts.

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7. Do not attempt to do any work on flapper unit system while it’s on motion. Before doing any work on flapper unit system please make it sure that the ball valve (air-line) should be closed and the power lines are “off “position

Equipment Arrival and Inspection: Inspection: 

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At the time of receipt, fully inspect Wave pool equipment, enclosure, and all contents for shipping damage or missing components. Checks the part list to confirm that all equipment’s and parts have been received. r eceived. If any equipment or parts are damaged or missing due to shipping please feel free to contact ARIHANT Customer care telephone no. +91-7507778271/72/73/74 or e- mail : [email protected] Care should be exercised to not drop or damage the blower assembly, air compressor Unit and flapper box unit when moving it.

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Welcome to ARIHANT WATER MOVERS We manufacture one of the best lazy River equipment systems in the world. ARIHANT has been the name in Manufacturing WATER PARKS & its equipment’s for over 27 years. Our products are the choice of leading Water parks, resorts and organizations worldwide because of unsurpassed performance, service and leading edge innovation. Proper installation, operation and maintenance of Wave pool equipment system will ensure years of reliable and trouble free service

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AREA

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Total Area

-: As Per lazy river layout

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Each Pump Room Area

-: 3 Square Meters

Water Body Area Length

-: 580 Meter.

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Water Depth

-: 1 Meter

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Water Channel width

-: 4 Meters

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No. of Pump Room

-: Placed at every 25 interval.

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Total Power Required

-: 20 HP x No. of pumps

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Total Water Volume

-: 23, 20, 000 liter.

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Lazy river layout

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Fig.: PUMP ROOM TYPE -1

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PUMP-MF-V-10

Head -: 7 M Discharge -: 8500 LPM Qty. : 1 per pump room

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Motor

Power -: 20 HP Qty. -: 1 per pump room

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Butterfly valves Qty. – 3 per pump room. Qty.1: 350 NB- Wheel handle. Qty.2: 200 NB

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GI pipes 200NB, &150 NB PIPES AS PER REQUIRMENT.

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Flexible connections and fixings

- 01 set

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Foundation bolts, supports, brackets & fixings

- 01 Set

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Selected Spare Parts

- 01 Set

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Before we begin with the assembly process we need to make sure of the following things: Check all the equipment is received as per the checklist provided if not make sure you provide the required materials. Check the actual condition of the construction if it is as per the civil drawings provided. If no then make sure the required changes are made. (Pipe inlet and outlet civil work needs to be checked). Check the foundation for pump if it is as per the drawings provided.

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There are 4 different types of pump rooms based on the suction and delivery. In order to place the pump-motor assembly we need to know the exact positions as shown in the table. The types are classified on the basis of the suction & delivery sides. The side across the river is called as the “opposite side”.

To get a better idea of the types the details are as follows:

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FIG. PUMP ROOM TYPE 1

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TYPE 1: 1.) Suction side: Both the side suction is taken The pump side as well as the opposite side of the river is called as the “opposi te side” as mentioned above. 2.) Delivery side: Both the side delivery is taken The pump side as well as the opposite side of the river.

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TYPE 2: 1.) Suction side: Both the side suction is taken. The pump side as well as the opposite side of the river is called as the “opposite side” as mentioned above. 2.) Delivery side: Only side delivery is taken. The pump side only not the opposite side.

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TYPE 3: 1.) Suction side: Suction is taken only on one side. The opposite side of the river suction is not taken. 2.) Delivery side: Only one side delivery is taken The opposite side of the river delivery is not taken.

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TYPE 4: 1.) Suction side: Suction is taken only on one side. The opposite side of the river suction is not taken. 2.) Delivery side: The pump side as well as the opposite side of the river. The pump side as well as the opposite side of the river.

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Now we shall begin with the actual installation process. We shall begin with the pump placement. From the above section we are now aware of the pump placement’s and there positioning-type wise. The general placement steps for the pumps are same for all 29 pumps. Which are as follows:

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Fig.: Foundation DWG. Blower IF/SO/1516/CL-LR-06 The foundation is to be kept ready on site before moving the pump into the pump room.

