“See you at the station” Do you know the Definitions of the components that make up a Packaged Waste Water Lift Station?

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Taylor Made Pump Stations “Writes The Book” or in this case a booklet on the definitions of the individual components that make a complete Packaged Waste Water Lift Station!

We will start with defining the basic parts of the Packaged Waste Water Lift Station.

 

  1. Packaged Waste Water Lift Station.  Is a concept of packaging all the electrical, mechanical and structural components that go into the making of a complete operational water or waste water lift station. As a part of the definition of packaging it is meant to assemble beforehand and usually in a controlled environment such as a building structure.
  2. Lined Wet Well. A methods of casting in place a non-corrosive membrane into the inside walls, floor and top of a concrete waster water lift station. The material most commonly set into the wet well to form a liner are made up of poly vinyl chloride (PVC) or high density poly ethylene (HDPE) in varying thicknesses but most commonly 30mil.
  3. A Concrete Wet Well.  When it is included as part of a packaged waste water lift station order is a reinforced precast structure formed in round sections called barrel sections in varying diameters and lengths .
    The base section of the wet well is the floor it comes with an anti-buoyancy block which is generally
    a thickened section of up to 18’’in diameter and also wider than the barrel sections, to create an
    loading area to resist uplift of the structure.
  4. Pre-Cored Pipe Penetrations. Usually applies to the situation of a waste water lift station having round holes pre-drilled to accommodate pipe entering the wet well. These core holes will be considerably larger than the pipe O.D. to allow for Elastomeric sealing products to be utilized.
  5. Field Core Pipe Penetrations. This mode of creating openings in a packaged waste water lift station is a service offered by Taylor Made Pump Stations and the equipment needed to drill the concrete structure in the field, is provided with the packaged waste water lift station. Field coring allows for a precise hole opening that may be required in the situation where an existing pipe elevation could vary.
  6. Valve vault.  The valve vault in a waste water lift station is most commonly a square concrete box structure as manufactured by Oldcastle Concrete. The pre-cast structure comes in varying sizes but an average dimension to suit most municipal waste water lift stations is 4’ wide by 6’ long by 4’ deep. In most all cases in will come with dual or single lids. Hatches are made of galvanized stainless steel or aluminum that are made of stainless or aluminum for their anti-corrosion capabilities.
  7. Control Systems.  Commonly conceived or designed for total automatic control of two motor driven pumps operating on standard 240V 3 Phase or 480V 3 Phase,(208 and 240V single phase are common on smaller HP motors, usually under 5HP).
  8. Programmable Logic Controller. (PLC) Is a digital computer used for automation of electrical/mechanical actions, such as control of “pumps, valves and warning alarms.” The abbreviation “ PLC” are registered 547px-RiserDiagram.2vg2trademarks of the Allen Bradley Company (Rockwell Automation). The PLC is a “current time” system since output results must be produced in conjunction to input conditions within a limited time, otherwise unintended actions will occur.
  9. Liquid Level Monitoring.   A wet well level is controlled commonly utilizing the following electronic equipment. Float Switches, present in many of today’s waste water lift station. These point level sensors comprised of a magnetic float moves in relation to the water’s surface. Usually tethered off a solid pole or rack floats are tied off to create an actuation range in which a certain volume of liquid will cause a rise or drop in the level of the liquid and thus cause a pump to turn on or off. Included as part of the packaged waste water lift station. These read type switch mechanisms can either be single pole, single throw or double pole, double throw.
  10. Transducer.   A hydrostatic pressure sensor is an example of a transducer; a transducer contains sensors and converts it signal to an electrical signal to operate other mechanical or electrical devices.
  11. Contact Ultrasonic Sensors.  A low energy field mounted sensor and integral solid state amplifier. These sensors will auto operate pumps, solenoid valves and high/low alarms.
  12. Power Distribution Block.  A main distribution block sized for incoming line power to a panel.
  13. Surge Protection. Made of a oxide silicon varistor. A lightening suppressor must be able to handle surges of a minimum of 60 thousand amps or 1,500 Joules.
  14. Phase Monitors.  Where 3 phase motors are installed a phase monitor is employed to monitor phase loss, under voltage and phase sequence with a single pole double throw switch.
  15. Variable Frequency Drives. Variable frequency drives operate under the principal synchronous speed of a AC motor is determined by the frequency of the AC supply and the amount of poles state of winding according to the relation: RPM= {{{60 \ times f}\over {p}}}.
  16. Circuit Breakers.  Taylor Made Pump Stations specifies in each packaged waste water lift station thermal magnetic breaker for each load served one for the transformer and one for each motor served.
  17. Contactor Overload Relay.  For motors less than 20 HP a magnetic across the line HP/Current rated contactor with a ambient temperature overload relay.
  18. Soft Starts.  Directly relates to reducing the torque delivered to the electric motor. This can be accomplished via a mechanical clutch, fluid drive, magnetic coupling or any derivative thereof that allows the across the line starting while decreasing the shaft torque to the load and thus avoid torque shock. Taylor Made Pumps Stations recommends soft starts as a money saving investment that increases overall MTBF, mean time before failure of the pump loader.

