(Click Here to Download .pdf)

I’ve taken on a new hobby… roller derby!  I was looking for a hobby that would be physically and mentally challenging where I could meet new, like-minded people as well as give back to my community. I figured that helping to start a league in my home town that was a non-profit organization would meet all of my goals for a hobby. So, how does this relate to teamwork at Romtec Utilities?

During derby practice this week, we practiced teamwork through communication. On the rink, a derby team has to be in constant communication to support each other and help keep everyone safe. Today, I realized that the Romtec Utilities staff has worked hard over the years to incorporate these same ideas into how we work together. Although our staff is spread over a few buildings, we have set up processes to keep the communication flowing.

A great example of this is how we handle pump station design changes. When we receive written or verbal comments from our customer, our documentation manager creates a “response document” that starts with a restatement of the comments or questions.

The response document is then delivered to the engineering department for answers. If the comments direct us to make changes, the engineering department updates the design drawings and the bill of materials and fills out a Design Change Form. This Form and the answers are sent back to our documentation manager, who finalizes our response letter and notes in the letter if any of the comments have created price changes.

The documentation manager takes the updated drawings from engineering and revises our Scope of Supply and Design Submittal. She then forwards the completed Design Change Form to operations for a revised quote (or change order if a purchase order has been received), and to the purchasing/production department if any of the system components are being purchased or manufactured. If there is a change order, operations forwards this change order to the accounting department to update any purchase orders.

It is amazing how one form keeps everyone in the loop and on the same page! The end result is an efficiently revised design and price that heads back to the customer is as little as one day.

No related posts.

Electrical Connection Methods in Wet Well Design

In pump station system design, it is common for some aspects of the electrical design to be given less than adequate attention.  This article focuses on electrical connection methods. Specifically, the designer must consider the connection of electrical equipment inside the underground wet well to the above-ground electrical control system.   In wastewater pump stations, the wet well is classified as a hazardous area, due to the potential build-up of explosive gas. Egress of electrical cables from the wet well can be tricky business, since there are a variety of ways to run the cables and make electrical connections. Romtec Utilities has devised three methods for electrical connection; direct connection, above-ground junction box and below-ground junction box.

Direct Connection
A direct connection is defined as conduits that run from the inside of the wet well directly to the electrical control panel.  The advantage of the direct connection method is simplicity.  Just before entering the panel, seal-offs are installed to prevent migration of hazardous gas from the wet well (when classified as hazardous area). The seal-offs would be omitted in unclassified systems.
When choosing the direct connection method the mounting location of the control panel is restricted by the maximum length of the cables on the pumps and floats.  Standard cable lengths are 50 feet.  Longer lengths up to 100’ can be special ordered. Remember to consider the wet well depth when determining the distance between the wet well and control panel.

Below-ground Junction Box
The below-ground junction box from Romtec Utilities contains components to meet hazardous area requirements and at the same time provides ease of maintenance without having to defeat seal-offs. See photo of the interior of a typical Romtec Utilities below-ground junction box.  Consider this method when:

• The wet-well is classified as a hazardous area.
• The control panel is mounted over  25 to 30 feet from the wet well.
• The wet well is located in a high traffic area.
• Removing pumps or float without defeating seal-offs is required.

Above -ground Junction Box
The above-ground junction box from Romtec Utilities combined with the cable tray provides the most user friendly method of pump and level sensor connection.  In addition to meeting most hazardous area requirements, the above ground junction box is impervious to ground flooding or corrosion.  See photo of the Romtec Utilities above-ground junction box. Consider this method when any of the following statements are true:

• The wet-well is classified hazardous area.
• The control panel is mounted over  25 to 30 feet from the wet well.
• Removing pumps or float without defeating seal-offs is required.
• Ground water or flooding is expected.

Related posts:

1. Hazardous Area Classification for Pumping Stations
2. Fish Love Pump Stations

Romtec Utilities has opened it’s doors to a whole new side of our pump station scope of work. In March, 2010 Romtec Utilities added a construction/installation branch to our vast pump station industry. Suncadia, LLC in Cle Elum, Washington was our first construction/installation project, and a very successful first project. Suncadia Resort, with its breathtaking views of the Washington Cascades, asked Romtec Utilities to design and build a 10ft diameter by 16 1/2ft deep pump station with a valve vault and pig launcher ( for flushing objects out of the 8 inch forced main ).

