Project Report 001FORRESTER HEIGHTS
Yelm, Washington
WATER BOOSTER PUMP STATION
PROJECT REPORT
Prepared for.
FH1, LLC
4200 6~" AVE SE
Suite 301
Lacey, WA 96503
16 October 2007
Prepared by:
Benjamin E. Enfield
Nicholas D. Taylor
Reviewed by
Project No.: 406050.10
WVi~ Cons ul fi n9 En 9ineers
4200 Sixth Avenue, Suite 309
Lacey, VJA 98503
Forrester Heights
Booster Pump Station Project Report
TABLE OF CONTENTS
Page
Overview and Planning
1. Sizing Analysis 1
2. Hydraulic Analysis I Equipment Specifications 3
3. BuildinglPump-house Details 7
4. Reliability 8
6. Ownership 9
7. Maintenance 9
APPENDICES
Appendix A System Plans Including Project Layout Map, Building/Pump-house Details,
Structural Details, and Site Piping Plan
Appendix B Equipment Specifications
Appendix C Booster Pump System Controls Electrical Schematic
Appendix D General Routine Operation and Preventative Maintenance Schedule
KPFF Consulting Engineers i 18 October 2007
Project No.: 406050.10
Forrester Heights
Booster Pump Station Project Report
Overview and Planning
This report has been submitted for the construction of a permanent closed system Booster
Pump Station (BPS) near the intersection of Forrester Heights Drive and Highway 507 in Yelm,
Washington, to meet required pressure demands for the proposed Forrester Heights
Development Phase 1, which consists of 24 single-family residential lots. The proposed BPS
includes three (3) skid-mounted booster pumps and their associated piping, a control system, a
bladder tank, a backup power generator, and a sheltering structure as specified in the
construction documents included in Appendix A. Manufacturers' material details, electrical
schematics, and structural calculations will be submitted as part of the construction submittal
package.
Pressure testing of the newly constructed 10-inch water main serving the Forrester Heights
Development indicates that adequate residual pressure is not available at the high point of the
system, which is approximately 60-feet higher than the proposed BPS. Analysis of alternative
solutions by the project engineer and the City of Yelm determined that the construction of a
BPS is the most economical means to provide adequate residual pressure for the proposed
residential lots. The proposed BPS will splice into the newly constructed 10-inch water main
and is designed to provide adequate residual pressure to the high point of the system for the
required fire flow and peak daily demand of the proposed Forrester Heights Development. The
proposed BPS shall be constructed upon project approval by the necessary agencies. This
report will demonstrate that the proposed BPS will provide adequate system capacity and
reliability for the proposed Forrester Heights Development.
The City of Yelm is aware of the proposed BPS and its necessity as well as the estimated
capital and operating costs associated with the water system Improvement.
This report has been prepared in accordance with Washington State Department of Health
(WSDOH) Water System Design Manual dated August 2001.
KPFF Consulting Engineers 1 19 October 2007
Project No.: 406050.10
Forrester Heights
Boaster Pump Station Project Report
1. Sizing Analysis
Determination of Pumoinc Svstem Discharoe Capacity Requirements:
The BPS must be able to provide minimum capacity for both normal operating conditions and
fire flow demand of the development.
Normal Ooeratino Conditions:
The BPS must be able to provide the peak hourly demand (PHD) to the service area and
maintain a minimum of 30 psi at all service connections. Peak hourly demand is calculated
using the Washington State Department of Health: Water System Design Manual, as follows:
Service area=24 single family residences
PHD = (MDD/1440)[(C)(N) +F] +18
Where: PHD = Peak Hourly Demand (gpm)
C = Coefficient Associated With Ranges of ERU's
N = Number of Service Connections, ERU's
F = Factor Associated with Ranges of ERU's
MDD = Maximum Day Demand, (gpd/ERU) =ADD x 2
ADD = Average Day Demand (gpd/ERU) =(8000/ARR)+200
ARR = Average Annual Rainfall, (in/yr)
Knowing that 24 residential service connections(ERU's) are proposed and using table
5-1 of the Water System Manual; N= 24, C=3.0, and F=O.
The closest rainfall monitoring station maintained by the Western Regional Climate
Center(WRCC) is in Olympia, WA. The WRCC online database shows that the
average annual rainfall is 50.68 in/yr. (ARR=50.88 in/yr)
Therefore:
ADD = (8000/50.88) +200 = 357.2 gpd/ERU'
MDD = 357.2 z 2 = 714.4 gpd/ERU'
PHD = (714.4/1440)[(3.0 z 24) + 0] + 18 = 53.7 gpm
The peak hourly demand of the system is 53.7 gpm with a minimum pressure of 30 psi
at all service connections.