 

For you readers of my “Blog For The Nog,” ” See You At The Station”, when you google definitions of the components that make up a packaged waste water lift station you will have the terms in a click of a button.

“See You at the Station” What kind of business is a supplier of “A Prepackaged Waste Water Lift Station“?

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The best definition of a Prepackaged Waste Water lift Station business is as follows.
“A business that assembles all the components necessary to make a complete working Lift Station, capable of moving the specific liquid waste as specified by a design engineer and shipped as a Prepackaged group of components, (usually in one large shipment, but sometimes two due to the size of the station) ready for install at the designated site”.

One day in the business of building “Prepackaged Waste Water Lift Stations”! Our first call is a customer who owns a Mobile Home park and needs a retrofit of an existing station.

Mark at Desk 3It is 8:00 am and a call came in for a small duplex pump arrangement with a duplex pump motor control panel and 3 float switches, i.e. the on/off, and high alarm for each pump. The gentleman to whom I was talking was very relieved that Taylor Made Pump stations, a large supplier of Prepackaged Waste Water Lift Stations for the municipal market, his words not mine, could help him with his small order for his mobile home park in Vale. Oregon. After some time of discussing the fixture load of the mostly single wide mobile home dwellings and determining the total dynamic head of the system as well as the liquid capacity of the waste water tank. It was determined that two Liberty FL 100 series Waste Water Pumps would adequately handle the peak flows. An Orenco High Density Polyethylene Screened Vault was also suggested as the current “screening method” was an old washing machine tub. A base model Allen Bradley duplex pump control was added to compliment the system and keep the entire operation simple. I was able to give this customer a price right away thanks to my relationships with my suppliers and the total cost of under of under $2,000.00 dollars. I was happy to hear that this customer heard about me through another customer and the last I heard referrals are a great way to build a business, including a Prepackaged Waste Water Lift Station business! I have several messages on my desk and all is good as I hear and see activity all around, but “Control Center” we have a problem.

A slightly alarmed caller says “The EZZ-Klean™ tube cannot be installed as planned into a waste water lift station as the tube was tested by a loaded dump truck”.

For the finest wet well cleaning system on the market today to work you must install it into the wet well. The dump truck running over the EZZ-Klean™ tube definitely put a “crunch” on the installation. The contractor had just received the EZZ-Klean™ Tube and Vacuum Head from Oldcatle Concrete out of Wilsonville,Ore. Taylor Made Pump Stations is the manufacture for the EZZ- Klean ™ System and the man on the other end of the line wanted to know what type of material the tube was made of. I assured the panicked supervisor that another piece of HDPE suction tube is readily available from most Ferguson supply houses, throughout the N.W.

The old saying “So much to do and so little time “ is so relevant to anyone involved in business in these times. We fielded calls from solicitors and the Google team of ad professionals on top of a few individuals looking for work and suddenly the day comes to a close.

At Taylor Made Pump Stations we are a team of Prepackaged Waste Water lift Station Builders that base our business on referrals and good service after the sale!

Taylor Made Pump Stations builds and constructs “Prepackaged Waste Water Lift Stations” Taylor Made Pump Stations has been involved in the Waste Water Pumping Industry for over 34 years. We started by serving the residential market by building the home micro treatment systems as designed by the Department of Environmental Quality. Some 25 years later that small septic system installer was working on and building a multimillion dollar waste water treatment plant with the variety of construction classifications, from electrical and mechanical to the structures that house all the complex components!

This view of a day in the business of Taylor Made pump Stations, is limited to about 650 words per the ability of the average blog reader to stay interested. I hope the referencing of my daily activities gives an insight to what a service based company, Taylor Made Pump Stations, is. Stop by again, for another day, and we will

“See You at the Station”

“Man Your Stations” Your Waste Water Pump Station That Is.

