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MSD Pump Station
Design Regulations
7/20/2020
Standard Pump Station 1 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
Table of Contents
PLAN REVIEW SUBMITTAL REQUIREMENTS................................................ 4 SECTION 1
1.01 GENERAL ................................................................................................................... 4
1.02 PUMP STATION DESIGN REPORT ............................................................................ 4
1.03 FINAL SUBMITTAL ...................................................................................................... 6
PUMP STATION AND FORCE MAIN DESIGN CRITERIA ...............................10 SECTION 2
2.01 GENERAL ..................................................................................................................10
2.02 METHODOLOGY FOR DETERMINING DESIGN FLOWS .........................................10
2.03 PUMP SELECTION DESIGN ......................................................................................11
2.04 DETENTION CHAMBER SIZING ................................................................................13
2.05 BUOYANCY CALCULATIONS....................................................................................14
2.06 FORCE MAIN DESIGN ...............................................................................................14
STRUCTURE REQUIREMENTS ......................................................................15 SECTION 3
3.01 DESIGN CRITERIA ....................................................................................................15
3.02 WET WELL AND VALVE CHAMBER SIZING .............................................................15
3.03 CONDITION MONITORING STRUCTURE .................................................................15
3.04 JOINING CHAMBERS ................................................................................................15
3.05 ACCESS HATCHES ...................................................................................................16
3.06 COMMON WALL ACCESS OPENINGS .....................................................................16
3.07 VALVE CHAMBER FLOOR ........................................................................................17
3.08 PIPE SUPPORTS .......................................................................................................17
3.09 ENTRANCE LADDER AND STEPS ............................................................................17
3.10 DETENTION CHAMBER ............................................................................................18
3.11 CONTROLPANEL PAD ..............................................................................................18
3.12 MISCELLANEOUS ITEMS ..........................................................................................18
PIPING AND VALVES ......................................................................................19 SECTION 4
4.01 GENERAL ..................................................................................................................19
4.02 FORCE MAIN PIPE MATERIAL ..................................................................................19
4.03 FORCE MAIN REQUIREMENTS ................................................................................21
4.04 TRANSITION PIPING .................................................................................................23
4.05 PUMP DISCHARGE RISERS .....................................................................................23
4.06 ISOLATION VALVE ...................................................................................................24
4.07 CHECK VALVES ........................................................................................................25
4.08 VALVE CHAMBER DRAIN VALVE .............................................................................26
4.09 PRESSURE SENSORS ..............................................................................................27
4.10 GRAVITY LINES .........................................................................................................27
Standard Pump Station 2 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
4.11 DETENTION PIPE ......................................................................................................27
SUBMERSIBLE WASTEWATER PUMPS ........................................................28 SECTION 5
5.01 MINIMUM STANDARDS .............................................................................................28
5.02 PUMP SPECIFICATIONS ...........................................................................................28
PUMP STATION APPUTENANCES.................................................................37 SECTION 6
6.01 GUIDE BAR RAILS .....................................................................................................37
6.02 LIFTING CHAIN ..........................................................................................................37
6.03 BOLTS ........................................................................................................................37
6.04 FASTENERS ..............................................................................................................37
6.05 FLOATS AND SETTINGS ...........................................................................................37
6.06 ACCESS HATCHES ...................................................................................................38
6.07 SAFETY POST ...........................................................................................................39
6.08 LOCKING HARDWARE ..............................................................................................39
6.09 PRESSURE SENSOR UNITS ....................................................................................39
6.10 INTRINSIC BARRIERS ...............................................................................................40
6.11 MAGNETIC FLOWMETERS .......................................................................................40
ELECTRICAL ...................................................................................................43 SECTION 7
7.01 PUMP CONTROL PANEL ..........................................................................................43
7.02 THREE PHASE MOTORS ..........................................................................................46
7.03 AmerenUE 3-PHASE SUPPLY CONTROL OPTION ..................................................46
7.04 PHASE CONVERTER OPTION ..................................................................................48
7.05 STATION INTERIOR WIRING ....................................................................................49
7.06 PRESSURE SENSOR WIRING ..................................................................................50
7.07 FIELD WIRING SPECIFICATIONS .............................................................................50
7.08 CONDUIT SPECIFICATIONS .....................................................................................50
7.09 CONTROL PANEL MOUNTING .................................................................................51
ALARM SYSTEM .............................................................................................52 SECTION 8
8.01 SYSTEM REQUIREMENTS .......................................................................................52
8.02 ANTENNA ..................................................................................................................52
8.03 POLE SPECIFICATIONS ............................................................................................52
8.04 POLE SITE LOCATION ..............................................................................................52
8.05 ALARM COAXIAL CABLE ..........................................................................................53
SITE REQUIREMENTS....................................................................................54 SECTION 9
9.01 SITE AND ACCESS ROAD PAVEMENT ....................................................................54
9.02 FENCING ...................................................................................................................55
9.03 SITE MAINTENANCE .................................................................................................56
Standard Pump Station 3 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
9.04 RESTORATION ..........................................................................................................56
INSPECTION AND ACCEPTANCE REQUIREMENTS ....................................57 SECTION 10
10.01 GENERAL ..................................................................................................................57
10.02 PRE-CONSTRUCTION MEETING .............................................................................57
10.03 STAGE ONE: SHOP DRAWING REVIEW ..................................................................57
10.04 STAGE TWO: PRE-STRUCTURE INSPECTION........................................................58
10.05 STAGE THREE: FINAL STRUCTURE INSPECTION/PRE-EQUIPMENT
INSTALLATION .....................................................................................................................58
10.06 STAGE FOUR: POST EQUIPMENT INSTALLATION .................................................59
10.07 STAGE FIVE: EQUIPMENT STARTUP ......................................................................59
10.08 STAGE SIX: FINAL COMPLETION INSPECTION ......................................................61
10.09 STAGE SIX A: POST-FINAL COMPLETION INSPECTION (IF REQUIRED) ..............61
10.10 STAGE SEVEN: FINAL ACCEPTANCE/DELIVERABLES ..........................................61
10.11 RE-INSPECTION OF WORK ......................................................................................62
Standard Pump Station 4 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
PLAN REVIEW SUBMITTAL REQUIREMENTS SECTION 1
1.01 GENERAL
A. These requirements and specifications apply to all pump station construction
projects intended to be dedicated to the District for maintenance. For District
contracted projects, these standard specifications may be used by the design
engineer for reference and the project specifications shall take precedence over
these standard specifications.
B. In addition to the requirements set forth in this document, design shall be in
accordance with the latest edition of the District’s “Standard Construction
Specifications”.
C. The following material must be submitted to the Engineering Department for
review of any proposed pump station. Material submitted to the District that does
not have the required drawings and/or pump station design report data shall be
returned to the design engineer with a “request for missing material.” No attempt
will be made to review incomplete submittals.
D. Upon completion of the review by the appropriate District personnel, the
Engineering Department will forward all comments to the designing engineer.
After the design engineer has reviewed the comments, a meeting may be
arranged with the Engineering Department to clarify any question that may arise.
1.02 PUMP STATION DESIGN REPORT
A. A pump station design report shall be in the following format:
1. Title Page
a. MSD P number, or MSD Contract number
b. Date
c. The developer/owner
d. Engineering firm preparing plans
e. Engineer’s Seal by a professional engineer registered in the State of
Missouri
2. Sewer System Information
a. Introduction
Type, location and size of development. i.
Number of and range in size of lots or buildings to be ii.
serviced.
b. Existing Sewer System
Location and type of gravity or pressure system the pump i.
station will service (if applicable).
Location and type of gravity or pressure system the force ii.
main will discharge to.
c. Future Sewer Service
State whether the proposed development will be serviced by i.
a single phase or if several phases will be involved. Indicate
when phases are anticipated to be developed.
State the number of lots each phase will encompass. ii.
State whether other areas outside of the development may be iii.
tributary to the pump station. Provide a drainage area map of
Standard Pump Station 5 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
the entire pump station service area.
3. Pump Station and Force Main Design Calculations (see Section 2)
a. Calculations verifying that the minimum pipe materials specified in
Section 4 are adequate.
b. Force Main Information:
Size i.
Material ii.
Type or Class iii.
Length iv.
Velocity at the pump’s operating point v.
Force Main Test Pressure - The value is derived from the vi.
selected pump manufacturer’s performance curve. It is the
maximum pump head or shut-off head, plus 50 PSI.
Location of discharge (i.e. existing gravity sewer or force vii.
main)
4. Storage Detention Chamber Calculations (See Section 2)
a. Calculations verifying that the minimum pipe materials specified in
Section 4 are adequate.
b. Volume for 24-hour detention or detention volume with generator
backup
5. Pump Design Summary (see Section 2)
a. For each phase of the proposed development provide the following
information:
Average Daily Flow i.
Peak Daily Flow ii.
Static Head iii.
Total Dynamic Head, Flow Rate in gallons per minute (GPM) iv.
and efficiency at the pump’s operating point
Pump Information: v.
Model number vi.
(a) Type
(b) Horsepower
(c) RPM
(d) Voltage
(e) Phase
Average Daily Flow Cycle Times: vii.
(a) Pump On
(b) Pump Off
Peak Daily Flow Cycle Times: viii.
(a) Pump On
(b) Pump Off
b. Indicate what phase of development and pump is proposed to be
initially installed.
6. Manufacturer’s Specifications, Performance Curves and Cut-Sheets
a. The manufacturer’s specifications, performance curves and cut-
sheets for the pumps and equipment shall be included in the back of
the Pump Station Design Report booklet.
b. The manufacturer’s cut sheets shall be marked to identify the
applicable items selected.
Standard Pump Station 6 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
c. Specifications and performance curves shall be included for each
pump proposed by the design engineer. Pump performance curves
shall indicate the pump’s Preferred Operating Range (POR) as
defined by the Hydraulic Institute Standards and the manufacturer’s
Acceptable Operating Range (AOR).
d. The pump performance curves shall have the worst case and best
case system TDH curves plotted on them. See Section 2 for plotting
instructions.
1.03 FINAL SUBMITTAL
A. GEOTECHNICAL REPORT
1. A geotechnical analysis of the soil conditions and foundation
recommendations in the area of the pump station shall be required. A
minimum of two (2) borings are required. A least one (1) of the borings
shall be at the proposed location of the wet well with the second being in
the area of the detention pipes. The borings shall extend a minimum of
five feet (5’) below the invert of the wet well and pipes.
2. Borings along the alignment of the force main shall be required for
restrained joint design.
3. Additional borings may be required by the District due to the size of the
pump station or detention pipes.
B. FLOOD PLAIN STUDY
1. The pump station shall be designed to remain accessible and operational
during a 100-year flood. Furthermore, the station shall be protected from
damage during a 100-year flood event. A flood plain study shall be
completed to determine the flood elevations.
C. STRUCTURAL CALCULATIONS
1. Buoyancy calculations (see Section 2)
D. DESIGN DRAWINGS
1. The design drawings shall be individual 2' x 3' design plan sheets. Each
sheet must indicate the District Project Number in the lower right corner
and must be sealed by a professional engineer registered in the State of
Missouri.
2. Cover Sheet (when submittal is separate from site improvement plans).
3. General Site Plan (1” = 50’ scale)
a. All buildings and/or residences with top of foundation (TF) and
basement floor (BF) elevations noted.
b. All sanitary sewers and storm sewers with manholes identified.
c. All streets.
4. Pump Station Site Plan (1/4” = 1’ scale)
a. All grading, access roads, fencing and pavement surrounding the
pump station. Provide spot elevations for proposed grading and
pavement.
b. Location and size of all storm and sanitary sewers.
c. Location of all utility lines, including water, gas, electric, etc. running to
or through the pump station property and easement.
Standard Pump Station 7 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
d. Location of wet well, valve chamber, bypass portal, condition
monitoring structure, incoming manhole and detention chamber.
e. Location of all pump station appurtenances, such as, control panels,
antenna poles, boxes, generators, transfer switches, etc.
f. Details on any proposed landscaping affecting the immediate area
surrounding the pump station site.
g. Property information indicating pump station ingress, egress and
sewer easements.
h. Adjacent private or common ground property lines.
i. Utility easements.
5. Force Main Plan and Profile (1” = 20’ scale horizontal and 1” = 10’
vertical)
a. Identify the force main size, pipe material and overall length.
b. Locate force main appurtenances, such as, discharge manhole,
clean-outs, combination air/vacuum release valves and isolation
valves. The distance between each structure shall be indicated.
c. Locate mechanically restrained joints at angle points. Also indicate
the number of restraining joints required both upstream and
downstream from an angle point.
d. Show the force main test pressure on each profile sheet. The
pressure value shall be clearly indicated on each force main profile
sheet as “FORCE MAIN TEST PRESSURE”.
e. Show locations of the force main Locator Balls on both the plan and
profile sheets. Refer to Section 4 for location requirements.
6. Gravity Sewer Profiles (1” = 20’ scale horizontal and 1” = 10’ vertical)
a. Provide a profile of each sanitary sewer reach showing the top and
flow line elevations at each manhole. Also indicate the lowest finished
floor connected to this sewer system.
b. Indicate the pipe size, length and slope of each reach.
c. Provide a profile of each detention chamber.
7. Pump Station Structure Sheet (1/2" = 1' scale)
a. The purpose of this sheet is to provide an accurate, complete, and
uncluttered drawing to aid the pre-cast company to fabricate the
structure. Only include measurements and information required for
this goal.
b. Plan and section view of the wet well and valve chamber to the scale
shown above.
c. In the section view, show the elevations of the:
Top of structure i.
Bottom of structure ii.
Sanitary sewer inlet flowline iii.
Pump discharge pipe iv.
d. Detail of the wet well and valve chamber hatch castings with the exact
location of hatches and hinges.
e. One detailed joint section shall be included. The pre-cast
manufacturer shall determine actual joint elevations.
f. A sectional view of the chamber tie walls detailing each wall as you
are facing it from the pump chamber side and from the valve chamber
side.
Standard Pump Station 8 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
g. On pre-cast stations, gravity lines must have their angles of entry into
the structure included. Also provide a description or detail of the pipe-
to-structure joint connection.
h. Miscellaneous Details:
Corbel i.
Valve chamber side wall electric conduit entry ii.
Tie wall pump cable opening iii.
Tie wall valve chamber drain opening iv.
8. Pump Station Mechanical Sheet (1/2" = 1' scale)
a. Plan and Section view of the wet well, valve chamber, incoming
manhole, detention chamber and condition monitoring structure the
scale shown above.
b. In the Section view show the elevations of the:
Top of structure i.
Bottom of structure ii.
Sanitary sewer inlet flowline iii.
12” D.I.P. detention pipe flowline iv.
Pump discharge and force main flowlines v.
Float elevations: vi.
(a) Off Float
(b) Lead Pump
(c) Lag Pump
(d) High Level Alarm
(e) Emergency High Level Alarm
c. Show the lift station piping and force main piping transition outside the
structure.
d. Show adjustable cradle jack valve supports.
e. Miscellaneous Details:
Valve chamber drain i.
Wet well pipe support ii.
Flow meter iii.
Bypass Portal iv.
9. Electrical Plans and Details(1/2" = 1' scale)
a. Plan and section view of the wet well and valve chamber to the scale
shown above. required for all pump station.
b. Electrical plans shall present the following:
Electrical routing and equipment locations (Control panel, i.
junction boxes, etc.)
Conduit and wire sizes ii.
One-line schematic iii.
Notes referencing documents where detail information is iv.
available on each of the major pieces of electrical equipment.
c. Miscellaneous Details:
Control panel plan and profile i.
Antenna ii.
Valve chamber junction boxes iii.
10. Miscellaneous Details:
a. Provide a sheet that will contain details on items such as:
Force main clean-outs i.
Combination air/vacuum release valve chamber ii.
Standard Pump Station 9 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
Force main taps iii.
Fencing iv.
Entrance gates v.
11. Pump Station Design Requirements
a. The District will provide a computer file of the Standard Pump Station
Design Requirements in AutoCAD format upon request. Modifications
may be required to this sheet for specific projects. All changes to the
Standard Sheet shall be noted in bold.
b. Should the design engineer elect not to use the District’s Standard
Sheets, all design requirements and specifications in Sections 3
through 10 of this Manual must be included on the sheets prepared by
the design engineer.
