Chapter 3

North and South Pump Stations

3.1 Existing Conditions
The City has two main pump stations that are located off-site and pump raw wastewater to the Headworks facilities at the WWTP. The North Side Pump Station (NSPS) is located on Fitzwater Street near the Perdue factory, which is approximately 0.85 miles from the WWTP. The South Side Pump Station (SSPS) is located on Ridge Road on the other side of the Wicomico River approximately 0.6 miles from the WWTP. The discharge force main from the SSPS runs under the Wicomico River to the WWTP. During the recent BNR/ENR upgrade, both pump stations were upgraded by removing the existing comminutors and installing three (3) new non-clog centrifugal pumps with variable frequency drives (VFDs). Both pump stations were sized so that the installed pumps could pump the projected future peak hour flow rates with two (2) duty and one (1) standby pump as shown in Table 3-1. In addition, the force mains from the two influent pump stations were interconnected.
Table 3-1. Existing Influent Pumping Stations Design Criteria
Parameter Firm Pumping Capacity (mgd) Type Suction / Discharge (in.) Sphere Passing (in.) Number of Pumps (Duty and Standby) Motor / VFD Size (hp) Design PointFlow Rate of Each Pump (gpm) Design PointTotal Dynamic Head (ft) Normal Operating Condition North Side Pumping Station 21.6 Yeomans, Vertical, Non-clog Centrifugal 12 / 12 6 3 (2 + 1) 300 7,500 120 75% Speed, 5,500 gpm South Side Pumping Station 9.1 Yeomans, Vertical, Non-clog Centrifugal 10 / 10 5 3 (2 + 1) 300 3,150 175 75% Speed, 2,250 gpm

The main issue with the influent pump stations is that they were sized to pump future peak flows with only two (2) pumps operating without accounting for the current and average conditions. Therefore, the influent pump stations are oversized for the daily average flow rates that are currently being experienced. In addition, the diurnal flows to the WWTP vary significantly with influent flow rates as low as 700 to 1,000 gpm during the night and on weekends. The reduced speed capacity (approximately 75 percent of speed due to flow required to open the check valve) of the NSPS and SSPS pumps are approximately 5,600 gpm (8 mgd) and 2,250 (3.2 mgd), respectively. These reduced speed capacities are significantly larger (by a factor of two) than the current average daily flows from these pump stations. Both pump stations cycle ON and OFF throughout the day, which results in significant hydraulic surging to the headworks of the WWTP. The continuous surging caused by the pumps at the SSPS and NSPS causes hydraulic and treatment process performance problems with essentially all of the WWTP liquid stream treatment processes.

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The existing comminutors were removed during the BNR/ENR upgrade, because the non-clog centrifugal pumps that were installed were supposed to be capable of handling a high concentration of large solids. However, the pumps have experienced ongoing ragging / plugging problems that require manual removal of the debris. These pumps also exhibited some vibration issues during the initial pump performance tests at certain operating speeds. According to Salisbury maintenance personnel, some effort has been made to program the pumps to avoid operating at the speeds that have caused vibration issues in the past. During a recent inspection by Brown and Caldwell, the vibration issues were not readily apparent during startup and operation of the pumps. After further discussions with Salisbury maintenance personnel, BC and the City have agreed that the past vibration issues have been rectified through the reprogramming effort. During construction, the flow meter planned for installation on the main header from the NSPS was deleted which makes it impossible to determine the actual flow from the pump station. Both the NSPS and SSPS are located in residential areas and currently do not have odor control systems installed.