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Sound familiar?

The famous saying is related to a call to General Quarters and that all sailors drop what they’re doing and report to their battle stations.  A far different scenario than those good people employed to man and run a waste water pump station but there is a link between the two environments- although granted the military call to duty is much more critical in nature let us play a bit with the words of “manning” ones station as it applies to the waste water sewer pump station.

A Waste Water Pump Station is dependent upon the men and women who oversee the daily operation of the station!

The most important aspect of any station is the condition of the equipment.  The men and woman of the military are trained constantly in the importance of maintaining their equipment, whether it be a riffle or their personal safety equipment, with very good reasons as to why.   Likewise the equipment in a waste water pump station is dependent upon good diligent people who understand the importance of inspection checks and the ensuing upkeep of the equipment.                                                                                                  So we will not go into detail of how to maintain the station, but how to hire so that the station is “manned “properly.  As the person responsible for hiring the sewer pump station technician insure you have a well defined scope of duties beforehand and any waste water or DEQ (Department of Environmental Quality) certifications, applicable to the position to be filled.  Once the applicants certifications are met insure the  distance from prospective employees home to the work station is not so far to prevent the worker from arriving quickly in case of an emergency.  For it is critical that you man the waste water station as soon as possible following a high level alarm!  A sanitation worker showing up a couple of hours after a sanitary sewer overflow has occurred  is practically relevant to “Dereliction of Duty” and outside the limits of the requirement “the pump station technician must be able to respond in a timely manner …”.

So, you believe you have found a “few good men” (women) with the experience to handle the day to day operation of that 4 MGD Sanitary Pump Station adjacent to the the Willamette River.  Here is what to look for in a waste water station operator. 

  1. Someone you feel is not an individual employee but will embrace a team member concept and that everyone is a safety captain. Re: Safety, most pump technician can quote OSHA’S 1910 .146.  The competent person duties section in regards to confined space rules & regulations.  Remember a waste water wet well rates the highest in the danger modifier scale as compared to the other confined space environments.
  2. Look for the employee who asks about your system and its components.  Who want to know brand names of equipment and can tell you why an Allen Bradley programmable controller is a good system.  This potential hire has already accessed your municipal infrastructure and its components by looking up articles on the internet that maybe relevant to the waste water pump station that he or she will be supervising.  So the good candidate for employment must show that they are a proactive type of person and will exhibit an erudite behavior beyond that of a regular journeyman.
  3. Here is a little secret on hiring good pump techs for the waste water lift station.  I of course, look first for those with prior waste water pump station experience.  However, if not much previous experience i will look for an automotive repair background, especially those with an ASE (Automotive Service Excellence) certification.   The individual who has a background in reading the logic readouts and diagnosing electronic faults of the new cars easily adapts to the basics of SCADA (supervisory control and data acquisition) and the iPhone, as a remote control unit to access the programmable logic features the waste water pump stations programmable logic control features.  They also have the engineering concepts of a pump.  The “Rotodynamic” automobile water pump works on the same principal as the centrifugal pump that moves the potable water in your water lift station as well as the submersibles, in your waste water station.  If you are a smaller water or sanitation district you will appreciate the mechanical background of the automotive tech in keeping all other equipment running from your service truck to your small trash pumps.
  4. Look for neat and properly dressed applicants.  Those who look like they could walk out into the work environment and operate your waste water pump station  the day of the interview.
  5. Dependability is of greatest importance.  I would have probably listed it at #1 in importance-but realizing most HR managers-have checked on the potential hire employees references as to his or hers punctuality and job attendance at the end of the interview this “If a waste water pump station is in an alarm condition with the potential overflow looming or worse yet a sanitary sewer overflow is in effect and the time is 12:00 AM would you respond quickly and work safely when there “?  If the potential employee responds without hesitation (this is important,no hesitation ) a resounding yes then I don’t have my next employee but I have just signed up a sanitation pump station technician that will be part of a team and properly man the waste water pump station.Lastly, keep your good people once you employ them, and keep reading “See you at the station”
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See you at the Station – Packaged Waste Water Lift Station

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“Pump City, USA” saves over $3,000.00 dollars annually on their power bill by retrofitting to a Taylor Made packaged waste water lift station”

As a member of the Energy Trust Alliance, Taylor Made packaged waste water lift stations, makes energy consumption the utmost of importance in every facet of the design of the packaged waste water lift station. Pumps in their varying applications and types use approximately 23% of the United States total energy consumption and nearly 30% of the world’s energy use! If we as professionals in the industry recall we owe one highly energy inefficient device all the credit for the “Bright Idea” to develop an energy efficiency policy in America.

bright ideaThe light bulb illuminates the highly inefficient operation of all the pumping stations in the world, including waste water lift stations!

