PEVI_200745_Drainage_Management_Plan.pdf

National Park Service

Perry’s Victory and International Peace Memorial Restoration of North and South Seawalls

Put-In-Bay, Ohio

Drainage Management Plan

January 22, 2020

Prepared by:

CH2M Hill, Inc.

New York, NY

Contract No. P15PC00018

Task Order No. 140P2019F0239

U.S. Department of the Interior

Perry’s Victory and International Peace Memorial Restoration of North and South Seawalls

Drainage Management Plan, January 22, 2020

Table of Contents Page i

Table of Contents

Acronyms and Abbreviations ............................................................................................ ii

Chapter 1 – Introduction ............................................................................................... 1-1

Chapter 2 – Background of Proposed Drainage Facilities ............................................ 2-2

2.01 Drainage System Analysis ........................................................................ 2-2

2.02 System Components ................................................................................ 2-5

Chapter 3 – Safety ....................................................................................................... 3-7

3.01 Lockout Procedures .................................................................................. 3-7

Chapter 4 – Regular Operation and Maintenance Procedures ..................................... 4-8

4.01 Storm Drainage Piping and Catch Basins ................................................. 4-8

4.02 Outfalls ..................................................................................................... 4-9

4.03 Isolated Valve Structures ........................................................................ 4-10

4.04 Pump Stations ........................................................................................ 4-11

4.05 Hydrodynamic Vortex Separator ............................................................. 4-13

Chapter 5 – Emergency Operation and Maintenance Procedures ............................. 5-14

List of Tables

Table 2-1. Rainfall Characteristics for Various Return Periods .................................... 2-2

Table 2-3. Future Conditions Stormwater Model Results for the 10-Year, 24-Hour Design Storm ............................................................................................................... 2-4

List of Figures

Figure 1-1. Project Location (USGS, EarthExplorer, 2019) .......................................... 1-2

Figure 2-1. Stormwater Catchment Areas .................................................................... 2-3

Figure 2-2. Stormwater Model Results for the 10-Year Design Storm - Future Conditions, Peak Ponding During Event ...................................................................... 2-5

List of Appendices

Appendix A – Manufacturer O&M Manuals

Appendix B – Construction As-Built Drawings

Drainage Management Plan, January 22, 2020

Acronyms and Abbreviations Page ii

Acronyms and Abbreviations

2D two-dimensional

CB catch basin

CFR Code of Federal Regulations ft feet ft2 square feet ft3 cubic feet gpm gallon(s) per minute h/h hydrologic/hydraulic in/hr inch(es) per hour

OSHA Occupational Safety and Health Administration

PEVI or Park Perry’s Victory and International Peace Memorial

TSS total suspended solids

Drainage Management Plan January 22, 2020

Chapter 1 – Introduction

CH2M HILL, Inc., a wholly owned subsidiary of Jacobs Engineering Group Inc., was retained by the National Park Service to provide engineering services for the repair and restoration of the seawall and upgrade the stormwater management system at Perry’s Victory and International Peace Memorial (PEVI or Park) to reduce the frequency and extent of Park flooding. The intent of this Drainage Management Plan is to provide a background of the proposed drainage facilities and outline operation and maintenance (O&M) procedures critical to its continuous function and reliability.

The project will repair and restore 1,900 feet (ft) of north seawall and 1,500 ft of south seawall at the Park located in Put-in-Bay, Ohio, on South Bass Island in Lake Erie (See Figure 1-1). Years of wave action, ice loading and geological processes have deteriorated and severely undermined the two seawalls resulting in the creation of sink holes and unsafe conditions in certain locations. Stormwater issues, including clogging of drains and flooding of PEVI property due to storm events and elevated lake levels, have also been identified.

As part of this project, the seawalls will be raised including maximum 12-inch increase to the north seawall and maximum 18-inch increase to the south seawall. The project also includes site improvements, including a new sidewalk along the north seawall and replacement of the existing sidewalk along the south seawall.

The stormwater system improvements will include new catch basins (CBs), drainage piping, two packaged pump stations and one hydrodynamic vortex separator.

Additionally, the updated stormwater system includes abandonment of several of the existing gravity outfalls, with improvements to those that remain to prevent lake water from inundating the stormwater system and causing dry weather surface flooding during high lake levels.

Figure 1-1. Project Location Source: United States Geological Survey, EarthExplorer, 2019

Chapter 2 – Background of Proposed Drainage Facilities

2.01 Drainage System Analysis

2.01.1 Rainfall

Rainfall characteristics for various return period storms at the site are provided in Table 2-1. Systems are designed to accommodate a storm with a 10-year return period. For a 24-hour storm duration, a 1 in 10-year return period storm provides 3.25 inches of rainfall.

Table 2-1. Rainfall Characteristics for Various Return Periods

Return Period Rain Depth (in) Duration (hrs) Peak Rainfall Intensity (in/hr)

5 year 2.78 24 2.094

10 year 3.25 24 2.448

25 year 3.93 24 2.960

50 year 4.50 24 3.389

Source: National Oceanic and Atmospheric Administration Atlas 14, Volume 2, Version 3

(Port Clinton, OH - Station ID 33-1353)

Note:

in/hr = inch(es) per hour

2.01.2 Drainage Areas

Stormwater subcatchment drainage areas were delineated for each CB utilizing the elevation data collected in the 2019 topography survey. Catchment areas were extended to surrounding areas that were not part of the topography survey area (i.e., elevation data is unknown) but identified by park staff to drain to the site. The subcatchment areas were combined into two overall drainage areas on the site: North and South. The drainage area associated with each catchment is summarized below and shown in Figure 2-1.