3.2 Corrective Action Plan

Both the NSPS and SSPS originally had four pumps each installed in them prior to the BNR/ENR upgrade. The jokey pump suction lines from the wetwell still exist and there is adequate room to install a fourth smaller capacity non-clog centrifugal pump to allow the pump stations to operate relatively continuously during the daylight hours and cycle less often during the low flow times at night and on weekends. The rated capacity of these jockey pumps will be approximately half the capacity of the existing pumps. Other recommended improvements for the off-site pump stations include: 1) installation of dimminutors to grind up the rags and other debris in the raw wastewater to reduce the wear on the pumps and time required to manually remove the debris, 2) odor control consisting of package bioscrubbing / biofilter systems consisting of inorganic media to reduce operating and maintenance costs, 3) installation of a flow meter on the main header from the NSPS, and 4) installation of fencing to surround both pump stations as a security measure. In addition, new evergreen trees such as junipers will be installed at both pump stations to provide visual screening. At the SSPS, the new trees will replace existing cypress trees that are being damaged during high winds.

3.3 Basis of Design

The North and South Pump Stations jockey pumps will be designed to handle approximately half of the flow of the current pumps. The pump stations will be designed to operate at the conditions represented in Table 3-2. The expected mechanical modifications in the drywell pump area of the pump stations can be seen in Figure 3-1, while Figure 3-2 shows the mechanical modifications associated with the dimminutors. The placement of the odor control units is illustrated in Figure 3-3.

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Table 3-2. North and South Pump Stations Equipment

Parameter Pump Station Firm Capacity (mgd): Jockey Pump (1): Type Suction / Discharge (in.) Sphere Passing (in.) Capacity (gpm) Head (TD) Motor/ VFD Size (hp) Normal Operating Condition Dimminutor: Number and Type Size (LxWxH) in Capacity (MGD) Unit/ Station Odor Control: Type Flow Rate (CFM) Air Changes per Hour (ACH) Tower Size, Diameter x Height (ft) Exhaust Fan (hp) Discharge Line Flow Meter: Size (in)
Notes: 1. 2. 3. 4. A spare jockey pump will be purchased for each pump station for backup purposes. The NSPS will have a set of dimminutors at each entrance, both of which will be able to handle the pump stations full capacity. The SSPS will have one duty and one backup dimminutor unit. A two-stage Biotricklilng filter/ carbon scrubber unit is currently being investigated as an alternative.

North Side Pumping Station 21.6

South Side Pumping Station 9.1

Vertical, Non-clog Centrifugal 12 / 10 6 3,750 120 200 75% Speed, 2800 gpm

Vertical, Non-clog Centrifugal 8 / 6 5 1,575 175 200 75% Speed, 1180 gpm

4 x In-Channel 35 x 36 x 35 11.5/ 23(2)

2 x In-Channel 35 x 36 x 35 11.5 / 23(3)

Bioscrubber / Biofilter(4) 1,000 12 9 x 15 5

Bioscrubber / Biofilter(4) 1,000 12 9 x 15 5

24

N/A

3.4 Process Control Description

3.4.1 Pumping
The North and South Side Pump Stations will normally be operated in Auto mode. In this mode, SCADA determines the speed of the pump(s) based on a Proportional-Integral-Derivative (PID) loop with the actual wet well level as the input and pump speed as the output. The actual wetwell level is compared to the calculated level based on the expected wetwell flow, and the pump speed is adjusted so that the difference between the actual and setpoint levels matches. All Duty pumps will operate at the same speed. A delay timer will be engaged allowing the added pump(s) speed to ramp to speed required, 30 seconds initial setting.

