OC Maintenance

Maintenance Event


 Back to Main OCRC Page

Event Videos 1/31/18
There are two videos on the KSB USA YouTube page (see link); the Detailed Process Video which is more of a step by step/one at a time rundown of the tasks/event and the Real Time Video which shows a team running the event from start to finish.  Keep in mind that the regulations/rules are different than what this video shows in some areas, and teams need to always refer to the latest edition of the regulations/rules on the team resource site.  The videos are for informational and training purposes for both participants and judges.  Note that the Fuse blocks that will be used for the event are shown in the detailed process video as  the Optional fuses.

Event Coordinator -
Steve Motley
Engineering Div Manager
City of Virginia Beach
Steve Motley photo
  2018 Maintenance Event Procedure - UPDATED  5/18/2018
2018 KSB Data Sheet - 2/2/2018
2018 Pump Event Setup Diagram - UPDATED 1/24/2018
Control Panel Photos - 1/24/2018

KSB Event Equipment Purchase Packages - 1/19/18
KSB Credit Card Authorization Form - 1/19/18
KSB Credit Application - 1/19/18
KSB Order Form - 1/19/18

Reid Lifting Rapide Gantry System Ordering Process 1/8/18



 Question  Answer  Date
When will the pump purchasing information be made available? We expect to have that information ready in early January.
Now available 12/27/17
When are we going to get a complete parts list so we will be able to order the new equipment in time for our regional conference? It should be available within the next two weeks.
What is the make and model number of the chain hoist for the event?
½ Ton Mini Hand Chain Hoist Harrington CX005-10 w/ 10 ft chain
I seen that the bolts that need torqued should be at 37 ft. lbs and 44 ft. lbs. Do you prefer a 3/8 drive or a 1/2 drive torque wrench for this application? So I know what size to purchase.
The torque settings may change in the final rules but everything is 1/2 inch drive.  The final tool and equipment list will be available very soon. 1/11/18
Will there be pictures of the wetwell setup and Both control panels posted on the site so that teams may have the capabilities to fabricate setups that may be reasonably close for practicing purposes. Or will Loaner units be made available to Teams that are budget challenged.
Pictures of the control panels have been uploaded to the team resource site.  Once the production of the final wet well design is completed I will get pictures of the wet well as well.
While the control panel is open and checking power to each leg. Will there be required PPE to be worn for any Arc Flash Hazards that could be present?
The beauty of the voltage test station is that it is a permanent electrical safety device that allows for a safer way to verify the presence or absence of voltage and arc flash potential from outside the electrical panel.  The voltage test station is mounted on the panel door thus you have access to it without opening the control panel.   During the event prior to opening the control panel you are required to verify the absence of voltage and arc flash potential as part of the required tasks.  The voltage test station has both a visual (lights) and manual (test points) to verify the presence or absence of voltage and arc flash potential.  Additionally the control panel that you will be working in (Control Panel #2) the fuse block is not connected and thus never live.  Please see the control panel pictures that have been uploaded to the team resource site.  The only PPE required for the event is Hard Hat, Safety Glasses, Safety Toe Shoes, and Gloves (must be leather if touching the impeller).
I cant find anything in the event description about the test that's in the video. Is there going to be a test, if so will it be basic pump questions or questions on this specific pump? There is no longer a test included in the event.
Can the torque wrench be used to remove hex bolts from pump?
No you cannot use the torque wrench as a ratchet for removal or installation of a bolt.  Doing so will result in a penalty.
what is the total height of the well? and the total height of the 3 inch ball valve? thanks The total height of the wet well as measured from the ground to the top of the wet well is 42.5 inches.  The total height of the 3 inch ball valve as measured from the ground to the top of the ball valve bonnet is 62 inches.
Have the torque settings been modified yet? We are setting to 35lbs the Impeller wrench and it seems to be too much for it. Any changes? Yes I am currently working on a rules update.  And the torque settings will change to 20 ft lbs for the Impeller bolt and 30 ft lbs for the volute bolts.
I know you have revised the torque settings down for the impeller and volute bolts but I referenced the pump manual and I believe the correct spec to be 19.2 ft/lbs for the impeller (page 77, Size 80-216, Impeller Type F). A setting of 19 might be cautiously preferable factoring in a competitor's dose of adrenaline and whatnot... What do you think? Thank you for bringing this to our attention, but for now the impeller torque setting will be 20 ft lbs.
In the event description it says whoever handles the impeller must wear leather gloves. I assume this is because of the sharp edges.
If so can cut resistant gloves be used instead of leather?
No the gloves must be leather.
What is the size of the pump service table and tool and equipment preparation table? The pump service table is as follows:
Manufacturer:  ULINE