• North Drainage Area: 488,600 square feet (ft2)

• South Drainage Area: 520,100 ft2

Figure 2-1. Stormwater Catchment Areas

2.01.3 Wave Overtopping

A coastal model identifying and analyzing the risks to the seawall and park from climate change natural hazards was developed. The analysis looked at lake level trends for Lake Erie to see if the 2019 high-water table is part of an upward trend the Park must prepare for. The model analyzed wind and surge analytically and/or with numerical models for various return period extreme events.

Wave overtopping volumes were included in the stormwater design calculations. This analysis provided estimated maximum overtopping volumes that would occur for a given return period event for the existing and proposed wall heights at both the north and south seawall. Detailed findings are summarized in a separate Climate Change, Natural Hazards, and Risk Assessment Report and Impacts of Proposed Seawall Report.

2.01.4 Stormwater Model

One-dimensional and two-dimensional (2D) hydrologic/hydraulic (h/h) models were developed utilizing PCSWMM Professional modeling software. The h/h model incorporates all proposed stormwater system infrastructure and raised seawalls. The model simulates the system’s response to various rainfall and wave overtopping events and provides resulting system flow rates and flooding elevations. An in-depth analysis of the stormwater model and its results is provided in the Basis of Design Report and Risk Assessment Report and Impacts of Proposed Seawall Report.

Model results for the 10-year return period event are provided in Table 2-2. Figure 2-2 shows the 2D model results for peak surface ponding during the 10-year event under the future conditions. The results show elimination of surface ponding and flooding during the peak of the design storm for the future conditions model for both drainage areas.

Table 2-2. Future Conditions Stormwater Model Results for the 10-Year, 24-Hour Design Storm

Drainage Area

Average Flow Rate at Pump Station (gpm)

Peak Flow

Rate at Pump

Station (gpm)

Max.

Surface Ponded Volume

(ft2)

Max.

Depth of Surface Ponding

(ft)

Extent of Flooding

(ft2)

Duration of Flooding (hours)

North 180 3,180 0 0 0 0

South 70 1,590 0 0 0 0

Note:

ft3 = cubic feet gpm = gallon(s) per minute

Figure 2-2. Stormwater Model Results for the 10-Year Design Storm - Future Conditions, Peak Ponding During Event

2.02 System Components

The design includes installation of stormwater drainage pipes to tie the existing CBs located along the north seawall together and the existing CBs located along the south seawall together to direct the flow to one of two packaged pump stations. Stormwater conveyance pipes along the north seawall will direct flow to a pump station in the northwest corner of the park. Stormwater conveyance pipe along the south seawall will direct flow to a pump station in the southeast corner of the park.

The design also includes abandonment of several of the existing outfalls along the north seawall to reduce dry weather surface flooding from high lake levels backing up into the system. Isolated valve structures will be installed on two of the gravity outfalls that will remain. The isolated valve structure includes an internal flap gate and slide gate to prevent backflow from the lake entering the stormwater system. Upstream of the Northwest Pump Station there will also be a vortex treatment structure installed to treat flow from State Route 357 and the added impervious area from the new sidewalk along the north seawall. The proposed drainage facilities are shown in the project as-built drawings, included in Appendix B.

2.02.1 Storm Drainage Piping and Catch Basins

The drainage system on the site includes approximately 5,000 linear ft of drainage pipes and 33 CBs. This infrastructure is necessary to direct stormwater runoff and lake water overtopping the wall to gravity outfalls and the pump stations.

2.02.2 Gravity Outfalls

Gravity outfalls allow stormwater to leave the system when lake levels are low. The drainage system includes four total gravity outfalls: two on the north seawall and two on the south seawall. One of the existing gravity outfalls collects flow from the monument and includes a backflow prevention check valve on the discharge line. This outfall will remain as is. No backflow prevention device is necessary for the gravity outfall from CB 1 because the elevation of the outlet conveyance pipe is greater than the maximum lake level elevation.

Two of the gravity outfalls (from CB 17 and CB 41) will be installed with an isolated valve structure that includes an internal flap gate and slide gate. The flap gate will allow water to exit the system and will prevent backflow from the lake. The slide gate is included to provide isolation from the lake and can be activated during high lake levels or during maintenance activities.

2.02.3 Pump Stations

Due to the high groundwater levels at the site and high lake levels, pumping is necessary to mitigate intermediate flooding and direct stormwater runoff from the site to Lake Erie. The new drainage system includes two underground pump stations, the Northwest Pump Station and the Southeast Pump Station. Each of the two duplex fiberglass pump stations will include the following equipment:

• Two 1,250 gpm submersible non-clog pumps with 7.5 horsepower, 460-volt motors

• Submersible pressure transmitter to regulate pump operation in relation to wet well water levels

• Guide rails for pump maintenance

• Control Panel

• External valve vault with two ball check valves

2.02.4 Vortex Separator Treatment Structure

The drainage system includes one hydrodynamic vortex separator installed upstream of the Northwest Pump Station to capture pollutants and floatables that may enter the system from State Route 357. The hydrodynamic vortex separator uses an induced vortex to separate pollutants from stormwater runoff. The system is self-activating with no mechanical parts or external power requirements. The purpose of the treatment system is to remove pollutants such as total suspended solids (TSS), oils, trash, and other miscellaneous debris. The structure includes both a sediment storage zone and oil storage zone for pollutants as they accumulate.