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Upon initial plant flow or during low flow conditions, the Jockey pump is started first upon reaching high level and run to maintain level setpoint. If this pump reaches full speed and high level is still active, the Lead Duty pump is started and the Jockey pump stops. If the wetwell level remains within the normal operating range under Jockey pump control, it will operate to maintain a setpoint level. Upon low level, the Jockey pump will stop, and restart upon reaching high level. Additional pumps are started or stopped based on control loop pump speed control signal (not VFD feedback speed) percentages. When the VFD speed is called to be above or below a certain percentage for a certain period of time, one additional pump is started or stopped, respectively. Initial settings are 95% for start, 50% for stop, and from 30 seconds for the delay. Speed is used in-lieu of level to reduce deviations from the setpoint allowed. The Level setpoint changes depending on the number of pumps running as discussed in the paragraph above. The three existing large pumps will be rotated through modes of Lead, Lag and Standby on a daily basis. Hardwired pump equipment related shutdowns including, but not limited to: High motor temperature, VFD fault, and submersible pump moisture detected if applicable. Normally reset at the VFD. Other modes of operation are as follows: Process Control System (PCS) [MANUAL] Control Mode When the Control Mode is selected for [MANUAL] at the PCS, the operator shall be capable of starting and stopping each of the pumps via [STARTISTOP] device control module at the PCS. If a pump is placed "Out of Service" in the pump sequence control matrix, no pump control shall be provided at the PCS. The pump operating speed shall be adjusted at the PCS via a speed control command displayed on the screen. The pump operating speed shall apply to any pump operating in the [MANUAL] control mode such that all pumps are operating at the same speed, except for the jockey pump. The speed of a pump shall not be allowed to be adjusted to a speed below the "Pump Minimum Operating Speed" setting selected at the PCS. Any pump that is running shall shut down when the "Wet Well Low Level" set point is reached. The pumps shall be capable of being restarted from the PCS as long as the level in Influent Wet Well is above the "Wet Well Low Level" set point. Off Mode When the Control Mode is selected for [OFF] at the PCS, the pump will not run and will be taken out of the LEAD, LAG, STANDBY sequence.

Figure 3-4 illustrates a schematic of the process flow through the pump station, including the new pumps, dimminutors and flow meters.

3.4.2 Dimminutor
The dimminutor shall be provided with a dedicated controller to control operation of the machine as well as a local HAND/ OFF/ AUTO switch. The controller shall have sensors designed to detect motor overload and initiate momentary reversal of cutter operation to cure the condition, and then resume normal operation. If the overload clears, normal operation shall be maintained. If the overload reoccurs, the process shall be repeated. If the overload still remains after three attempts within 30 seconds, the controller shall lock out the dimminutors control circuits and initiate alarm through dry contacts to an external circuit.

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3.4.3 Odor Control

The odor control units will run continuously pulling air from the pump stations and providing positive pressure to drive the air through the odor control units, as can be seen in Figure 3-5. Pressure will be measured at the fan and across the media at both the biofilter and bioscrubber. A High Pressure alarm will sound if trans-media pressure or pressure across the fan increases above a field set level. Internal temperature will also be measured within the biofilters media, with an associated High Temperature Alarm. The pH will be measured in the units sump, and will control a solenoid valve solution blow down, as well water feed. The internal recycle pump run continuously. The solution feed will batch run based upon the manufacturers recommendations.

3.5 Relation to Other Unit Processes

The North and South Pump Stations are the influent pump stations for the WWTP. The existing operating pumps are oversized for the flows the plant is currently receiving. Therefore, they are operating in a fill and draw control sequence. This is causing hydraulic surging within the WWTP. This surging is causing both hydraulic and treatment process performance problems with essentially all of the WWTP liquid stream treatment processes. These improvements should minimize the hydraulic surging and the associated issues to periods of extremely low flow such as nights and weekends.

