Upgrading Aging Flood Pump Stations

Josh Dickerson, P.E.Flood Protection Engineering Supervisor

Agenda

• Louisville's Flood Protection System

• Common problems and Reason to Upgrade

• MSD’s recent/current Upgrades

• Lesson’s Learned and Big Take Aways

24.4 miles of earthen levee

4.5 miles of concrete floodwall

16 pumping stations, including Riverfront Station when it goes into operation

49 movable street closures 21 sandbag closures

53 Flood Control Gates 150 Process Gates= Protects 87,000 homes, over 200,000 people, and $23.8 Billion in assets

Louisville’s System

Location of MSD Flood Protection Facilities

1957-Beargrass Creek to Rubbertown (17 miles)Late 1980s-Rubertown to Pond Creek

Flood Pumping Station Common Problems and Reasons for Upgrades

• Pump corrosion/deterioration – Environmental– Vibrations

• Mechanical• Hydraulic Cavitation

• Bearings• Reliability• Electrical • Replacement Parts• Too much cash on hand and need to spend it on

something!

4th St Flood Pumping Station

4th St Flood Pumping Station

• Duel Sanitary and Flood Pump Station• Three 450 hp flood pumps• Three 60 hp sanitary pumps• Downtown Louisville

4th St Flood Pumping StationPhysical Constrictions

• Work area

• Over head space

4th St Flood Pumping StationPumps

• Pump Design– Pull out pump– Voltage– Raising discharge

• Outage Schedule– Pump Capacity

Pull Out Pumps, Shaft and ImpellerThis image cannot currently be displayed.

Beargrass Flood Pumping Station -Electrical Improvements project

8 Pumps with a total capacity of 3532 MGD6-3,000 hp, 1-2,500 hp & 1-600 hp

Beargrass Flood Pumping Station Electrical Improvements project

• 4160V Substation upgrades• 480V load distribution• Motor control switchgear• Electrical wiring replacement• New PLC and instrumentation

connections,• Ventilation/dehumidification• New roof

• Pump RTD replacement• New hoist and trolley in the lower level• New lubrication system for the pumps• Actuators for Gates 4 and P-1• Asbestos mitigation• Internal and external lighting upgrades• An Arc Flash study

The project scope of design included:

Challenges Faced During Construction

Beargrass Flood Pumping Station Electrical Improvements project

Louisville Metropolitan Sewer District• MSD Flood Protection Engineering Supervisor/

Project Manager• MSD Flood Protection Operations Manager• MSD Flood Protection Operations Supervisor• MSD Flood Protection Construction Inspector

Contractors• Glenwood Electric (Prime)• Dugan and Myers (Subcontractor)

o Various subcontractors

Jacobs Engineering• Project Manager• Construction Manager• Resident project Representative• Sub-consultants

Beargrass Flood Pumping Station Electrical Improvements project

• Sequencing the construction • Limiting Construction During Flood Season• Switchgear was installed in 2 sections to keep

pumps running with minimum downtime. • Controls Narrative for new PLC

Beargrass Flood Pumping Station Electrical Improvements project

Document control is a critical path item

Submittals (489)Request for Information (23)Request for Contractor Pricing (10)

The window for construction is in the non-flood season

Documentation & Communication is the Key!

Beargrass Flood Pumping Station Electrical Improvements project

After 60 years wire lubricant is not quite the same

Pulling old wires and reusing good conduit was determined the acceptable method for several circuits

Paddy’s Run Flood Pumping Station

Paddy’s Run Flood Pumping Station

• Replacing pump Columns on 1 & 2• Dual stage pump• Motors in good shape

New Vs Rehab’ed- $ & Time

Top-side Cavitation

Lesson’s Learned and Big Take Away’s

• Planning and Site Visits

• Drawings & Specs

• Prep for Change

RiskGame Plan can be more Important sometime then Actual Plan

Lesson’s Learned and Big Take Away’s

More Reused Parts = More Contingency Needed

= $Possible

Risk

Flood Pumping Station

QUESTIONS?

Josh Dickerson, PE502-475-2957Josh.Dickerson@louisvillemsd.org