'The City of Yelm has documented an ADD of 300 gpd.
Fire Flow Condition:
The BPS must be able tc provide a fire flow of 750 gpm, as dictated by the City of Yelm, plus
the calculated peak hourly demand to the service area and maintain a minimum of 20 psi at all
points in the distribution system.
Fire Flow Demand = 750 gpm + 53.7 gpm = 803.7 gpm
The fire flow demand of the system is 803.7 gpm with a minimum pressure of 20 psi at
all points of the distribution system.
KPFF Consulting Engineers 2 16 October 2007
Project No.: 406050.10
Forrester Heights
Booster Pumc Station
Total Dvnamic Head Required:
The total dynamic head (TDH) that the booster pump must work against is shown as follows:
TDH = He+ ~' Hr+ H~- Hs
Where: HQ = Static Discharge Head (ft)
s'. Hr = Sum of Minor Losses (ft) [pipe friction, fittings, etc]
H~ = Discharge Head (ft)
Hs = Suctign Head (ft)
He= 65ft (elevation difference between high point of system and pump)
Minor losses include friction losses (His), fittings losses and losses through the pumps.
Friction losses were computed using the Hazen-Williams equation. Fora 10" PVC pipe
at 804 gpm the friction loss is 0.316 ft/100-ft of pipe.
Added to this is a conservative estimate of 10.0 ft for fittings losses and 15.0 ft of
losses through the BPS itself.
~'Hr= (1580ft/100)x0.316+30ft
For peak hourly demand and fire flow demand a minimum pressure of 30 psi and 20
psi is required respectively. A pressure of 30 psi correlates to H~ of 69.3 ft and 20 psi
correlates to a H°of 46.2 ft. The existing pressure of 44 psi at the connection
correlates to a Hsof 101.6 ft. Therefore:
Peak Hourly Demand TDH @ 30 psi, 53.7 gpm
= 65ft + 30ft + 69.3ft - 101.6ft = 62.7ft
Fire Flow Demand TDH @ 20 psi, 803.7 gpm
= 65ft + 30ft + 46.2ft - 101.6ft = 39.6ft
The system demand information was used to select the pumps and equipment for this project.
2. Hydraulic Analysis/Equipment Specifications
Pumps
The specified pumps are three (3) Grundfos CR 64-1-1 vertical, non-self priming,
multistage, in-line, centrifugal, variable speed pumps.
Figure 1 below indicates that one (1) Grundfos CR 64-1-1 pump will be capable of
supplying the required residual PHD pressure of 30 psi (62.7 ft TDF) at 339 gpm; much
more than the required 53.7 gpm. Single pump effciency will be 70.8%.
KPFF Consulting Engineers 3 18 October 2007
Project Na.: 406050.10
Forrester Heighfs
Booster Pump Station Project Report
Figure 1
37253000 CR 647-1
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KPFF Consulting Engineers 4 180ctober 2007
Project No.: 406050.10
Forrester Heights
Booster Pump Station Project Report
Figure 2
37257000 CR 547-0
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fftY C= eA ^5 @PM
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KPFF Consulting Engineers 5 18 October 2007
Project No.: 406050.10
Forresfer Heights
Booster Pump S[ation Project Report
2. Hydraulic Analysis /Equipment Specifications (Continued)
Figure 2 above indicates that two (2) Grundfos CR 64-1-1 pumps in parallel will be capable
of supplying the required residual fire flow demand pressure of 20 psi (39.6 ft TDH) at 821
gpm; more than the required 803.7 gpm. Dual pump efficiency will be 52.9% and is
acceptable as very infrequent use of a second pump is foreseen.
The third pump shall only operate in a backup capacity and will be utilized during
maintenance or emergency periods when another pump is off-line.
The specified pumps are variable speed and shall be operated by the control system as
specified below. Technical specifications for the proposed pumps are provided in
Appendix 8.
Pump startup and performance testing routines shall be performed as prescribed by the
pump manufacturer's data.
Pioin
All interior piping and fittings within the pump house shall be ductile iron, AWWA C205
steel, galvanized iron pipe, or copper piping. PVC piping shall not be used. All piping to
and from the BPS is in place and connection of the BPS shall entail ftting the intake and
outlet pipes of the BPS to the existing 10"x6" reducers. Due to the supplemental nature of
the proposed BPS, a pipe by-pass around the pumping equipment is already in place.
All piping shall be secured using strapping, thrust blocking, and/or necessary restraint as
prescribed by AWWA specifications.
Valvino
All system valves shall be resilient wedge, non-rising stem, with o-ring seals. Valve ends
shall be mechanical joint or ANSI flanges. Valves shall conform to AWWA C509-80. Valves
shall be Mueller, M & H, Clow, Kennedy, or equal.