Standard Pump Station 10 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
PUMP STATION AND FORCE MAIN DESIGN CRITERIA SECTION 2
2.01 GENERAL
A. In designing all components of the pump station and force main, consideration
must be given to the potential need to expand or modify the facility to
accommodate future phases of the proposed development and future
development of the area tributary to the station.
B. If substantial differences exist between initial development phases and ultimate
proposed development, consideration may be given for initial pump installation to
accommodate initial development phases only. Developer may be responsible
for station upgrades as additional development phases are implemented.
C. As a minimum the following items should be considered:
1. The ultimate proposed development flow should be considered in sizing
the following:
a. Wet well
b. Valve chamber
c. Detention chamber
d. Pump selection
e. Force main
f. Electrical requirements
2. The ultimate future development of the pump station tributary area should
be considered in the configuration of the detention chamber to allow for
future expansion. Adequate area adjacent to the detention chamber must
be provided to allow for this expansion.
2.02 METHODOLOGY FOR DETERMINING DESIGN FLOWS
A. The Average Daily Flow (ADF) and Peak Daily Flow (PDF) for each phase of
development should be determined.
B. Average Daily Flow (ADF):
1. ADF (GPD) = F + I, where
a. F = Residential Development Area Flow (FR) + Non-Residential
Development Area Flow (FNR)
b. I = Infiltration
2. ADF (GPM) = ADF (GPD) / 1440 (min/day)
C. Peak Daily Flow (PDF):
1. PDF (GPD) = 2.5 x ADF (GPD)
2. PDF (GPM) = 2.5 x ADF (GPM)
a. The use of a peaking factor of 2.5 is a variance from the MoDNR
regulations due to the safety factor provided by the twenty-four hour
detention requirement.
D. Residential Development Area Flow (FR)
1. The average daily flow (excluding infiltration) for residential development
areas (FR) shall be based on the following:
a. FR = Population Equivalent Flow = Pe x 100 (gal/person/day), where
Standard Pump Station 11 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
Pe = Population Equivalent = Nb x Np, where i.
(a) Nb = Number of single family residences and other
identified types of buildings
(b) Np = Number of persons per unit = 3.7
E. Non-Residential Development Area (FNR)
1. The average daily flow (excluding infiltration) for non-residential
development areas (FNR) shall be based on one of the following:
a. Actual Water Use Records of like facilities.
b. The current Rules of the Department of Natural Resources Division
20, Clean Water Commission, Chapter 8. Design Guides (10 CSR 20-
8.021, 1.E.1).
c. Industry Standards.
F. Infiltration
1. The infiltration flow amount (I) shall be determined by:
a. I = Piping diameter (in.) x piping length (miles) x 200 (gal. /in.
dia./mi./day)
2. The infiltration flow shall be determined for the following systems:
a. Gravity system.
b. Detention chamber (including detention pipe(s) and detention
manifold).
3. For proposed pump station that will serve areas with existing gravity
sewers, the District may require an infiltration rate greater than the 200
gal/dia/mi/day. The design engineer should contact the District prior to
submittal to determine if a greater rate will be required.
G. Future Development Area
1. Future residential and non-residential development of areas tributary to
the pump station should be noted and a drainage area map of the pump
station area should be provided.
2.03 PUMP SELECTION DESIGN
A. Pumps should be selected that most closely match the pump’s Best Efficiency
Point (BEP) when operating at the station’s Average Daily Flow (ADF). Pump
selection should be where the system curve intersects the pump curve to the
right of the pump’s BEP, but to the left of the maximum limit of the Preferred
Operating Range (POR) when operating at full speed. POR shall be as defined
by the Hydraulic Institute Standards and shown on the pump’s performance
curve.
B. The following basic principles shall govern overall pump selection in order of
importance:
1. Pumps must be capable of meeting all design operating conditions.
2. Pumps should operate within the POR for the most frequent operating
conditions.
3. Pumps must operate within the manufacturer’s Acceptable Operating
Range (AOR) even for less frequent operating conditions such as
minimum and maximum pumping rates. AOR shall be shown on the
pump’s performance curve.
Standard Pump Station 12 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
C. The design engineer shall select from the three approved manufacturers (see
Section 5).
D. Use the following equations and procedures to develop the system curve:
1. Total Dynamic Head (TDH)
a. TDH (feet) = Static head plus friction losses in force main and station
piping = Hs + Lf + Ls
2. Static Head (Hs)
a. Worst case static head: Hsw (feet) = Eh – E1
b. Best case static head: Hsb (feet) = Eh – E2
Eh = Maximum force main elevation i.
E1 = Wet well low water elevation (Pump Off) ii.
E2 = Wet well absolute highest water elevation (75% iii.
Detention Chamber Alarm)
3. Loss (Lf) from friction in force main
a. Lf (feet) = Length x Friction Factor/100
Length = Total equivalent length of force main pipe, valves i.
and fittings (feet)
Friction Factor = Friction head loss (feet) per 100' pipe = ii.
0.2083 x (100/C)^1.85 x Q^1.85/d^4.8655 (Hazen and
Williams)
C = Hazen and Williams C-Factor (see 5 below) iii.
Q = Flow rate (GPM) iv.
d = Inside diameter of pipe (inches) v.
4. Loss (Ls) from friction in the station piping
a. Ls (feet) = Length x Friction Factor/100’
Length = Total equivalent length of the station piping, valves i.
and fittings (feet)
5. The following Hazen and Williams C-Factors shall be used for
computation of friction losses:
a. The worst-case system design shall be used for determining the pump
operating point or Constant Speed Rating (see definition of CSR in B.
below):
Unlined iron or steel pipe C=100 i.
All other pipe (including Plastic and lined DIP) C=120 ii.
b. To check the pump motor does not overload after installation, use the
best-case system design C-Factor:
Plastic pipe C=150 i.
All other pipe (including steel and lined DIP) C=140 ii.
6. Plot a worst case TDH curve and a best case TDH curve on a
manufacturer’s pump performance curve sheet.
a. The worst-case curve begins with the worst-case static head (TDH =
Hsw) at Q = 0 and increases with friction losses determined by using
the lower C-Factors in 5.a above.
b. The best-case curve begins with the best case static head (TDH =
Hsb) at Q = 0 and increases with friction losses determined by using
the higher C-Factors in 5.b above.
c. A minimum of four flow rates shall be used to plot each curve.
E. Constant Speed Rating
Standard Pump Station 13 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
1. The Constant Speed Rating (CSR) or the pump’s operating point is the
point where the worst-case TDH curve and the pump manufacturer’s
pump performance curves intersect.
F. Pump Motor Overload Check
1. Find where the best-case TDH curve and the pump manufacturer’s pump
performance curves intersect and check the pump is not in an overloaded
condition.
G. Cycle Times – General
1. The volume (Vr) of water required to raise the level in the wet well for the
primary pump to turn on:
a. Vr (gal.) = E5 x Vpf
b. Elevation difference (E5) between primary Pump On elevation (E3)
and Pump Off elevation (E4), i.e. E5 (feet) = E3 - E4
Volume (Vpf) of water per vertical foot in the wet well: Vpf (gal. i.
/ft.) = A x 7.481 (gal. /cu.ft.)
A = the inside area of the wet well (sq. ft.) ii.
H. Cycle Time – ADF
1. Time (Tfa) required for volume in wet well to reach Vr (Pump On):
a. Tfa (min.) = Vr / ADF (GPM)
2. Time (Tpa) required for pump to return water level to the pump off
elevation (Pump Off):
a. Tpa (min.) = Vr / (CSR-ADF)
3. Because the pumps alternate in a duplex station, after a pump turns off it
remains off until the wet well fills (Tfa), the second pump lowers the wet
well level (Tpa), and the wet well fills a second time or T off (min.) = 2 x Tfa +
Tpa. Therefore, the Total Cycle Time Tc for one pump is:
a. Pump On for Tpa plus Pump Off (Toff) or Tca (min.) = 2 x (Tfa + Tpa)
I. Cycle Time – PDF
1. Tfp (min.) = Vr / PDF (GPM)
2. Tpp (min.) = Vr / (CSR - PDF)
3. Tcp (min.) = 2 x (Tfp + Tpp)
2.04 DETENTION CHAMBER SIZING
A. All pump stations will require detention. Standard detention volume requirements
are provided below. The District, on a case-by-case basis due to site restrictions
or other considerations, may reduce the amount of the detention required.
Requests for variance must be submitted in writing with justification provided.
1. Storage Volume Requirements
a. 150,000 GPD or Less Average Daily Flow
Twenty-four-hour storage will be required for all pump i.
stations with average daily flows of less than 150,000 gpd.
Generators or alternate power sources will not be considered
in lieu of twenty-four-hour detention chambers.
b. 150,000 to 250,000 GPD Average Daily Flow
For pump stations with 150,000 to 250,000 gpd flows, where i.
the District determines that it is impractical to provide 24-hour
Standard Pump Station 14 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
detention, only 12-hours of storage will be required, provided
an approved secondary power source is also supplied.
c. 250,000 GPD or More Average Daily Flow
The storage requirements and secondary power requirements i.
for pump stations with average daily flows greater than
250,000 gpd shall be determined on a case by case basis by
the District. Where detention is not required the pump station
design may require the use of a peaking factor greater than
2.5 as determined by MSD.
2. Twenty-Four Hour Storage Volume Requirements:
a. The volume of the detention chambers (Vs) is: Vs (gal.) = ADF (GPD) x
1 Day = Cylindrical Volume of detention chamber pipe used.
B. The detention chamber shall be sized to handle the entire storage volume
requirement. The volume of the incoming gravity lines and wet well shall not be
utilized in providing for the required storage volume.
C. The lowest development elevation must be above the elevation of the highest
point of the detention chamber plus two feet (2’).
2.05 BUOYANCY CALCULATIONS
A. The buoyancy potential of the pump station structure and the detention pipe(s)
shall be analyzed to ensure that floatation of the structure and detention
chambers will not occur. The total weight of the structure (W t) shall be greater
than the weight of the displaced water (W s).
1. Wt = W w + We + W f (or weight of detention chambers and backfill
overburden)
a. W w = Weight of concrete wet well
b. We = Weight of earth backfill on footing
c. Wf = Weight of concrete bottom slab
d. Ws = Weight of displaced water
e. Wt > W s
2.06 FORCE MAIN DESIGN
A. At design average daily flow, a minimum cleansing velocity of two feet per
second (2 fps) shall be maintained with maximum velocity not to exceed eight
feet per second (8 fps).
Standard Pump Station 15 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
STRUCTURE REQUIREMENTS SECTION 3
3.01 DESIGN CRITERIA
A. All reinforced concrete structures shall be designed using the Load and
Resistance Factor Design (LRFD). At a minimum this includes the wet well, valve
chamber, condition monitoring structure and control panel pad. The structures
may be either pre-cast or cast-in-place as approved by the District.
3.02 WET WELL AND VALVE CHAMBER SIZING
A. The pump station wet well and valve chamber shall each be sized as determined
by the design engineer and as noted on drawings.
B. The top elevation shall be one inch (1”) higher than the surrounding ground
elevation.
3.03 CONDITION MONITORING STRUCTURE
A. A condition monitoring structure shall be provided to house the magnetic flow
meter located on the force main. See Section 6 for magnetic flow meter
specifications.
B. The structure shall be located downstream of the valve chamber and with a
minimum of seven feet (7’) and maximum of 15 feet (15’) clearance provided
between the valve chamber and the structure.
C. The structure shall have a minimum inside diameter of four feet (4’) and be
provided with an access hatch.
D. The top elevation shall be one inch (1”) higher than the surrounding ground
elevation.
E. When site restraints do not permit a condition monitoring structure to house the
magnetic flow meter, the magnetic flow meter may be placed in the valve
chamber with MSD approval. In this instance, the magnetic flow meter would
need to meet Class 1 Division 1 requirements per NFPA 70 - National Electric
Code.
3.04 JOINING CHAMBERS
A. The valve chamber shall rest on a base slab poured integral with the wet well
walls. Both chambers shall be tied together with a minimum of two (2) threaded
tie bolts. The design engineer shall specify the bolt diameter and material
strength. Bolts are to be eighteen inches (18") down from top of structure. For
top slab thickness greater than twelve inches (12”), place the bolts down six
inches (6") from bottom of top slab.
B. One-half inch (½") thick six inch (6") by six inch (6") backing plates shall be used
as washers on each end of the tie bolts. Both structure tops shall be at the same
elevation separated by a one-inch (1") square flexible rubber mastic sealant
placed along the perimeter of the valve chamber where it meets the wet well.
The tie bolts and the backing plates shall be stainless steel.
Standard Pump Station 16 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
C. To prevent the possibility of the valve chamber pulling the top section of the wet
well off of the joint, a poured counter-weight is required to offset the mechanical
lever arm tipping force. The counter-weight shall be monolithically poured at the
bottom of the upper-most wet well section opposite of the valve chamber tie wall.
Size and weight of the counter-weight shall be shown on the plans.
3.05 ACCESS HATCHES
A. Access hatches shall be cast in the top slabs of each chamber. The hinged side
of the valve and pump chamber hatches shall be located on the wall opposite
from each of their respective common tie wall.
B. For valve chambers requiring double hatch doors, the hinges shall be placed on
the common wall and the wall opposite the common wall.
C. See Section 6 for hatch and safety grating specifications.
D. Access hatches shall be correspondingly sized to the chosen structure size.
VALVE CHAMBER WET WELL
Inside Area Hatch Size Inside Area Hatch Size
4' x 4' 30" x 48"
6' x 6' 72" x 72" 6' x 6' 48" x 72"
7’ x 7’ 84" x 84" 7' x 7' 60” x 84”
8' x 8' 84" x 84" 8' x 8' 60" x 84"
3.06 COMMON WALL ACCESS OPENINGS
A. Two (2) six-inch (6") holes shall be centered in the valve chamber tie wall, twenty
inches (20”) from the structure top. A four-inch (4”) rigid coupler shall be cast in
the center of the wet well tie wall and centered on the valve chamber six-inch (6”)
hole. After the two (2) chambers have been tied together, a four-inch (4") rigid
stub shall be glued in the coupler on the valve chamber side through the six-inch
(6") hole. The space between the pipe and the chamber walls shall then be filled
and sealed with non-shrink grout. This opening will be used for power and
control wire passage between chambers.
B. A six-inch (6”) hole shall be centered at the bottom of the valve chamber floor in
the tie wall. A four-inch (4") PVC coupler shall be cast in the wet well tie wall and
centered with the valve chamber six-inch (6") hole. After the two (2) chambers
have been tied together, two (2), four-inch (4") PVC stubs shall be glued into the
coupler on each side of the tie wall. These stubs will be used for the valve
chamber drain piping.
C. Four three quarter inch (3/4") holes shall be placed on the side of the valve
chamber sidewalls nearest the control panel, a minimum of eighteen inches (18")
from the top of the structure. For a top slab thickness greater than ten inches
(10"), place the holes down a minimum of eight inches (8") from the bottom of the
top slab. Coordinate depth required with submitted junction boxes dimensions. A
three quarter inch (3/4") rigid coupler shall be cast in each hole. Two (2) of the
openings shall be used for pump power, One (1) for pump pressures, and One
Standard Pump Station 17 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
(1) for intrinsically safe floats. Two (2) additional openings shall be provided for
flexibility. The openings not used shall be stubbed and capped.
3.07 VALVE CHAMBER FLOOR
A. The valve chamber floor shall be sloped with a three-sided invert towards the
four-inch (4") drainpipe using a two-inch (2") fillet.
B. Gravity pipes, detention pipes, and electrical conduit may not be run beneath the
valve chamber.
3.08 PIPE SUPPORTS
A. Valve Chamber piping shall be supported as follows:
1. After discharge piping and valves have been installed in the valve
chamber an adjustable pipe cradle jack shall be installed under each
valve and tee. Clearance between the floor and valves shall be per
manufacturer recommendations, but at least a minimum of ten inches
(10") between the floor and valve flanges. The supports shall be firmly
bolted to the valve chamber floor.