Chapter 3 – Safety

Before performing work, personnel must take time to ensure they are taking the proper safety precautions. Some general safety guidelines are provided below:

• All government regulations, local health and safety directives must be observed.

• Always be aware of the area surrounding the equipment, and any hazards posed by the site or nearby equipment.

• Use personal protective equipment as needed. Examples of personal protective equipment include, but are not limited to, hard hats, safety goggles, protective gloves and shoes, and breathing equipment.

• A certified electrician must supervise all electrical work. Comply with all local codes and regulations.

• Make sure that all safety features for the equipment are functioning and in use at all times when the unit is being operated.

• Handle and dispose of all waste in compliance with local laws and regulations.

• Before starting work on the pump unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized. This applies to the control circuit as well.

• When lifting the pumps from the wet well, always lift the unit by its designated lifting points. Use suitable lifting equipment and ensure that the product is properly harnessed and wear personal protective equipment. Stay clear of cables and suspended loads. Never lift the unit by its cables or hose.

• Pump stations and equipment must be installed, operated, and maintained by qualified personnel only.

• See manufacturer’s O&M manuals in Appendix A for additional safety requirements and hazards related to maintenance activities.

3.01 Lockout Procedures

When performing maintenance on energized equipment (pumps, lighting system, control panel, etc.), personnel shall follow standard lockout procedures to ensure that the machine or equipment is stopped and isolated from all potentially hazardous energy sources. Lockout procedures for equipment shall be followed in accordance with Occupational Safety and Health Administration (OSHA) Title 29 of the Code of Federal Regulations Part 1910.147 (29 CFR 1910.147). Per this standard, the minimum lockout procedures to be followed are listed below:

1. Notify all affected employees that servicing or maintenance on the equipment is required and the equipment must be shut down and locked out to perform the servicing or maintenance.

2. The authorized employee must identify the type and magnitude of the energy that the machine or equipment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy.

3. If the machine or equipment is operating, shut it down by normal stopping procedure (stop button, disconnection switch, close valve, etc.)

4. De-activate the energy isolating device(s) so that the machine or equipment is isolated from the energy source(s).

5. Lock out the energy isolating device(s) with assigned individual lock(s).

6. Stored or residual energy must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc.

7. Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel are exposed, then verify the isolation of the equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate. Caution: Return operating control(s) to neutral or "off" position after verifying the isolation of the equipment.

8. The equipment is now locked out.

Per U.S. Occupational Safety and Health Administration (OSHA) 29 CFR 1910.147, procedures for restoring the equipment to service are provided below:

1. Check the machine or equipment and the immediate area around the machine to ensure that nonessential items have been removed and that the machine or equipment components are operationally intact.

2. Check the work area to ensure that all employees have been safely positioned or removed from the area.

3. Verify that the controls are in neutral.

4. Remove the lockout devices and reenergize the machine or equipment. Note:

The removal of some forms of blocking may require reenergization of the machine before safe removal.

5. Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready for use.

Chapter 4 – Regular Operation and Maintenance Procedures

4.01 Storm Drainage Piping and Catch Basins

Stormwater assets should be routinely inspected to ensure they are functioning as designed. Assuring the structures between piping are clean is the most effective measure for keeping debris out of the pipes and preventing clogging of the system.

Catch basins are structures, which allow surface water runoff to enter the stormwater conveyance system. The grates on the CBs are designed to minimize the amount of debris entering the storm system. Many of the CBs include a sump below the invert of the outlet pipe intended to capture and retain sediment. This capture prevents solids and other floatables from clogging the storm sewer system and from entering receiving waters.

4.01.1 Inspection

Generally, CBs should be inspected on a quarterly basis. Conditions where maintenance is needed are listed below:

• Trash or debris is located immediately in front of the CB opening or blocking inletting capacity by more than 10 percent

• Sediment or debris within the basin exceed 60 percent of the sump depth

• Trash or debris in any inlet or outlet pipe blocking more than one-third of its height

• Organic material or dead animals present in CB that could generate odors

• Structural damage is present (e.g., cracks, holes, frame or cover not securely attached)

4.01.2 Maintenance

Proper periodic cleaning of the CBs is critical to maintain their ability to capture sediment and prevent flooding. The cleaning process for CBs includes removing debris from grate openings and clearing out any sediment accumulated in the sump of the CB.

For maintenance on the CB grate and cover, a shovel may be used to remove any sediment or trash that is obstructing flow at the surface. For the collection sump, a vacuum truck will likely be needed to clear sediment from the sump when more than 60 percent full. Due to the remoteness of the site, a vacuum truck may not always be accessible. It is recommended that the maintenance staff coordinate with the Village of Put-In-Bay (Village) to schedule periodic rentals of a vacuum truck to perform routine maintenance.

Cleaning of CBs may be difficult during the winter when snow or ice are present. It is recommended that one of the cleanings occur in September or early October prior to the first frost and again in the early Spring to clean sediments associated with winter road sanding.

