Sanitary Pump Station Rehabilitation

How to Drag a 1960s Lift

Station Leaking & Squeaking

into the 21st Century

Presented at the Arkansas Water Environment Federation

2008 Conference in Hot Springs Arkansas April 29, 2008

David E. Mizell, P.E.

Jon A. Kremer, P.E.

Burns & McDonnell - St. Louis, MO

David Moss, P.E.

Paragould Light Water & Cable

Agenda

� Pump Station History

� Project Objectives

� Project Challenges� Project Challenges

Agenda

� Pump Station History

� Project Objectives

� Project Challenges� Project Challenges

� Design Factors

� Construction

� Lessons Learned

� Operational Experience Apr 07 – Mar 08

History, Part 1

� Built 1965

� Concrete cast-in-place

� All-Brick above grade � All-Brick above grade

� Wet well 12’ W by 8’ L by 34’ D

� Dry well 12’ W by 12’ L by 34’ D

� 3 pumps, vertical shaft, motors at surface

� Discharge out east and west walls!!

Service Area

� This Lift Station Serves:

• 4 other pump stations

• 486 acres total

• 814 homes and businesses• 814 homes and businesses

• Avg. Flow = 0.375 MGD

• Peak Flow = 1.75 MGD est

Project Objectives – 1

� Fix leaks at wall of

wet well

� Wall pipe with leaded

seal seal

� Replace intake piping

to pumps


� Replace old water pumps

� Replace old pump motors & pump motors & eliminate shafts

� Valves & couplings for future repairs


� Stop leaks at wall

discharge points

� This leak was

suspected ground suspected ground

water infiltration

� Actually was a

crack in the pipe!


� Convert to VFD

control

� Install pressure

transducer in wet transducer in wet

well for primary

level control

� Floats as

secondary control

Project Challenges

� Maintain Service

at all times

• Short breaks OK

� Tight cramped � Tight cramped

vertical space

View down Dry Well

Design Objectives

� Create single discharge line

• Old pumps 1 & 2 discharged out West side

• One pump 3 discharged out East side

Design Objectives


• Old pumps 1 & 2 discharged out west side

• One pump 3 discharged out east side

� Improve reliability and redundancy� Improve reliability and redundancy

Design Objectives


• Old pumps 1 & 2 discharge out west side

• One pump 3 discharges out east side

� Improve reliability and redundancy� Improve reliability and redundancy

� Keep Station in service during

construction

• Bypass wet well to existing 12-inch force main

• Replace 3 pumps in 2 phases

3 Replacement Pumps

One New Pump 1

� 400 gpm

� 115 feet total

dynamic head

� 8-inch suction

� 4-inch discharge

� 30 HP motor

� 1,800 rpm

� 480 V, 3 Ph

3 Replacement Pumps

New Pumps 2 & 3

� 1,000 gpm each

� 115 feet total

dynamic head

One New Pump 1

� 400 gpm

� 115 feet total

dynamic head

� 8-inch suction


� 50 HP motor

� 1,800 rpm

� 480 V, 3 Ph

� 8-inch suction


� 30 HP motor

� 1,800 rpm

� 480 V, 3 Ph

Use 3-D Design

Looking Southeast Looking South

Pre-Bypass #1 Activities

� Expose Force Main &

install tapping sleeve &

valve

� Set up bypass pumps � Set up bypass pumps

and piping

• Pump out of manhole upstream of lift station

• Feed force main through tapping sleeve & valve

During Bypass #1

� Pump out wet well

� Turn off Pump 3 & close

valves to isolate

� Remove Pump 3 & piping

Core drill into wet well for

Phase 2Phase 1

� Core drill into wet well for

new intake

� Install new suction elbow,

pipe spool & valve for

Pump 3

� Re-activate Pumps 1 & 2

P-3 P-2 P-1

After Bypass #1 Activities - 1

� Core drill North wall for new discharge pipe

� Install Pump 3 base & vibration isolatorsvibration isolators

� Install new Pump 3 & Motor

� Install new conduit, wiring, etc.

After Bypass #1 Activities - 2

� Install piping & valves to outside

� Outside: install meter vault & bypass piping vault & bypass piping & valves

� Install wet well water level transducer & redundant floats

Meter Vault

� Dismantling Coupling

� Mag. Flow Meter

� Tee

� Full Size Valve

Air release valve

� Air Release Valve

• If future emergency occurs,

remove air release valve,

install connector, bring in portable pump, and discharge at Tee into force main

� Full Size Valve

During Bypass #2

� Turn off Pumps 1 & 2,

close valves to isolate

� Pump out wet well

� Disassemble piping &

remove Pumps 1 & 2remove Pumps 1 & 2

� Core drill into wet well for

intakes 1 & 2

� Install new suction elbows, pipe, & valves

� End bypass #2

After Bypass #2

� Install Pumps 1 & 2, motors & wiring

� Install piping and valves to new discharge headerdischarge header

� Start up Pumps 1 & 2

� Demolish Old Piping Outside

Actual Construction

� Contractor did one LONG

Bypass Period

• Elec Feeds

• Two portable pumps

� Tackle all pump & piping � Tackle all pump & piping

replacements at once!

� All Core Drilling 1 mob

� Weather cooperated,

No big storms!

New Pump Station Operations

� April 2007 – March 2008

• Total Pump Cycles = 42,749 (Avg. 118/day)

•• Total Flow = 137 MG (377,000 gpd)

Pump Cycles Apr-07 to Mar-08

200

250

300

350

400

Pu

mp

Cycle

s /

Day

0

50

100

150

200

Apr-

07

May-

07

Jun-

07

Jul-

07

Aug-

07

Sep-

07

Oct-

07

Nov-

07

Dec-

07

Jan-

08

Feb-

08

Mar-

08

Date

Pu

mp

Cycle

s /

Day

Daily Flow Apr-07 to Mar-08

800

1,000

1,200

1,400

Daily F

low

(000 g

al)

0

200

400

600

Apr-

07

May-

07

Jun-

07

Jul-

07

Aug-

07

Sep-

07

Oct-

07

Nov-

07

Dec-

07

Jan-

08

Feb-

08

Mar-

08

Date

Daily F

low

(000 g

al)

Dry Day Operation 5/28/2007

800

1,000

1,200

1,400

Flo

w R

ate

(g

pm

)

0

200

400

600

0:00 3:00 6:00 9:00 12:00 15:00 18:00 21:00 0:00

Time of Day

Flo

w R

ate

(g

pm

)

Flows on 5/28/07 from 6:00 to 8:00 AM

800

1,000

1,200

1,400

Flo

w R

ate

(gpm

)

0

200

400

600

6:00 6:15 6:30 6:45 7:00 7:15 7:30 7:45 8:00

Time of Day

Flo

w R

ate

(gpm

)

Wet Day Operation 11/25/07

800

1,000

1,200

1,400

Flo

w R

ate

(g

pm

)

0

200

400

600

0:00 3:00 6:00 9:00 12:00 15:00 18:00 21:00 0:00

Time of Day

Flo

w R

ate

(g

pm

)

Conclusion

� 1960s era Pump Station was an O&M nightmare

� Many ways to modernize this facility

� 3-D design was effective tool� 3-D design was effective tool

� Over-core of pipe penetrations was key

� Bypass pumping successful

� Nightmares Over!

Questions?Questions?

Sanitary Pump Station Rehabilitation

Business

Transcript of Sanitary Pump Station Rehabilitation