2. A second adjustable pipe cradle jack shall be placed against the back of
the discharge tee and then bolted to the common chamber tie wall to
prevent piping thrust movement. The thrust jack shall be shown on the
valve chamber plan drawing.
B. After discharge piping and flow meter have been installed in the condition
monitoring structure, an adjustable pipe cradle jack shall be installed under the
flow meter. Clearance between the floor and meter shall be per manufacturer
recommendations, but at least a minimum of ten inches (10”) between the floor
and meter flanges. The supports shall be firmly bolted to the valve chamber floor.
3.09 ENTRANCE LADDER AND STEPS
A. Wet well, valve chamber and conditioning manhole entrance access shall be
installed as follows:
1. A safety ladder shall be required when the structure is greater than five
feet (5’) deep. The ladder shall be constructed entirely of aluminum, with
rungs that flat, slip-resistant rungs. The ladder shall be anchored into the
concrete wall of the structure. Anchor bolts shall be Type 316 stainless
steel expansion bolts.
2. Entrance steps may be installed when the structure is less than five feet
(5’) deep. Entrance steps shall be per the District’s Standard
Construction Specifications.
3. Entrance access shall not be placed in front of the incoming gravity line.
4. Entrance access shall not be located under or next to any obstructions.
5. Entrance access should provide clear-in-line unobstructed access from
the top of the structure to the bottom of the structure.
6. Entrance access should be placed on the wet well and valve chamber
sidewalls closest to the control panel, approximately in the center of the
hatch cover.
Standard Pump Station 18 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
3.10 DETENTION CHAMBER
A. The detention system must be a dedicated system; neither the gravity system nor
wet well may be used as part of the detention volume calculations (See Section
2).
B. The detention system shall be installed below ground with a twelve inch (12”)
diameter pipe (manifold) connecting the detention pipe(s) to the pump station’s
incoming manhole. The manifold shall be a minimum of twenty feet (20’) in
length.
C. An access manhole shall be installed at the downstream and upstream ends of
each detention pipe to connect each pipe to the manifold. Manholes shall be per
the District’s Standard Construction Specifications.
D. A pre-cast bulkhead shall be installed at the upstream end of each detention
pipe.
E. The detention pipe(s) and manifold shall be laid with a minimum one percent
(1%) slope.
F. See Section 4 for detention pipe specifications.
3.11 CONTROLPANEL PAD
A. The control panel concrete pad shall be a minimum of four inches (4") thick,
reinforced with 8-gauge, 6 x 6 welded wire mesh. The concrete shall have a
well-compacted four inches (4") thick stone base (minimum) with frost legs to
prevent heaving.
B. The pad shall be poured next to the pump station, parallel to the length of the
station structure and centered between the two (2) chambers. Pad dimensions
shall be as required by submitted equipment with minimum six inches (6”)
overhang in all directions.
3.12 MISCELLANEOUS ITEMS
A. Incoming Manhole Placement: A manhole shall be placed on the incoming
gravity line a minimum of twenty feet (20’) and a maximum of twenty-six feet (26’)
from the pump station structure. The detention chamber connecting line shall
discharge into this manhole. Manhole shall meet the requirements of the
District’s Standard Construction Specifications, latest edition.
B. Construction Tolerance of Wet Well: The wet well shall be installed so that it is no
more than 3 inches per 25 vertical feet out of plumb.
C. Exposed Bolts: All bolts located in the structures shall not extend more than two
inches (2”) from the wall.
D. Connection of Piping through structure walls: All incoming gravity lines and
discharge piping shall have a compression fitting cast-in-place where the pipe
passes through the walls.
1. The maximum angle of deflection shall follow manufactures
recommendations.
Standard Pump Station 19 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
2. All piping outside diameters shall be located a minimum of six (6) inches
above or below structure joints.
PIPING AND VALVES SECTION 4
4.01 GENERAL
A. The following specifications shall be used for installation of the pump station
piping and valves. Flanged and grooved end piping shall be acceptable means of
connecting piping and valving.
B. All pipes must enter the structure walls with a six-inches minimum clearance from
the outside face of the pipe to the face of the adjoining wall to allow for proper
pipe gasket placement.
4.02 FORCE MAIN PIPE MATERIAL
A. Ductile Iron Force Main
1. From the individual pump discharge bases through the header tee to a
point a minimum of four feet (4’) outside the valve chamber wall or
condition monitoring structure (if applicable), the following materials shall
be used:
a. Four Inch (4”) Diameter and Above:
Flange Installation: Ductile iron pipe Class 53 ANSI A-21.51 i.
(AWWA C -151). All bolts and nuts for flange connections
must be 304 stainless steel (minimum). All flange gaskets
must be full face 1/8” thick red rubber.
Grooved End Installation: Ductile iron pipe Class 53 ANSI A-ii.
21.51 (AWWA C-151) with rigid radius grooves for end
preparation in accordance with AWWA C606. Mechanical
couplings shall be of ductile iron conforming to ASTM A-536,
Grade S nitrile gasket compounded to conform to ductile iron
pipe surfaces with 316 stainless steel nuts and bolts.
2. The following materials shall be used for the force main from four feet (4’)
outside the valve chamber wall or condition monitoring structure (if
applicable) to the discharge manhole:
a. Four-inch (4") Diameter and Above:
Ductile iron pipe Class 52 ANSI A-21.51 (AWWA C-151) i.
b. Three-inch (3”) Diameter:
Ductile iron pipe Class 52 ANSI A-21.51 (AWWA C-151). i.
3. Joints: Push-on joints, mechanical joints, and flanged joints as indicated
in the Drawings. Push-on and mechanical joints shall conform to AWWA
C111 (ANSI A21.11). Provide gasket composition suitable for exposure
to sanitary sewage. Flanged joints shall conform to AWWA C115 (ANSI
A21.15). Component flanges shall be rated for a working pressure of 250
psi or greater.
4. Fittings: Ductile iron, manufactured in accordance with AWWA C110
C153 Class 250. Fittings to be designed to accommodate the type of
pipe used.
Standard Pump Station 20 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
5. Lining: Protecto 401TM for all ductile iron pipe, joints, and fittings in
accordance with specifications provided by Protecto 401 Ceramic Epoxy
Company.
6. Exterior Coating: Coat exterior of pipe intended for below grade
installation with an bituminous material as specified in AWWA C151,
approximately one (1) mil thick.
7. Polyethylene Encasement: Install a black polyethylene encasement in
accordance with AWWA C105 (ANSI A21.5), on all buried pipe and
appurtenances (fittings, valves, etc.).
8. Painting: Ductile iron pipe intended for above grade installation shall be
painted as follows:
a. Surface Preparation: Remove all dirt, dust, grease, oils, and all other
foreign matter from the surface. Clean the surface in accordance with
SSPC SP-6 Commercial Blast Cleaning, latest revision. The surface
shall be clean and dry prior to painting.
b. First Coat: Apply Tnemec Series 66 Hi-Build Epoxoline at 4.0-6.0 dry
mils. This coat shall not exceed 3.0 dry mils. Allow coat to dry
overnight, minimum 12 hours, to cure.
c. Second Coat: Apply Tnemec Series 73 Endura-Shield at 2.0-3.0 dry
mils. Color shall be 33GR Gray. Allow coat to dry overnight,
minimum of 12 hours.
d. Third Coat: Apply Tnemec Series 76 Endura-Clear at 1.5-2.0 dry
mils. Allow coat minimum 12 hours to cure.
e. Flanges and fittings shall be shop primed with Tnemec Series 66
Epoxoline Primer at 3.0-4.0 dry mils. These surfaces shall then be
touched up in the field and receive application of the three coat
system listed directly above.
B. PVC Force Main
1. From the individual pump discharge bases through the header tee to a
point a minimum of four feet (4’) outside the valve chamber wall, the
following materials shall be used:
a. Three-inch (3") Diameter:
Solvent-Weld Installation: ASTM 1785 Schedule 80 PVC. i.
Grooved Installation: ASTM 1785 Schedule 80 PVC roll ii.
grooved pipe in accordance with C-606. Mechanical
couplings shall be of ductile iron conforming to ASTM A-536,
Grade T or S nitrile compound gaskets conforming to ASTM
D-2000 designation 5BG615A14B24 with stainless steel nuts
and bolts.
2. The following materials shall be used for the force main from four feet (4’)
outside the valve chamber wall to the discharge manhole:
a. Four-inch (4”) Diameter and Above:
AWWA C-900 PVC Class 150 i.
AWWA C-900 PVCO ii.
b. Three-inch (3") Diameter:
3. PVC pipe meeting ASTM D2241 (SDR 21) with integral bell and gasket
joint design meeting the requirements of ASTM D3139 and F477,
minimum pressure class shall be PC 150.Joints: Join by means of a push
on bell joint which is to be an integral part of the barrel in conformance
Standard Pump Station 21 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
with AWWA C900. Provide gasket composition suitable for exposure to
sanitary sewage.
4. Fittings: For pipe less than four-inch (4”) in diameter, PVC fittings to
conform to the material requirements for PVC pipe described herein. For
pipe diameters four-inch (4”) or greater, provide mechanical joint fittings.
Provide gasket composition suitable for exposure to sanitary sewage
5. Pipe to bear the national Sanitation Foundation Seal of approval. Comply
with the requirements of Type I, Grade I of the ASTM resin specification
D-1784. Certificates of conformance with the foregoing specifications to
be furnished with each lot of pipe supplied.
6. Thermoplastic pipe shall not be used above grade.
4.03 FORCE MAIN REQUIREMENTS
A. The following elements shall be included in the force main system design:
1. Air Relief / Vacuum Valves (ARV): Automatic combination vacuum air
relief valves shall be placed at high points in the force main as required.
a. The valve shall be equipped with all backwash accessories.
b. The body of the ARV shall be supported to the wall of the structure by
a 1-1/4" x 1-1/4" x 1/8" stainless steel angle bracket.
c. For underground installations, provide precast manhole with cover
and frame and a concrete valve marker post for each valve location.
d. Coat air release manholes and pipes inside air release manholes with
Raven 405 Epoxy Coating or approved equal at 120 mils nominal
thickness.
e. Acceptable Manufacturer: ARI (no substitutions)
2. Connection to Gravity System: Force main shall discharge to the
receiving gravity sewer system at a manhole. The point of connection
shall be no more than one foot (1’) above the flow line of the receiving
manhole. Inside drops will not be permitted.
3. Existing Gravity Manhole Rehabilitation: The sides and bottom of the
force main discharge manhole and a minimum of five (5) manholes
downstream of the point of connection shall be lined with a solventless,
100% solids, corrosion resistant epoxy coating or a lining have multiple,
structural fiberglass layers with a non-porous diaphragm bonded between
the layers of fiberglass and molded to the existing structure.
a. Acceptable Manufacturer: Raven Lining Systems AquataPoxy A-6,
Terre Hill Composites Multiplex Liner THC-610-SL-68 or approved
equal.
4. New Manhole Construction: When a new force main discharge manhole
is to be constructed at the point of connection to the gravity system, the
manhole shall be manufactured with a flexible sheet liner with locking
extensions. The bottom of the new manhole and the sides and bottom of
the five (5) manholes downstream of the point of connection shall be
treated with the epoxy coating specified above.
a. Acceptable Manufacturer: Ameron Protective Lining Division, Amer-
Plate T-Lock, or approved equal.
5. Connection to Force Main: In limited circumstances, when proposed force
main discharges to an existing force main, design engineer shall notify
District at the Pump Station Design Report Submittal stage. Upgrades to
Standard Pump Station 22 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
existing pump station and force main may be required prior to
construction of proposed pump station.
6. Mechanically Restrained Joints: The force main shall be fitted at all angle
points with mechanically restrained joints designed to withstand the thrust
developed under the test pressure plus 50 psi. The required number of
mechanically restrained joints from the angle point shall be determined by
the design engineer and shown in plan and profile (see Section 1).
7. By-Pass Portal: A by-pass portal shall be installed within twenty-five feet
(25’) downstream of the valve chamber or condition monitoring structure
(if applicable).
a. The portal shall be the same size as the force main. For force mains
larger than four-inch (4”), calculations can be provided to allow for a
smaller pumping portal than the force main. All piping within the by-
pass assembly shall be meet the requirements of the “Force Main
Pipe Material” as described above.
b. The connection shall consist of a 90 degree bend with a blind flange
connection, with centerline located two and one-half feet (2.5’) above
grade.
c. The system shall consist of three (3) buried plug valves with
associated valve boxes. One (1) valve shall be located on the by-
pass portal line. One (1) valve shall be located upstream of the force
main/portal connection tee and one (1) valve shall be located
downstream of the connection tee.
d. Plug valve shall meet the specifications of “Isolation Valves” as
described below.
e. The connection shall be surrounded by a minimum of four (4) pipe
bollards and labeled “For Emergency Bypass Pumping Only”. Pipe
bollards shall extend forty-two inches (42”) above grade and be
constructed of six inch (6") diameter concrete filled steel or iron pipe.
Posts shall be set forty-two inches (42") below grade in an eighteen
inch (18") by forty-eight inch (48") poured concrete base. A twelve
inch (12”) long, #5 bar shall be installed near bottom of the pipe.
f. See standard details for installation details.
8. Clean-Outs: The need for clean-outs on the force main shall be
determined during plan review by the District. As a general guide, clean-
outs will not be required on force mains less than 1800 feet in length. If
clean-outs are required, refer to the District’s Standard Construction
Specifications.
9. Locator Marker Rope: Locator marker rope shall be placed on top of the
force main for the entire length. The rope shall be laid parallel to the
ground surface at a minimum depth of two and one-half feet (2.5’) and a
maximum depth of four feet (4’). A minimum six inch (6”) separation shall
be maintained between the top of the force main and the rope. Rope
shall be 3M Electronic Marking System (EMS) Rope, 7700 Series.
10. Locator Balls: Locator balls shall be placed over the top of the force main
during force main installation. The balls shall be installed per
manufacturer recommendations. Balls shall be 3M ID Electronic Marking
System (EMS) Ball Marker 1424-XR/ID. Balls shall be installed at the
following locations:
a. Every twenty-five feet (25’) along force main runs.
Standard Pump Station 23 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
b. Five feet (5’) from the pavement edge on both sides of a road
crossing.
c. Fifteen feet (15’) and five feet (5’) back from each side of an angle
point and on the angle point itself.
d. As directed by the District.
11. Tracer Wire: Tracer wire can be installed on a case-by-case basis where
approved by the District. There shall be a connection point to the tracer
wire a maximum of 400-feet and at every structure along the alignment.
Inspection of the tracer wire shall show that the entire length of the force
main is locatable using the tracer wire. Any breaks or faults of the tracer
wire will be repaired prior to acceptance, or the installations of locator
rope will be required.
4.04 TRANSITION PIPING
A. When PVC pipe (See Section 4) is used for force main outside the structural
walls, a transition in pipe material must be made.
B. When a condition monitoring structure is used, a transition pipe must be used to
make the transition between the flow meter inside the condition monitoring
structure and the force main outside the structure. A flanged DIP stub shall be
bolted to the flow meter then passed through the gasket installed in the condition
monitoring structure wall. The PVC force main shall be attached to the DIP stub
outside the structure by a long pattern sleeve mechanical joint with Mega-Lug
retainer glands.
C. When no condition monitoring structure is used, a transition pipe must be used to
make the transition between the header tee inside the valve chamber and the
force main outside the structure. The following methods shall be used:
1. Four Inch (4") Diameter and Larger: Both pump discharge lines shall be
joined to a flanged cast iron tee. A flanged DIP stub shall be bolted to the
tee then passed through the gasket installed in the valve chamber
discharge wall. The PVC force main shall be attached to the DIP stub
outside of the valve chamber by a long pattern sleeve mechanical joint
with Mega-Lug retainer glands.
2. Three Inch (3") Diameter: Both pump discharge lines shall be joined to a
Schedule 80 PVC socket tee. From the tee, a Schedule 80 PVC stub
shall pass through the gasket installed in the valve chamber discharge
wall. Transition the stub to the SDR-21 PVC force main with a PVC
coupling outside of the valve chamber.