4.02 Outfalls

Outfalls should be routinely inspected on a quarterly basis to ensure the opening is functioning properly and is not clogged. If sediment or debris is blocking more than one-third of the outfall pipe, the outfall should be maintained in order to clear out the build-up of sediment. If sediment begins to build up or the outfall is buried, excavation by shoveling around the outfall may be required.

Stormwater system assets should typically only exhibit flow during or after precipitation events. During dry weather periods, it is expected that minimal flow, if any, will be observed from stormwater outfalls. If heavy dry weather flow is observed, the upstream infrastructure should be inspected to identify the source.

4.03 Isolated Valve Structures

Isolated valve structures are installed on gravity outfalls that are subject to backwater flow from Lake Erie. The isolated valve structure includes an internal flap gate installed on the inlet pipe and a slide gate installed on the outlet pipe. The flap gate will allow water to exit the system and will prevent backflow from the lake. The slide gate is included to provide isolation from the lake. This slide gate should be activated to the closed position during extreme high lake levels or during maintenance activities.

4.03.1 Inspection

The isolated valve structures should be inspected on a quarterly basis to monitor conditions and verify proper functionality of equipment. Examples of conditions where maintenance is needed are listed below:

• Sediment or debris within the basin exceed 60 percent of the sump depth

• Trash or debris in inlet or outlet pipe is inhibiting proper operation of the flap gate and/or slide gate

• Organic material or dead animals present in sump that could generate odors

• Structural damage is present (e.g., cracks, holes, frame or cover not securely attached, hatch not securely closing or locking)

• Ladder is unsafe due to missing rungs, misalignment, not securely attached to structure wall, rust, or cracks

4.03.2 Maintenance

Maintenance will be required in the isolated valve structure if the flap gate becomes obstructed by debris and is not closing properly. If this is the case, personnel should engage the slide gate to the closed position to isolate this structure from flows entering via the lake. Personnel entering the valve structure to perform maintenance shall be trained for confined space entry per OSHA 29 CFR 1910.146.

Dewatering of the pit may be necessary prior to performing maintenance in the isolated valve structure. If the water level in the structure is high and the maintenance activity is not critical, personnel may choose to wait to perform the maintenance until lake levels have lowered.

For the collection sump, a vacuum truck may be needed to clear sediment from the sump when more than 60 percent full. Due to the remoteness of the site, a vacuum truck may not always be accessible. It is recommended that the isolated valve structures be vacuumed when the vacuum truck is on site for cleaning of the CBs and/or hydrodynamic vortex separator.

4.04 Pump Stations

4.04.1 Operation

The pump stations are designed to be automatically operated by the float switches, which regulate pump operation on a start-stop basis in relation to wet well water levels.

The initial settings for the float level switches are listed below based on the International Great Lakes Datum of 1985:

• Low Low Level, Pumps off: 563.50 ft

• Low Level, First pump on: 569.00 ft

• High High Level. Alarm: 571.00 ft

• High Level, Second pump on: 572.00 ft

Before the pump is started, the following requirements should be fulfilled:

• The pump is free from damage

• There is oil in the oil housing

• The cables are correctly tightened and free from damage

• The monitoring equipment is correctly connected and free from damage.

• All system components are correctly installed.

The pump housing (volute) must be filled with water before starting the pump, and during operation.

In case of alarm, analyze the alarms using the controller. Refer to the manufacturer’s O&M manual in Appendix A for actions to take depending on the alarm source.

4.04.2 Inspection

Initial inspection of the pump station will be performed by an authorized representative from the manufacturer within the first year of operation. The representative will recommend an interval for periodical inspection and overhaul. Typical intervals and requirements of these inspections are listed below:

Periodical Inspection: Up to 12,000 hours or three years, whichever comes first. This inspection prevents operational interruptions and machine breakdowns. The measures to increase performance and pump efficiency are decided for each application.

Overhaul: Up to 24,000 hours or six years, whichever comes first. The overhaul lengthens the operating lifetime of the product. It includes the measures taken during an inspection as well as replacement of key components.

Below is a list of items to be checked during a periodical inspection or overhaul with the manufacturer’s authorized representative:

1. Check the outer jacket of the cable. If damaged, the cable shall be replaced.

2. Check that the cables do not have any sharp bends and are not pinched.

3. Check that the electrical connections are properly secured.

4. Check that the electrical cabinets are clean and dry.

5. Check the clearance on the impeller and adjust if necessary.

6. Drain any liquid from the stator housing.

7. Check the condition and functionality of the float level switches.

8. For the lifting device, check that the local safety regulations are followed.

9. For the lifting handle, check the screws, condition of the handle and chain.

Replace if necessary.

10. Change the oil in the oil housing, if necessary.

11. Replace the O-rings of the oil plugs and replace the O-ring of the inspection plug;

Lubricate the new O-rings.

12. Check the correct settings for the overload protection and other protections.

13. Check personnel safety devices including the guard rails, covers, and other protections.

14. Check the running values for the voltage and amperage.

15. Check for corrosion and paint damages. Touch up if necessary.

Routine visual inspections, that do not require removal of the pumps or entrance into the wet well, should also be performed on the pump station and valve vault by site personnel to periodically check that the equipment is clean and functioning properly.

4.04.3 Maintenance

After initial installation of the pump station, an authorized manufacturer’s representative will conduct post-startup training of Owner’s personnel. Instruction materials will be provided. After initial start-up, the Park may choose to conduct subsequent training for new staff or schedule trainings with an authorized representative from the manufacturer.