That is quite a claim. The truth is the energy draw of the incandescent bulb was so much of a kilowatt consumer that the bright idea that we should look at all areas of energy use, was cast upon all sectors, from residential to industrial and beyond. The June 3rd, 1993 executive order 13123 was spawned as a method to show President Bill Clinton as an environmental President, but from that soon an outline of an energy policy that would soon benefit the owners of Waste Water Lift Stations worldwide.  Shortly after the order went into effect, American industry revealed the small bulb florescent technology, (Which over a decade later most people feel the eye strain blindness that has occurred in many Americans as result of trying to read In the dim glow of a florescent bulb is hardly worth it)

“Taylor Made Packaged Waste Water Lift Stations, balances the initial capital cost versus overall life cycle cost in the specifying of each energy consuming item in the packaged waste water lift station”

Being green does not necessarily mean saving green, especially in the decision to purchase energy efficient technology in pumpyour packaged waste water lift station. It is important to note, that residents of Pump City, USA mentioned in the title of this blog, did not just save money by buying an extra $10,000.00 dollars in frequency drives and premium efficiency motors for their packaged waste water lift stations. They netted over $3,000.00 annually by making buying decisions based on long term cost analysis. Very few if any products within the energy efficient realm save energy from the perspective of “no negative offset” The variable frequency drives and all their derivatives have cost and energy draw considerations that could make their purchase a net cost increase in the overall long term cost analysis. About the only product that saves energy, (net/net) in the endeavor of moving liquid is within the hydraulic design area and that is utilizing HDPE pipe in lieu of ductile iron in the design of the station, (that information, at another “See you at the station, blog). You as a design professional must be able to balance the critical decision of the type and the quality, with initial cost factors as compared to MTBF (mean time before failure) as well as long term operating cost of all energy efficient products in the market.

A Packaged Waste Water Lift Station as a lean, green energy saving machine!

Sometime back, there was a television commercial, in which the spokesperson for a company which manufactured oil filters for the automobile industry made what I believe was a catchy and accurate statement that particularly applies to the purchase of energy efficient equipment in the pumping industry “pay me now or pay me later”. Remember, the fluorescent bulb has an initial cost of nearly four times that of the incandescent but over the  life span of the florescent and LED bulbs compared to that of incandescent (nearly 20,000 hours, compared to 5,000) the overall cost evens out and even saves money in the end. In summing up the world of optimizing pumping efficiency, think of hydraulics first. The liquid pumped and the flows both current and future, will drive the decision of what electrical and control equipment to buy. Finally, the cost of .10 cents per kilowatt for most industrial and public agencies will climb like that of fossil fuel. It is important when considering your next purchase of a packaged waste water lift station, to be aware of what products constitute net dollars saved over the life of cycle of the packaged waste water lift station and its components. Be wise up front, for the long run, to be truly energy efficient.

Stay in touch for next time, when I’ll “See you at the station”

 

See you at the Station – Save Your Prefabricated Waste Water Lift Stations

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Congress authorizes omnibus spending bill under the title “Save our Stations” to fund the purchase of prefabricated waste water lift stations in an effort to quickly rebuild our aging sewage system!

I do not believe that this is something that I read, probably more like something I imagined while pouring over the numerous articles of pump station overflows and in general the problems with our nation’s infrastructure. A big question surfaces when it comes to our infrastructure in America. The first question that comes up is “How bad is it?” The simple answer is “It’s pretty bad”.

Most independent agencies as well as government entities rate our infrastructure as a “D”. In my limited assessment of seeing the varying state of condition of over 40 waste water lift stations throughout the western states I would assess the state of these waste water lift stations as such. A quarter of them are in general good condition and the other three quarters range in condition from operationally functional to dangerously close to failure, or worse a safety hazard to the workers who are charged with maintaining them.

But what do I know?

