DESIGNERS NOTEBOOK

Designing and Constructing a Sewage Lift Station

Part 1: The Vessel
Timothy A. Smith, CPD Lift stationswhat a deep subject! Figure 1. Three-Dimensional Image of a Prefabricated Steel Lift Station System Wet well versus dry well, vertical inline pumps versus submersible pumps, open impeller efficiency versus closed impeller efficiency, feet of head, gallons per minutethe list goes on and on. Most lift station design work is in the territory of civil engineering. Usually lift stations are located too far away from the buildings footprint to be in the plumbing designers domainalthough there is no reason for the plumbing design engineer not to do this work. The lift station probably is part of a municipal project in which storm or sanitary sewage must be pumped up to a central treatment or collection point. Most lift stations serve neighborhoods or other geographic areas at lower elevations than the treatment system or reservoir into which their sewer lines feed. The majority of plumbing designers and engineers have designed ejector systems or sump pumps for buildings. Lift station design is not too different. The concept and sizing criteria are the same, but the construction is different Reprinted with permission of Metropolitan Industries, Inc. because of exterior environmental and maintenance considerations. struction has no joints, so there is no Prefabrication also offers labor savings The vessels can be dry wells or wet potential for leakage. Built-up concrete during installation. wells. Construction is the same for both. barrel sections require application of a Structure depth and exterior ground Specified vessels must be watertight bituminous mastic and sealant between forces dictate the thickness and reininside and out, and they must be able to the sections. Some jurisdictions even forcement of the steel. Steel vessels are counteract buoyancy forces require an exterior ethyleneshipped to the job site in one piece so they will not float out of propylene diene monomer and dropped into the excavation. Steel The most the ground when empty. The (EPDM) or fiberglass bandis lighter than concrete and thus more most commonly used vessel buoyant, so a steel vessel must be commonly used ing over each joint. To promaterials are concrete, steel, vide additional protection mounted on and secured to a reinvessel materiand fiberglass. from corrosion and leakage, forced concrete hold-down pad. All als are conConcrete can be monolithit is recommended that two steel vessels require interior and extericrete, steel, ically poured in place or coats of bituminous material or tar-based epoxy coatings to protect built up utilizing precast, be applied to all interior and the steel against corrosion. In addition, and fiberglass. reinforced concrete barrel exterior concrete surfaces. installation of an impressed current sections. Most concrete vesPrefabricated steel vessels anode system to provide cathodic prosels are heavy enough to are widely used (see Figure 1). They tection against corrosion is recommendcounteract buoyancy forces without offer several benefits over concrete vesed. The solid-state circuitry of an anchoring or hold-down pads. sels. Usually they are fabricated in a impressed current anode cathodic proMonolithically poured-in-place conshop, protected from the weather. tection system automatically adjusts the 36 Plumbing Systems & Design Nov/Dec 2002

DESIGNERS NOTEBOOK
Figure 2. Submersible Pump Lift Station Detail (Prefabricated Fiberglass Wet Well and Dry Well Valve Vault Configuration)
MANHOLE STEP

PORTABLE PUMP EMERGENCY CONNECTION

PERFORATED SUMP COVER IN VALVE VAULT BASIN 4" PUMP DISCHARGE AUDIBLE AND VISUAL ALARM C/T METER CABINET CONTROL PANEL PLUG VALVE CHECK VALVE TEMPORARY POWER QUICK CONNECT LUG COVERS AND OPENINGS SEALED WITH AIR TIGHT GASKETING MATERIAL PIPING (BURIED)

INTERIOR TOP BASIN VIEW

PUMP BASIN INSPECTION OPENING STEEL COVER, 5/8" THICK ACCESS COVERS

VALVE VAULT BASIN 4" VENT (TYPICAL)

APPROX. GRADE ELEVATION +0.00 4" MIN.