3.6 MDE Guidelines

Chapter 3 of the 1978 Design Guidelines for Sewage Facilities from the State of Marylands Environmental Health Administration covers Sewage Pumping Stations and Force Mains. The following guidelines are pertinent to the current upgrades. Pump Selection: Pumps must be capable of passing spheres of at least 3 inches in diameter. The suction and discharge openings shall be at least 4 inches in diameter. The additional jockey pump will meet these requirements. Pumps must be placed such that under normal operating conditions a positive suction head will exist, preferable such that positive suction shall be maintained during all normal operating conditions, and be installed with individual intakes. The new jockey pump will be installed with accordance with these requirements. Pump Protection: It is preferable that pumps be preceded by bar racks and where it is warranted also a grinder or dimminutor. The previously installed bar screens were removed in the previous upgrade and will not be reinstalled. However, dimminutors will be re-installed in order to minimize pump downtime due to clogging and ragging. Valves: Suitable shutoff valves shall be placed on suction and discharge lines of each pump. A pump control valve shall be placed on each discharge line, between the shutoff valve and the pump. The jockey pump will be installed with a plug valve on both the inlet and discharge sides with a check-valve on the discharge side of the pump preceding the discharge side plug valve. Wet Well Capacity: The wet well shall be sized to provide a capacity with a minimum pumping cycle of 7 minutes. The new jockey pumps will be sized to ensure a capacity that results in a minimum of a 7 minute pump cycle. Ventilation: A ventilation system shall be sized to provide a minimum of 30 complete air changes per hour. In addition to manual control, time clock operation of fans shall be provided to allow a minimum of 12 complete air changes per hour. Ventilation, accomplished by introduction of fresh air in to the wet well under positive pressure is recommended. The planned odor control units will not provide 30 ACHs per MDEs standard. The units will be designed to complete 12 air changes per hour per the requirements of NFPA 820. Allowing for a minimum of 30 complete air changes per hour for the wet well

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areas would result in a gross over sizing of the equipment. Additionally, the odor control units would be very large and unsightly. Water Supply: If a potable water supply is brought to the station, installation of a backflow prevention valve on the water main prior to any point of use is required. An air break shall be provided between any potable water and sewage handling equipment which might cause contamination of the potable water system. Any new connections between the potable water supply and sewage handling equipment will be designed to meet these standards. Safety Features: Safety features such as hand-rails, fixed grab bars or other provisions for safe access, operation and maintenance must be provided. Any newly modified areas will have applicable safety features installed. Force Mains: Velocity: At a minimum pumping rate, a velocity of at least 2 feet per second is recommended. The planned jockey pumps will be supplied with a minimum flow rate such that the minimum velocity in all discharge force mains will be maintained at or above 2 feet per second.

3.7 Constructability
Modifications to the North and South Pump Stations will consist of the addition of a jockey pump, dimminutors, and odor control equipment to both facilities. Structural adjustments will need to be made in order to facilitate proper placing of the dimminutors, however these are expected to be minor. The installation of the jockey pumps will require the existing suction piping to be re-engaged. This will involve the installation of a new gate valve, and a re-arrangement of the piping for the dry-wells sump suction piping. It is anticipated that this work can be completed in such a manner as to not interfere with the operation of the pump stations. At the North Side Pump Station, there is one operational influent line, through the existing dimminutor chamber and one line with no entry to the wetwell through the dimminutor room. The construction will need to be phased in such a manner that the dimminutor room is brought online while using the dimminutor chamber. Then the opposite can occur. The equipment is being sized such that only one influent line will be necessary at any given time. At the South Side Pump Station, the dimminutor room is the only influent line to the pump stations wetwell. Therefore, each dimminutor channel with have to be taken offline one at a time, for device installation, in order to keep the pump station online at all times. The North Side Pump Station currently only has a flow meter installed on the 18 discharge line. During this upgrade a flow meter on will be installed on the 24 discharge line. It is expected that this line will be taken offline in order to install the meter using existing shut-off valves while the other discharge line is used in order to keep the pump station operational. Both facilities will require a connection to a water line, as well as a power connection and a drain line to and influent sewer or the pump station wetwell. The installation of the ductwork and the equipment is expected to be completed so that the pump stations operations are not impacted.

3.8 Future Expansion Issues

The installation of a jockey pump will take up the remaining open spot for a pump within the pump stations. If either the NSPS or the SSPS capacity needs to be upgraded in the future, the jockey pump could be replaced with a larger sized pump. This upgrade will not increase the current capacity for either pump station. However, the capacity currently handled by the pump stations meets the current future firm capacity needs as met by the BNR/ENR upgrades.

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