I recognize that my assessment of the prefabricated waste water lift stations that I’ve viewed over the years is not a sophisticated analysis as to the stations definitive condition. What I have assessed clearly as a builder of high quality prefabricated waste water lift stations is that we have to get away from all the regulatory “Red Tape” of improving our countries aging infrastructure. Do you believe like I do?  That if a Professional engineer, licensed to do business in the state in which he or she is working, that it should be a less burdensome task than it currently is to get approval for a change out of an existing waste water lift station.

President Obama, at the State of The Union Address a few years back mentioned the excessive regulation as a burden when he said  “We have regulation on the fish as it swims in fresh water then we have more regulation as it approaches the salt water, then again additional regulation when it comes time to smoking the fish at supper time”.

Prefabricated waste water lift stations help in a great way to lessen the time and burden of regulation in the goal to get a waste water lift station constructed and placed into operation safely, with all factors of regulation considered. At Taylor Made Pump stations we insure that our prefabricated waste water lift stations conform to the pump flow and suction head specification designated by the P.E. Taylor’s prefabricated waste water lift station performance curves are then confirmed by the manufacture as well as our applications technician that the specifications of the design engineer are followed with the additional backing and insurance of the “Team Concept”.

To rebuild your next waste water lift station, consider The Taylor prefabricated waste water lift stations!

Taylor Made Waste Water Lift Stations, are a great and cost efficient means to “Save a Station” that is in disrepair. You can rest assured as the owner of one of Taylor Mades’ prefabricated waste water lift stations, you have the reliability of high quality components built into every waste water lift station we build, but in the event of a pump failure, the Taylor Made Station, has the added advantage over our competitors, in that we design in the “EZZ-Klean”™ .

This bright red high density polyethylene suction tube works great for cleaning the wet well but also serves as peace of mind as a quick by-pass connection in an overflow condition!


The future of our waste water infrastructure will improve, as we bring efficiency into the cauldron of government contracting by reducing the regulations to a more practical level. When the government itself wants to get a project done expeditiously the same government exercises the edict of an emergency “to get the job done quickly” The term “critical” has been thrown out by both political parties. Our Waste Water Lift Stations in the United States are in critical need of repair. I cannot think of terms that are more closely related than, critical and emergency. At Taylor Made Pump Station we stand ready to “Save Our Stations“ and supply our nation with its critical need of prefabricated waste water lift stations. We will also keep you informed as you continue to read,

“See you at the station”

See you at the Pump Station It Pays to Compute

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The most advanced wastewater lift station, uses the most advanced computer Technology

A wastewater lift station operator knows the basic truth regarding the operation of a wastewater lift station. A good PLC (programmable logic controller) installed in the modern wastewater lift station is more than a convenience, it is an efficient necessity. In this Blog, I am going to discuss the comments of many of the operators that I have visited over the years. Quite honestly, I learn more about the best operating systems integrated into a wastewater lift station from the visits with the wastewater operators that I occasionally drop in on. I will give them all the credit where credit is due. A big thank you to all the wastewater lift station operators throughout the North West, all these men and women do a wonderful job in what is usually a demanding and difficult job.

The human machine interface or HMI, made easier to input and program than the VCR of old, and it records too!

One thing most humans, beginning with the Neanderthals, to today’s modern man strive for and that is to keep it simple. Wastewater lift station operators have to perform many different tasks each and every day and the last thing the operator needs is to have multiple blinking lights, and complicated reset methods or reliability issues. What is becoming the best feature of a supervisory control and data acquisition or SCADA, is that it is easy to learn.  In as little as one day of training most lift station operators can become proficient in keying in commands and remotely monitoring each wastewater lift station to ensure normal operations.  The operator keys in the level control parameters through the HMI connected to the master PLC.  The convenience of the PLC is most evident in the man hours saved in monitoring the wastewater lift station.  As the computer world grows around us, it envelopes the wastewater industry, an industry in which monitoring is of paramount importance.

We can see you at the Wastewater Lift Station while we’re at Home

So we have found that a Supervisory control and data acquisition is a fundamental element of a wastewater lift station network.  The SCADA system in actuality is a broad scope of centralized monitoring technology over anything from an irrigation system to a nation’s nuclear weapons arsenal.   It is quite comforting for most public works managers to know that if a key wastewater lift station technician is home for a day the critical needs of the remote wastewater lift station can be monitored from the employee’s home.

Industrial PCUn-Complicating the terms that define the scope of the complete logic controlled wastewater lift station!