MANHOLE STEP (TYPICAL)

LIFTING LUGS (TYPICAL) INCOMING POWER SUPPLY POWER CABLE IN CONDUIT (BURIED) CABLE HOOK SEAL WATERTIGHT VALVE VAULT PUMP DISCHARGE PIPING PLUG VALVE CHECK VALVE

DUPLEX RECEPTACLE WIRED TO CONTROL PANEL WITH CIRCUIT BREAKER 2 1/2" QUICK DISCONNECT HOSE COUPLING WITH DUST PLUG 2 1/2" BYPASS GATE VALVE 4" PUMPED DISCHARGE INV. -5.00

FIBERGLASS BASIN 5'-0" DIA. MERCURY FLOAT MOUNTING ROD QUICK REMOVAL GUIDE RAILS FLEXIBLE COUPLING PLUG VALVE

PIPE SLEEVE SEALED WATERTIGHT SWING CHECK VALVE PIPE SLEEVE, SEALED WATERTIGHT SUMP PUMP FOR VALVE VAULT BASIN WIRED TO CONTROL PANEL THROUGH SAFETY DISCONNECT SWITCH WITH INDIVIDUAL DISCONNECT IN CONTROL PANEL. PUMP DISCHARGE PIPING

INLET - SEE PLANS FOR SIZE INLET INV.

MERCURY FLOAT SWITCHES (FIVE REQUIRED)

HIGH LEVEL ALARM LAG PUMP ON STAINLESS STEEL LIFTING CABLE LEAD PUMP ON POWER CABLES PUMPS STOP FIBERGLASS FILLET BASIN MOUNTING FRAME (LEVELED) HYDRAULIC SEALING FLANGE, NO MECHANICAL CONTACT, SELF CLEANING

LOW LEVEL ALARM SUBMERSIBLE PUMP BASIN INV. 6"

ANCHOR RODS (MIN. 8) 8" MIN. REINFORCED CONCRETE SLAB WITH 3/8" dia. BARS, RUN BOTH WAYS, TOP AND BOTTOM. 3500 PSI CONCRETE.

10" MIN. SAND CUSHION, WASHED, CLEAN, WELL GRADED, TAMPED SMOOTH, COMPACTED AND LEVELED.

INTERIOR ELEVATION VIEW

SUBMERSIBLE PUMP LIFT STATION DETAIL

NO SCALE

Reprinted with permission of Metro Design Associates, Inc. Nov/Dec 2002 Plumbing Systems & Design 37

DESIGNERS NOTEBOOK
Continued from page 37

applied anode voltage to provide adequate cathodic protection regardless of soil resistivity. This type of system typically utilizes cast iron high-siliconecontent sacrificial anodes. Like steel vessels, vessels made of fiberglass are prefabricated and lightweight. Fiberglass is a corrosionresistant material, so protective coatings and cathodic protection systems are not required. One drawback is that fiberglass is lighter than steel and thus more buoyant. It requires a heavier concrete base and hold-down pad. Usually fiberglass is used only for shallow installations. Its structural capability must be analyzed carefully against the surrounding ground forces whenever depths approach 1620 ft. Below 20 ft, the thickness and reinforcement required for fiberglass structures begin to make steel and concrete more economical materials. Figure 2 shows a detail of a submersible pump lift station with a prefabricated fiberglass wet well and dry well valve vault configuration. Municipalities usually prefer submersible pump stations for smaller applications but lean toward dry pit pump stations for critical or very highflow applications. Because sewage flows are typically intermittent, a wet pit collection and surge vessel still is required in dry pit pump applications. All designs have advantages and disadvantages, so it is very important to discuss and review your designs with the agency that will operate and maintain the lift station. Some end users do not have the tools and equipment to operate and maintain every type of lift station. Furthermore, they may not employ the level of technician required to support the advanced lift station control technology available today. (In the next issue of Plumbing Systems & Design, technology and controls will be discussed in more detail). You can develop a repeat client by designing a lift station that is within your clients resources and capabilities. Some lift stations are very deep, so the cost of excavation and backfill can be an important consideration. An