An authorized warranty repair service representative for the manufacturer can perform outside service that includes troubleshooting control panels, pumps, valves, and systems, or pulling pumps. When needed the pump can be hoisted up along the guide bars for inspection without the need for personnel to enter the station. Fasten the lifting chain and the motor cables on the cable holder. Use appropriate support grips for the cables.

Procedures and diagrams for various maintenance activities that may be required for the pump station components are provided in the manufacturer’s O&M manual attached in Appendix A. Please refer to these instructions when performing any maintenance.

If there is an issue with pump operation, refer to troubleshooting guidelines and procedures in the manufacturer’s operation and maintenance (O&M) manual in Appendix A. If the problem persists, contact a sales or authorized service representative for further assistance.

4.05 Hydrodynamic Vortex Separator

4.05.1 Operation

The hydrodynamic vortex separator has internal components designed to remove and retain gross debris, TSS, and hydrocarbons. The system is self-activating with no mechanical parts or external power requirements. No manual procedures are required to operate the unit.

Stormwater runoff enters the inlet chute from an inlet pipe. The inlet chute introduces flow into the chamber tangentially to create a low energy vortex flow regime that directs sediment into the sump while oils, floating trash and debris rise to the surface. Treated stormwater exits through a submerged outlet chute located opposite to the direction of the rotating flow. The system will capture and retain sediment and oil until the sediment and oil storage volumes are full to capacity.

Higher flows bypass the treatment chamber to prevent turbulence and washout of captured pollutants. An internal bypass conveys infrequent peak flows directly to the outlet eliminating the need for, and expense of, external bypass control structures. A floatables draw off slot functions to convey floatables into the treatment chamber prior to bypass.

4.05.2 Inspection

During the first two years of operation, the unit should be inspected every six months to determine the rate of sediment and floatables accumulation. A simple probe can be purchased to determine the level of accumulated solids stored in the sump. This information should be recorded in a maintenance log to establish a routine maintenance schedule.

4.05.3 Maintenance

Periodic removal of captured pollutants is essential to the continuous, long-term functioning of the hydrodynamic vortex separator. Maintenance events may include inspection, oil and floatables removal, and sediment removal. Maintenance events do not require entry into the structure, nor do they require the internal components of the structure to be removed.

In the case of inspection and floatables removal, a vacuum truck is not required. This type of maintenance can be performed by Park staff on a regular basis. However, a vacuum truck is required if the maintenance event is to include oil removal and/or sediment removal. Due to the remoteness of the site, a vacuum truck may not always be accessible. It is recommended that the maintenance staff coordinate with the Village to schedule periodic rentals of a vacuum truck to perform routine maintenance on this system as well as CBs.

The internal components of the hydrodynamic vortex separator have a centrally located circular shaft through which the sediment storage sump can be accessed with a sump vac hose. The open diameter of this access shaft is 15 inches in diameter. Therefore, the nozzle fitting of any vacuum hose used for maintenance should be less than 15 inches in diameter.

Additional maintenance steps and diagrams are provided in the manufacturer’s O&M manual in Appendix A.

Chapter 5 – Emergency Operation and Maintenance

Procedures

The pumps are supplied by the emergency generator in the basement of the monument so that in case of power failure, the pumps should remain in operation. A second pump is provided in each pump station as a redundancy measure in case the lead pump were to fail. In case of dual-pump failure during a storm event, open slide gates in isolated valve structures to allow for stormwater to exit the system via gravity flow. If lake levels are high, surface flooding may persist for several hours until lake levels return to lower levels or pump power is regained. For dual-pump failure during the 10-year, 24-hour design storm of 3.25 inches, this would result in surface flooding extending approximately 25,000 ft2 across the site.

Appendix A – Manufacturer O&M Manuals

INSTALLATION, CARE AND

MAINTENANCE MANUAL

FLYGT'S TOP PRE-ENGINEERED

PACKAGED PUMP STATIONS

FOR FLYGT'S TOP PRE-ENGINEERED PACKAGE PUMPS STATIONS

MB042546

Typewritten Text PLACEHOLDER - CONTRACTOR TO REPLACE WITH MANUFACTURER'S O&M MANUAL FOR FINAL EQUIPMENT INSTALLED

CONTENTS

Safety __________________________ 4

Guarantee ____________________________ 5

Product description _______________ 6 Introduction _________________________ 6 Application _________________________ 6 Materials ___________________________ 7 External loads _______________________ 7 Pipe material ________________________ 7 Weight _____________________________ 7 Diagram of typical installation __________ 8

Transportation and storage __________ 9

Installation __________________________ 10 Safety precautions __________________ 10 General ____________________________ 10 Handling ___________________________ 10 Elevation adjustment ________________ 11 Site preparation & concrete ballast _____ 12 Concrete placement _________________ 12 Before backfilling ___________________ 14 Soil backfill, backfill envelope and soil compaction _________________ 14 Flexible connector __________________ 14 Concrete __________________________ 14 Backfilling time after casting anchor ___ 14 Field repairs and level changes ________ 14 Soil properties ______________________ 15 Electrical connections _______________ 16 Pump station grounding______________ 16 Installation of Sleeve, if not factory installed ____________ 17 Installation of Link-Seal® ____________ 18

Hand tools ______________________ 18

The Do's ________________________ 18 The Don'ts ______________________ 18 Installation instructions ___________ 20

Installation of Electrical Bulkhead Fitting _________________21 Installation of the air vent pipe ________ 22 Installation of the level regulators ______ 22 Installation of the pump ______________ 22

Start up and operation ______________ 23 Before installation ___________________ 23 Start-up check ______________________ 24

Care and maintenance ______________ 25

This manual contains basic information on the Instal-lation, Operation and Maintenance and should be followed carefully. It is essential that these instruc-tions are carefully read before installation or commis-sioning by both the installation crew as well as those responsible for operation or maintenance. The oper-ating instructions should always be readily available at the location of the unit.

