PUMP STATION REHABILITAITON

ON A BUDGET

An Operators Solution to a Safety and Operational Challenge

PRESENTERS:

JIM BAIRD, GENERAL MANAGER ROSEBURG URBAN SANITARY AUTHORITY

JADE MECHAM, PROJECT MANAGER IIJACOBS ENGINEERING

Fairgrounds pump station owned by Douglas County,operated and maintained under contract by Roseburg Urban Sanitary Authority.

Constructed in 1970.

Operations and Maintenance provided by Roseburg Urban Sanitary Authority through the Authority’s contract with Jacobs Engineering.

O&M included equipment replacement by RUSA and reimbursed by the County.

ORIGINAL DESIGN

EXISTING PUMP STATION

• ORIGINAL DESIGN VACUUM-PRIMING

PUMP , ABOVE-GROUND DESIGN

• CONSTRUCTED A SUBMERSIBLE PUMP

WITH GUIDE RAILS, WET WELL

MOUNTED DESIGN

• WHAT CHANGED ???

ORIGINAL DESIGN22 feet of lift in the design (actual lift 24 feet).Approaching the limit of a vacuum priming pump.

WHAT WAS THE OPERATOR LEFT WITH ?

• A FULL CIRCLE METAL WET WELL COVER

• ACCESS HATCHES FABRICATED INTO THE COVER

• CONTROL PANEL MOUNTED ON THE COVER

• ELECTRICAL CONDUCTOR WITH SEAL-OFFS

• SHUTOFF VALVES MOUNTED INSIDE THE WET WELL

• CHECK VALVES MOUNTED INSIDE THE WET WELL

• DISCHARGE ELBOWS MOUNTED TO A STEEL PLATE INSTALLED IN THE

BOTTOM OF WET WELL

• THANK YOU DESIGN ENGINEER !!!!!!!!!!!!!!

IMPROVEMENTS REQUIRED

AS PART OF AN ANNUAL PUMP STATION INSPECTION THE RUSA STAFF

DETERMINED THE FOLLOWING:

• THE PUMPS WERE IN NEED OF REPLACING

• ONE OF THE CHECK VALVES WAS LEAKING

• THE METAL HATCH WAS DETERIORATING CREATING SAFETY CONCERNS

• THE LOCATION OF THE CONTROL PANEL WAS PROBLEMATIC

• THE PUMP STATION WAS PAST IT’S DESIGN LIFE AND A HAZARD TO OPERATE

BUDGET AND TIME CONSTRAINTS

• DOUGLAS COUNTY HAS SEEN DECREASED REVENUE OVER SEVERAL YEARS

• THE FAIRGROUNDS COMPLEX HAS A VERY LIMITED BUDGET FOR REPAIRS

• THE DOUGLAS COUNTY FAIR IN AUGUST IS PEAK FLOW SEEN DURING THE YEAR

• QUESTION:

• HOW TO MAKE THE NECESSARY IMPROVEMENTS ON A LIMITED BUDGET

• HOW TO COMPLETE THE PROJECT WITHIN THE CONSTRUCTION WINDOW.

• HOW TO REPLACE THE EQUIPMENT WHILE MAINTAINING THE FLOW.

THE PLAN

STAGED IMPROVEMENTS OVER TIME

PROJECT COST

THE PLAN

STAGED IMPROVEMENTS OVER TIME

PROJECT COST

BE CAREFUL WHAT YOU ASK FORDOUGLAS COUNTY BUGET

COMMITTEE LOOKED AT THE BOTTOM LINE $52,000 AND

FUNDED ALL THE IMPROVEMENTS FOR ONE YEAR

THE NEW PLAN

• LAYOUT NEW PUMP ELBOWS TO

MOUNT IN THE EXISITNG WET

WELL

• ELIMINATE THE NEED FOR SHUT-

OFF VALVES AND CHECK VALVES

• LAYOUT A DUAL FORCE MAIN

• ADD A NEW MANHOLE TO THE

EXSITNG GRAVITY SEWER

PUMP SELECTION

INSTALL A NEW MANHOLE

New manhole constructed over existing gravity sewer. Tideflex check valves installed on each force main.

NEW DUAL FORCE MAIN

Installed approximately 160 feet of dual force main. This length is about as far as you want to use a dual force main.

MAKE NEW FORCE MAIN/WET WELL CONNECTION

INSTALL NEW CONDUITS AND A CONTROL PANEL SLAB

New underground power service. New power and level control conduits to existing wet well.

INSTALL NEW CONTROL PANEL SHELTER

INSTALL A NEW FULL CIRCLE ALUMINUM HATCH WITH FALL CONTROL

Out with the old

In with the new

THE BIG CHALLENGE

• INSTALL NEW PUMP ELBOWS

• INSTALL NEW DISCHARGE PIPING

• INSTALL NEW PUMP GUIDE RAILS

• MAKE THE PIPE CONNECTION FROM THE DISCHARGE

PIPING TO THE NEW FORCE MAIN

• INSTALL THE NEW PUMPS AND WIRE THEM TO THE

CONTROL PANEL

• REINSTALL THE LEVEL CONTROL

ALL OF THIS WORK NEEDED TO BE DONE IN ONE DAY AS WE

COULD NOT UTILIZE A BYPASS PUMPING SYSTEM DUE TO

THE SITE CONSTRAINTS.

ALL HANDS ON DECK !!!!!

• REMOVAL ALL OF THE INTERIOR

PIPING, SHUT-OFF VALVES AND

CHECK VALVES

• REMOVE THE EXISTING PUMP

ELBOWS

• REMOVE THE STEEL PLATE IN

THE BOTTOM OF THE WET WELL

D -DAY

REMOVE THE PUMPS

GUIDE BARS MUST GO SCRAP THE HATCH

THE REAL WORK BEGINS

DISCHARGE PIPE NEEDS TO BE

REMOVED

CAN’T UNSCREW THE BOLTS

GET THE SAW

SAFETY FIRST

FIVE WATCHING ONE

WORKING

BUILDING FROM THE BOTTOM UP

NEW PUMP ELBOWS READY TO LOWER

SAFETY FIRST

FIVE WATCHING ONE

WORKING

JUST ANOTHER DAY AT RUSA

TIME TO WIRE UP THE PUMPS

CONNECT THE DISCHARGE PIPING TO THE FORCE MAIN

NEW PUMPS LOWERED INTO PLACE

THE END OF A LONG DAY

A JOB WELL DONECompleted August 3rd just in time for the Douglas County Fair• $52,000 in new equipment and improvements

• New pump elbows• New pumps• New power feed (no more overhead wires)• New discharge piping• New guide rail system• New full circle hatch with fall control • New control panel shelter• New SCADA (Mission M800 real-time monitoring)• New manual transfer switch• New dual force main and discharge manhole

RUSA completed the site improvements over several days.RUSA and Jacobs Engineering made the final push in a 14 hour day with the collection crew of 7, one person from the Engineering department and Jacobs head mechanic.

A needed improvement completed by a great group of professionals.