4.05 PUMP DISCHARGE RISERS
A. When the pump discharge riser exceeds twelve feet (12’) in length, a stainless
steel support brace must be installed between the riser and wet well wall. The
brace shall be placed approximately in the middle of the riser but kept above the
normal operating level of the well. A minimum of two (2) braces will be needed
on lengths in excess of twenty feet (20’).
B. Pump discharge riser pipes shall be installed straight and plumb.
Standard Pump Station 24 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
4.06 ISOLATION VALVE
A. One (1) non-buried isolation valve shall be placed on the discharge line of each
pump, downstream of the check valve. Valves shall be located so that each
pump may be isolated from the common discharge header. No pump discharge
valves shall be vertically mounted or located in the wet well area.
B. Three (3) buried isolation valves shall be provided on the by-pass portal system.
Valves shall be located so that by-pass pumping can occur along with isolation of
the force main and pump station.
C. All valves shall be rated so as to withstand normal working pressure plus
allowances for water hammer.
D. Isolation valves shall be plug type valves.
1. Materials
a. Valve bodies and covers shall be constructed of ASTM A126 Class B
cast iron for working pressures up to 175 psig and ASTM A536 Grade
65-45-12 for working pressures up to 250 psig.
b. The words “SEAT END” shall be cast on the exterior of the body seat
end.
c. Plugs shall be of one-piece construction and made of ASTM A126
Class B cast iron or ASTM A536 Grade 65-45-12 ductile iron and fully
encapsulated with resilient facing per ASTM D2000-BG and
ANSI/AWWA C517 requirements.
d. Plug valves shall have radial shaft bearings constructed of self-
lubricating Type 316 stainless steel. The top thrust bearing shall be
Teflon. The bottom thrust bearing shall be self-lubricating Type 316
stainless steel. Cover bolts shall be corrosion resistance with zinc
plating.
e. Plug valves shall have a valve seat that is a welded overlay of 95%
pure nickel applied directly to the body on a pre-machined, cast
seating surface and machined to a smooth finish.
f. Permanently lubricated, radial shaft bearings shall be supplied in the
upper and lower bearing journals. Thrust bearings shall be provided
in the upper and lower journal areas, except for threaded type which
only have upper thrust bearings.
g. Threaded and all other valves under four inch (4”) shall have port
areas of not less than 100% of pipe area. Port areas on other sizes
are 85% on sixteen inch (16”) and smaller, 80% on eighteen inch (18”)
to twenty-four inch (24”) and 75% on thirty inch (30”) and larger.
h. The exterior of the valve for non-buried service shall be coated with a
universal alkyd primer. Valve exterior for buried service shall be
coated with an epoxy coating.
i. Manufacturer shall demonstrate a minimum of ten (10) years’
experience in the manufacture of plug valves. The manufacturer shall
provide test certificates, dimensional drawings, parts list drawings and
operations and maintenance manuals.
2. Connection Types
a. Non-buried application
Flange valves shall be in accordance with ANSI B16.1 Class i.
Standard Pump Station 25 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
125 standards.
Grooved end valves shall have end-to-end dimensions in ii.
conformance with AWWA C-509 with the grooved ends
conforming to AWWA C-606 rigid grooving dimensions.
b. Buried application: Mechanical Joint
3. Valve Operators
a. Six-inch (6”) and smaller valves shall be provided with a two-inch (2”)
square operating nut and wrench head for direct quarter turn
operation. The packing gland shall include a friction collar and an
open position memory stop. The friction collar shall include a nylon
sleeve to provide friction without exerting pressure on the valve
packing.
b. Valves larger than six inch (6”) shall be provided with a Manual Gear
Operator sized so that the maximum rim pull required is not more than
80 pounds.
c. When specified, valves four inch (4”) and larger shall include a totally
enclosed and sealed worm gear actuator with position indicator (non-
buried service only) and externally adjustable open and closed stops.
The worm segment gear shall be ASTM A536 Grade 65-45-12 ductile
iron with a precision bore and keyway for connection to the valve
shaft. Bronze radial bearings shall be provided for the segment gear
and worm shaft. Alloy steel roller thrust bearings shall be provided for
the hardened worm.
4. Valve Box and Extension Stem
a. For buried valve applications, valve boxes shall be provided. The
valve box shall extend to the elevation as shown on the drawings.
b. All buried valves shall have a hot dipped galvanized steel extension
stem keyed to the valve and the operating nut brought to within six
inches (6”) of the top of valve box.
5. Acceptable Manufacturer: Valves are to be Milliken, fig. #601-N, Victaulic
Series 365, Val-Matic Valve and Mfg. Corporation Series 5800 or 5900, or
approved equal.
4.07 CHECK VALVES
A. A check valve shall be placed on the discharge line of each pump. The check
valve shall be located between the shut-off valve and the pump. All valves shall
be rated so as to withstand normal working pressure plus allowances for water
hammer. No pump discharge valves shall be vertically mounted or located in the
wet well area.
B. Check valves shall be of the swing check type with iron body and bronze trim.
Check valves shall be outside spring, lever, weighted arms, or flexible disc type.
1. Materials
a. The valve body and cover shall be constructed of ASTM A536 Grade
65-45-12 ductile iron.
b. The top access port shall be full size, allowing removal of the disc
without removing the valve from the line. The access cover shall be
domed in shape to provide flushing action over the disc for operating
in lines containing high solids content.
2. Connection Types
Standard Pump Station 26 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
a. Flange valves shall be in accordance with ANSI B16.1 Class 125
standards.
b. Grooved end valves shall have end-to-end dimensions in
conformance with AWWA C-509 with the grooved ends conforming to
AWWA C-606 rigid grooving dimensions.
3. Disc Types
a. Flexible Disc - The seating surface shall be on a 45-degree angle to
minimize disc travel. A threaded port with pipe plug shall be provided
on the bottom of the valve to allow for field installation of a backflow
actuator or oil cushion device without special tools or removing the
valve from the line. A threaded port with pipe plug shall be provided
in the access cover to allow for field installation of a mechanical, disc
position indicator. The disc shall be of one-piece construction,
precision molded with an integral O-ring type sealing surface and
reinforced with alloy steel. The flex portion of the disc contains nylon
reinforcement and shall be warranted for twenty-five years. Non-Slam
closing characteristics shall be provided through a short 35-degree
disc stroke and a memory disc return action to provide a cracking
pressure of 0.25 psig. The valve disc shall be cycle tested 1,000,000
times in accordance with ANSI/AWWA C508 and show no signs of
wear, cracking, or distortion to the valve disc or seat and shall remain
drop tight at both high and low pressures. The disc shall be precision
molded Buna-N (NBR) ASTM D2000-BG.
b. Metal Disc - The valve body shall be full flow equal to nominal pipe
diameter area at all points through the valve and shall be equipped
with a threaded adjustable open stop. The body seat shall be O-ring
sealed and field replaceable without removing the valve from the line.
The disc shall be of one-piece construction and connected to the shaft
with a disc arm and two pivot pins to provide pivot action to allow self-
adjusting seating at all pressures. 14” and larger discs shall be
convex shape for lift, stabilization and strength. The disc seat shall be
resilient with integral O-ring type sealing surface for drop tight shut-off
at high and low pressures and for easy replacement in the field
without removing the valve from the line. The shaft seals shall consist
of V-type packing in a fixed gland with an adjustable follower designed
to prevent over compression of the packing and to meet design
parameter of the packing manufacturer. Removable, slotted shims
shall be provided under the follower flanges to provide for adjustment
and prevent over loading of the packing. The valve shall be factory
equipped with a lever and weight assembly. The lever shall be
equipped with three holes for adjusting the bolted weight assembly.
When the valve is closed, the lever and weight shall be located 30
degrees below horizontal.
4. Acceptable Manufacturer: Check Valves shall be Clow Style 1106SL,
Victaulic Series 317, or Val-Matic Series 7800 Swing Check, or MSD
approved equivalent.
4.08 VALVE CHAMBER DRAIN VALVE
A. A backwater check valve shall be installed on the valve chamber drain line. The
valve shall be installed as follows:
Standard Pump Station 27 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
1. A four inch (4”) diameter PVC stub shall be glued into the four inch (4”)
diameter coupler cast into the wet well wall at the valve chamber floor line
(See Section 3). A 90-degree elbow shall be glued to this stub and
directed toward the wet well floor. A four inch (4”) by three feet (3’) long
PVC pipe shall be glued into the other end of the elbow. The check valve
shall be installed on the pipe end and attached with two (2) stainless steel
clamps to be supplied by the vendor.
2. Acceptable Manufacturer: The valve shall be a four inch (4”) slip on check
valve, "Tide-Flex" series TF-2 by Red Valve Co. or EVR Type CPO-4", or
MSD approved equivalent.
4.09 PRESSURE SENSORS
A. Each installed pump shall have an in-line full ported pressure sensor installed on
the pump side of the discharge line. The sensor shall be located in the valve
chamber between the pump and check valve. Sensor specifications are provided
in Section 5.
4.10 GRAVITY LINES
A. Ductile iron pipe shall be used:
1. Between the incoming manhole (last manhole preceding the station) up to
the wet well.
2. The twelve inch (12”) diameter pipe (manifold) connecting the detention
chamber and incoming manhole.
B. Concrete or PVC pipes in these areas will not be acceptable.
C. Gravity pipes shall be per the District’s Standard Construction Specifications,
latest edition.
4.11 DETENTION PIPE
A. Detention pipe(s) shall be selected from current approved materials for large
diameter sanitary sewers, and installed under current MSD construction
specifications. Pipe materials shall be labeled on the plans, and notes added for
installation requirements.
B. The detention pipe ends shall be bulk headed with a gasket installed in the outfall
side.
C. Buoyancy calculations shall be submitted as part of the pump station design
report. Measures to restrain the pipe from floatation shall be shown on the plans.
Standard Pump Station 28 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
SUBMERSIBLE WASTEWATER PUMPS SECTION 5
5.01 MINIMUM STANDARDS
A. Pump selection shall be based on the following minimum standards:
1. Type
a. Submersible, non-clog pumps are preferred.
b. Grinder pumps and vertical lift pumps may be approved by the District
upon receipt of a written request for variance and acceptable
justification.
2. Electrical
a. Three-phase pumps are preferred.
b. Pumps less than three horsepower (3 Hp) are not acceptable.
3. All pumps, with the exception of grinder pumps, shall be capable of
passing spheres of at least three inches (3”) in diameter.
4. Pump suction and discharge piping shall be at least three inches (3”) in
diameter.
5.02 PUMP SPECIFICATIONS
A. The pump shall be non-clog solids handling submersible capable of handling
raw, unscreened sewage.
B. The discharge connection elbow shall be permanently installed in the wet well
along with the discharge piping.
C. The pump shall automatically connect to the discharge connection elbow when
lowered into place and shall be easily removed for inspection or service. There
shall be no need for personnel to enter the wet well. A simple linear downward
motion of the pump shall accomplish sealing of the pumping unit to the discharge
connection elbow.
D. A sliding guide bracket shall be an integral part of the pump unit. No portion of
the pump shall bear directly on the floor of the sump.
E. The pump, with its appurtenances and cable, shall be capable of continuous
submergence underwater without loss of watertight integrity to a depth of 65 feet.
1. Major Components
a. Major pump components shall be of gray cast iron, ASTM A-48, Class
35B with smooth surfaces devoid of blowholes and other irregularities.
Where watertight sealing is required, O-rings made of nitrile rubber
shall be used. All exposed nuts and bolts shall be of AISI type 316
stainless steel.
b. The pump shall be equipped with an open lifting hoop suitable for
attachment of standard chain fittings, or for hooking from the wet well
surface. The hoop shall be stainless steel, 1.4401 (AISI 316), and
shall be rated to lift a minimum of four (4) times the pump weight.
2. Watertight Seals
a. All mating surfaces where watertight sealing is required shall be
machined and fitted with nitrile O-rings. Fitting shall be such that
sealing is accomplished by metal-to-metal contact between machined
Standard Pump Station 29 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
surfaces. This will result in controlled compression of nitrile rubber O-
rings without requirement of a specific torque limit. No secondary
sealing compounds, rectangular gaskets, elliptical O-rings, grease or
other devices shall be used.
3. Cooling System
a. Each unit shall be provided with an adequately designed cooling
system.
When thermal radiators (cooling fins) are used, they shall be i.
integral to the stator housing and shall be adequate to provide
the cooling required by the motor.
When water jackets are used, the water jacket shall encircle ii.
the stator housing. The water jacket shall be provided with a
separate, self-contained liquid cooling system.
b. Regardless of the cooling system used, the motor must be capable of
pumping under full load continuously with the water level only to the
top of the volute.
c. Motors with intermittent full load ratings or motors requiring oil for
cooling will not be allowed.
4. Impellers
a. Semi Open with Adjustable Bottom Plates
Impeller: The impeller shall be of gray cast iron, ASTM A-48, i.
Class 35B. The impeller shall be of the semi-open, non-
clogging, single vane design, and shall be capable of passing
solids as are commonly found in wastewater. The impeller
shall be highly clog resistant by virtue of its single or dual
vane semi open design. The impeller shall have a slip fit onto
the motor shaft and drive key and shall be securely fastened
to the shaft by a stainless steel bolt which is mechanically
prevented from loosening by a positively engaged ratcheting
washer assembly. The head of the impeller bolt shall be
effectively recessed within the impeller bore to prevent
disruption of the flow stream and loss of hydraulic efficiency.
The impeller shall be dynamically balanced to the ISO 10816
standard to provide smooth vibration-free operation.
Self-Cleaning Wear Plate: The wear plate shall be ii.
constructed from gray cast iron ASTM A-48, Class 35 B. The
wear plate shall be designed with an inlet incorporating
strategically placed cutting grooves and an outward spiral V-
shaped groove on the side facing the impeller, to shred and
force stringy solids outward from the impeller and through the
pump discharge. The wear plate shall be mounted to the
volute with four stainless steel securing screws and four
stainless steel adjusting screws to permit close tolerance
adjustment between the wear plate and impeller for maximum
pump efficiency. Adjustment to allow for wear and restore
peak pumping performance shall be accomplished using
standard tools, and without requiring disassembly of the
pump. The use of fixed or non-adjustable wear plates or
rings, or systems that require disassembly of the pump or
shimming of the impeller to facilitate adjustment shall not be
Standard Pump Station 30 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
considered equal. The suction flange shall be integrated into
the wear plate and its bolt holes shall be drilled and threaded
to accept standard 4-inch ANSI Class 125 flanged fittings.
b. Vortex
The Vortex impeller shall be of gray cast iron, EN-GJL-250 i.
(ASTM A-48, Class 35B). The impeller shall be an open vane
design, capable of passing a minimum of 3-inch diameter
spherical solids as are commonly found in wastewater. The
impeller shall have a slip fit onto the motor shaft and drive key
and shall be securely fastened to the shaft by a stainless
steel bolt which is mechanically prevented from loosening by
a positively engaged ratcheting washer assembly. The head
of the impeller bolt shall be effectively recessed within the
impeller bore to prevent disruption of the flow stream and loss
of hydraulic efficiency. The impeller shall be dynamically
balanced to the ISO 10816 standard to provide smooth
vibration-free operation.
The pump volute shall be single piece gray cast iron, ASTM ii.
A-48, Class 35B non-concentric design with centerline
discharge. Passages shall be smooth and large enough to
pass any solids which may enter the impeller. Discharge size
shall be three inch (3”) minimum. The discharge flange
design shall permit attachment to standard ANSI or metric
flanges/appurtenances. The discharge flange shall be slotted
to accept both three inch (3”) ANSI Class 125 (rotated 22.5
degrees) and metric CN80 (PN10) flanged fittings.
Proprietary or nonstandard flange dimensions shall not be
considered acceptable. The minimum working pressure of
the volute and pump assembly shall be 10 bar (145 psi).
c. Enclosed Impeller
An enclosed or channel impeller shall be of gray cast iron i.
ASTM A-48, Class 35B. The impeller shall be of the double
shrouded, non-clogging, two vane design, meeting the Ten
States Standards requirement for minimum solids passage
size of three inches (3”).