Don’t you just hate it when the acronyms start flying off from the instructors tongue or some “Blogster” starts off with the mnemonic RTU, or CPU, and as he tells you how they are linked, you have missed the connection, because the part of one is intrinsically linked to the other?

It sounds important and it is!

The electronic equipment is less complicated if we know the definition of each unit or part. So, although I can’t put the terms in alphabetical order, I can start with the biggest pieces of the puzzle first and that will let you view the complete picture quickly.

1. The HMI is a key component, because you read it. Quite simply what you see is what you read. We know that an HMI stands for human machine interface. This device allows you to work the machine; the interface simply lets you interact with the pump controller or other type of electromechanical equipment.

2. The PC, well it could stand for pump controller, and the personal computer can be a pump controller but the personal computer is mentioned, because it can be a powerful tool in orchestrating the components of a wastewater lift station.  As basic as it seems the personal lab top can be a mobile “plug in “ diagnostic #tool to gain a  level of troubleshooting  only limited by the operators training.

3. Where does the PLC, fall into the line-up in the overall SCADA system within the wastewater lift station and its automatic and programmed operation. Another device to control and monitor the lift stations daily condition. You are beginning to see the picture. With all the different letters indicating a uniquely different electronic device, they are really very similar in so many ways. The different analog and digital designed devices are all of a family of controllers. A PLC, is a lightweight, usually hand held controller, that is both economical and user friendly as it can be as common as the iphone or ipad.

4. Another related component to all the above is the RTU, or remote terminal unit. It is what its name implies a electronic unit mounted near the pump station in most cases, and processes signals in deliverance of this digital data to the supervisory acquisition system as related to the wastewater lift station and its many performance markers

5. A foundation is an important feature in most buildings and the reason I put the Supervisory Control and data acquisition, SCADA at the bottom of all of the other very important interfaces and devices is that SCADA supports the whole family of monitoring and control components. A wastewater lift station is supported by a concrete foundation, and for all elements of temperature, liquid level, hours run, even security issues at the station, they are all supported by an advanced SCADA system. At the “Station” we don’t have to ask “Mom” “How high is the water mama?” We rely on the advancements in technology!

I’ll rely on you to check in next time, when I’ll “See you at the station”

See you at the Station – Keep it Simple Waste Water Lift Station

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“Keep it simple, Sir”, when designing a Packaged Waste Water Lift Station.

No disrespect here as the acronym “KISS” is well known to stand for “Keep it simple stupid”. Sir, is much more appropriate as we are dealing with professional engineers and public works officials who undertake a difficult task when specifying a packaged waste water lift station. As experienced packaged waste water lift station builders, designing an easy to operate waste water lift station is beneficial to both the end user, and the maintenance workers charged with overseeing the stations daily operations.

Packaged waste water lift stations need not be complicated in their design. Specifications are DEQ (Department of Environmental Quality) originated in most cases and because the regulations governing waste water lift stations are generally standardized, with some variance, making it easy for an experienced builder to follow and construct. The licensed engineer will work with the packaged builder of the waste water lift station from the concept to test run-up.

 

This scenario can be reversed if the builder of the waste water station is the generator of the order, either way it is close working relationship. The municipal waste water station is always a custom station but that has more to do with add on equipment and mostly as it applies to electric equipment. An easy to operate waste water lift station may function fine without Variable Frequency Devices (VFD), noting if they are low horsepower pump motors and flows are fairly constant, the basic across the line start, adequate capacity non clog pumps would be appropriate.

Remember in the laws of physics you do not get something for nothing. The VFD has an initial capital cost that must be considered and there is additional cost in energy use (slight as it is) that the VFD requires at BEP or higher flows. This can actually increase energy costs over time.

A waste water lift station is comprised of four basic components.

  • The Pre- Cast Concrete section is where we find the concrete structure consisting of the standard 6’ diameter barrel sections, occasionally lined with High Density Polythylene (HDPE) , and commonly in depths of 20’.
  • The base of the station is also concrete and historically sloped where the sides have a fillet design to keep sludge from settling at the outer circle. This design is changing as of recent to an easier to clean design to save on fuel and labor cost as well as the regulatory costs in conforming to OSHA.
  • Discharge piping and valves are usually housed in a concrete vault and included in the scope of supply “Precast Concrete”   The mechanical equipment includes the pump and motors,in a duplex configuration with the pump of choice being  of a submersible design. Valves and discharge piping, with  pressure gauges to withstand the demands of waste water are and specified in the mechanical package.
  • All submersible pumps need a retrieval system and we include all stainless steel guide rails in the metals section. Hatches and lids, made of stainless steel but sometimes aluminum and are included under specialty metals.

