new wastewater pumping station development manual

New Wastewater Pumping Station Development

Manual

Town of

Virginia

Updated: 2015

New Wastewater Pumping Station Development Manual Table of Contents

Page 1 of 2 Page Number I. Introduction

A. Design Phase ......................................................................................1 B. Construction Phase.............................................................................1 C. Substantial Completion Phase ...........................................................2 D. Post Construction Phase .....................................................................2 II. Pump Station Design Criteria A. Site .....................................................................................................3 B. Building Type and Utilities ................................................................3 C. Pump Station Size and Type ..............................................................3 D. Pump Manufacturers ..........................................................................4 E. Pump Controls ...................................................................................4 F. Generator and Fuel Storage Tank ......................................................4 G. Alarm System and Flow Measurement ..............................................4

H. Diagnostic and Information System ...................................................4 I. Forcemain ..........................................................................................4 J. Wet Well ............................................................................................5 K. Power .................................................................................................5 L. Odor and Corrosion Control Equipment ............................................5 M. Station Bypass ....................................................................................5 N. Surge Analysis ...................................................................................6 O. Shop Drawings ...................................................................................6 P. Warranty .............................................................................................6 Q. As-Builts ............................................................................................6 R. Door Locks .........................................................................................6 S. Operation and Maintenance Manual ..................................................6 T. Manholes ............................................................................................6 U. Storage/Holding Capacity ..................................................................6 V. Grinder Manhole ................................................................................6 W. Shower/Eyewash Combination Station ..............................................7

III. Major Equipment Start-Up, Testing and Training ..................................7

Attachments

1. New Wastewater Pumping Station Development Sequence 2. Certificate of Substantial Completion 3. Details

a. Forcemain Sewage Air Release Valve b. Forcemain Cleanout c. Chain Link Fence

i New Wastewater Pumping Station Development

New Wastewater Pumping Station Development Manual TABLE OF CONTENTS (CONCLUDED)

PAGE 2 OF 2

d. Emergency Pump Connection e. Buried Plug Valve f. Cabinet Style Shop Desk g. Offline (Emergency) Storage Schematic h. Grinder Manhole Schematic i. Inside Drop Connection j. Typical Site Plan k. Typical Street Section

ii New Wastewater Pumping Station Development

1 New Wastewater Pumping Station Development

New Wastewater Pumping Station Development Manual I. Introduction

These wastewater pumping station development guidelines are intended to assist designers in the development of plans and specifications for the Town of Leesburg. As well as coordinate all activities between responsible organizations involved in the development of new wastewater pumping stations within the Town of Leesburg’s service area. These guidelines represent the minimum acceptable level of quality expected in pumping station design and do not supersede the requirements of any organization, may not include all activities, and may require modification for site specific requirements. A. Design Phase

1. Pre-Design Meeting with Utilities Department: Review Town of Leesburg’s (TOL) Wastewater Pump Station Development Guidelines for specific project.

2. Preliminary Plans & Specifications submitted to TOL for review and comments.

3. Final Plans & Specifications submitted to TOL and DEQ for review and approval.

4. Flow Acceptance Letter issued by TOL to DEQ for project. 5. Certificate To Construction (CTC) issued by DEQ. 6. Deed and Plat of property dedicated to TOL. 7. Performance bond is posted.

B. Construction Phase

1. Pre-Construction Meeting held with TOL's Engineering and Inspection Division.

2. Permits Obtained by Contractor: a. Loudoun County: Grading Permit, Erosion & Sediment Control,

Building Permit, Mechanical, Electrical, Plumbing, Occupancy, Substantial Completion, Flammable/Combustible Use Permit (FMD if Day Tank >25 gals.)

b. Town of Leesburg: Zoning Permit, VDOT Entrance Permit (if applicable), Utilities Permit (if applicable)

3. Permits Obtained by Town: a. Air Pollution Permit Application to DEQ

4. Utilities: a. Electric: Virginia Power or NOVEC (3-phase, Schedule 120) b. Telephone: Verizon c. Water and Sewer: Town of Leesburg Utilities


5. Inspections: a. Loudoun County: Mechanical, Electrical, Plumbing and Occupancy. b. Town of Leesburg: Building and underground utilities. c. Cross Connection Inspection by TOL's environmental Compliance

Inspector. d. Engineer: Entire project.

6. Shop Drawings:

a. Submitted to Engineer and Town for concurrent review and approval prior to release to contractor.

b. Approved copies (2) submitted to Town with an electronic copy. 7. Tests:

a. Submit soil and concrete test results to TOL. b. Start-up testing and training for all equipment. c. Draft O&M Manual developed during this phase.

C. Substantial Completion Phase

1. Deficiencies and Omissions List developed by TOL and Engineer. All "As-Built" information compiled by Engineer for Record Drawings.