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Document name: LAZY RIVER MANUAL ---------------------------------------------------------------------------------------------------------------------------------

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First and foremost check the dimensions and verify the civil work, incase its inappropriate make the required changes. After verifying the place makes sure that there is enough space for moving the pump into the pump room.

Fig.: Pump & stand assembly.  

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The pump assembly is as shown in the diagram along with the pump. The ideal way of assembling is with the stand outside the pump room and lifting it inside along with the stand on to the foundation. This method is convenient as there is very less space inside the pump room to assemble. Alternative method of assembling inside the pump room can also be done. The assembly of the motor need not be done from the start as there is no requirement of using it as of yet. The motor assembly will be done in detail latter on in the electrical assembly section.

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After the pump is installed we need to move ahead with the plumbing. The pump has two sides, 1.) Discharge side and 2.) The delivery side, the side coming from the river end is the suction side. The suction side has two inlets one is 200 NB and the other is 150 NB. The discharge side goes out to the delivery side on to the next chamber. The outlet has the size of 200 NB two pipes with a header of 300 NB. Let’s begin the assembly from the suction side. The important point is not to start assembly from both the sides as the required adjustments become very difficult otherwise for alignment purposes. Secondly necessary 90 Deg. From the ground needs to be maintained at all connections as the plumbing won’t be appropriate for further conditions.

The suction side assembly begins with a reducer and ends with a nozzle. We will begin the assembly in the following steps as shown in the fig. There are two types of suction assemblies according to the construction. 1.) For Pump Room -Type 1 & Type 2, the assembly is common. 2.) For Pump Room -Type 3 & Type 4, the assembly is common.

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The assembly is done as per the description shown below; we will begin from reducer to header:

Fig. suction type-3 & 4 assembly - A 1.) First we will assemble the “reducer 250NB x 300 NB x 330Lg”. along with the suction side of the pump. The suction side is of 250 NB, we will use a “ gasket of 250NB – OD 405 X ID 276 X 3 THK”. 2.) To assemble the “ reducer of 250NB x 300 NB x 330Lg” with pump we will use M16 X 70 bolts. Each flange has 12 holes.

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3.) Second we will assemble the “ reducer 250NB x 300 NB x 330Lg” with the suction pipe size 350NB with flange-300Lg. We will use the “ gasket of size OD 525 X ID X 359 X 4 THK.” For the connection. 4.) To assemble the suction pipe size 350NB with the “reducer 250NB x 300 NB x 330Lg” we will use the M24 X 100 bolts. Each flange will have 12 holes. 5.) Third we will assemble the 350 NB. Butterfly valve. It is assembled between two parts 1.) Suction pipe-350NB with flange-300Lg 2.) Header 350 NB - 597 x 798. 6.) We will fix the butterfly valve between them using M24 X 200 bolts. Each flange will have 12 holes. 7.) The header has two inlets one side it has a flange of 200NB & the other side it has 150 NB flange inlet. The assembly up to the header inlet is same for all assembly types except for the header as it is shown in the fig.

Fig.: Header types 23


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Fig.: Suction side assembly 150 NB side type 1 & 2. The plumbing from the header onwards is as follows for the type 1 and type 2 pump rooms. 1.) We will start from the header 150 NB side. First we will connect 150NB pipe with flange -394 Lg. Along with the header. We will use gasket 150NB- OD 280 X ID 171 X 3 THK. 2.) We will use M16 X 50 bolt. Each flange will have 8 holes.

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3.) After 150NB pipe with flange -394 Lg. we will assemble “150 NB-Pipe puddle flange.” with 90 deg. Bend. 4.) The puddle flange is casted in the wall latter on. In the beginning it is kept open to allow making adjustments during alignment. The puddle flanges are casted after all the plumbing connections are fit appropriately aligned.