All of these components are complimented by the electrical components. The controls of increasing proficiency are integrated in the manner that they are matched to the motors and in most cases made by the VFD manufacturer when drives are specified. All things done repetitively will usually get easier! General Contractors often comment to me of the need for a “Packaged waste water lift stations”. I always compliment their knowledge but state I believe there is advantage to having a station built by a supplier who is working with the components daily whether shipping a complete station or assisting with a retrofit of a jockey pump in  an existing waste water lift station. When you live and yes sometimes (have to breathe) waste water lift stations you design in simple, but well planned and of superior quality components. SEE YOU NEXT WEEK AT THE PUMP STATION

 

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See You at the Station – NPSH

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A Positive Story about Managing the Liquid Limit in a Waste Water Lift Station

 

Here is the good news about understanding the concept of, Net Positive Suction Head or NPSH. If you understand the theory of Bernoulli’s principle you probably do not need a basic overview of NPSH. The bad news is maybe you haven’t the foggiest idea of how this mathematical equation helps one determine the value of NPSH.

 

Photo Credit Wikipedia

Photo Credit Wikipedia

After sometime spent on the internet I believe the best definition of NPSH:

 

“NPSH is used to denote the suction performance of a pump without regards of the system to which it is installed.”

 

Sounds simple enough, but it is not.

 

In all actuality submergence level of a pumps intake in relation to the surface of the water above creates a better picture of what we are attempting to define. Remember that the height of water produces head, or what is called pressure head. The distance of the pumps intake below the surface of the liquid gives us the basic concept of suction head.

 

With the basic understanding of NPSH you can better conceive of what is meant NPSHa or suction head available. As an installer of packaged waste water pump stations, NPSHa became easy for me to understand. I associated the dynamic of suction head available by thinking of the term available as synonymous with tools or means available. For example, nature supplies a means or tool for those of us concerned with suction head available in the form of our atmosphere. This important sphere (slightly more important as it supplies us with the oxygen we breathe) is an element in creating pressure head on the water’s surface and thus helping to create suction head available.

 

At sea level the atmosphere produces the same amount of pressure as a column of water approximately 30’ high.  Hydraulic modeling is something that is usually beyond the capabilities of station builders. When it comes to a Basic simulation of how a pump in a waste water lift station performs in relation to NPSHa ,(net positive suction head available) the station supplier can run some basic empirical tests.

 

The applications engineer can put the pumps through some differing suction head conditions that would apply to the hydraulic performance of the pumps under differing liquid levels in the waste water station. The packaged waste water station designer, as a professional in the industry, has to be concerned with cavitation and should attain from the manufacturer the NPSHr (net positive suction head required). In any “run up” performance test on the pumping operation cavitation is a paramount concern. The   potential for the temperature of the effluent in the waste water lift station to increase can affect the NPSHa.

 

It’s getting hot in here!

 

All liquids have a vapor pressure. Vapor pressure of a liquid is the transformation of a liquid to a gas. As the temperature of the liquid increases vapor pressure rises to the point of gas escaping in the form of bubbles or cavities in the liquid. These air pockets will collapse as they go from the low pressure vortex to the pressure stream. There is actually less NPSHr in the pumping of warmer water, but the challenge is to keep the fluid in its liquid form and warm water poses a challenge in this respect.

 

 In closing:

 

There are many mathematical equations that analyze fluid flow dynamics problems where cavitation may occur. Math formulas are tools that give the pump technician the ability to check the actual field and environment conditions against known mathematical values. Computing all the variables that contribute to cavitation in the submersible sewage pump can be done by a wonderful program called excell. So, to keep a waste water lift station pump on the positive side of suction head and positively produce a pump station with a long MTBF, let’s not get negative.

 

 

 

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See you at the Station- Lets make a Deal on a Pre-Fabricated Waste Water Pump Station

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 For sale one “Taylor Made pre-fabricated Waste Water pump station”

Play along with me on this blog as I attempt to create the analogy in the sale of a used pre-fabricated waste water Pump station to that of the actions a person might take in selling their automobile. It is a comparison that makes one think.