excavation using a 45 sloping side to protect against cave-ins can become huge if the depth is more than 10 ft. Shoring and trench boxes are commonly used to protect workers from excavation collapse and reduce the required structural backfill. The auger method can be safely and effectively used for shallow installations. This method is used with round, prefabricated steel and fiberglass structures. The fabricator can provide concrete anchor plates at the bottom of the vessel and several inches above the bottom. After auguring the hole, the contractor pours a couple of feet of 4,000-lb concrete into the bottom of the hole, then lifts the structure directly into the hole in one piece. After the vessel is in place, more concrete is poured around it to encase the concrete anchor plates. The concrete provides the weight required to resist buoyancy forces and hold the vessel in place. For maintenance access, all vessels must have frames and covers. Usually they are constructed of epoxy-coated steel or iron, corrosion-resistant aluminum, or stainless steel. Lift stations typically are located in open, unprotected areas, so a locking hasp should be installed on the cover to prevent access by unauthorized individuals. OSHA regulations and many codes require installation of safety cargo nets below the cover to protect the openings. The top of a sanitary lift station must be at least 46 in. above the surrounding grade to keep storm water from infiltrating the lift station and putting an unnecessary additional load on the tributary sewage treatment plant. Special precautions must be taken in designing a sewage lift station to be located in an area prone to ponding water or flooding. Dikes or dams can be installed to keep water away from the lift station. To facilitate maintenance, a pumpremoval rail system or hoisting equipment is typically included for municipal or public lift station systems. These systems operate constantly, so several of their mechanical components require frequent inspection and maintenance. Municipal lift station pumps are large,

heavy, and cumbersome. Usually they are in a deep pit. A vertical rail system can be installed inside the lift station, and the pumps can be fitted with guide rings attached to the rails to allow for a winch or hoist to pull the pumps straight up out of the pit along the rails. Diaphragm-type hydraulic sealing flanges can be used on pump-pipe connections to eliminate the need for operating personnel to enter the lift station structure to remove the pumps. The sealing flanges fit onto the pump and pipe connections with surfaces that have been machined to very high tolerances to ensure a tight seal. The pump discharge pressure forces the diaphragm against the flange to create a tight seal. When the pump is idle, there is no pressure on the seal. The pump can be removed from the vessel without mechanical contact of sealing flanges. The weight of the pump guides it into place against the angled face-sealing flange when it is lowered back into service. It is important that a bottom support plate be used and that none of the pumps weight be transferred or exerted onto the sealing flange or guide rail. The use of a rubber or EPDM diaphragm seal is important, because metal-to-metal sealing flanges can be subject to corrosion welding. Designers Notebook in the upcoming January-February 2003 issue of PSD will cover controls, accessories, and more installation recommendations for sewage lift stations.

Acknowledgment
The author thanks Robert Wedell, municipal sales manager of Metropolitan Industries, Inc., for providing the illustration as well as technical clarification.

Tim Smith is vice president, partner, and founding member of Metro Design Associates, Inc., in Schaumburg, IL. He has more than 23 years experience covering all aspects of consulting engineering, specializing in plumbing, fire protection, and civil engineering.

38 Plumbing Systems & Design Nov/Dec 2002

DESIGNERS NOTEBOOK

Designing and Constructing a Sewage Lift Station

Part 2: The Controls
Timothy A. Smith, CPD The Vessel, Part 1 of Designing and Constructing a Sewage Lift Station, appeared in Plumbing Systems & Design NovemberDecember 2002 (pages 3638). Figure 1. Two SCADA System Graphic Displays

The Control System The brain of the system

The control system is the brain of a sewage lift station. Not only does it control the pumps operation but it also communicates with the operators, protects the motors, and provides for emergency standby power switching. All components of the control system are housed in a heavy-duty weatherproof traffic box with plain frontlocking doors. To meet the National Electrical Manufacturers Association 3R weatherproof construction standards and allow for the panel enclosure to be mounted exposed and adjacent to the lift station, the construction of the enclosure usually is steel and gasketed. The electrical service current/transformer meter cabinet usually is mounted on the side of the traffic box adjacent to the temporary-power quick-connect lug. The traffic box usually contains an audiovisual alarm to indicate trouble. This can be the primary alarm indicator, but with the application of supervisory control and data acquisition (SCADA) systems it will act as a secondary alarm. A small building is constructed when a permanent on-site emergency power system is required. In this case, the controls would be mounted inside the building beside the emergency generator power unit, thus eliminating the need for a weatherproof trafficbox enclosure.