Fig.: Suction side assembly 200 NB side type 1 & 2. 5.) The 200 NB flange is connected to the 200 NB puddle flange-2 sided. As mentioned above the puddle flange assembly is casted in the wall after all alignment is finalized. 6.) We use M16 X 70 bolts are used for puddle flange to header assembly. There are 8 holes on flange. 7.) The puddle flange is assembled with the delivery pipe that goes across the river for suction. The “ 200NB puddle flange pipe-2sided ” is assembled with “200 NB delivery pipe with bend-4072 Lg.”

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8.) We use M16 x 70 bolts. Each flange has 8 bolts. 9.) Similar to the above installation we will assemble “200 NB pipe nozzles LHS 675Lg.” & “200 NB delivery pipe with bend-4072 Lg.” 10.) We use the same M16 x 70 bolts. Each flange has 8 bolts.

1.) As mentioned previously the assembly up to the header inlet is same for all assembly types except for the header as it is shown before. 2.) The assembly from the header onwards for TYPE 3 & 4 is as follows:

Fig.: Suction side assembly 200 NB side type 3 & 4.

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3.) The assembly of header is divided in to 2 sides 150 NB end and 200 NB end. The assembly for the 150 NB side is similar to as explained above. The 200 NB side is explained as per the fig. 4.) First we will start from the 200 NB-Pipe Puddle flange with 90deg. Bend. We will use rubber “ gasket-200NB –OD 335 x ID 221 X 3Thk .” 5.) We will use M16 X 70 bolts. Each flange has 8 holes. 6.) Second we will assemble “ 200NB-Pipe nozzle” with “ 200 NB Pipe puddle flange with 90 deg. Bend.” 7.) We will be using M16 X 70. Each flange has 8 holes. 8.) The 150 NB end assembly is same as the type 1 & 2. For all the types the 150 NB assemblies is same as shown in the Fig.

Fig.: Suction side assembly 150 NB side type 3 & 4. 9.) After the nozzle we come to grating assembly which will be done later after the civil work will be complete.

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b.) Pump room in-house assembly:

Fig. Discharge side plumbing. The delivery side assembly begins with a reducer and ends up with the butterfly valve as shown in the figure. 1.) First we will assemble the “reducer: 250NB x 300NB x 203 Lg.” . the outlet or the discharge end of the pump is of size 250NB. We will use a “ gasket of OD405 X ID 276 X 3 THK.”

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2.) From pump to “reducer 250 NB X 300 NB” we will be using bolts of M24 x 80 each reducer flange will require 12 bolts. 3.) Second we will assemble the header it is a 300 NB PIPE-1000 x 556. We will use the “ gasket size of 300 NB OD-335 X ID 221 X 3 THK. “ 4.) From the 250 NB. X 300 NB. Reducer, to the header of 300 NB. Pipe-1000 x 556 we will use M24 x 80 bolts. Each flange will require 12 bolts. 5.) After the Header pipe comes the delivery pipe. The header has one inlet of 300NB and two outlets of 200NB each. To each outlet we connect a delivery pipe. “The delivery pipe size is 200 x 300 Lg. ” We use a “ gasket of OD 335 X ID 331 X 3 THK”. 6.) For the assembly of “Header of 300 NB. Pipe-1000 x 556” to the delivery pipe size of 200 x 300 Lg. we will use M16 X 70 BOLTS. Each flange will require 8 bolts. 7.) After the delivery pipes comes the butterfly valves. They are used to control the flow of the pump one for each delivery pipe. The butter fly valve size is for 200 NB pipe. 8.) For assembly of delivery pipe to butterfly valve 200 NB. We use M16 x 120 bolts. Each delivery pipe has 6 holes. 9.) After the delivery pipe and valve assembly comes the puddle flange assembly which we will do latter. We will not make any fixing of the puddle flange or the assembly itself as we need to keep ends open for adjustments. 10.) We will assemble and bolt the puddle flange as we require fixing the butterfly valves between the delivery pipe and puddle flange. 11.) For assembling the delivery pipe to the puddle flange with the butterfly valve we will use M16 X 120 bolts. Each flange has 8 holes. The butterfly valve is squeezed in between. 12.) With the completion of the two delivery pipes we have completed the inhouse plumbing assembly for the pump room now we need to align all the pipe inlets and outlets as per the requirement. We might have to move the assembly in order to align it properly for the puddle flange placement. We need to make sure the flanges are perpendicular to the ground. 13.) Once all pipes are determined appropriately aligned we will need to fix them with the civil structure casting at all puddle flanges.