Item #:                  H-2484-steel, Packing Table
Size:                       96” x 30”, steel top
                                500 lbs capacity
Legs:                      Adjustable 28 – 35” (For WEFTEC the Legs will be set at a height of 28 inches)
The tool/equipment table is as follows: 6 ft long x 30 inches wide x 30 inches tall
Two questions.
1. Is there anyway to rent the new maintenance event to practice with? Details?
2. Is there still a need for judges and if so how would a person sign up?
  1.  There is currently not a formal established rental procedure however please contact Sherry Heinly with KSB at Sherry.Heinly@ksb.com to discuss the options available.
  2. A private email has been sent to you to provide instructions on how to volunteer to judge the maintenance event at WEFTEC.
Due to the impeller blades being as sharp as they are and removal rotation of the impeller being counter clockwise, will it be acceptable without penalty to use the provided screwdriver in conjunction with the hammer in one of the slots to aide in keeping the impeller from moving?
Sorry but we do not want you using the screwdriver or pry bar to hold the impeller.  If too much pressure was applied then it is possible that the impeller bolt could be bent or the impeller itself could be damaged.  In the events that have already taken place teams did not have any trouble just using the dead blow hammer to block the impeller.
Will the pump be taken completely apart prior to the first team’s run? While the pump is apart, will the loctite be removed from all bolts, and newly revised torque settings be applied prior to first team’s run. This will assure that every team starts and finishes with same torque settings and disadvantages? Yes at WEFTEC the pump will be taken apart before the competition begins and the pumps will be put back together in accordance with the torque settings in the official rules of the event.
As has been permited the past, will grease monkey gorilla grip gloves model # 25052-08, be acceptable for handling the impeller No you must wear leather gloves to touch/handle the impeller.
We are having problems with the 9/19 bolts and nuts from the guide rail flange (rubber compression fittings) in which they are binding so bad that we have to cut them off. If I remember right this happened at the Myrtle Beach event. It was suggested that stainless steel seems to be the problem. Is anyone else having this issue and if so, will they be replaced with steel bolts and nuts. Any thoughts. We have switched the nuts on those rubber compression fittings to a mild steel they are no longer stainless and this seems to have resolved the issue.
We are have the same binding issues with the 9/16 nuts and bolts that attach the guide rail flange to the wetwell, will you be switching them to a mild steel also?
Yes they will be mild steel 
Are batting gloves acceptable Yes they are fine, if you are touching/handling the impeller make sure they are leather batting gloves. 5/2/18
In the event description it says whoever handles the impeller must wear leather gloves. I assume this is because of the sharp edges.
If so can cut resistant gloves be used instead of leather?
No the gloves must be leather.
Can the discharge valve be closed after the submersible centrifugal pump has been shut off before Lockout/Tagout has been completed on the electrical panel? No lockout/tagout on the control panel must be completed by the individual that is closing the discharge valve before they can close the discharge valve.  This is clearly stated in in Task 3.a.
Do you have to wear the leather gloves to move the old impeller back to the the tool table at the end of the event or can someone else move it with out wearing the leather gloves? Yes if you touch the impeller at any point you must be wearing leather gloves.
Is the judges sheet going to be available by WEFTEC? Most likely yes but it may or may not tell you the penalty times associated with each penalty.  I can tell you that the penalty for breaking the pump during the event is 20 minutes and the penalty for ignoring the judges warning for not having metal on metal contact before installing volute bolts is 10 minutes. 5/21/18
Since the O-ring around the bottom of the pump unit where it meets the volute will be removed, do we still have to apply a small bead of oil around the entire circumference of the pump base along the “O-ring” and communicate out loud “Lubrication applied to pump”? Or is this step now a simulation of us doing it and not actually applying oil? Yes you still need to actually apply the oil and communicate out loud.
Will the electrical panels be located back to back or side by side? Which way do they face? Back to back, see the event setup diagram on the Team Resource Center Site.
In removing the trolley and chainfall at the end of event. Can the chainfall be left on the trolley and just pull the 2 pins to remove trolley and than remove chainfall from trolley once it is on the ground? As long as the two are separated and in their designated locations when you end the event you may separate them however you choose.
Is anyone else having issues with the impeller sticking to the pump and not being able to get it off?
Not that I have heard of.  Having said that I would not be leaving the pump sitting in water when not in use, you may even want to remove the impeller when not practicing to help with this issue. 8/20/18
Will mechanix grip gloves be acceptable to remove impellar or do they need to be regular mechanix gloves?