2. Engineer's Certification To Construction (CTC) to DEQ and TOL, TOL recommends DEQ issue a Certificate to Operate (CTO).

3. CTO Inspection by DEQ, TOL, Engineer, Developer and Contractor. 4. Conditional CTO issued by DEQ to TOL. 5. Substantial Completion granted by TOL. Pump stations must be ready to be

put into operation with no significant operational items unfinished which would affect its operation or reliability. Must also provide final equipment O&M manuals, draft station O&M manual, and spare parts inventory.

6. Warranty periods begin with Substantial Completion documented by a letter from General Contractor and a Gen-Set service contract.

7. Electric and telephone service accounts transferred to TOL. 8. TOL places property and liability insurance on the structure.

D. Post Construction Phase

1. As-Built Drawings submitted to TOL by Engineer for review and comments. 2. Deficiencies and Omissions (D&O) list items corrected by Contractor. 3. Conditional CTO and Final CTO by DEQ. 4. Final Inspection by TOL, Engineer, Developer & Contractor. 5. Performance Bond Release requested by Developer (for PS only). 6. Director of Public Works recommends Town Council release bond. 7. Town Council passes resolution to release bond. 8. Town & Developer Attorneys: Release performance bond and initiate

maintenance bond (property transferred previously). 9. Maintenance bond is released after all deficiencies have been addressed.


II. Pump Station Design Criteria

The design criteria listed below are guidelines only, and site-specific modifications can be discussed with TOL on a case-by-case basis. A. Site

1. Site will be owned by the Town of Leesburg and be of adequate size for station infrastructure, roads, turning radius, and required buffer zones.

2. Paved access (6" of 21A, 3" BM-25 and 1-½" SM-9.5A) with roadway accessible to a standard unit (SU) truck. Grade not to exceed 10%. See attached TS-13 Detail.

3. Site enclosed with 8-foot chain link fence (specification and details are available) and landscaped with 6-foot evergreen trees. See attached details SS-18 and Typical Suction Lift Pumping Station Site Plan.

4. Entrance to Town or VDOT roadways will require separate permits to be secured by developer.

B. Building Type & Utilities 1. Brick structure with 3:1 pitched roof with asphalt shingles, and aluminum

soffits, gutters, downspouts and fire retardant plywood or sheetrock. 2. Appropriate access doors (insulated) for personnel and removable

doors/hatches for all equipment. Illumination using photo cell lights capable of manual or automatic operation.

3. Water line with meter, exterior hose bib with hose rack, and a wash sink inside. Water line protected by an RPZ (approved list is available). The water meter will be purchased from the Town and installed either indoor or outdoor. If indoor, the MTU will be wired and installed on the exterior wall.

4. Phone service with a standard push button phone. 5. Sink and floor drains into wet well with appropriate traps/vents and tide

valve. 6. Provisions for pump removal (i.e., stanchion or hoist system). Portable units

are acceptable for pump stations less than 300 gpm. 7. Colors and paint manufacturer per Town standards (list is available). 8. Electric heater (suspended) and thermostat operated, exhaust fans. 9. A suitable metal work desk shall be provided as manufactured by PENCO,

model 430091PY or equal. (See attached detail) 10. The influent to the station shall be provided with a Muffin Monster® or

approved equal to handle large objects. See grinder manhole schematic of a suggested design. Alternate designs will be considered.

11. Provide minimum of two Solatubes in the building. 12. Provide a point of use water heater.

C. Pump Sizes and Types

1. Qpeak ≤ 300 gpm: Submersible pumps, passing 2" sphere. 2. 300 gpm ≤ Qpeak ≤ 500 gpm: Suction lift (18' maximum), passing 2" sphere. 3. 500 gpm ≤ Qpeak ≤ 700 gpm: Dry well/wet well, constant speed. (Note:

Dry mounted submersible pumps are preferred)


4. Qpeak > 700 gpm: Dry well/wet well, variable speed pumps. grinder manhole is required. (Note: Dry mounted submersible pumps are preferred).

D. Pump Manufacturers 1. Qpeak ≤ 100 gpm: Flyte, Scan, Hydromatic, Barnes and Gorman Rupp 2. 100 gpm ≤ Qpeak ≤ 300 gpm: Smith & Loveless, Fairbanks-Morse

(USEMCO) and Gorman Rupp 3. 300 gpm ≤ Qpeak ≤ 700 gpm: Flyte, Scan, and Gorman Rupp 4. Qpeak > 700 gpm: Flyte, Scan, and Gorman Rupp

E. Pump Controls

Bubbler system and one backup mercury float for the high water level. Bubbler tube to be stainless steel.