Controls
All three (3) BPS pumps shall be connected by wire to the BPS control system. The control
system shall consist of a surge arrestor, voltage control monitor, ammeters, enclosure
lighting control, system alarm control, thermostat, emergency operation controls, control
panel signal unit, primary and suction pressure sensors, water shortage switch, external
fault, remote setpoinVredundant sensor, overpressure protection, system fault, facility data
communication link, surge suppression capability, and the like.
The BPS control system electrical wiring schematic featured in Appendix C is the Grundfos
Model F, 3-pump control system. Final control system wiring schematic and/or any
variation from the specified control system shall be approved by the design engineer prior
to construction. The proposed electrical system shall meet all applicable federal, state, and
local codes.
KPFF Consulting Engineers 6 18 October 2007
Project No.: 406050.10
Forrester Heights
Booster Pump Station Project Report
The control system shall be equipped with a generator activation feature to start the
emergency power generator, which is specified in section 4 of this report, during loss or
surge of power.
The control system alarm shall feature an external visual and auditory alarm that is
signaled by a pump failure, overheating, loss of necessary net-positive suction head, dry
running, and any other less than ideal operating states. An alarm battery back-up shall be
provided to operate the alarm system during power outages.
Bladder Tank/Surge Protection
Although the specified pumps are equipped with variable speed motors, constant running
and frequent starts lead to faster pump degradation, more frequent maintenance, and
earlier replacement. The proposed BPS system shall include a 132 gallon, American
Society of Engineers (ASME) certified bladder tank. The tank size is specified by the
Grundfos pump manufacturer to adequately protect boaster pumps. A bidder proposed
bladder submittal shall be approved prior to construction of the proposed BPS. The
bladder tank will also act as surge and water-hammer protection for the BPS.
General
All materials, installation, and workmanship shall conform to the Standard Specifications for
Road, Bridge, and Municipal Construction published by the Washington State Department
of Transportation (WSDOT) and the American Water Works Association (AWWA) standard
specifications latest editions thereof.
Performance and sizing standards shall conform to AWWA, American Public Works
Association (APWA), WSDOT, and WSDOH guidelines. All components in contact with
water shall be NSF approved.
48 hours notice shall be given to customers for a planned interruption of service. Every
effort shall be made to keep the service interruption to a minimum. Excavations and shoring
shall conform to Labor and Industries (LI) standards for worker safety.
3. Building/Pump-house Details
The pump-house shall be bidder designed, however certain pump-house features, as
outlined below, are required. The final pump-house design shall be approved by the design
engineer prior to construction based on contractor provided submittals. A conceptual
pump-house layout is included in Appendix C.
Mounting Surface
The proposed pump-house shall be mounted to a flat reinforced broom-finished concrete
pad and shall be affixed to the pad by embedded threaded anchors. Concrete pad,
reinforcement, and mix design shall be constructed as specified in the construction
documents included in Appendix A.
KPFF Consulting Engineers 7 18 October 2007
Project No.: 406050.10
Forrester Heights
Booster Pump Station Project Report
Electrical Panel
The electrical panel shall be wall or post mounted and shall be a 200 amp 120/208V/B-
phase panel with auto-transfer switch. The panel shall also include one (1) 120 volt, 20
amp, GFI outlets
Temperature Control
Pump-house temperature shall be monitored by the BPS control system. Internal high
ambient temperature thermal protection is provided by the specified pumps. Low
temperature thermal protection shall be provided by a single 1500 watt forced air electric
heater that is wall mounted and Includes a remote thermostat. One 50 cfm exhaust fan
shall be installed with a remote timer and shall be ducted to the exterior to control humidity
and prevent overheating in the summer.
Pump-house insulation shall be provided as required by the pump-house equipment
manufacturer's specification.
Liohtin
Besides exterior alarm system lighting, one exterior 200 watt flood light shall be provided.
Two interior 100 watt lights shall be provided with a switch near the pump-house door.
Security
The BPS doors shall be kept locked at all times. A City of Yelm official or appointed facility
management agency shall maintain responsibility for access to the proposed BPS.
The exterior generator area shalt be surrounded by a 6 foot high chain-link security fence
with a locking gate. Access to the fenced area shall also be controlled by a City of Yelm
official or appointed facility management agency.
Miscellaneous
A sample tap shall be installed within the pump-house and shall be connected to the BPS
outflow pipe. A pressure relief valve shall be installed on the outlet side of the BPS.
Pump-house and pump-house access shall be constructed in a manner that will allow
access to the BPS by any necessary equipment.