Identification of safety and warning symbols

General Danger:

Non-observance given to safety instructions in this manual, which could cause danger to life have been specifically highlighted with this general danger symbol.

High Voltage:

The presence of a dangerous volt-age is identified with this safety symbol.

Non-observance to this warning could damage the unit or affect its function

Unilateral modification and spare parts manufacturing.

Modifications or changes to the unit/installation should only be carried out after consulting with Xy-lem, Flygt Products.

Original spare parts and accessories authorized by the manufacturer are essential for compliance. The use of other parts can invalidate any claims for war-ranty or compensation.

The pictures in this manual may differ somewhat from the delivered pump station depending on size and configuration.

WARNING!

Qualifications of personnel An authorized (certified) electrician and mechanic shall carry out all work.

Safety regulations for the owner/operator All government regulations, local health and safety codes shall be complied with.

All dangers due to electricity must be avoided (for details consult the regulations of your local electricity supply company).

SAFETY

GUARANTEE

Xylem, Flygt Products undertakes to remedy faults in their products provided that:

• the fault is due to defects in design, materials or workmanship;

• the faults are reported to Xylem, Flygt Prod-ucts or their representative during the guaran-tee period;

• the product is used only under conditions described in the Installation, Care and Mainte-nance manual and in applications for which it is intended;

• the monitoring equipment incorporated in the product is correctly connected and in use;

• all service and repair work should be done by Xylem, Flygt Products Authorized service per-sonnel;

• genuine Xylem, Flygt Products parts are used.

Hence, the guarantee does not cover faults caused by deficient maintenance, improper installation, in-correctly executed repair work or normal wear and tear.

Xylem, Flygt Products assumes no liability for either bodily injuries, material damages or economic losses beyond what is stated above.

Application This pump station is intended to be used for;

• pumping of wastewater-domestic, commercial or industrial

• pumping of raw or clean water

For further information on applications, contact your nearest Flygt product representative.

PRODUCT DESCRIPTION

Introduction

In this Installation, Care and Maintenance manual you will find information on how to handle, install and maintain the pump station to give it a long and reli-able life.

The pump is installed by means of twin guide bars with automatic connection to the permanently in-stalled discharge connection at the bottom of the sump.

The unique design of the sump and the integrated pump discharge connections has been hydrauli-cally optimized to improve the flow over the sump floor during pumping. This increases turbulence and causes re-suspension of settled solids and entrain-ment of floating debris. The result: more solids are removed from the sump, leaving minimal residue beneath the pumps which is ready to be removed during the next pumping cycle.

Materials The pump station is fabricated of Fiberglass Rein-forced Plastic (FRP), i.e. thermosetting resins in-corporating reinforcement materials and processing agents and possibly fillers and/or additives.

Design Criteria The pump station is designed in respect of a subsoil water table up to the ground level.

The pump station carries a pedestrian load rating and shall be installed in such a way that traffic load can not get closer than 3 ft. from the tank edge.

Stations rated for use in H20 traffic loading applications can be provided on a case by case basis, after consultation with the Flygt engineering depart.

Pipe material The pump station is available with piping in 316 stain-less steel and PVC.

The guide bars are 316 stainless steel.

Table 1 PUMP STATION WEIGHT

TOP 4 TOP 5 TOP 6

Station Weight Weight Weight Depth (ft.) (lbs.) (lbs.) (lbs.)

10 1482 1947 2591 15 1903 2685 3540 20 2236 3201 4236 25 2568 4231 5201

Note: All weights assume the use of 316 stainless steel pipe, internal valves within the sta-tion, and are deemed approximate. Actual station weight will depend on the specific configuration within the station in question.

This weight will be marked on the outside of the station prior to shipment, and can be estimated by engineering if required prior to shipment.

Weight Approximate total weight (lb.) of pump station ex-cluding pumps:

MB042546

Rectangle

TYPICAL INSTALLATION

Portable Hoist

Control Panel

Liquid Level Sensors

Vent Pipe

Aggregate Base/Crushed Stone

Integral Anti-Flotation Flange

Inlet Pipe

Compacted Sub Base

TOP Fiberglass Basin

Concrete Ballast

Cable Holder

Access CoverDischarge Pipe

Pump

Backfill

The pump station is delivered in a horizontal position.

Make sure that the station is unloaded from the truck with a suitable crane or lifting equipment.

Always lift the pump station by the appropriate load-rated lifting straps.

Do not use chain as chain may damage the station.

Unload and put it down carefully on the ground.

If the pump station shall be stored for some time be-fore installation – keep it in a horizontal position!

TRANSPORTATION AND STORAGE

• The pump station and pumps are delivered separately.

• Never install the pumps before the pump station is permanently installed.

• Make sure that pump station cannot roll over or fall.

