LIFT STATION INSPECTION & ASSESSMENT Presentation Outline

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David E. Koberlein, PE, GISPBurgess & Niple, Inc.

LIFT STATION INSPECTION & ASSESSMENT

Why Perform Lift Station Assessments

System Components and What to Look For

What to do with Your Findings

Questions

Presentation Outline

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Wide Range of Design and Construction Methods Nothing is Standard – Even the Standards Lots of Moving Parts

Lift Station Location At the lowest point in the gravity system At the highest point in the pressure system Critical point in the conveyance pathway to the WWTP

Determine Station Performance Characteristics Normal Operation and Wet Weather

Regulatory Compliance


Asset Management Programs Expensive, Non Standard Assets Require the Most Attention

Force Main Condition

Safety Issues Workers

Public

Elimination or Combination


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Lift Stations are the Final Resting Place (FRP) for ALL of the Interesting Things People put in sewers


Lift Station Site Access, Security, Signs, Operational Alarms

Structural Systems Wet Well, Concrete Pads, Entryways, Equipment Access

Electrical Systems Controls, Conduits, Power, SCADA, Monitoring

Hydraulic Systems Pumps, Force Mains, Gravity Systems

System Inspections

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What to Inspect Access Road, Fencing, Controlled Access, and Site Security Adequate Parking for Equipment and Vehicles External Station Operation Alarms and Lights Signage – Warnings, Station Identification, Emergency Contacts Station Protected from 100 Year Flood Station Accessible During 25 Year Flood Station Shelter or Housing Note Type of Lift Station Odor Control/Chemical Feed Systems Others

Lift Station Site

What to Look For General Condition of: Access Road Site Fencing, Gates, and Locks Record Type of Fence and Gates

Site Security Features (Cameras, Lighting) Parking Area for Equipment and Vehicles General Overall Appearance of the Station Signage Station Shelter or Housing Record Type of Shelter or Housing

Lift Station Site

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What to Look For Check Operation of: External Station Operation Alarms and Lights

Site Security Features (Cameras, Lighting)

Site Fencing, Gates, and Locks

Site Drainage and Stormwater Control Features

Odor Control/Chemical Feed Systems

Lift Station Site

What to Inspect Wet Well, Dry Well, Valve Pit

All Concrete Flatwork

Anchors, Mounting Bolts, Connections

Hatches/Entryways/Ladders/Stairs/Rails

Sump Pumps

Pump and Motor Fittings, Hardware, Mounting Points, Rails

Pipe and Conduit Penetrations

Pipe/Valve/Motor Stands, Mounting Points, Anchors

Lift Station Structural Systems

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What to Inspect Conduits and Fittings Air Handling Systems and Ventilation Lighting and Illumination Systems Emergency Communications Systems Weather/Freeze Protection Systems Any Installed Liner Systems Electrical and Instrumentation Enclosures and Panels Trash/Solids Handling Systems Hoist/Crane Systems Other


What to Look For General Condition of: Wet Well, Dry Well, Valve Pit Record Dimensions and Construction Material High Resolution Digital Photograph Record Presence of Grease/Debris/Stormwater Accumulation Record Influent and Force Main Elevations

All Concrete Flatwork Anchors, Mounting Bolts, Connections, and Joints Hatches/Entryways/Ladders/Stairs/Rails Sump Pumps Record Nameplate Information

Pump and Motor Hardware, Mounting Points, Rails Pipe and Conduit Penetrations


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What to Look For General Condition of: Conduits and Fittings Air Handling Systems and Ventilation Lighting and Illumination Systems Emergency Communications Systems Weather/Freeze Protection Systems Wet/Dry Well Liner Systems Electrical and Instrumentation Enclosures and Panels Hoist and Pump Removal Systems Screens


What to Look For Rust, Corrosion, Fatigue Noisy Components Unusual Odors Non-Functional Systems Chipped or Missing Paint Discolored Concrete, Spalling, Unsupported Slabs or Walls Cracks, and

Fractures Exposed Piping and Valves Free Movement of Gates, Hatches, Entryways High and Low Water Marks Leakage of Any Fluid Presence of Vandals or Vermin


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What to Look For Noisy Station Components/Unusual Odors Provision for Pipe, Valve, Motor, or Pump Replacement All Joints are Flanged

Non-Functional Ventilation Systems Confined Space Explosion Hazards

Non-Functional Electrical Systems Fans, Lights, Alarms, Controls, SCADA

Cracks, Tears, Delamination of Liner System Exposed Rebar/Reinforcement Components Evidence of Overflows Room for a Spare Pump Operations and Maintenance Manuals