Romtec Utilities’ Vice President Mark Sheldon took the opportunity to pitch the idea to have a chance at quoting the installation of these large structures. Within a week Romtec Utilities was designing and estimating the construction and installation of this project. Romtec Utilities’ engineering department worked with Suncadia’s contracted engineering firm Goldsmith, and proposed a set of drawings. One drawing was inside the work zone, which Romtec Utilities did the plans for, and the other set was outside the work zone, which Goldsmith drew up. “Inside the work zone” consists of the three concrete structures with elevations, mechanical fittings and locations, pumps, valves, pig launcher, electrical control panel, and shelter. “Outside the work zone” consisted of 8”- 12” PVC gravity sewer pipe, 8” PVC C-900 forced main pipe, and 2” CTS poly pipe with elevations, manholes, and water backflow preventer. After a couple weeks of site visits, design engineering, and estimating we were awarded the entire project.

Following the stages of pre-construction we launched into finalizing the project schedule, starting production of concrete structures, and approval of submittals. We broke ground on May 3rd, with Italics Construction as prime subcontractor and Neatline Construction as their subcontractor – diesel smoke was in the air. Twelve days later all installation and construction was completed and testing was done and approved. Overall the project was a great success, congratulations to all involved.

Related posts:

1. Suncadia pump station installation

One of the first, (and most important consideration) in system design is area classification.  Area classification, will at a minimum, dictate the required components necessary to meet code.  NFPA 820 along with NEC defines the classifications for Wastewater Treatment and Collection Facilities.  It is important to note NFPA 820 covers “Pumping Stations” which is a broad term and is inclusive of most waste water pump systems.  For this reason NFPA is pertinent in nearly all in ground waste water pumping systems.

In general, residential collection systems serving 5 or less dwelling units are “Unclassified” and thus fire and explosion hazard is not applicable.  NEC still applies for general guidance in these systems.  For systems larger than 5 residential units sewers are categorized by usage type. The type categories are:

•   Storm Water Pumping Wet Well – serving storm sewer system.
•   Residential Wastewater Pumping Wet Well – serving primarily residential wastewater.
•   Wastewater Pumping Station Wet Well – serving a sanitary sewer or combined sewer.

A combined sewer is defined as a system containing domestic, commercial, industrial and storm wastewater.  the, Wastewater Pumping Station Wet Well category, is the most diverse classification and usually applies to municipal wastewater pumping stations.

The area classifications for the above categorized pump station are as follows:

•   Storm Water Pumping Wet Wells are classified as Class 1 Division 2, Group D.
•   Residential Wastewater Pumping Wet Wells are classified as Class 1 Division 2, Group D without venting and can be declassified with venting creating 12 air changes per hour.
•   Wastewater Pumping Station Wet Wells are classified as Class 1 Division 1, Group D without venting and can be classified as Class 1 Division 2, Group D with venting creating 12 air changes per hour.

It is not generally practical to ventilate a wet well at 12 changes per hour therefore in most all cases NEC article 500 applies to all the above wet well installations.

Class 1 areas require FM rated pumps and intrinsically safe electrical sensing equipment, further, Class 1 Division 1 requiring explosion proof equiptment.  It is important to consider space classification in Electrical Design and selection of the wet well components.

No related posts.

Here are some examples of hazardous components in storm water runoff.

Sediment – Reduces visibility in rivers and streams, impeding the ability of aquatic life to capture food.  It also reduces the amount of sunlight in waterways making it hard for vegetation to grow.

Roadside Runoff – Can be potentially hazardous wastes like auto fluids or pesticides which can poison aquatic life and destroy habitat.

Roadside trash – Litter and refuse from passing cars, plastic bottles and cans.

Excess Nutrients – Can cause algae blooms, algae grow in large numbers, die and in their decomposition reduce the oxygen levels in water and kill fish.

A Romtec Utilities’ Storm Water Pump Station essentially collects this “runoff” and pumps it to the waste water treatment plant.  The waste water treatment plant “cleans” the water by removing the solids, reducing the organic matter and hazardous pollutants and restoring the oxygen to the water.   The water can then be safely returned to the environment.

Related posts:

1. Hazardous Area Classification for Pumping Stations
2. Urban Stormwater Retrofit Projects – reprinted from Stormwater, Sept. 2008
3. Electrical Connection Methods in Wet Well Design

Before the recession, Romtec Utilities built lots of pump stations for developers.  Folks building pump stations these days are more often municipalities, public agencies, and private companies that need pumping systems for industrial situations.  However, as the housing market regains its strength and developers start building more homes, it is highly likely that they will need pump stations.  Why?  Well, most of the land that “slopes” to central wastewater treatment facilities has been built on.  These new developments often require some type of “lift” to get the wastewater from the homes to the treatment plant.