Will you be able to put a hand on impeller to help hold impeller as sometimes the hammer slips from underneath the impeller?
If the Mechanix Grip gloves are made with leather like the Original Mechanix Gloves then Yes, otherwise No.   As stated in the rules you must be wearing leather gloves to touch the impeller.    The impeller must be blocked using the hammer, if you cut/damage/hurt your hand while holding the impeller you will be assessed a severe penalty for an unsafe practice.
At the end of event, can the discharge valve be opened by someone other than safety supervisor as long as safety supervisor is the last one to remove his or her lock? Or must the valve be opened by the supervisor after removing his lock? Someone else may open the valve.  Each person is responsible for removing their own locks. 8/21/18
Do you need to reinstall 4 washers in between volute n pump housing prior to installing bolts into pump? Thought at Atlantic city these were removed along with o-ring? The o-ring is removed. There are 4 washers present in between the volute and pump and you will be supplied with 4 new washers to reinstall as a part of the event.
Is there a list of the tools/equipment that will start on the table and end up on the table at the end of the event. At this time there is not.
On the chain there is a warning tag. Will this be present on the chain during the competition? If the tag will be on there is there a penalty for accidently pulling the tag off of the metal ring? Yes the tag will be present and yes a penalty will be assessed for pulling the tag off.
1. We are having trouble locating the Washers: 7/8” OD, 1/2" ID, 1/8” (0.125”) thick, yellow zind coated (zinc?). Can you please provide a source?
2. The Spare Fuse Container (Clear 4 oz Plastic Jar with screw on White lid) is used for the bad fuses so they are not mixed with the box of good fuses? This bad-fuse jar ends up where at the end of the event?
  1. Please contact Sherry Heinly with KSB (Sherry.Heinly@ksb.com) to get the washers.
  2. The fuses in the plastic jar will contain both bad and good fuses thus you must test any fuse before it is put into the control panel.  The plastic jar will start and end on the tool table and lid must be on at the end of the event.
Can you perform any maintenance work on the tool table?
No you cannot perform any maintenance work on the tool table other than testing the fuses (if so desired).
When applying the small bead of oil around the pump base along the O-ring, can the pump be in the horizontal position or does it have to be vertical?
Either is fine as long as the oil is applied all the way around.
During the final multi meter test on the voltage test points if the pump is not running the voltage reads 0. Is the pump supposed to be running prior to voltage test or are we supposed to simulate the readings.
No the pump should not be running but the main breaker only should be turned on when doing this test.
Can members working inside the electrical cabinet, not touching the impeller, wear rubberized or nitrile gloves? I understand any team member handling the impeller MUST wear leather gloves.
Yes 9/13/18