F. Generator & Above Grade Fuel Storage Tank (FST) 1. Gen-set installed indoors for noise reduction and ease of maintenance

(mounted on a minimum 2″ high housekeeping pad), Louver closure by gravity is preferred.

2. Acceptable manufacturer, Caterpillar, Cummins/Onan and Katolight/MTU Detroit Diesel for gen-sets up to 600 kW.

3. Two-year service and maintenance contract must be provided. 4. Fuel tank will be above grade type stored under the generator set. It will be

of double wall construction meeting EPA requirements, minimum size 600 gallons (specification available). Tank must be sized for 5-days of operation at 1/2 load or 600 gallons whichever is greater. Tank shall be full when ownership transferred to the Town.

G. Alarm System and Flow Measurement 1. Automatic dialer system to monitor high and low water levels, pump failure,

power failure and generator running. Dialer shall be Kaye Instruments, or equal.

2. Flow meter to be mag meter as manufactured by Dynasonics/Badger, ABB or approved equal (transmitter, indicator and totalizer).

H. Diagnostic and Information System Diagnostic and Information System shall be an acceptable unit manufactured by ABB Inc. or approved equal. The unit node box is to be installed in NEMA 4X enclosure with door lock for indoor/outdoor use, equipped with the most current system upgrades. For additional information, contact Town for representative name and phone number.

I. Force Main 1. 4" minimum size, epoxy coated DIP Class 52. 2. Detail of air or air/vacuum release vault attached. 3. Clean-outs shall be required for all force mains 6" ID or less, and will be

located every 500-feet and/or at every deflection (sum of horizontal and


vertical deflections, i.e., (1) 45º horizontal plus (2) 22.5º vertical ells) (see attached detail).

4. All wall penetration shall utilize sleeves (i.e., link seal or other approved methods).

5. A 6" metallic warning tape indicating “Buried Pipe” shall be installed at least one foot above the pipe.

J. Wet Well

1. Wet well sizing must be such that there is at least 60 minutes between the high water level alarm and occurrence of an overflow at station, upstream manhole, or any residential basement. (Lowest Point)

2. Wet well shall be designed to have not less than 1-foot between each alarm. 3. Wet wells shall be painted with Raven 405 (or approved equal) epoxy coating

on the inside and bituminous coating on the exterior. Exterior coating needs to be field applied after completion of successful testing of structures.

K. Power 1. Three phase power if available; otherwise, single phase is acceptable for

stations with capacity of 300 gpm or less. 2. Separate grounding of dialer, flow meter (not to building grounding girdle),

and line power isolation transformer comparable to Topaz Ultra Isolator to protect the circuits from voltage swings on ground and line.

3. No grounding to waterline allowed.

L. Odor and Corrosion Control Equipment 1. All pumping stations shall be provided with an odor control system designed

to mitigate odors from the wet well and influent manhole. Different acceptable methods include but are not limited to: Carbon adsorption (air scrubbing), chemical addition to sewer and force mains upstream of the station, chemical addition at the wet well or influent manhole, and soil odor filters. Pumping stations should be designed to minimize the possible formation of odors by limiting wet well detention times, and avoiding high drops for influent sewers and force mains which cause odors to be released.

2. 170-gallon polyethylene self-contained chemical tank manufactured by Poly Processing Company, Winchester, VA, or equal for hypochlorite solution.

3. Chemical metering pump manufactured shall be Peristaltic type pump by Blue-White Series A-100NA Meter Feeder Pump 3/8" – 45 RPM or equal, piped for liquid hypochlorite addition to the wet well.

M. Station Bypass Pumping stations shall be provided with an auxiliary force main connection

downstream of the wet well to enable the station wet well to be taken off-line for periodic maintenance or repairs. (See detail)


N. Surge Analysis A surge analysis of the pump station discharge force main shall be performed when the velocity exceeds 5 ft/s and/or the total dynamic head (TDH) for the system design condition exceeds 150 feet. For package and wet well/dry well stations, surge relief valves shall always be provided.

O. Shop Drawings Shop drawings are to be submitted to the Department of Utilities for simultaneous review with the engineer.

P. Warranty One full year warranty from general contractor to Town shall be provided from the date of Town's acceptance of the station.

Q. As-Builts Submit one hard copy of plans and a CD of CAD and PDF files.

R. Door Locks

Door locks shall be ILCO RIM Cylinders, Weiser # A1054WC with Falcon Keyway. Key control number for the Falcon key must be obtained from the manager of facility.

S. Operation and Maintenance Manual (O&M) 1. A complete O&M manual shall be provided and contain approved shop

drawings, catalog cut sheets, equipment model with serial numbers, installation instructions, maintenance schedules, list of recommended spare parts, warranties, names and telephone numbers for local equipment representative for each item of equipment.

2. Approvals are required from Department of Environmental Quality (DEQ) and Town of Leesburg (TOL). O&M manual must be approved by TOL prior to release of maintenance bond.