Romtec Utilities is the perfect answer for developers who need a pump station!  We will design the complete system for free, as part of our supply.  We help the developer will coordinate the pump station with the overall design of the development.  How, you ask?

Romtec Utilities will work closely with the site engineer to design the pump station based on the needs of the project.  We often help engineers design a system that will work with an initial flow requirement that is also easily upgraded for future increases in flow to the system.  In other words, we can design systems that will service 30 homes now and 150 homes later.

Romtec Utilities will also layout our equipment on the civil engineer’s site plan.  This gives everyone a “real world” look at how all of the components will fit on-site.  This helps the civil engineer plan a realistic space for the pump station and any related components.

Romtec Utilities also reviews any municipal or agency requirements and helps the developer by creating a design that meets those standards.  These standards can be very confusing to someone who is not familiar with pump stations.

Romtec Utilities creates a complete, comprehensive design submittal for review by the site engineer and reviewing agency.  Through the review process, Romtec Utilities works diligently to receive approval in a speedy manner.  We respond to written comments, in writing, within 1-3 days from receiving comments.  We are always ready for a conference call to bring all parties together to solve issues and/or confusion.

Once the system is approved, Romtec Utilities works closely with the contractor to ensure that the pump station is installed correctly and efficiently.  We also provide start-up services and training of the end users.  Romtec Utilities’ systems include a one year warranty.

We are here for you!  Our quality systems will last for decades and provide worry free service.

Related posts:

1. Romtec Utilities to Exhibit & Present at WEFTEC 2010
2. Wastewater Pump Stations 101: Working With Municipal Authorities
3. Fish Love Pump Stations

Valve assemblies in Romtec Utilities pump stations

Romtec Utilities pumping systems include the complete valve assembly between the pumps and force main. The basic valve assembly includes a check valve and a plug (isolation) valve in the discharge line from each pump. But that’s about it for basics, because each pump station has unique requirements for the valves and where they are located. Depending on various factors, the valve assembly can be located within the wet well, within a separate underground vault or above ground within an enclosure or right out in the open.

In-well valves – For submersible pump stations, reduced cost is an important factor in locating the valve assembly inside the wet well. Less pipe, fewer fittings and no underground vault or above ground enclosure are required, thus reducing cost.

Sufficient space inside the wet well can be a factor; the valves have to fit in the vertical pipe riser. The pre-assembled manifold with valves and piping for one, two or three pump systems can be quickly lowered in place, fitted to the pump discharge elbows and secured with brackets to the wet well.

Consideration must be given to how to maintain valves and pumps when the valves are located inside the wet well. Confined space safety requirements add some maintenance costs, so it is very advantageous to have less frequent valve maintenance. This is partly why pumping systems with in-well valves are often specified for stormwater or clean water rather than municipal wastewater since the hazard of entering the wet well to maintain valves is somewhat lessened. Sewage lift stations with in-well valves are often equipped with grinder or chopper pumps, because there is less potential for damage or clogging of a valve when solids are macerated, thus reducing the potential for valve maintenance inside the wet well.

Underground valve vaults – Most Romtec Utilities pump stations are supplied with an underground valve vault with pre-assembled valves and piping tested to 100 psi. The complete unit is delivered to the project site, positioned near the wet well and connected to the discharge pipes leaving the pumps. Prefabricating the valve assembly inside an underground concrete or fiberglass vault offers many advantages:
1.    Protection from freezing and security for equipment
2.    Fast installation without expensive field assembly
3.    Safe valve operation and maintenance without entering confined space
4.    Space in vault for other equipment: emergency pumping port/pig launcher, pressure sensors, etc.

Above-ground valve assemblies – In climates where freezing is not a factor, valves can be located above ground without insulation. In cold weather areas, above-ground valve assemblies must be fitted with insulating jackets.

Romtec Utilities offers a variety of valve assemblies with precast concrete pads ready for placement at the project site.  Discharge pipes leaving the wet well are field fitted to the valve assembly. Various kinds of pumping systems often use above-ground valves:
1.    Industrial plants frequently prefer the simplified operation and maintenance offered by above-ground valves.
2.    Vertical turbine pumps are often fitted with above-ground valves.
3.    Emergency pumping systems generally have the valves exposed for quick access.