The impeller shall have a slip fit onto the motor shaft and ii.
drive key and shall be securely fastened to the shaft by a
stainless steel bolt which is mechanically prevented from
loosening by a positively engaged ratcheting washer
assembly. The head of the impeller bolt shall be effectively
recessed within the impeller bore or supporting washer to
prevent disruption of the flow stream and loss of hydraulic
efficiency. The impeller shall be dynamically balanced to the
ISO 10816 standard to provide smooth vibration-free
operation. Impeller designs which do not meet the Ten
States Standards requirement for three inch (3”) solids
passage size, those that rely on retractable impeller designs
to pass three inch (3”) solids, or those that rely on fins or pins
protruding into the suction path to assist in the handling of
fibrous material shall not be considered equal.
A replaceable wear ring of cast iron ASTM A-48, Class 40 or iii.
Standard Pump Station 31 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
AISI 318 shall be securely fitted into the pump casing (volute).
The optional impeller wear ring shall be stainless steel AISI
316Ti.
d. Chopper/Cutter Type
Impeller: Shall be semi-open type with pump out vanes to i.
reduce seal area pressure. Chopping/maceration of materials
shall be accomplished by the action of the cupped and
sharpened leading edges of the impeller blades moving
across the cutter bar of 0.010” to 0.015”. Impeller shall be
cast steel heat treated to minimum Rockwell C 60 and
dynamically balanced. The impeller shall be keyed to the
shaft and shall have no axial adjustments or set screws
required.
Cutter Bar Plate: Shall be recessed into the pump bowl and ii.
shall contain at least 2 shear bars extending diametrically
across the intake opening to within 0.010-0.015” of the
rotating cutter nut tooth, for the purpose of preventing intake
opening blockage and wrapping of debris at the shaft area.
Chopper pumps utilizing individually mounted shear bars shall
not be acceptable. Cutter bar shall be T1 plate steel heat-
treated to minimum Rockwell C 60.
Cutter Nut: The impeller shall be secured to the shaft using a iii.
special cutter nut, designed to cut stringy materials and
prevent binding. The cutter nut shall be ASTM A148 cast
alloy steel heat treated to minimum Rockwell C 60.
Upper Cutter: Shall be threaded into the back pull-out iv.
adapter plate above the impeller, designed to cut against the
pump-out vanes and the impeller hub, reducing and removing
stringy materials from the mechanical seal area. Upper cutter
shall be cast steel heat treated to minimum Rockwell C 60.
5. Volute
a. The pump volute shall be single piece gray cast iron ASTM A-48,
Class 35B non-concentric design with centerline discharge.
Passages shall be smooth and large enough to pass any solids which
may enter the impeller. Discharge size shall be as specified on the
pump performance curve. The discharge flange design shall permit
attachment to standard ANSI or metric flanges/appurtenances. The
discharge flange shall be drilled to accept both ANSI Class 125 and
metric flanged fittings. Proprietary or non-standard flange dimensions
shall not be considered acceptable. The minimum working pressure
of the volute and pump assembly shall be 10 bar (145 psi).
6. Pump Motor
a. The Premium Efficiency motor shall meet efficiency standards in
accordance with IEC 60034-30, level IE3 and NEMA Premium. Motor
rating tests shall be conducted in accordance with IEC 60034-2-1
requirements and shall be certified accurate and correct by a third
party certifying agency. A certificate shall be available upon request.
IE3 and NEMA Premium efficiency levels are equivalent, i.
however the NEMA Premium standard is intended to cover
dry installed motors only, not integrated submersible motors.
Standard Pump Station 32 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
b. The Premium Efficiency motor shall be housed in a water tight gray
cast iron, EN-GJL-250 (ASTM A-48, Class 35B) enclosure capable of
continuous submerged operation underwater to a depth of 20 meters
(65 feet) and shall have an IP68 protection rating. The motor shall be
of the squirrel-cage induction design, NEMA type B, Premium
Efficiency.
The copper stator windings shall be insulated with moisture i.
resistant Class H insulation materials, rated for 180°C
(356°F).
The stator shall be press fitted into the stator housing. ii.
The use of bolts, pins or other fastening devices requiring iii.
penetration of the stator housing is unacceptable.
The rotor bars and short circuit rings shall be made of cast iv.
aluminum.
c. The motor shall be designed for continuous duty. The maximum
continuous temperature of the pumped liquid shall be 40°C (104°F),
and intermittently up to 50°C (122°F). The motor shall be capable of
handling up to 10 evenly spaced starts per hour without overheating.
The service factor (as defined by the NEMA MG1 standard) shall be
1.15 minimum. The motor shall have a voltage tolerance of +/- 10%
from nominal, and a phase to phase voltage imbalance tolerance of
1%. The motor shall be FM and CSA approved for use in NEC Class
I, Division I, Groups C & D hazardous locations. The surface
temperature rating shall be T3C. The motor shall meet the
requirements of NEMA MG1 Part 30 and 31 for operation on PWM
type Variable Frequency Drives.
7. The motor shall be capable of operating, completely submerged, partially
submerged, or unsubmerged. For submerged (wet pit) applications, the
motor shall be self-cooling via the process fluid surrounding the motor.
For unsubmerged (dry pit) applications an integrated oil cooling system
shall be utilized to enhance heat transfer and allow the motor to operate
at full rated power continuously without the need for de-rating or reduced
duty cycle. No external coolant supply or external cooling jacket shall be
required for dry pit applications. The motor shall have a NEMA Class A
temperature rise for submerged service, and class B rise for dry pit
service, providing cool operation under all operating conditions.
8. Thermal Sensors
a. Each phase of the motor shall contain a normally closed bi-metallic
temperature monitor switch imbedded in the motor windings. These
thermal switches shall be connected in series and set to open at
140°C +/- 5°C (284°F). They shall be connected to the control panel,
and used in conjunction with, and supplemental to, external motor
overload protection.
9. Pump Shaft
a. Each pump shall be provided with an oil chamber for the shaft sealing
system. The drain and inspection plug, with positive anti-leak seal,
shall be accessible from the outside.
b. Shaft:
The pump shaft and motor shaft shall be an integral, one-i.
piece unit adequately designed to meet the maximum torque
Standard Pump Station 33 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
required at any normal start-up condition or operating point in
the system.
The shaft shall have a full shutoff head design safety factor of ii.
1.7, and the maximum shaft deflection shall not exceed 0.05
mm (0.002 inch) at the lower seal during normal pump
operation.
Each shaft shall be stainless steel 1.4021 (AISI 420) material iii.
and shall have a polished finish with accurately machined
shoulders to accommodate bearings, seals and impeller.
Carbon steel, chrome plated, or multi piece welded shafts
shall not be considered adequate or equal.
c. Bearings:
Each pump shaft shall rotate on two (2) high quality i.
permanently lubricated, greased bearings.
The upper bearing shall be a single row deep grooved ball ii.
bearing and the lower bearings shall be a heavy duty double
row angular contact ball bearing.
Bearings shall be of sufficient size and properly spaced to iii.
transfer all radial and axial loads to the pump housing and
minimize shaft deflection.
L-10 bearing life shall be a minimum of 50,000 hours at flows iv.
ranging from ½ of BEP flow to 1 ½ times BEP flow (BEP is
best efficiency point).
The bearings shall be manufactured by a major internationally v.
known manufacturer of high quality bearings and shall be
stamped with the manufacturer’s name and size designation
on the race. Generic or unbranded bearings from other than
major bearing manufacturers shall not be considered
acceptable.
10. Mechanical Seal
a. Each pump shall be equipped with a tandem mechanical shaft seal
system consisting of two totally independent seal assemblies. The
seals shall operate in a lubricant reservoir that hydro-dynamically
lubricates the lapped seal faces at a constant rate. The lower,
primary seal unit, located between the pump and the lubricant
chamber, shall contain one stationary industrial duty silicon-carbide
seal ring and one rotating industrial duty silicon-carbide seal ring.
The stationary ring of the primary seal shall be installed in a seal
holding plate of gray cast iron EN-GSL-250 (ASTM A-48, Class 35B).
The seal holding plate shall be equipped with swirl disruption ribs to
prevent abrasive material from prematurely wearing the seal plate.
The upper, secondary seal unit, located between the lubricant
chamber and motor housing, shall contain one stationary industrial
duty silicon-carbide seal ring, and one rotating industrial duty
silicon-carbide seal ring. Each seal interface shall be held in contact
by its own spring system. The seals shall not require routine
maintenance, or adjustment, and shall not be dependent on the
direction of rotation for proper sealing. Each pump shall be provided
with a lubricant chamber for the shaft sealing system which shall
provide superior heat transfer and maximum seal cooling. The
Standard Pump Station 34 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
lubricant chamber shall be designed to prevent overfilling, and to
provide lubricant expansion capacity. The drain and inspection plug
shall have a positive anti-leak seal, and shall be easily accessible
from the outside of the pump. The seal system shall not rely upon the
pumped media for lubrication and shall not be damaged when the
pump is run dry. Lubricant in the chamber shall be environmentally
safe non toxic material.
b. The following seal types shall not be considered equal: Seals of
proprietary design, or seals manufactured by other than major
independent seal manufacturing companies. Seals requiring set
screws, pins, or other mechanical locking devices to hold the seal in
place, conventional double mechanical seals containing either a
common single or double spring acting between the upper and lower
seal faces, any system requiring a pressure differential to seat the
seal and ensure sealing.
c. Mechanical Seal Protection System: The primary mechanical seal
shall be protected from interference by particles in the wastewater,
including fibrous materials, by an active Seal Protection System
integrated into the impeller. The back side of the impeller shall be
equipped with a sinusoidal cutting ring, forming a close clearance
cutting system with the lower submersible motor housing or seal plate.
This sinusoidal cutting ring shall spin with the pump impeller providing
a minimum of 75 shearing actions per pump revolution. Large
particles or fibrous material which attempt to lodge behind the
impeller, or wrap around the mechanical seal shall be effectively
sheared by the active cutting system into particles small enough to
prevent interference with the mechanical seal. The Seal Protection
System shall operate whenever the pump operates, and shall not
require adjustment or maintenance in order to function. Submersible
pump designs which do not incorporate an active cutting system to
protect the primary mechanical seal shall not be considered
acceptable for wastewater service.
d. Seal Failure Early Warning System: The integrity of the mechanical
seal system shall be continuously monitored during pump operation
and standby time. An electrical probe shall be provided in a sensing
chamber positioned between the primary and secondary mechanical
seals for detecting the presence of water contamination within the
chamber. The sensing chamber shall be filled with environmentally
safe non-toxic oil. A solid-state relay mounted in the pump control
panel or in a separate enclosure shall send a low voltage, low
amperage signal to the probe, continuously monitoring the
conductivity of the liquid in the sensing chamber. If sufficient water
enters the sensing chamber through the primary mechanical seal, the
probe shall sense the increase in conductivity and signal the solid
state relay in the control panel. The relay shall then energize a
warning light on the control panel, or optionally, cause the pump to
shut down. This system shall provide an early warning of mechanical
seal leakage, thereby preventing damage to the submersible pump,
and allowing scheduled rather than emergency maintenance.
Systems utilizing float switches or any other monitoring devices
located in the stator housing rather than in a sensing chamber
Standard Pump Station 35 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
between the mechanical seals are not considered to be early warning
systems, and shall not be considered equal.
11. Power Cable
a. The power cables shall be sized according to NEC and CSA
standards and shall be of sufficient length to reach the junction box
without requiring splices. The outer jacket of the cable shall be oil and
water resistant, and shall be capable of continuous submerged
operation underwater to a depth of 65 feet.
12. Cable Entry System
a. Plug Assembly:
The cable entry system shall consist of submersible plug i.
assembly which allows the cable to be easily disconnected
from the pump for service or replacement.
Cable sealing shall be accomplished by a Nitrile compression ii.
grommet with both cylindrical and conical sealing surfaces,
flanked by a stainless steel washer and an integrated strain
relief.
A brass (C3604) compression nut shall be threaded into the iii.
cast iron EN-GJL-250 (ASTM A-48, Class 35B) cable plug
housing, compressing the grommet ID to the cable while the
grommet OD seals against the bore of the cable entry
housing.
Cable conductors shall be terminated in copper pin iv.
connectors which are separated and retained by a circular pin
retainer fabricated form high dielectric strength Polyamid
(30% GF). Each pin shall pass through its own hole in the pin
retainer, maintaining the perfect alignment with the mating
pins in the motor body. The corresponding motor body pin
assembly shall be manufactured from high dielectric strength
Polyamid (30% GF), with copper connector pins. The pin
assembly shall be sealed with an O-ring to prevent water
entry into the motor, and retained in the motor housing bore
via a retaining ring. Attachment of the plug assembly to the
motor shall engage the corresponding copper pins, creating a
complete circuit between the motor cable.
The plug assembly shall be fastened with stainless steel v.
fasteners, and shall be sealed by an O-ring.
The cable plug and sealed entry system as part of the motor vi.
shall be FM and CSA approved for use in NEC Class I,
Division I, Groups C & D hazardous locations. The system
shall be anti wicking by design, and shall prevent any water
that enters the cable through damage to the jacket from
entering the motor. Cable entry designs which utilize potting
compounds to provide a water tight seal, or those which do
not allow the cable to be easily changed in the field shall not
be considered equal.
b. Cable Entry/Junction Chamber:
The cable entry design shall not require a specific torque to i.
ensure a watertight seal.
The cable entry shall consist of cylindrical elastomer ii.
Standard Pump Station 36 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
grommets, flanked by stainless steel washers.
A cable cap incorporating a strain relief and bend radius iii.
limiter shall mount to the cable entry boss, compressing the
grommet ID to the cable while the grommet OD seals against
the bore of the cable entry. The junction chamber shall be
isolated and sealed from the motor by means of sealing
glands.
Electrical connections between the power cables and motor iv.
leads shall be made via a compression or post type terminal
board, allowing for easy disconnection and maintenance.
c. Acceptable Manufacturer:
Flygt i.
Sulzer ii.
KSB iii.
Vaughan (Chopper/cutter type only) iv.
No other manufacturers shall be acceptable v.
Standard Pump Station 37 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
PUMP STATION APPURTENANCES SECTION 6
6.01 GUIDE BAR RAILS
A. Two (2) guide bar rails shall be installed for each pump to facilitate pump
removal. Rails shall be made of Type 316 Schedule 40 stainless steel pipe,
installed and sized per manufacturer's recommendations. The rails shall be
firmly braced to the wet well wall with stainless steel support brackets. Maximum
spacing between brackets shall be per pump manufacturer’s recommendations.
Rails shall be sparkless design suitable for use in Class 1, Division 1, Group D
hazardous location as defined in NFPA 70 – National Electric Code (NEC).
6.02 LIFTING CHAIN
A. Pump lifting chain, clevises and shackles shall be made of Type 316 stainless
steel and provided by the pump manufacturer. The chain shall be sized to
accommodate the installed pump weight but shall not be sized smaller than 3/16"
stainless steel diameter links.
6.03 BOLTS
A. All field-installed bolts, nuts, and washers used inside either the wet well or valve
chamber shall be made of Type 316 stainless steel.
6.04 FASTENERS
A. All concrete fasteners used for installation of braces, brackets or boxes shall be
stainless steel wedge type stud anchors. Anchor holes shall be drilled to the
manufacturer's recommended depth. Pump base anchor studs shall be sized per
manufacturer recommendations, with the following minimums:
1. 4" pumps and smaller = 5/8" minimum
2. 6" and 8" pumps = 1" minimum
3. Pumps larger than 8" shall be installed with stainless steel anchors sized
per the pump manufacturer instructions.
6.05 FLOATS AND SETTINGS
A. General
1. Floats shall be located near the flow of the incoming sanitary lines. All
floats shall be located away from the turbulence of the incoming flow.
Sewage shall not rise to the level of the incoming gravity lines or the
detention pipes during normal pump operation. All floats shall be utilized
in intrinsically safe applications.