The SCADA system

The control system includes safety disconnect switches, fuses, magnetic starters, level transducers, the motor protection module, variable speed

drives, the transfer switch, automatic phone dialers, pilot lights, selector switches, and sometimes SCADA systems. A SCADA system allows for complete control, diagnosis, and

monitoring of the lift station from a remote location through an Internet or telephone link. All pump functions can be controlled by a remote personal or laptop computer. The operator

36 Plumbing Systems & Design Jan/Feb 2003

DESIGNERS NOTEBOOK
can obtain operating data for any point on the illustrated operating system. The pumps run times are logged to the minute and day. The run times and associated pumping volume also are logged. The software can be programmed to monitor many other functions, including trouble and failure alarms. The ability to obtain, log, chart, and graph this information helps system operators be more efficient and precise in planning a preventative maintenance and inspection program for the lift station. In many instances, maintenance personnel can diagnose a system failure with the SCADA system before visiting the site (see Figure 1). source. Before the motor starts, they perform tests and impose time delays, as programmed, to ensure proper voltage and power quality across all three phases. The module also stops pump operation if any irregularity or loss of phase is detected during operation. Motor protection devices can provide protection against ground faults, over- or undervoltage, phase loss, and over-temperature faults that can burn out or damage motors. Motor protection modules are available that can directly link and report all functions to a SCADA system. In turn, the SCADA system can be programmed to chart the consistency and quality of the stations incoming power supply. when the pump needs to be removed or maintained. Make sure to match the check valve style with the type of sewage being pumped. The guides, pins, and springs in a spring-loaded wafer check valve allow sanitary sewage debris to become entangled, preventing a complete seal. Singledisc swing check valves are recommended for sewage applications, although center-guided spring-loaded wafer check valves may be acceptable for storm water applications. The most popular isolation valves are full-port plug valves or resilientwedge, full-port gate valves. Full-port valves are important in lift station piping design because they eliminate obstructions and reduce the stations friction losses.

Transducers

Programmable level transducers are Coordinating the design most frequently used today to measThe plumbing design engineer ure levels in the wet well basin and to understands how the station should initiate and start and stop operate and what mechanithe pumps operation. Solid cal equipment is needed for In many state technology provides proper operation. The instances, more accurate control (i.e., design of the interconnec+ or -1%) and greater tion between the many maintenance dependability than mercury electrical devices associated personnel can float switch technology. with the control of a lift stadiagnose a Level transducers use a tion, including switches, system failure one-piece stainless steel fuses, and control modules, probe, so the problem of with the SCADA as well as determination of tangled mercury float any code requirements for system before switch cords is eliminated. safety disconnect switches, visiting the site. warrants consulting a qualiThe installation of mercury float switches at municipal fied electrical engineer. or public lift stations as a Careful coordination is secondary means of pump operation, essential between these two important in conjunction with the primary transdisciplines in lift station design. ducer system, is a reliable design. For Accessories a lift station that is critical to public A myriad of accessories and composafety, a mercury float switch back-up nents can be fitted to a sewage lift stasystem is very cheap insurance. tion. Some may be code required, and

Temporary pumping connections

The importance of public lift stations often requires using the beltand-suspenders design approach to averting system failure. Nonetheless, the one-in-a-thousand chance of complete system failure still exists. Many municipal and regional codes require temporary pumping connections for use during complete failure of the station. Temporary pumping equipment can be transported to the site and activated to keep the sewage flowing from the inlet to the discharge outlet. A temporary pumping connection is nothing more than a siphon pipe with a cam-lock termination on the wetwell side and an additional isolation valve with the same cam-lock termination located downstream from the pump check or isolation valve. Utilization of three-way plug valves will allow the third port to be used as a temporary pumping connection.