Related posts:

1. Electrical Connection Methods in Wet Well Design

12' dia. prefabricated fiberglass wastewater pump station

Romtec Utilities’ complete sewage pumping systems are available with wet wells and vaults of either fiberglass or concrete. The high-quality Xerxes fiberglass underground tanks are delivered to the job site fully assembled and ready for pipe and pump installation. Here are some of the advantages of fiberglass:

1. Complete one-piece structures require no field assembly. Pre-assembled fiberglass wet wells are ready to receive influent and discharge pipes, submersible or dry pit pumps and liquid level sensing devices.
2. One-piece fiberglass vessels up to 12 feet diameter and 40 feet long can be shipped to any project location.
3. Tanks have no joints to be sealed, so there is no potential for groundwater incursion.
4. Unique rib design makes wet wells more resistant to uplift the deeper the tank is placed underground.
   

   Romtec Utilities factory assembled and tested valve vault

5. Tanks can be oriented either vertically or horizontally and fitted with a variety of pumps: submersible pumps, short set vertical turbine pumps and dry pit pumps in horizontal or vertical configuration.
6. Wet well’s truncated base with sloping sides helps prevent build-up of grease and other solids.
7. Fiberglass is not degraded by the hydrogen sulfide gas present in sewage, and it will not break down from exposure to petrochemicals, acids or caustic fluids. No additional sealing or coating of the fiberglass surface is required.

Click here to read more about recent installation of a Romtec Utilities-Xerxes prefabricated fiberglass pump station.

Related posts:

1. Valve assembly location – 3 options makes a difference
2. Distribution warehouse gets submersible sewage pump station

Edge of El Modena Park basin before plants grew in

Storm basin pump station performs during wet California winter.

Folks at Irvine Ranch Irrigation District (IRWD) in Orange County, Calif. are pleased with the performance of the El Modena Park storm basin, part of the San Diego Creek Natural Treatment System (www.naturaltreatmentsystem.org), a regional approach to treating urban runoff. In the first wet winter experience with the storm basin, some lessons have been learned while achieving nitrate removal.

During precipitation, runoff in the nearby flood control channel is diverted into the park’s man-made wetland. Besides reducing the direct flow into San Joaquin Marsh in the upper reach of Newport Bay, the constructed wetland is designed to naturally cleanse urban runoff before it reenters the channel. Plants at the perimeter of the basin help remove nitrates and other pollutants from the water. Keeping the water at just the right level for these plants to thrive, a key factor in  biofiltration system’s success, is the job of the Romtec Utilities duplex submersible stormwater pumping system installed in 2008.

Panorama view of pumping system at one end of stormwater treatment basin

During large storm events, the pond and the area around it are allowed to be completely flooded as the water level rises. The wet well is designed to be flooded during these occasions as well, and the pumps automatically shut down. After the storm, the pumps are allowed to operate normally, draining the wetland to its “normal” level so the biofiltration function can continue.

Flood control channel alongside El Modena Park

The natural treatment system has been in place for just over a year. Unusually heavy rains during the 2009-’10 winter caused some unexpected erosion around the basin’s inlet structure, but the pumping equipment at the other end of the basin was not affected.

In general, the system has performed well. “The focus of the system is to remove nitrates from the water—to treat it in the watershed before it goes down to the ocean,” says Lou Denger, IRWD’s wetland field operations supervisor. “Over the last year, we have seen a 79% nitrate removal rate, with a total number of 1,200 pounds removed. That definitely meets our expectations.”

Click here to read more about this project in WaterWorld online.

Related posts:

1. An Innovative Solution to Building Capacity – reprint from Stormwater Solutions
2. Urban Stormwater Retrofit Projects – reprinted from Stormwater, Sept. 2008
3. Distribution warehouse gets submersible sewage pump station

Distribution warehouse pump station collects combined sanitary sewer, storm runoff and, potentially, water from the building's fire suppression sprinklers.

Pumping system handles combined sanitary sewer, stormwater and potential fire suppression system water.

Romtec Utilities recently supplied a sewage lift station to the new 750,000 square foot Ferguson Enterprises Regional Distribution Center built on the site of a former US Navy facility in Stockton, Calif. Thomas Graham Civil Design Group was the project engineer and pm2i was general contractor.

Romtec supplied all structural, mechanical, electrical andtelemetry systems in the station, which features a 6’ dia. pre-cast concrete wet well to collect the combined sanitary sewer and stormwater runoff, as well as potential drainage from the building’s fire suppression sprinkler system. Also included in the complete system are a pre-assembled valve vault and all ductile piping, U.L. listed electrical controls and SCADA, and two ITT Flygt submersible pumps that discharge through a 4” dia. force main to the municipal gravity sewer.

Related posts:

1. Stormwater Pump Station – Franklin Park, IL
2. Pump station odor & corrosion control with chemical feed system
3. Urban Stormwater Retrofit Projects – reprinted from Stormwater, Sept. 2008