B. Float Levels
1. The following levels shall guide the setting of float levels:
Off Float The Entire Pump Shall be Covered at the Off
Level
Lead Pump No Less than 1-1/2 Feet above Top Of Pump
Standard Pump Station 38 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
Motor
Lag Pump No Less than 2 Feet above Top of Pump Motor
High Level Alarm No Less than 2-1/2 Feet above Top of Pump
Motor and No More than 1-Inch Below the 12-Inch
Pipe to the Twenty-Four-Hour Detention Tank
Emergency High Level
Alarm
Set to a Level Equivalent to 75% of the Detention
Chamber Capacity
C. Float Leads
1. Float leads shall be hung with stainless steel kellum grips from a stainless
steel bracket, Series J by Halliday. The bracket shall be attached to the
wet well hatch cover or firmly bolted to the concrete immediately below
the hatch cover.
D. Float Wires
1. Float wires shall be neatly routed from the wet well to the valve through
the access sleeve (see Section 3), without excessive wire strain or pull.
Wire length on all float wires shall be such that each float may be
adjusted to the bottom of the station wet well.
E. Acceptable Manufacturer:
a. Flygt model ENM-10
b. Anchor Scientific type eco-float.
c. MSD approved equivalent.
6.06 ACCESS HATCHES
A. The access hatches shall be aluminum, rated for a 300 lbs/sf live load. Door size
and orientation shall be as described in Section 3. The access frame and cover
shall be flush with the top of the concrete, complete with hinged and flush locking
mechanism, upper guide holder and level sensor cable holder. Frame shall be
securely placed. Hatches shall be equipped with form skirts, sized for the top
slab thickness. Doors shall be provided with padlock lugs.
B. Safety grating shall be factory installed on all hatches and rated for a 300 lbs/sf
live load. Grating shall be aluminum “I” bar grating with powder coated finish.
Grating shall be hinged to open in same direction as aluminum hatch and
supplied with positive latch to maintain unit in upright position. A viewing area
shall be provided on each lateral unhinged side of panel for visual observation
and limited maintenance procedures. All hardware and fasteners shall be
stainless steel.
C. All access hatch construction materials and appurtenances shall be
manufactured from stainless steel, aluminum or brass.
D. Acceptable Manufacturer:
1. Halliday Model S1S or S2S
Standard Pump Station 39 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
2. Approved equal
6.07 SAFETY POST
A. A stainless steel or aluminum safety extension post shall be provided on the top
two steps under the access. When entrance steps are utilized (depth less than 5
feet), the safety extension post shall be anchored into the concrete wall of the
structure using a manufacturer-provided bracket. When access ladders are
installed (depth greater than 5 feet), the safety post shall be connected to the
access ladder itself. All bolts and hardware shall be stainless steel. Contractor
shall verify required spacing.
B. Acceptable Manufacturer:
1. Halliday L1E Ladder Extension
2. Approved equal.
6.08 LOCKING HARDWARE
A. All equipment enclosures, access hatches, entrance gates and service
disconnect arms shall be provided with stainless steel locks. Locks shall have
two inch (2") high shackles with 5/16" diameter shanks. Temporary construction
cores and keys will be provided by the manufacturer until such time as the facility
is inspected and accepted for maintenance by the District. All temporary keys
and cores will be turned over to the District at acceptance.
B. Acceptable Manufacturer:
1. Best Access Systems. Best Stock #21B772-L with stainless steel body.
6.09 PRESSURE SENSOR UNITS
A. Pressure sensors shall be of the full flange design with through boltholes or one-
piece wafer style with carbon steel flanges. Sensors shall clamp between
standard ANSI pipeline flanges. All exposed surfaces shall be epoxy painted or
of a non-corrosive material. Sensor shall be flow through design with flexible
Buna-N elastomer sensing ring around the full circumference.
B. Sensors shall be provided to the installer, assembled complete, from the
supplier. The units shall be filled with a 50/50 ethylene glycol and water mixture
and have no entrapped air in the system. The supplier shall pre-test the unit at
the minimum operable sensing level of the switch prior to delivery to the installer.
C. Pressure sensors units shall include loop powered pressure instrumentation for
both analog and discrete pressure signals. Instrument shall have NEMA-7
Housings with two programmable set point fail-safe solid state relays. Switches
shall be wired normally closed, with adjustable pressure settings. The pressure
range shall be specified for each specific installation. Pressure sensor shall also
include manual gauge.
D. Acceptable Manufacturers:
1. Gauges: SPAN Model LFS 210 with 1/4" connection and 2-1/2” dial.
2. Instrumentation: United Electric “One Series” 1XTXSW
3. Pressure sensors: “ONYX VALVE” wafer pressure sensor type PSW.
Standard Pump Station 40 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
4. Accessory piping: 1/2" or 1/4" Parker Hex stainless steel with reducing
fittings where necessary to connect instruments.
6.10 INTRINSIC BARRIERS
A. The interior of the wet well and the valve chamber is a Class 1, Division 1, Group
D hazardous location as defined in NFPA 820 - Standard for Fire Protection in
Wastewater Treatment and Collection Facilities. Therefore, intrinsic barriers shall
be installed for all intrinsically safe instruments such as floats per NFPA 70 –
National Electric Code.
B. Acceptable Manufacturer:
1. MTL 5016 dual channel
2. Approved equal.
6.11 MAGNETIC FLOWMETERS
A. Flow Tube
1. The flowmeter shall be of the electromagnetic type, utilizing pulsed DC
excitation with microprocessor-based converter/transmitter. The
flowmeter shall measure flow throughout the cross-sectional area. Single
or multi-point measurement devices are not acceptable.
2. Unless otherwise specified, all magmeter applications shall utilize full-pipe
measurement and will always flow full.
3. The flowmeter accuracy shall be better than ±0.5% of measured value or
better in both forward and reverse flows.
4. As a minimum, the magmeter shall be capable of operating at specified
accuracy with flow velocity between three feet per second (3 fps) and
thirty feet per second (30 fps).
5. The repeatability shall be ±0.1% of reading or better.
6. Magnetic flowmeters shall operate with process streams having
conductivity of 20 µS/cm.
7. The meter shall offer a stable zero and shall not require routine zeroing.
The meter shall automatically indicate zero under empty sensor
conditions.
8. Once installed in process pipeline, the magmeter and
converter/transmitter shall be capable of digital set-up and commissioning
in order to verify the integrity of sensor, cabling and transmitter. The
testing technique shall provide verification of the complete flow system,
i.e., sensor and transmitter in-situ, without removal of, or access to, the
sensor. A verification certificate shall be provided. Upon request,
references indicating successful installations with over two years
operation shall be provided.
9. The flowmeter shall be designed and manufactured in an ISO 9001
certified manufacturing facility.
10. The wetted materials shall be compatible with the process stream.
11. Unless otherwise specified, the liner material shall be either neoprene or
hard-rubber. Magmeter electrodes shall be compatible with raw,
unscreened sewage.
Standard Pump Station 41 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
12. The magmeter body (flow-tube) shall be rated to NEMA 6P (IP68) and
suitable for indefinite (continuous) submergence in water to a depth of 30
feet.
13. Magmeter Bodies shall be suitable for installation in a NEC Class 1,
Division 2, Group D Hazardous Location. The metering tube shall be
constructed of Type 304 stainless steel with 150# ANSI carbon steel
flanges. Meter body shall be fully welded no bolt on “clam shell” type
meters. Coil will be located behind the measurement tube. Tube coils
imbedded in the liner or not located behind the measurement tube will not
be acceptable. Meter liner shall be recessed into the flange face on
meters over twenty-four inches (24”) and supplied with AWWA flanges to
maintain the integrity of the Flat Faced Flanges.
14. All conduit entrances shall be either ½” or ¾” NPT.
15. All magmeters shall be furnished with one of the following, grounding
electrodes, a pair of compatible grounding rings or Virtual Grounding.
Where ground rings are furnished, install per all manufacturer’s
requirements. All grounding and bonding per manufacturer’s
requirements are considered incidental to this section.
16. Flow meter shall be installed per manufacturer recommendations,
including minimum required length of pipe upstream and downstream of
flow meter.
B. Remote Flow Converter
1. Converter shall provide separate isolated outputs for analog transmitter
(4-20mA) and pulse outputs (volt free). The working flow range shall be
fully configurable in the field by the end user.
2. Instrument power shall be 120 VAC, 60 Hz.
3. Magmeter Converter/Transmitter housing shall be rated NEMA 4X (IP65),
non-hazardous unless specified as a hazardous classified area. All
conduit entrances shall be either ½” or ¾” NPT.
4. The input impedance shall be 1015 Ohms or greater so that the electrode
fouling does not affect signal and electrode seal integrity.
5. The converter/transmitter display shall be capable of indicating flowrate
and totalization simultaneously in user selectable engineering units. The
totalizer shall be nine (9) digits minimum. Display shall also be capable of
indicating alarm status, percentage of span, and velocity along with
measuring bidirectional flow. Display shall be mounted in Pump Control
Panel.
6. The transmitter shall be configurable by use of a keypad located on the
front face of the transmitter.
7. Magmeter cables between magmeter body and remotely mounted Flow
Converter/Totalizer shall be furnished by the manufacturer in sufficient
length to permit field installation without splicing. Cables installed without
meeting this requirement will be rejected and shall be replaced at
Contractor’s expense.
C. Manufacturers
Standard Pump Station 42 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
1. Siemens – Sitrans F M Mag 5100W with Sitrans F M Mag 5000
transmitter
(Base Bid)
2. Toshiba – Mount Anywhere Sanitary LF494 with LF622F transmitter
3. Krohne – Optiflux 2000 with IFC 100 transmitter
Standard Pump Station 43 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
ELECTRICAL SECTION 7
7.01 PUMP CONTROL PANEL
A. The General Contractor shall be directly responsible for all panel fabrication and
component installations. The pump control panel shall meet the following
specifications. Any deviations from the standards specified below shall be
approved prior to manufacture or installation.
B. General Contractor shall submit shop drawings that include detailed panel
drawings, component cut sheets, etc. Use of provided drawings is not sufficient
to meet these requirements. The District will provide the programming.
Contractor and panel fabricator shall be responsible for testing IO for proper
operation.
C. Panel Configuration
1. The pump controls shall be housed within a NEMA-3R, floor mount
enclosure, constructed from 12-gauge 304 stainless steel, with a #4
finish. Enclosure shall be two door construction with three-point latching
and pad-lockable stainless steel handles. One side shall be designed to
contain Line Voltage (480, 240, 208VAC) and the other side shall contain
controls (120VAC, 24VDC, Intrinsically Safe Circuits). Panel shall be
designed with removable center post for easy panel installation and
maintenance. Panel shall include Heavy Duty Lifting Eyes. Eyes shall be
stainless steel or removed after installation and replaced with gasketed
stainless steel bolts.
2. No operators shall be mounted on exterior of enclosure doors. Control
Panel shall include door in door construction with all operators mounted
on inner doors with continuous hinge swing out kits that allow the
operator to interface with controls without being exposed to live and
energized components. During maintenance inner doors may be opened
by quarter turn latches which allow access to subpanel components.
Inner doors shall be set back to allow room for circuit breaker handles,
pilot lights, displays, etc. All control switches, hour and event meters, GFI
receptacles, indicator lights and circuit breaker toggles, shall be mounted
on the hinged inner door.
3. All compartment exterior doors shall be mounted to the enclosure with
stainless steel full-length continuous hinges. Hinges shall be welded to
the enclosure.
4. Full sub-panels shall be mounted within each door interior. The sub-
panels shall be formed from mild steel. Panel edges shall be turned
down to form a 3/4" lip. All panels shall be painted white and mounted on
3/8"-16 standoff studs per NEC and UL 508
5. All hardware on the panel exterior shall be stainless steel.
6. The control section shall be used for installation of the Supervisory
Control and Data Acquisition (SCADA) system. The primary element of
this system is a combination radio and remote terminal unit (RTU)
manufactured by Motorola. The unit’s name is ACE3600. This system
will be referred to as ACE3600 throughout the remainder of this
Standard Pump Station 44 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
document. Additional space shall be provided for future cellular
communications. Open space shall be of 18” x 18” dimensions.
7. Distribution Equipment for incoming service and backup power generation
shall be installed via stainless steel strut mounted on the back of the
Control panel. Panel enclosure shall be modified to support equipment
without compromising NEMA rating.
D. Thermal Magnetic Breakers
1. Individual thermal magnetic circuit breakers shall be provided for branch
disconnecting service and short circuit protection of all motor and auxiliary
circuits. Combination circuit breaker and overload mechanism shall not
be allowed. Motor circuit protectors may be magnetic only.
E. Float Switches
1. Five floats shall be provided with sufficient length cord to extend
uninterrupted to the valve chamber control junction box. The five float
levels shall be: pump off, lead pump on, lag pump on, wet well high-water
alarm, and detention tank high level alarm. An additional float shall be
provided in the valve chamber for high water alarm. All floats shall be
connected to an intrinsic safety barrier powered by ACE3600 and located
in the pump control panel.
F. Forced Entry Limit Switch
1. A forced entry limit switch shall be wired directly to the ACE3600. The
limit switch shall alarm the opening of the control panel outer doors.
Multiple switches shall be wired to single input.
2. Acceptable Manufacturer: Micro Switch Model 1AC2 or MSD approved
equal.
G. LED Work Light
1. A minimum 12-inch LED work light shall be mounted at each enclosure
door inside the top of the control panel without penetrating the panel outer
skin with screws or fasteners. The light shall be operated with an on/off
switch mounted on the inner door.
H. Panel Heater
1. Low wattage strip heaters shall be installed on inner compartment doors
to prevent the accumulation of condensation. Heaters shall be sized per
submitted enclosure dimensions.
I. Enclosure Fans
1. Enclosures shall include fans to provide adequate cooling for included
components where required. Fans/Vents shall be located to allow airflow
across the panel without short circuiting. Supply and exhaust many not be
installed on the same side of the control panel enclosure. Fans shall
maintain NEMA3R or highest rating of the panel.
J. Wiring
1. All wires in the pump control panel shall be numbered with either clip
sleeve or heat shrink type markers. Wrap on or adhesive type wire
markers shall not be allowed. Approved Control panel schematic shall
Standard Pump Station 45 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
show wire and terminal numbers. A physically separated terminal section
shall be dedicated for the ACE3600 and control wiring. This terminal
section shall consist of a minimum of 80 terminal points and shall be
separated from 120-volt terminals by a minimum of 4". A final 11" x 17"
as-built schematic shall be laminated to the inside of the control panel
exterior door.
K. Surge Protection Device (SPD)
1. A type 1 SPD shall protect the pump station and integrated into the
incoming power or within the service disconnecting means. The arrestor
shall be sized for the incoming power service voltage and shall be
provided in addition to the ACE3600 control surge arrestor.
L. Service Disconnect
1. All stations shall be supplied with service disconnecting means. Fused
disconnect shall be 304 stainless steel minimum NEMA 3R rating rated
minimum 200A. Service Disconnect shall be installed on back of pump
control panel via stainless steels strut and hardware integral to control
panel.
2. Acceptable Manufacturer: Square D, Cutler Hammer, or ABB
M. Utility Meter
1. Contractor shall coordinate utility requirements with servicing utility.
Contractor shall procure and install all equipment, accessories, and
appurtenances required by utility. Equipment shall be minimum NEMA 3R
and installed on back of pump control panel via stainless steel strut and
hardware integral to control panel.
N. Manual Transfer Switch
1. All stations shall be supplied with Double Throw Manual Transfer Switch.
Transfer Switch shall be 304 stainless steel minimum NEMA 3R rating
rated minimum 200A. Transfer Switch shall be installed on back of pump
control panel via stainless steel strut and hardware integral to control
panel.
2. Acceptable Manufacturer: Square D, Cutler Hammer, or ABB
O. Generator Tap Box
1. All stations with Manual Transfer Switch shall be provided with Generator
Tap Box. Box shall be 304 stainless steel minimum NEMA 3R rating.
Generator tap box shall be a junction box with power distribution blocks
for phase, neutral and ground connections to be used with portable
generators. Junction box shall be secured by quarter turn latches with
white subpanel for equipment installation. Contractor shall install 1 x 4”
PVC coated aluminum conduit nipples with cap for temporary connection
of generator cables out the bottom of the generator tap box. Generator
Tab Box shall be mounted approximately 5’-0” above finished grade to
allow easy connection during emergency operations.