 The public works manager or the asset manager should equate the regular maintenance of a pre-fabricated waste water pump station to its current  “used” value along any point of its life cycle. I can’t think of any method that is better to show the current value of a used asset, than to put it up for sale.

So, here we go, are you ready for your first buyer?

Our interested party is a very sophisticated customer named  John. John reads a lot of blogs, including “See you at the pump station” so he is really in the know. Now, our professional public works representative, who we will call Tom, is already a little rattled as he can’t find the “Pump Fax” report and he knows the buyer will want to see the work report on this 2007, Taylor Made prefabricated waste water pump station.

 Alas, at the last moment the work order logs are located, and after a look our customer states that the reports are well formatted. Tom is quick to point out that the detail in the paper work specifications from the inspection and work order sheets as well as the OSHA required confined space signage is included in the purchase of the Taylor Made pre-fabricated waste water pump station”.

John knows the value of the “Pump fax” report but is giving no sign that this station is the one. Being a good asset manager of this imaginary city , John wonders “who would find their financial situation so dire to have to sell a sewage pump station?’”

 

Tom kicks his salesmanship 101 into gear, and mentions the energy efficient motors that come with the purchase of the “Taylor Made sewage pump station”.  All the documents are there in the purchase order and its plain that Taylor Made Pump Stations, one of the few “Energy Trust” pump station builders with this designation, puts a great deal of emphasis in pumping optimization from both the hydraulic design as well as motor efficiency.

 

John finally nods in approval and almost shows his enthusiasm in this rare opportunity to purchase a low hour Top of The line Taylor Made pre-fabricated waste water pump station. Noticing this Tom moves on the performance aspect of the drives, which are likened to an Energy-Efficient “Gas Pedal” for electric motors, these speed controllers are of crucial importance in saving energy and reducing operating costs. The Taylor Made pre-fabricated waste water pump station, was specified for the pump supplier to utilize their controls and VFD’s for efficiency and single source responsibility.

The Taylor Made Pre-fabricated waste water station has both Brains & Beauty.

It was becoming plain to Tom that John was very impressed with all the features of the station as well as the maintenance records produced by the city. The PLC, with a Modbus connection provides all level control monitoring, status and alarm conditions notifications would be easy for his small public works department to learn and operate.

Now it is time to check under the hatch. John, had already done his homework on the 25HP submersible non-clog pumps and with under 1,000 hours on each pump he had little concern that the pumping ends and motors were of high quality and “top flight”(not to relate the pumps to the high quality brand of a similar sounding name, but excellent sewage pumps none the less).

The Taylor Made Pre-fabricated waste water station is also designed with easy clean in mind!

John, our  buyer couldn’t help but notice the bright red tube standing out at the top of the station. He recognized the Patented EZZ-Klean device as the asset manager of his city he had them installed in two of his pre-fabricated waste water pump station. He is very aware of how they increase the MTBF (mean time before failure) of the pump station. John said, “I really haven’t seen anything with this station that I don’t like. I cannot take the concrete wet well with me, but if you will throw in the top and hatch we can put the lid on this deal”. Tom, thought it would be a month or two before this sewer line was converted to a gravity line and thus the station could be decommissioned and removed. So If you’ll excuse the pun, it was a “crappy” deal but both men came out smelling good.

 

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What makes a Taylor Made Prepackaged Pump Station a Superior Product?

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Prepackaged pump station components depend on an understanding of customer needs.

It is best, although not a requirement, if the package builder works closely with the project engineer in the design phase of the project. This assures that the waste water station will optimally satisfy project needs with consideration of on-going maintenance needs, confined space safety considerations, Davit Crane (for later removal of pumps) design and placement for ease and safety of use, hose reel bracket design and placement, and OSHA required warning-safety signage.

Optimize performance with a prepackaged pump station

A very important component of a prepackaged pump station is the control package that is designed to optimize pump performance for the project needs. Controls are like a conductor of an orchestra that assures all components in it perform as composed. In the case of a pump station the composer is the design engineer and/or project Owner with input by an experienced prepackaged pump station provider. Considerations include performance requirements, ease of maintenance, safety features and applicable code requirements.

Taylor made, means knowledge and experience.

The prepackaged pump station designer-builder should be one who has extensive experience in building and installing pump stations. We, as a General Contractor for 35 years have this experience. We design from knowledge and experience, not by just thumbing through trade catalog’s. We know what works for a given site and its unique requirements, specifications and control requirements.