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Fig.: Puddle flange in wall assembly.

Each pump room type has its pumps discharge side going out to the delivery or the discharge end. We will further on see the installation of the delivery end plumbing. The plumbing for the pump delivery is same for Type 1 & Type 4. The plumbing for the pump delivery is same for Type 2 & Type 3.

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1.) Type 1 & 4

Fig.: Type 1 DELIVERY SIDE PUMP ROOM 1.) First we will assemble “ 200 NB delivery pipe with bend ” with “200 NB pipe nozzle” on the opposite side of the river. 2.) We will use M16 X 70 bolts. Each flange has 8 holes. 3.) Second we will assemble “ 200 NB delivery pipe with bend ” with “Puddle flange 200NB pipe – 2 sided.” On the same side of the river. 4.) We will use same M16 X 70 bolts for assembly. Each flange has 8 holes. 5.) Third we will assemble the “ 200NB pipe nozzle” and “ 200 NB with puddle flange 90deg. Bend.” On the same side of the river. 6.) We will use M16 X 70 bolts for assembly with 8 holes for each flange. 7.) The same configuration is followed for the TYPE-4 as well.

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Fig.: Type 4 DELIVERY SIDE PUMP ROOM

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2.) Type 2 & 3

Fig.: Type 2 DELIVERY SIDE PUMP ROOM 1.) First we will assemble “ 200 NB delivery pipe with bend ” with “Puddle flange-200NB pipe – 2 sided.” On the same side of the river 2.) Both the 200NB deliveries are on the same side of the river for type 2 & 3 as shown in fig. above. 3.) We will use same M16 X 70 bolts for assembly. Each flange has 8 holes. 4.) The same configuration is followed for the TYPE-3 as well.

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Fig.: Type 3 DELIVERY SIDE PUMP ROOM

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After all plumbing connections are done we need to get the civil work done. All the puddle flanges and nozzles once are done we need to cover the respective outlets and inlets from the river. The grating assembly is as shown in the fig. above. 1.) Frist we need to fit the frame in the civil assembly by bolting as shown in the fig. The frame and the grating are also assembled together by bolting. 2.) The shown grating is the design suggested for the grating. The detail drawings are sent along with the equipment. 3.) The grating is required in order to prevent any external bodies entering the plumbing.

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We have given a total of 6 panels along with the equipment’s. Each panel will control 5 pump rooms; the final panel will only have 4 pumps to control. The panel can be installed in any required pump room as per the convenience. All the panels have their own individual control on off buttons and auto manual switches. Each pump comes with its own digital ammeter all in compact easy to assemble panel box. The size of the panel is 1000 H x 800 W x 600 D. It comes with a wall mounting provision for easy assembly.

The logical layout of the electrical assembly is as follows: IF/SO/12/1415/CL-06

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It is a desk which can be placed at a centralized position, anywhere in the park from where a person can control all the pump rooms. It has a desk with LED indicators and control buttons for the entire river. It has ON & OFF buttons for each pump. It also has an EMERGENCY STOP button which switches off all the pumps in case of emergencies. The layout is as shown printed on the control desk top for easy operating.

Fig.: Control desk top.  

The wiring for the panels and between the panels will be done after all the panels are installed in their respective pump rooms. The panels are connected to the control desk, the connection wiring details are sent along with the details of the panel. We will require a control wiring to be done for & before operation.