P. Phase Sequence and Loss Monitor
Standard Pump Station 46 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
1. All stations shall be protected by a phase sequence and loss monitor.
This monitor/relay shall be a plug-in-type with automatic reset. The relay
shall interrupt the control circuit immediately after the control fuse.
2. Acceptable Manufacturer: The relay shall be a Diversified Electronics
VBA or SLA as appropriate for utility source.
Q. Relays
1. All control and time delay relays shall be at a minimum DPDT 8 or 11 pin
octal base D.I.N. rail mounted.
2. Acceptable Manufacturer:
a. Control Relays: IDEC RH4B-ULand DIN-rail socket or MSD approved
equal
b. Time Delay Relays: IDEC RTE-P2D12 and DIN-rail socket with
additional control relay, or IDEC GT5Y-4SN3D12 and DIN-rail socket
or MSD approved equal.
R. Main Terminal Strip
1. The main terminal strip at the lowest portion of the sub panel shall have a
minimum clearance of six inches.
S. Control Power
1. The control power shall be 120 volts. If 120-volt, single phase is not
available, a minimum 5 KVA transformer shall be supplied with primary
and secondary protection. Individual 120-volt circuit breakers shall be
provided for each separate power requirement. The ACE3600 shall be
powered from a separate dedicated 5-amp circuit breaker, fed from the
control circuit. A 15-ampere Ground Fault Interrupter receptacle shall be
mounted on the inner door of the control panel.
T. Control Panel Name Plate
1. All pump control panels shall have a 4" x 6" phenolic name plate firmly
fastened to the lower right front side of the cabinet inner door. The
nameplate shall include the following:
a. Manufacturer's job number
b. Manufacturer's name, location, phone number
c. Site name
d. Pump model, pump serial numbers, horsepower, voltage, amperage
7.02 THREE PHASE MOTORS
A. All pumps will operate using three phase power. Pumps may either be 208VAC,
240VAC or 480VAC.
B. Any station may use the single phase power source with converter option upon
District approval. Allowance of such a system will depend on the cost analysis
presented by the designer/owner. Allowance will be determined on a case –by-
case basis. Three phase power is the preferred option.
7.03 AMERENUE 3-PHASE SUPPLY CONTROL OPTION
A. MSD will provide generic electrical drawings and the ACE3600 control program.
All 3-phase installations shall meet the following requirements:
Standard Pump Station 47 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
1. Magnetic Motor Starters (NEMA)
a. Magnetic across the line horsepower rated motor starters shall be
supplied for each pump under 20 horsepower. Pumps 20 horsepower
and larger shall be supplied with soft starters with bypass contactors.
b. Acceptable Manufacturer: Cutler Hammer ,Square D, ABB or MSD
approved equal.
2. Soft Starters
a. The solid state reduced voltage starter shall be UL and CSA listed
and consist of a silicon controlled rectifier (SCR) based power section,
logic board and paralleling bypass contactor.
b. The SCR based power section shall consist of six (6) back-to-back
SCR’s and shall be rated for a minimum peak inverse voltage rating of
1,500 peak inverse voltage (PIV). Units using triacs or SCR/diode
combinations shall not be acceptable.
c. Resistor/capacitor snubber networks shall be used to prevent false
firing of SCRs due to dv/dt characteristics of the electrical system.
d. The logic board shall be mounted for ease of testing, service and
replacement. It shall have quick disconnect plug-in connectors for
current transformer inputs, line and load voltage inputs and SCR gate
firing output circuits. The logic board shall be identical through all
ampere ratings and voltage classes and shall be conformally coated
to protect from environmental conditions.
e. The paralleling bypass contactor shall energize when the motor
reaches full speed and close/open under 1 x motor current. The
contactor shall be fully rated for across-the-line starting duty should
this be desired. The contactor shall utilize an energy balanced
contact closure to limit contact bounce and an intelligent coil controller
which optimizes coil voltage during varying system conditions. The
coil shall have a lifetime warranty.
f. The overload protection shall be electronic and be based on an
inverse time/current algorithm. Overload protection shall be
adjustable, and Class 10/20 shall be selectable. Units using bimetal
overload relays are not acceptable. Over temperature protection (on
heat sink) shall be standard.
g. The solid-state logic shall be phase sensitive and shall inhibit starting
on incorrect rotation. Improper phase rotation shall be indicated on
the starter.
h. Starters shall protect against a phase loss/unbalance condition
shutting down if a 35% current differential between any two phases is
encountered.
i. A normally open (NO) contact shall annunciate fault conditions, with
contact ratings of 60 VA resistive load and 20 VA inductive load. In
addition, an LED display shall indicate type of fault (current trip, phase
loss, phase rotation).
j. The following adjustments are required:
Ramp time: 1-45 seconds i.
Initial torque: 100-200% current ii.
Current limit: 100-500% current iii.
FLA of motor: 4-1 range of starter iv.
Standard Pump Station 48 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
k. Smooth stopping shall be available to provide a linear voltage
deceleration. It is to be adjustable from 1-45 seconds.
l. Acceptable Manufacturers: Cutler Hammer Square D or ABB
3. Pump Control Circuits and Indicator Lights
a. Individual pump control circuits shall be provided with 30mm Nema 4
H-O-A switches, elapsed time meters and re-settable event counters
for monitoring pump cycles. Provide green pump running lights, white
control power available light and individual red indicator lights for
faults and amber indicator lights for warnings. Indicator lights shall be
30 mm full-voltage LED push to test type (white with colored lenses)
or MSD approved equal. The above switches, lights, meters and
counters shall be mounted on the inner door of the control section of
the panel.
b. Momentary Contact NEMA 4 30mm pushbuttons shall be installed to
test float operations.
4. Starter Control and Back Up Control
a. The starters shall be controlled by ACE3600 and the District will
provide a standard control program to operate the station. All floats,
auxiliary starter contacts and pressure switches shall be wired to the
ACE3600 as digital inputs as shown in the generic electric drawings.
A Pump Run digital output shall switch 120 VAC to the starter coil via
an interposing relay and the pump’s H-O-A switch. A normally closed
contact of another interposing relay shall interrupt the starter coil
when a Pump thermal or starter overload is activated. Pump Failures
shall be reset by switching the H-O-A switch to the off position. The
contact ratings of the interposing relays shall be 10 amperes
minimum.
b. As a backup control, the high-level float will latch a relay that will start
the two pumps at the station and that relay will release when the wet
well water level falls below the stop float. The backup start command
will be wired in parallel with the ACE3600 Pump Run relay contact.
5. Device Identification
a. All devices mounted flush on the inner cabinet door shall be identified
with phenolic legend plates. All switches, pumps, lights, breakers,
relays, and auxiliary devices mounted to the sub-panels shall be
identified with engraved phenolic legend plates.
7.04 PHASE CONVERTER OPTION
A. Because of the higher probability of electrical failure from using a phase
converter, this type of system shall only be considered after investigating the
feasibility of having three phase power brought onto the job site. Three phase
power shall be used unless installation costs justify the installation cost of a
converter. All phase converter installations shall meet the following
requirements, any deviations shall be approved by MSD prior to manufacture and
installation:
1. Converter
a. The converter shall be a variable frequency drive unit set up to run at
100% speed. The converter shall be de-rated to account for the
single-phase power supplied to the unit. Converter shall have
EMI/RFI filtering built in to the front end to inhibit harmonic
Standard Pump Station 49 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
interference. It shall be programmed and controlled from a
keypad/display unit. The following functions will be available:
Local/Remote with Start/Stop keypad pushbuttons. i.
Keypad and hardwired reset functions. ii.
Hardwired input for external failure points (high pump iii.
temperature and seal failure)
Hardwired remote start/stop through a single contact iv.
(ACE3600 or high-level alarm relay)
Ramp up, ramp down settable 0-30 second v.
Status display vi.
Under-voltage protection. vii.
Over-current protection. viii.
Ground fault protection. ix.
Failure log. x.
Hardwired run and failure output contacts. xi.
2. Converter Control and Back Up Control:
a. Converters will be controlled by the ACE3600. All floats, run and
failure feedback, and pressure switches will be wired to the ACE3600
as digital inputs. The digital outputs will be wired to start/stop and
reset inputs on the converters. The District will provide a standard
control program to operate the station. As a backup control, the high-
level float will latch a relay that will start the two pumps at the station
and that relay will release when the when the wet well water level falls
below the stop float. This start command will be wired in parallel with
the ACE3600 run command.
b. The converters shall be mounted in the line voltage section of the
control panel. Cooling ventilation with fan and filter will be provided
and sized to ensure no failures due to over temperature of the
converter unit. AC units shall be stainless steel with minimum NEMA
3R rating.
c. Acceptable Manufacturer: Cutler Hammer, Square D, ABB or MSD
approved equal.
7.05 STATION INTERIOR WIRING
A. The interior of the wet well and valve chamber are Class 1, Division 1, Group D
hazardous locations. All electrical installations within these areas shall be
explosionproof in accordance with minimum requirements set forth by NFPA 70 –
National Electrical Code (NEC).
B. Wet well level control float leads shall be hung with stainless steel kellum grips
from a series J Halliday stainless steel cable holder. The holder shall be bolted
to the inside of the wet well hatch, immediately below the hatch cover and shall
be located to not interfere with the wet well entrance steps. The pump power
cables shall be hung with stainless steel kellum grips from the upper pump guide
rail brackets. Power and control wiring shall be routed with adequate separation.
All excess wires shall be rolled up inside the valve chamber.
C. Passage of the pump and float wires from the pump chamber to the valve
chamber shall be made through two (2) open ended lengths of four inch (4”) PVC
coated aluminum conduit installed between the valve and pump chamber. A
Standard Pump Station 50 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
minimum of twelve inch (12”) separation should be maintained between the
control and power wiring.
D. There shall be no electrical connections made in the pump chamber. All wiring
shall run unbroken from the pump chamber to the valve chamber through the
four inch (4”) PVC coated aluminum conduits and terminated at a properly sized
terminal boards inside a NEMA 7 junction box. Intrinsically safe conductors may
be spliced in NEMA 4X 304 stainless steel junction box. Power and control
conductors shall be spliced in separate junction boxes. Conduits leaving the
junction box shall include Class 1, Division 1, Group D conduit seals. Conduits
and seals shall be PVC coated aluminum conduit as manufactured by Calbond or
MSD approved equal.
E. Valve chamber junction box connections are to be made with Class 1, Division 1
Group D cord connectors.
F. All wiring in the valve chamber shall be routed and fastened securely along the
chamber walls with non-corrosive stainless steel wire straps and fasteners.
7.06 PRESSURE SENSOR WIRING
A. Each pump shall include a discharge pressure sensor. Wiring from the pressure
sensors shall be in accordance with NEC minimum requirements for classified
locations. Wiring may be in conduit with flexible connection at instrument or by
use of type MC-HL cable with listed fittings.
7.07 FIELD WIRING SPECIFICATIONS
A. Control panel wiring shall be as follows:
1. All wiring installed on the line and load side of the electric meter shall be
THHN copper wire.
2. Electric service to the station shall be sized to provide the maximum total
station amperage with all installed pumps running under a fully loaded
condition.
3. All pump station control panels shall be provided with a minimum 100-
amp service.
7.08 CONDUIT SPECIFICATIONS
A. The following conduit sizes are to be used on any combination of pumps with a
total station HP of less than 60 HP. For larger HP stations, contact MSD Pump
Station Division for specific conduit sizes.
1. All above grade and exposed conduits shall be PVC coated aluminum.
Conduits installed below grade may be schedule 80 PVC with minimum 2
foot burial depth. Install line marking tape 6 inches above conduit.
Transition from PVC to PVC coated aluminum conduit below grade.
2. A 2-1/2" conduit shall be used to run from AmerenUE supply source to
the electric meter mounted on the control panel. The meter disconnect
switch, manual transfer switch and generator tap box are to be connected
together with PVC coated aluminum. A 2-1/2" conduit shall be used to run
all power wires from the control panel, to the power junction box in the
valve chamber. Conduit to include conduit seal.
Standard Pump Station 51 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
3. A 2-1/2" conduit shall be used to run all control wires from the control
panel, to the control junction box in the valve chamber. Conduit to include
conduit seal.
4. A 2-1/2" conduit shall be used to run the antenna coax from beneath the
antenna pole to the control panel.
5. PVC coated aluminum conduit shall be used below grade for pump power
conduits, including all fittings and transition points, when a converter is
used with single phase utility supply.
7.09 CONTROL PANEL MOUNTING
A. The station pump control panel shall incorporate the pump controls, alarm
system and power distribution into one stainless steel structure. The panel shall
be placed as follows:
1. The control structure shall be set on a 4-inch concrete pad (see Section
3).
2. Conduits shall be run into the control panel from beneath the structure per
the detail drawing.
3. The panel shall be centered on the concrete pad and set a minimum of 4-
inches in from the rear edge of the pad.
4. Prior to setting and securing the panel to the concrete mounting pad, a
strip of 2”x1/4” solid rubber gasket material shall be placed against the
bottom frame to create a seal between the concrete mounting pad and
the panel bottom.
5. The control panel shall be firmly anchored to the concrete mounting pad
with six, 3/8-inch stainless steel Wej-It type stud anchors. Anchor holes
in the concrete pad shall be drilled to the manufacturer’s recommended
depth.
B. Acceptable Manufacturer: Anchors shall be Hilti Quick Bolt Two or MSD
approved equal.
Standard Pump Station 52 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
ALARM SYSTEM SECTION 8
8.01 SYSTEM REQUIREMENTS
A. Each pump station shall have a ACE3600 RTU conforming to the District's
existing system.
B. The District's system operates on utilizing a Motorola ACE3600
Central Station Transceiver for interrogation and acknowledgment of alarms.
C. The RTU shall be provided by MSD for contractor installation. Contractor shall
install and terminate the RTU per the construction drawings. The RTU shall not
be energized until MSD personnel are present for program download and startup.
D. Additional space shall be provided for future cellular equipment. A clear space of
18” x 18” shall be provided.
8.02 ANTENNA
A. The minimum acceptable transmission strength shall be determined as +20 db.
above the threshold of the closest satellite receiver.
B. The antenna azimuth shall be in the direction of the nearest satellite receiver +/-
15 degrees.
C. The actual working antenna height is to be determined by contractor to ensure
direct communications with SCADA Central. The minimum height allowable per
MSD is 20' above finished grade. If topography requires the antenna to be
located higher than 20', contact the Pump Station Division for additional pole
specifications.
D. Acceptable Manufacturer: Antenna - Decibel Model #DB230-L or Comtelco or
equal
8.03 POLE SPECIFICATIONS
A. The antenna shall be mounted a minimum of 20' from finished grade on a
minimum 24' long fiberglass street light type pole. The pole base shall be set 4'
below ground with 4-1/2' deep and 1-1/2' round concrete base poured around it.
The pole must be installed so that it is vertical +/- 1 degree. The top of the pole
shall be sealed against water penetration with a cover cap. A grounding rod
installed at the base of the tower must protect all antennas. Grounding rod
length shall follow national electric code requirements.
B. Acceptable Manufacturer: Fiberglass Pole - Whatley #E3029-01-59-S or MSD
approved equal.
8.04 POLE SITE LOCATION
A. Antenna poles shall be installed behind the control panel as indicated on the
control panel drawings or as approved in the field by MSD personnel.
Standard Pump Station 53 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
8.05 ALARM COAXIAL CABLE
A. The alarm coaxial cable shall be installed as follows:
1. The coaxial cable is to be run in one continuous length with no splices.
The coax shall be terminated at the antenna connector on one end and a
lightning arrestor on the other end. Another cable shall be connected
from the lightning arrestor to the connector on the outside of the radio
cabinet (to be installed per drawing).
2. All R.F. cable connectors outside of the radio cabinet shall be properly
terminated and sealed with 3M Cold Shrink.