Denny

Skid

INSTALLATION

Safety precautions In order to minimize the risk of accidents in con-nection with transportation and installation work the following rules should be followed:

General

The responsibility for installing the pump station is always borne by the installing contractor.

The Flygt brand's Top pre-engineered fiberglass pump station packages are designed for installation with a bottom concrete ballast poured in place in an annular ring around an anti-flotation flange located at the bottom of the straight portion of the shell. The following instructions are an efficient and economical method for installing the Flygt brand's Top pre-engi-neered fiberglass pump stations. Follow all applicable local and national codes. The installer is responsible to comply with OSHA regulations and all other safety requirements.

• Always pay extra attention to safety aspects when working with lifting equipment.

• Never work alone.

• Use safety helmet and protective shoes.

• Make sure that the lifting equip-ment is approved and in good condition.

• Check that the lifting straps are in good condition.

• Stay clear of suspended loads.

• Read the installation, care and maintenance manuals for pumps and other equipment.

• Follow all other health and safety rules and local codes and ordinances.

Handling Contractor shall take due care in handling the Flygt brand's Top pre-engineered fiberglass pump station package.

Please be aware of the following restrictions:

• Do not drop or impact the pump station.

• Do not use chain or steel cables in direct contact with the fiberglass. Store pump station in a hori-zontal position using the included shipping skids or chocks such as tires, sand bags or other pli-able materials.

• Do not permit pump station to rest on large solid objects such as rocks, wood, brick, blocks, and so forth.

• Do not permit the pump station to be moved by rolling.

• Do not roll or set the pump station on any pipe stubout, accessory or appurtenance installed on the pump station.

• When raising from horizontal to upright position the pump sta-tion will jolt and possibly sway slightly towards the end of the raising position.

• To avoid accidents, stand at a safe distance until this move-ment has stopped!

• Place the pump station on a rigid horizontal surface and make sure it cannot fall.

Elevation adjustment If necessary, use shims in the excavation to adjust pump station to correct elevation. Shims can be of any appropriate material that will not degrade, cause locally high contact stresses to the pump station, or rot. An examples of an appropriate shim would be sand bags.

Site preparation & concrete ballast Provide adequate working room around the pump station. See diagram below and tables on page 13 for concrete ballast dimensions. The concrete ballast shall be reinforced as required by local codes.

Concrete ballast design should be sufficient to re-sist head pressure and soil loading with pump sta-tion completely empty and water to grade. Refer to tables 2. 3 and 4 for the required concrete ballast dimensions.

1. Compacted sub base

2. Anti-flotations flange

3. Aggregate base/ crushed stone

4. Concrete ballast

Concrete placement Do not let concrete free fall to bottom of hole more that 3 to 4 feet. Place concrete using a tremie chute to help preclude segregation of the aggregate from the matrix. Ensure that concrete flows under the fiberglass anti-flotation flange. Consolidate concrete with proper vibration per the recommended practice of ACI 318-05 section 5.10.

Wconcrete min.

6" min.

3" min.

For Wconcrete, min. refer to specific station configuration in the tables on page 13

Ballast calculated based on worst case piping configuration. Application specific calculations can be made available if required.

Table 3 TOP 5

Diameter (in.)

Overall tank length (in.)

Concrete Ballast Requirements

Wconccrete, Width of concrete bal-last ring

60 60 Ballast not required

60 72 Ballast not required

60 84 3” min.

60 96 4” min.

60 108 5” min.

60 120 6” min.

60 132 6” min.

60 144 7” min.

60 156 8” min.

60 168 9” min.

60 180 9” min.

60 192 10” min.

60 204 11” min.

60 216 11” min.

60 228 12” min.

60 240 12” min.

Table 4 TOP 6

Diameter (in.)

Overall tank length (in.)

Concrete Ballast Requirements

Wconccrete, Width of concrete bal-last ring

72 60 Ballast not required

72 72 4” min.

72 84 5” min.

72 96 6” min.

72 108 6” min.

72 120 7” min.

72 132 8” min.

72 144 9” min.

72 156 10” min.

72 168 11” min.

72 180 11” min.

72 192 12” min.

72 204 13” min.

72 216 14” min.

72 228 15” min.

72 240 15” min.

Table 2 TOP 4

Station type

Diameter (in.)

Overall tank length (in.)

Concrete Ballast Require-ments

Wconccrete, Width of con-crete ballast ring

Top 4 48 60 Ballast not required

48 72 Ballast not required

48 84 Ballast not required

48 96 Ballast not required

48 108 3” min.

48 120 4” min.

48 132 5” min.

48 144 5” min.

48 156 6” min.

48 168 6” min.

48 180 7” min.

48 192 7” min.

48 204 8” min.

48 216 8” min.

48 228 9” min.

48 240 10” min.

MB042546

Rectangle

Before backfilling Check that the pipe work and the electrical connec-tions are well protected and supported during back-filling around the station so no load is applied to them by compaction operation.

Place crushed stone uniformly around the base to prevent sideways surge. The pump station shall be adequately braced to prevent movement either by sideways movement or by leaning.