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The lazy river in order to run smoothly we need to do maintenance on regular basis. The general inspection checks are as follows: 1. After 1000 hours or 3 months whichever earlier i. Oil in bearing housing for water contamination and sediment (replace oil if necessary) ii. Oil ring for proper working iii. Constant level oiler for proper working iv. Gland packing (for leakage) v. Condition of mechanical seal vi. Cooling water flow vii. Condition of coupling guard viii. Condition of bearing by sound and temperature ix. Electric motor load current (at discharge valve shutoff and open condition) x. Performance of all measuring instruments (pressure/ temperature gauges and flow meters); xi. Greasing of bearing; if bearings are grease lubricated 2. After 4000 hours or 1 year whichever earlier i. Repeat all checks per No: 1.

ii. Flushing of cooling water lines and cleaning of Strainers, whether carried out or not (to ensure proper flow of cooling water)

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iii. Condition of coupling (in decoupled condition ) iv. Coupling end support for any abnormality v. Foundation, foundation bolts and supports. vi. Alignment (Realign, if necessary) vii. Performance of all measuring instruments and recording of readings viii. Suction line strainer for cleanliness 3. After 8000 hours or 2 years whichever earlier Complete overhauling of the pump shall be carried out. This shall include part wise inspection as per item ‘V’ and all checks per item 2 Notes: i. After completing the checks listed above the pump shall be started and the following shall be checked during the trial run (the trial run duration shall be half to one hour for electric driven and 3 to 4 hours for diesel driven): a) Discharge pressure b) Suction pressure c) Liquid flow (if possible) d) Condition of mechanical seal / gland packing e) Electric motor load current at discharge valve shutoff and open condition f) Condition of bearing by sound and temperature g) Any Leakage h) Vibration and shock pulse reading ii. Pumps in hot service shall not be rotated unless it is gradually heated up to a temperature close to that of the working fluid.

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Sr. no. 1 2 3 4 6 7 8 9 10

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Since a very few moving parts are involved in a pipeline, it does not require much attention. Still one should not take it for granted that he will get a trouble free operation. The valve glands, flange joints, etc. may leak; the supports and clamps may get loosen and start vibrating; the pipe may get corroded internally or externally within a very short time of its commissioning. Therefore, it is necessary that a scheduled inspection be carried out on the items which may give trouble and a logbook maintained for taking necessary preventive maintenance. For every process pipe a check list may be prepared and hung in the office of maintenance in-charge. A check list for such operation may be prepared

FREQUENCY OF INSPECTION

ITEM Pressure reducing valves Threaded and flanged joints Stop valve/isolation valve Glands: Flow control valves glands Safety valves All indoor pipes (overhead) All indoor pipes (in trenches, tunnels etc.) All outdoor pipes (overhead) All outdoor pipes (underground)

Daily once Daily once Weekly once Weekly once Weekly once Quarterly Quarterly Half-yearly Every five years or so.

The jobs carried out in connection with preventive maintenance must be recorded in log book for future reference. In a pipeline, generally maintenance of leaking valves is a major problem. Therefore, standard practices followed for replacement of gland packing or gasket of a flanged joint must be noted serially, operation-wise under a heading ‘Valve Maintenance’, ‘Replacement of gland packing in running line’; Repair of flange joints, etc. and hung in the office of maintenance in-charge for future guidance of the maintenance staff.

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1.) Daily:   

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Check 3 phase Power supply. Check if starter is provided for motors to provide sufficient starting time Check all incoming and outgoing cable and connection, if loose, tighten It Properly. Check the motor fan over heating Check the motor condition. Check motor cable connections, tighten it properly.

2.)Monthly:   

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Check the main control panel and clean all contactors.(Use contact cleaner) Check DOL operation for the pump motor Examine visually “Earth Connections” and over all condition of pumps, motors and its cables. Check the motor winding insulation resistance.

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