T. Manholes

The interiors of the first three manholes downstream of the force main outfall shall be epoxy coated.

U. Storage / Holding Capacity All pumping stations shall be provided with a minimum of one day storage/ holding capacity. This provision can be satisfied either by use of under or above ground holding capacity. See detail.

V. Grinder Manhole Pumping stations shall be provided with the provisions for an influent grinder to capture debris that may potentially clog pipes and pumps. Grinder system to be a Muffin Monster® or approved equal. See detail.


W. Shower/Eyewash Combination Station

1. Indoor Safety Shower/Eyewash Combination shall be freestanding, rough chrome-plated shower head, aerated eye/face wash with stainless steel bowl, stanchion and floor flange, and interconnection piping. Provide water flow alarm switch. Acceptable manufacturers are Speakman Model SE-603, Haws Model 8346 or approved equal. Provide details and riser diagram.

2. Outdoor Frost-Proof Emergency Shower/Eyewash Combination shall be both chrome-plated deluge shower head and stainless steel eyewash bowl mounted on a common freestanding 1-½″ galvanized steel pipe standard suitable for 4-foot bury. Provide water flow alarm switch. Acceptable manufactures are Speakman, Model SE-609, Haws Model 8300-FP or approved equal. Provide details and riser diagram.

III. Major Equipment Start-Up, Testing and Training

A. Pumps and Control Systems B. Gen-set C. Flow Meter and Recorder D. Dialer E. Others as determined by Town

New Wastewater Pumping Station Development Sequence

ITEM DESCRIPTION DATE

Pre-Design Meeting

Preliminary Plans/Specifications and Calculations to Town of Leesburg (TOL)

Comments from TOL Resolved

Final Plans/Specifications to TOL

Flow Acceptance Letter from TOL to DEQ

DEQ Approval for CTC

Sales Tax Exemption Request by TOL

Performance Bond Approved by TOL

Deed and Plat Dedicated to TOL

Pre-Construction Meeting

Permits Obtained from Loudoun County/TOL and etc. as applicable

Submit Shop Drawings

Begin Site Work

Inspections & Soil Testing

Begin Building & Mechanical Work

Draft O&M Manual @ 50% Construction

Testing/Training for Pumping System, Gen-Set/UST System and Alarm & Control Systems

Final O&M Manual

Engineer's Certification of Completion in accordance with approved plans

Draft As-Built Record Drawings to TOL

Fire Marshall’s inspection and occupancy permit approval by Loudoun County

Load testing of generator

Written pump test report and spare parts to TOL

ITEM DESCRIPTION DATE

Written generator test report and spare parts to TOL

Submit letter to DEQ Air Division for generator

Pump Station Site plan and associated easements are recorded

Generator Air Permit from DEQ

TOL requests to DEQ to initiate Certificate to Operate (CTO)

CTO Inspection by DEQ & TOL, D&O List Developed

DEQ Issues letter to operate and recommends CTO

DEQ Issues CTO to TOL

Substantial Completion granted by TOL

Occupancy permits for homes can now be obtained by Contractor

Contractor, Engineer & TOL complete final consolidated punch list items

D&O Item List Completed

Final inspection performed by TOL

Request for Performance Bond Release (Pump Station only)

Council Approves Performance Bond Release

One Year Warranty Bond Started

Maintenance Bond Released after 12 months

As-Builts Electronic version on a CD of the CAD drawing and PDF to Utilities Department.

Project:

Owner:

Contractor:

Engineer:

Date of Issuance:

Designated Area Shall Include:

The Work performed under this contract has been inspected by authorized representatives of the Contractor, Engineer and Owner, and the Project is hereby declared substantially completed. The Substantial Completion Date for the designated area is , which is also the date of commencement of all warranties and guarantees required by the Contract document, unless otherwise specified. The Contractor acknowledges receipt of this Certificate of Substantial Completion and agrees to complete or correct the Work on the list of items appended hereto within the Contract Completion period. Contractor: Signature/Title/Firm Date The Contractor has complied with all the requirements of Substantial Completion, as stated in the GENERAL CONDITIONS of the Contract for this project, or designated portion thereof. Town of Leesburg signature/Title Date The Owner accepts the Project, or designated portion thereof, as substantially complete and will assume full possession thereof at o’clock, (AM/PM) on , 20 . The responsibility of the Owner and the Contractor for security, operation, safety, maintenance, heat and utilities shall be set forth on the attachments. (Note: Owner’s and Contractor’s legal and insurance councel should determine and review insurance requirements and coverage.) Attachments (Describe): Attachment A: Punchlist

Attachment B: Responsibilities

CERTIFICATE OF SUBSTANTIAL COMPLETION

new wastewater pumping station development manual

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