Soil backfill, backfill envelope and soil compaction Native soils suitable as backfill are shown in table

5. Do not use soils such as muck, bog, peat, and loess. The ideal backfill is well-graded sand, as this will compact relatively easily and typically retains its strength in submerged conditions. Do not use fine silts in areas subject to large seismic activity such as on the west coast in seismic zones 3 and 4 per the 1997 UBC. As a minimum Xylem, Flygt product recommends using well-graded sand compacted to 95% standard proctor density, or crushed stone or pea gravel with size ranging from ¼ in to 3/4 in.

In these areas, install a filter fabric between the se-lected backfill and the native soil. At owner’s option, consult local geotechnical engineer for determining adequate backfill material and compaction require-ments in these areas.

Contact a qualified geotechnical engineer when installing the Flygt brand's Top pre-engineered fiberglass pump station packages in muck, bog, peat, and loess and/or for other difficult soil con-ditions or in areas such as e.g. a steep slope.

Do not permit ice to form in the backfill and keep backfill material as dry as practical by using adequate drainage techniques and good construction practices.

The size of the backfill envelope is dependent on the in situ soil properties. For native soils with an un-confined compressive strength (UCC) of 0.75 tsf or lower, or an allowable bearing capacity of 3500 psf or lower, the backfill shall extend one radius of pump station away from the pump station wall but not less than 2 ft. For soils exceeding these values the back-fill envelop shall be 2 ft.

Compaction of the backfill is highly recommended and beneficial as this helps control long term settle-ment. See table 5 for compaction requirements and for additional information of soil stiffness and applica-bility as backfill material.

Flexible connector Use flexible connectors for each stub-out to connecting pipe to help preclude stresses from long-term settling due to ground consolidation. These connectors should extend 2 stub-out diameters away from the stub-out pipe end.

Concrete Concrete shall have a minimum 28-day compressive strength of 3000 psi and all reinforcing shall be ASTM A 615 grade 60. Place concrete using a tremie for free fall distances greater than about 3 to 4 feet.

Ensure that concrete extends at least 6” above anti-flotation flange (anchor lip). Refer to figure on page 12.

Backfilling time after casting concrete ballast Do not backfill until concrete ballast has gained sufficient strength to provide rigid support for both pump station and backfill (typically 1 to 2 days or as specified by EOR). Add backfill in 6 to 8 in lifts for proper compaction evenly all around pump station to avoid uneven backfill loads.

WARNING!

Pump station top is pedestrian rated as standard and is not designed for wheel loads or other heavy loads unless specifically noted as otherwise by engineering..

Field repairs and level changes Pump stations can be damaged if not properly handled, installed or backfilled. If repair or modification work is required, contact your local Flygt product representative for instruction.

Table 5 Soil Properties (ref AWWA M45 1st ed, Table 5-5 page 49 1996)

E’ for degree of compaction of bedding, lb/in2

Soil type-pipe bedding material (Unified Classification System) Dumped

Slight, <85% proc-tor, < 40% relative density

Moderate, 86% - 95% proctor, 40% - 70% relative density

High, >95% proctor, 70% relative density

Fine- grained soils (LL > 50) Soils with medium to high plasticity CH, MH, CH-MH

No data available, consult a geotechnical engineer; otherwise use E’ = 0

Fine- grained soils (LL < 50) Soils with medium to no plasticity CL, ML, ML-CL, with less than 25% coarse-grained particles

50 200 400 1000

Fine grained soils (LL < 50) Soils with medium to no plasticity CL, ML, ML-CL with more than 25% coarse-grained particles. Coarse grained soils with fines GM, GC, SM, SC contains more than 12% fines

100 400 1000 2000

Coarse-grained soils with little or no fines GW, GP, SW, SP contains less than 12% fines

200 1000 2000 3000

Crushed Rock 1000 3000 3000 3000

Do not use shaded area for backfill

Degrees of compaction

• Dumped – No compaction effort

• Slight – Some compactive effort. In-place den-sity <less than 85% standard Proctor Density.

Or less than 40% Relative Density

• Moderate – Intermediate level of compactive effort, In-place density greater than or equal to 85% and less than 95% standard Proctor Den-sity, or greater than or equal to 40% and less than 70% Relative Density

• High – Considerable compactive effort, In-place density greater than 95% standard Proctor Den-sity, or greater than or equal to 70% Relative Density

A slight degree of compaction can significantly add to soil density and long-term performance. Greater compaction improves installation and performance.

Definitions:

LL = Liquid Limit Standard Proctor Density per ASTM D-698 Relative Density Dr = (emax – e)/( emax – emin) Where e = void ratio = Vv/Vs Vv = volume of voids Vs = volume of solids

CH - Inorganic clays or high plasticity, fat clays.

MH - Inorganic silts, micaceous or diatomaceous fine sand or silty soils, classic silts.

CL - Inorganic clays of low to medium plasticity, gravelly clays, sandy clays, silty clays, lean clays ML - inorganic silts and very fine sands, rock flour, silty or clayey fine sands with slight plasticity.

SC - Clayey sands, poorly graded sandy-clay mixtures.

SM - Silty sands, poorly graded sand-silt mixtures.

GC - Clayey gravels, poorly graded gravel and clay mixtures.

GM - Silty gravels, poorly graded gravel-sand-silt mixture.

NOT S

UITA

BLE

Install the control panel at the pump station so it is easily accessible during, operation, service and in-spection.

Check the data plate on the pump to determine valid voltage supply.

Check that the main voltage and frequency agree with the specifications on the pump data plate.

Thoroughly read the Installation, care and mainte-nance manual delivered with the pump…