Check Operation of: Ventilation Systems Lighting and Illumination Systems Gates, Hatches, Locks, Entryways Sump Pumps Emergency Communications Systems Conduits and Fittings Weatherproof and Watertight

Piping and Valve Systems Watertight Vibration


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What to Inspect Motor/Pump Controls Wet Well Level Control Systems Record Pump On/Off Levels for Various Combinations of Pumps

Instrumentation/Recoding Systems SCADA and Telemetry Systems Emergency Communication Systems Site and Interior Lighting and Illumination Humidity Control Systems Enclosures and Panels Conduit/Fittings/Wiring Schematics Emergency Power/Generator/Connections Main Power Disconnect Switch

Lift Station Electrical Systems

What to Look For Presence of “Hot Spots” in Enclosures and Panels Frequently Tripped Breakers Smoke/Ozone Odor/Evidence of Sparks Frayed/Exposed Wiring Extensive Repairs to Electrical System Open Conduits/Broken Fittings/Liquid in Conduit Actual Electrical Schematics Accuracy

Terminal Block Connections with Printed Labels Accuracy


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What to Look For Emergency Generator and Connections Compatibility

Humidity Control/Ventilation System Operational

Instrumentation/Recording System Functional Gages Operational

Wet Well Level Control System Functional

Rust/Corrosion Spare Parts Inventory


Check Operation of: Everything

Individual Systems/Components All Systems Functioning at Once

Lighting and Illumination Systems Emergency Generator and Connection to Station All Motor Control Center Functions

Instrumentation Gauges Power Usage Motor Stop/Start Records Pump On/Off Runtime Records Wet Well Level Controls

Emergency Communications Systems External Station Alarms and Lights Spare Parts


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What to Inspect Pumps

Motors

Screens

Upstream and Downstream Gravity Manholes

Lift Station Performance

Pump and Motor Documentation

Lift Station Hydraulic Systems

What to Look For General Condition of: Pumps/Motors Missing Paint/Coatings Rust/Corrosion/Scaling Excessive Vibration Bent Drive Shafts Excessive Start/Stop Cycles Excessive Noise During Operation Hard to Start/Slow to Start Leaking Fluids Start/Stop Cycles are Properly Recorded by Instrumentation Installed Priming Systems


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What to Look For General Condition of: Electrical Connections Conduits and Fittings Weather/Freeze Protection Systems Hoist and Pump Removal Systems Functional and Properly Lubricated

Screening Devices Functioning as Intended

Coating and Liner Systems Cracks/Tears/Delamination/Scaling

Debris/Grease Buildup in Wet Well


What to Look For General Condition of: Station Piping and Valves Peeling Paint, Scaling, Rust, Corrosion Loose Flanges/Connections Displaced Piping/Valves Leakage External Lever on Check Valves Gate Valve Operation

Force Main Piping Corrosion/Rust/Deterioration in Connecting Manholes Pump/Motor Mounting Pads Cracks/Spalling/Loose Hardware

Spare Parts for Pumps and Motors


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Performance Testing Draw Down Testing Basically a Bucket and a Stopwatch

Record Wet Well Fill and Empty Times for: Individual Pump Operating Alone

Various Pumps Operating in Combination

Use with Wet Well Dimensions to Determine Pump Performance

Pump Performance Degrades over Time


Take Pictures of Everything with a GPS Enabled Camera Start and end the assessment with a photo of the station identification

sign Consider the amount of light when taking photos of the interior of

structures and appurtenances Have a predefined format for collecting data and use it. Flexible enough to record the presence and condition of assets Rigid enough to utilize standard methods for assessment

Always set up temporary safety equipment (traffic control, fall protection, etc.) and gas detectors first

The electrical equipment in a lift station is “intrinsically safe” for a reason – Don’t bypass this feature

Lift Station Assessment Advice

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Someone somewhere has the Operations Manual for the Lift Station – Find it and keep it at the Station

Make sure the backup generator works and can be quickly connected to the station to provide power in an emergency

Unless you are a Qualified Lift Station Operator/Electrician/Pump Mechanic – Don’t try to Fix Something

Lift Station Assessment Advice

Improve Station Operation

Make Recommendations for Improvements

Determine the Monetary Value of the Station

Extend the Life of the Station Through Proactive Maintenance

Asset Management Program Data

Lift Station Findings

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Questions/Comments?

Contact InformationDavid E. Koberlein, PE, GISP

Burgess & Niple, Inc.Phone (512) 306-9266x6270

Email: [email protected]

Documents

LIFT STATION INSPECTION & ASSESSMENT Presentation Outline