B. Acceptable Manufacturers:
1. Coax: Beldon #8267
2. Lightning Arrestor: Polyphasor: # IS-50NX-C2
3. RF connector: Amphenol - Male: #82-202, Female: #82-63
4. Cold Shrink: 3M P/N (8425-7 and 8426-9)
Standard Pump Station 54 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
SITE REQUIREMENTS SECTION 9
9.01 SITE AND ACCESS ROAD PAVEMENT
A. Pavement will be required at the pumping station as follows:
1. Station Area
a. The wet well, valve chamber, and condition monitoring structure shall
have a minimum six feet (6') paved apron installed around the
structures. The pavement shall be sloped so as to permit surface
water to drain away from the station.
b. When fencing is required around the station area, the entire area
within the fence shall be paved, with the pavement extending an
additional one foot (1’) beyond the fencing perimeter.
2. Station Access Road
a. The access road shall:
Be a minimum of twelve feet (12’) wide. i.
Be designed to limit the access road grade to a 10% ii.
maximum. If the road grade must exceed a 10% slope, a
combination of step type sloping and protection barriers will
be required.
Have a turn around area at the station end of the access road iii.
large enough to accommodate the turning radius of a sixteen
feet (16’) service van.
b. The centerline of the entrance road shall bisect the station gate
entrance, security fence, and the valve chamber and wet well
structures. If this type entry is not feasible for a particular site, the
closest structure to the gate and road shall be the wet well.
3. Pavement Specifications:
a. Asphaltic Concrete
The access road and area surrounding the station shall be i.
paved with two inches (2") of type "C" asphaltic concrete laid
over six inches (6") of type "X" asphaltic concrete. All
subgrade shall consist of six inches (6") of well-compacted
crushed limestone.
b. Poured Concrete
Concrete pavement shall be Class A six inch (6") thick, six (6) i.
sack mix with a four inch (4") slump. Pavement shall be
reinforced with 8 gauge, 6 x 6 welded wire mesh. The
concrete shall be laid over a well-compacted four inch (4")
stone base.
4. Entrance Road Barriers
a. Stations requiring entrance roads shall have thirty-six inch (36”) high
barrier posts installed at the road entrance. Post shall be constructed
of six inch (6") concrete filled steel or iron pipe, or six inch (6”) by six
inch (6”) cedar posts. Posts shall be set thirty inches (30") below
grade in an eighteen inch (18") by thirty-six inch (36") poured concrete
base. A 5/16" diameter galvanized chain locked on one end and
firmly fastened to the other, shall be run between the poles. For safety
purposes, a four inch (4") by twelve inch (12") reflective plate reading
“NO PARKING” shall be attached to the chain at the span center.
Standard Pump Station 55 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
9.02 FENCING
A. Fencing shall be required around all pump station sites unless it can be
satisfactorily shown by the design engineer that no safety hazard or vandalism
threat would exist by the absence of fencing. Fencing limits must be included on
the pump station site plan. Elimination or alterations to the approved fencing
plan shall only be considered for compliance with municipal requirements.
B. Fencing Specifications
1. Chainlink Fence
a. Wire fabric for the fence shall be brown or green vinyl clad six feet (6')
high chain link fabric. Wire shall be No. 11 gauge woven in a two inch
(2") mesh. Top and bottom salvages shall be barbed.
b. All posts and other appurtenances used in the construction of the
fence shall be brown vinyl clad schedule 40 pipe. All posts shall be
equipped with tops. Fiberglass fencing components will not be
acceptable.
c. A twelve feet (12') wide entrance gate shall be provided for access to
the station grounds.
d. Posts shall be sized and set as follows:
TYPE SIZE PULL
Top Rails & Brace 1-14” Nominal (1.66” O.D.) 2.27 lbs./ft.
Line Post & Gate Frame 1-1/2” Nominal (1.9” O.D.) 2.72 lbs./ft.
End Corner or Pull Post 2” Nominal (2.375 O.D.) 5.79 lbs./ft.
Gate Post 3-1/2” Nominal (4” O.D.) 9.11 lbs./ft.
e. Posts shall be set in the concrete bases so that the pole bottom rests
six inches (6") higher than the concrete base bottom.
f. Horizontal support bars shall be installed half way between the top rail
and the ground.
g. A #7 tension wire shall be installed at the bottom of the fencing fabric
and stretched taught enough so as to not allow the bottom of the
fencing fabric to be lifted away from the fencing poles and/or ground.
2. Wrought Iron Fence
a. Fencing shall be Heavy Industrial Steel Ornamental Fence System –
Fusion Welded.
b. The system shall include all posts, panels, and mounting accessories.
c. Grade: Industrial
d. Standard Style: 3-3/4 inch air space between pickets
Invincible Style: Pressed pointed pickets extended above the i.
top rail, curving outward.
e. Steel (ASTM A924/A924M): Steel for tubular pickets, rails and posts
have minimum yield strength of 45,000 psi (310 MPa).
f. Galvanizing (ASTM A653/A653M): Prior to forming, hot dip galvanized
with minimum zinc coating weight of 0.90 oz/ft2, Coating Designation
G-90.
g. Rails:
Steel channel, 1.75 inches x 1.75 inches i.
Standard Picket Spacing: Picket holes shall be spaced at ii.
4.715 inches o.c.
Standard Pump Station 56 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
h. Pickets: 1 inch square x 14 gauge tubing.
i. Racking/Biasability (Ability of Panels to Follow Grades): able to follow
varying grade changes to a maximum of 48 inches rise in an 8 foot
run.
j. Posts:
Size: 2.5 inches by 2.5 inches by 12 gauge with standard post i.
cap
Size: 3 inches by 3 inches by 12 gauge with standard post ii.
cap
Size: 4 inches by 4 inches by 11 gauge with standard post iii.
cap
k. Acceptable Manufacturer:
Montage II, Invincible design by Ameristar Fence Products, i.
Inc., or approved equal.
3. Fencing Placement:
a. Fencing shall be located so that:
There is a four-foot (4') space between all auxiliary pump i.
station equipment, panels, antenna poles, generators, etc.
and the fence perimeter.
The access gate shall be located so that hoisting or cleaning ii.
equipment can easily access the valve and wet well
chambers.
9.03 SITE MAINTENANCE
A. Temporary erosion control shall be provided in accordance with state and local
requirements.
B. Surface water must be directed away from the pump station structures and
paved areas to prevent debris from washing over the paved area or ponding of
water at the pump station site. Ground shall be sloped at a minimum two percent
(2%) grade away from the pump station. Spot elevations should be included on
approved plans prior to Construction.
9.04 RESTORATION
A. Restoration shall be in accordance with the District’s Standard Construction
Specifications, latest edition. Final acceptance of the station shall be withheld
until the site is restored to the District’s satisfaction.
Standard Pump Station 57 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
INSPECTION AND ACCEPTANCE REQUIREMENTS SECTION 10
10.01 GENERAL
A. In addition to the ongoing construction inspection by District Engineering
Construction Inspectors, District Operations/Pump Station personnel shall make
inspections of the constructed work at specific stages of the pump station
construction. Any inspection of the work by the MSD Construction Inspectors or
Pump Station personnel shall not relieve the Contractor of its responsibility to
comply with the plans and specifications and to perform all work in a good and
workmanlike manner in accordance with the approved plans and specifications
and the contract documents. The Contractor responsible for constructing the
pump station shall notify the District Construction Development Inspection
Division when the facility is ready for each inspection. Failure to have the
inspection performed at the proper time during the construction process could
result in the District requiring the removal and reconstruction of the completed
work.
10.02 PRE-CONSTRUCTION MEETING
A. Contractor will schedule a pre-construction meeting through the MSD
Division/Resident Inspector. MSD Operations will be involved in this meeting as
well. This meeting will cover construction phase requirements and inspections,
as detailed below.
10.03 STAGE ONE: SHOP DRAWING REVIEW
A. Purpose
1. Verify Contractor’s proposed pump station components, including
structures, piping and equipment, meet the approved construction
specifications and plans prior to ordering material.
2. All Shop drawings shall be reviewed by Design Engineer and stamped
prior to submittal to MSD.
3. Submittals shall be made using Accela.
B. Suggested Shop Drawings
1. Construction schedule
2. Pre-cast structures
a. Manholes
b. Wet well (if applicable)
c. Valve chamber (if applicable)
d. Detention chamber (if applicable)
3. Cast-in-place structures
a. Concrete mix design
b. Concrete reinforcing
4. Piping
a. Influent sewer
b. Pump discharge piping
c. Pump forcemain
d. Pipe supports
e. Detention chamber (if applicable)
Standard Pump Station 58 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
f. Bypass portal
5. Equipment
a. Submersible pumps and appurtenances
b. Pump station control panel (Contractor to request radio from MSD
upon shop drawing approval).
c. Pump station appurtenances
d. Valves
e. Floats or level measurement
f. Flow meter
g. Hatches
h. Antenna
i. Pressure sensor
j. Pressure transducer
k. Miscellaneous electrical
l. Gate (if applicable)
m. Hoists or davit cranes (if applicable)
n. Generator (if applicable)
10.04 STAGE TWO: PRE-STRUCTURE INSPECTION
A. Purpose
1. Verify excavation and subgrade placement for the pump station.
2. Verify any fillets and that the site has proper drainage.
3. Verify contractor is not encroaching on adjacent property, is minimizing
disturbance to the extent practical.
4. If pre-cast structures are approved, verify structures match approved
shop drawings, prior to installation. Also check condition of precast and
ensure no damage is evident. Check mastic sealant, and that it meets the
specifications. Ensure that the precast exterior is waterproofed with
bitumastic/asphaltic material. If piping penetrations are cast in, verify the
number of holes and that their location generally matches the drawings.
This could include wet well, valve chamber, manholes, detention
chamber, etc.
5. If cast-in-place structures are approved, verify rebar on site matches
approved shop drawings, prior to installation. Ensure the rebar is
adequately supported, and measure to verify the thickness of the base
slab matches the drawings.
6. Verify any piping and equipment that is on-site matches approved shop
drawings
B. Timing
1. Following excavation and backfilling of subgrade, prior to installation
and/or construction of any structures.
C. Suggested Certifications/Reports received prior to inspection
1. Subgrade compaction testing (if required)
2. Geotechnical boring logs (if required)
10.05 STAGE THREE: FINAL STRUCTURE INSPECTION/PRE-EQUIPMENT
INSTALLATION
Standard Pump Station 59 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
A. Purpose
1. All structures shall be cleaned and acceptable for manned entrance for
inspection.
2. Verify all pump station structures have been installed/constructed
correctly
3. Verify influent sewer and associated manholes have been installed
correctly.
4. Locate forcemain and verify it was installed correctly.
5. Verify detention chamber and associated manholes have been installed
correctly.
6. Inspect control panel prior to install.
B. Timing
1. Following Stage 2, after installation/construction of all structures, influent
sewer and detention basin, but prior to backfilling.
C. Certifications/Reports received prior to inspection
1. Wet well hydrostatic test (if required)
2. Influent sewer pressure test (if required)
3. Detention chamber hydrostatic test (if required)
4. Concrete testing reports (if required)
10.06 STAGE FOUR: POST EQUIPMENT INSTALLATION
A. Purpose
1. Verify pumps, control panel, and radio have been installed correctly.
2. Verify remaining equipment and associated ancillary items are per
specifications and have been installed correctly.
3. Inspect yard piping and electrical conduit installation.
4. Verify Grounding Electrode System is installed at service disconnect.
5. Inspect trench excavation and pipe bedding.
6. Verify thrust restraint is installed at all pressure fittings.
7. Pipe supports for vertical forcemain piping in wet well.
8. Correct configuration of piping and appurtenances in valve chamber.
9. Measure distance upstream of magnetic flowmeter to tee or fitting.
10. All pipe supports in valve chamber are secure.
11. Pipe penetrations through structures and method of sealing.
12. Pressure testing of gravity sewer, isolation valves, and cleanouts.
B. Timing
1. Following Stage 3, after installation of all piping, valves and fittings, prior
to trench backfill.
10.07 STAGE FIVE: EQUIPMENT STARTUP
A. Purpose
1. Pull pumps from the pump station for inspection.
Standard Pump Station 60 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
2. Verify each manufacturer has field-verified their specific devices.
3. Demonstrate that all equipment is installed and operates as an integrated
system.
4. Complete startup testing.
B. Timing
1. Following Stage 4, after installation of pumps and all electrical and
controls systems.
C. Suggested Certifications/Reports
1. Submersible pump equipment start-up report and certification (includes
pumps, control panel, and related appurtenances).
2. Standby generator start-up report and certification (if required).
D. Testing
1. Performance Acceptance Test (by Contractor)
a. In the presence of the District Operation/Pump Station personnel, the
Contractor shall subject the pump equipment to such operating tests
as may be required by the District to demonstrate that the equipment
performs in accordance with the design requirements. At a minimum,
the following two (2) tests shall be performed:
The insulation resistance of the pump’s windings and cables i.
shall be tested. The installed pumps shall not register less
than 100 meg-ohms resistance per winding on a meg-ohm
meter.
The pumps shall be subjected to start-up tests with the ii.
voltage, current and other significant parameters being
recorded on the standard forms provided by the
manufacturer. The contractor shall arrange for an adequate
supply of water for the tests. The minimum quantity of water
to be provided shall be equivalent to 1.5 minutes of
continuous pumping at the rated pump capacity for each
pump operating alone. Each pump shall be tested a minimum
of two (2) times. In addition to the water required for the
Contractor’s test, the Contractor shall supply an adequate
water supply for all of MSD’s pump startup described below.
2. Pump Startup (by MSD)
a. Drawdown test
b. Check for leaks in pump mating surface and discharge piping
c. Test alarms
d. Pump station testing for full flush of the forcemain. Testing will include
single pump operation and multiple pump operation.
e. Check pump guiderails
3. Flowmeter Startup (by MSD)
a. Verify flowmeter installation and check accuracy
4. Instrumentation/Control Panel Startup (by MSD)
a. PLC Program test
b. Communication test
5. Generator Startup (by MSD)
Standard Pump Station 61 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
a. Load test for station operation
b. Test automatic switchover cycle
c. Validate manual transfer switch (if applicable)
10.08 STAGE SIX: FINAL COMPLETION INSPECTION
A. Purpose
1. Verify sitework, including grading and pavement, has been completed per
approved construction plans and specifications.
2. Verify fencing has been installed correctly.
3. Verify Conduit Seals have been poured.
B. Timing
1. Following Stage 5, after installation and construction of all sitework,
including grading, paving, fencing, etc.
10.09 STAGE SIX A: POST-FINAL COMPLETION INSPECTION (IF REQUIRED)
A. Purpose
1. Verify final punch list items have been completed as required
B. Timing
1. Following Stage 6, after notice by contractor that punch list items have
been corrected.
10.10 STAGE SEVEN: FINAL ACCEPTANCE/DELIVERABLES
A. A Reliability Acceptance Test shall occur for the first thirty (30) days of the pump
station being in service. If the pump station operates as intended for the entirety
of this period, the pump station will be ready for acceptance by the District.
B. Prior to District Operations/Pump Station Division accepting this facility, the
following submittals must be provided thru Accela:
1. Four (4) sets of as-built electrical schematics.
2. Four (4) sets of as-built prints of the pump station site, prepared by an
engineer or land surveyor registered in the Missouri, certifying that all
structures, sewers, roads and other pavement were built in accordance
with the approved plans and located within existing easements.
3. A complete set of the as-built drawing computer files (including structural
and mechanical details) in AutoCAD Lt format (jump drive).
4. Pump manufacturer’s start-up test procedures; the recorded factory test
readings for voltage, current and other significant parameters
documented on standard forms; and blank forms for the field test.
5. Letter of completion from paving contractor, guaranteeing that all
pavement and pavement subsurface have been installed per the
approved plans and specifications.
6. Control panel schematics, 11”x17” in size, laminated to the inside of the
control panel exterior door.
7. Operating manuals and specification literature (both hardcopy and digital
copy).
8. Equipment Warranties (both hardcopy and digital copy).
Standard Pump Station 62 Metropolitan Saint Louis Sewer District
Design and Construction Requirements July 2020
9. Copy of electric, gas and water bills to facilitate the transfer of these
accounts to the District at the time of dedication.
10.11 RE-INSPECTION OF WORK
A. The District will perform one (1) inspection and one (1) re-inspection at each
stage of the construction at no charge to the contractor. The contractor will be
responsible for all additional costs associated with the District’s re-inspections
due to the failure of the contractor to satisfactorily correct the identified
deficiencies.