Motor protection modules

Motor protection modules should be installed whenever large and expensive pump motors exist. The meaning of large and expensive is relative to the systems operation and maintenance budget. The owner should be consulted on this point during the design process. Motor protection modules monitor the incoming power

some may be added to increase the efficiency of the stations operation and maintenance.

Sump pumps
The majority of lift station designs include separate dry wells and wet wells. Wet wells are always wet, and dry wells are intended to be dry. Whether or not the dry well is used to contain the pumps or valves, keeping the well dry is important. Installation of a small sump pump is required at

Valves
Outlet isolation valves and check valves are code required, just as they are in sewage ejector designs for buildings. The check valve prohibits sewage from flowing back into the pump, and the isolation valve is used

Jan/Feb 2003 Plumbing Systems & Design 37

Sewage Lift Station continued from page 37

the bottom of dry wells to remove any accumulated water. A simplex or duplex sump pump can be selected, depending on the critical nature of the stations application. Because they typically are low-voltage motors with simple controls, the sump pumps can easily be connected to the emergency back-up power systems through the systems control section. Solid state technology has made sump pump control panels both inexpensive and technologically advanced and has made their operation compatible with SCADA technology. The discharge from these sump pumps usually is minimal, so it is feasible to pump the discharge into the wet well.

Installation
Engineering specifications typically require the contractor and supplier to provide fabrication and installation shop drawings, including all data on components and products as well as wiring diagrams. To avoid contractual responsibility disputes during the installation, it is recommended that all prefabricated lift stations come from a single supplier. The fabricator or manufacturer also should be responsible for final start-up and training of operating personnel. The quality control section of the specifications can include the requirements for certified pump curves. Many fabricators and manufacturers of lift station pumps have testing facilities. The quality control paragraphs can be

written to ensure that pumps are tested before shipment and the test reports are certified to verify pump performance upon installation. The installation contract can be written to compensate the manufacturers authorized representative for field inspections during the installation.

Tim Smith is vice president, partner, and founding member of Metro Design Associates, Inc., in Schaumburg, IL. He has more than 23 years experience covering all aspects of consulting engineering, specializing in plumbing, fire protection, and civil engineering.

Minimum Plumbing Fixture Requirements continued from page 25

one urinal for males and three water closets for females in the UPC. If the restaurant occupancy is 1,000, both codes require 14 fixtures for males and 14 fixtures for females. Even though the two codes are developed under different procedures, with major differences in philosophy regarding participation, both encompass a public code submission and hearing process. It would not be fair to characterize either as having arbitrary values. The absolute best values can be obtained with the participation of every ASPE member in every step of the code process. The UPC looks forward to seeing you there! Allen Inlow has evolved during the past 50 years. Many of the numbers are based on studies or come from a group directly involved in the building type. As time progresses, the plumbing fixture requirements in the two major plumbing codes should become more similar.

Wanted: Manuscripts

PSD Manuscripts can be submitted in the form of feature articles, brief reports, or letters to the editor. The following topics are of particular interest: Building commissioning Building types (health care, educational, marine) Codes CPD certification preparation Domestic water heating Drainage systems Emergency fixtures Engineering concepts (formulas) Forensic engineering High-rise systems Hot water systems Professional practices (legal practices) Pumps Special systems (process piping, compressed air, natural gas laboratory gasses) Thermal expansion Venting systems

Conclusion
Both responses show that the requirement for the minimum number of plumbing fixtures in a building

Ray Moore is a principal with Professional Engineering Services, Salt Lake City, UT. As ASPE Secretary and Treasurer, he is a member of the ASPE Board of Directors. He also is chair of the Utah Building Codes Commission Plumbing Advisory Committee and past president of the ASPE Intermountain Chapter. He teaches seminars in plumbing and mechanical codes throughout the intermountain area.

38 Plumbing Systems & Design Jan/Feb 2003