4. Reliability
The BPS is designed to provide adequate service during periods when one pump is not in
operation. This designed redundancy will ensure that peak hourly and fire flow demand at
the required residual pressure are available to the service connections at all times.
A configuration of three identical pumps in parallel is specified with the third pump strictly
for redundancy in the case that one pump fails. The system will be setup with one variable
frequency drive (VFD) in the control panel to provide more efficient operation for average
KPFF Consulting Engineers 8 18 October 2007
Project No.: 406050.10
Forrester Heighfs
Booster PUmo Station
system demands. When the demand increases beyond the capacity of the first pump then
the other pumps will activate one by one as needed. One pump will be able to supply
domestic demand and two pumps will be able to supply fire flow demand. The third pump
is provided for redundancy In case of a pump failure or maintenance outage.
The BPS will also include a 35 KW diesel generator, as specified in Appendix B, to supply
power to the pumps in the event of a power outage. Any power outage or interruption of
normal BPS operation shall be signifed by an exterior visual and auditory alarm.
5. Ownership
After construction and acceptance, the water system infrastructure will be owned and
maintained by the City of Yelm as part of the City water system.
6. Maintenance
Table A, General Routine Operation and Preventative Maintenance Schedule, which is
included in Appendix D, outlines suggested daily, monthly, quarterly and annual
maintenance activities for the system. It is the responsibility of the system owner to ensure
that maintenance of the water system as described in the table is carried out. Records of
maintenance performed, as well as any repairs made to the system, shall be kept on file
with the water system.
Operational data shall be recorded monthly. A log shalt be maintained recording system
pressure, service logs, run-time meter readings, etc.... Provided herein are more specific
guidelines for operation and maintenance of equipment for this water system:
Booster Pumps
This centrifugal pump requires little or no service other than reasonable care and periodic
cleaning. Occasionally, however, a shaft seal may become damaged and must be replaced.
The procedure as outlined by the manufacture will enable replacement of the seal.
Most pump problems are caused by electrical problems. Minor control boz components or
outside electrical difficulties (such as low voltage) can cause a malfunction. Before
removing the pump from service, check motor windings for damage (check winding
resistance with an ohmmeter per owners manual).
Centrifugal pumps need to be manually operated on a monthly basis to ensure that they are
functioning properly. Also, on a monthly basis the hourly run-time meters for each pump
must be read and recorded.
Bladder Tanks
Bladder tanks are relatively maintenance free. The air pressure in each tank should be
checked monthly and the air replenished as needed. Each bladder tank should be drained
and recharged with air annually to ensure that it is functioning properly.
With age, the bladder inside the tank may develop small cracks. This allows water inside
the tank between the bladder and the tank wall. This is not a sterilized area and may be a
KPFF Consulting Engineers 9 18
Project No.: 406050.10
Forrester Heights
Booster Pump Station Project ftepoR
source of bacterial contamination. If a tank does become waterlogged due to a failure of the
bladder membrane, the tank must be replaced. Until the tank can be replaced, it should be
taken out of service to prevent any possible contamination of the water system.
Svstem Valves
All the valves in the water system shall be operated quarterly through their full operating
range. Exercise valves once a year to ensure that they will be operable when needed for
maintenance or emergency repairs. Replace or repair valves that do not operate properly.
Electrical Svstem
A complete Inspection of the electrical system shall be performed annually. Loose
connections shall be tightened. Pump relays, switches, and all other controls shall be
checked to ensure they are in operating order. Be sure to check the ground system ground
as well.
Backup Generator
An automatic transfer switch starts the generator when there is a power failure. The
generator will also start up once a week and run for approximately 15 minutes. This will
ensure the system is working when the power goes out. Check weekly to make sure the
system is operating properly, especially during winter months.
The fuel for this generator is diesel. The fuel level must be checked monthly at a minimum.
Replenish fuel as required. Fluid levels in the generator engine must be checked and
replenished as required. Follow the manufacturers recommendations. Make necessary
repairs in a timely manner so that the generator is functional when needed.
Disinfection
If a distribution main breaks or other components of the water system that are in contact
with the water are exposed to the atmosphere or other potential contamination source, the
equipment shall be disinfected prior to being put back into service per the appropriate
AWWA specification for disinfection. The following is a list of the AWWA specifications.
AWWA C651, Disinfecting Water Mains
AWWA C652, Disinfection of Water Storage Facilities
AWWA C653, Disinfection of Water Treatment Plants
AWWA C654, Disinfection of Wells
KPFF Consulting Engineers 10 18 October2007
Project No.: 406050.10
Appendix A
Sysfem Plans Including Project Layout Map,
Building/Pump-house Details, Structural Details, and
Site Piping Plan