Water pumping station with an integral valve vault

Abstract

A waste or storm water pumping station and system used to pump water from a lower elevation to a higher elevation during the process of moving or managing the water is disclosed herein. The pumping station has a wet well collection chamber with a sloped floor and an integral valve vault chamber cast within the pump station body, which results in increased storage capacity in the wet well chamber for pump station components. Additionally, the pumping station may be installed as a single unit of equal depth to eliminate differential settlement and multiple or uneven excavations.

Claims

1. A multi-part, precast concrete enclosure for a below-grade pumping station for moving liquids, comprising: a top slab; a monolithic, precast concrete upper section comprising: two vertically extending sidewalls and two arcuate end sections; a vertical partition wall extending from one vertically extending sidewall to the other vertically extending sidewall; a horizontal floor extending from one of said two arcuate end sections to said vertical partition wall; a portion of a water collection chamber positioned on one side of said vertical partition wall; and a valve chamber positioned on the other side of said vertical partition wall and separated from said water collection chamber by said horizontal floor and said vertical partition wall, wherein said upper section is engaged on an upper end to a lower surface of said top slab, wherein an upper surface of said vertical partition wall is in contact with said lower surface of said top slab, and wherein said monolithic, precast concrete upper section is one piece; an inlet positioned proximate to said water collection chamber, wherein said inlet allows fluid to enter said water collection chamber; an outlet positioned proximate to said valve chamber; a precast concrete bottom section further defining said water collection chamber, said bottom section comprising: a concrete base slab with an upper surface and a perimeter edge; and a wall extending upwardly from said upper surface of said concrete base slab, said wall comprising vertically extending sidewalls and arcuate end sections which define a footprint; a sloped floor portion extending upwardly from a center portion of said upper surface of said concrete base slab to a portion of an inner surface of said wall; a beveled corner section joining a lower portion of said inner surface of said wall to a portion of said upper surface of said concrete base slab, wherein said beveled corner section has a first height as measured from said upper surface of said concrete base slab to a top of said beveled corner section, and wherein a tallest portion of said sloped floor portion as measured from said upper surface of said concrete base slab to a top of said sloped floor portion has a second height that is taller than said first height of said beveled corner section; and wherein said bottom section is monolithic; a first access opening for access into said water collection chamber; a second access opening for access into said valve chamber; wherein said bottom section and said upper section are sealingly engaged; wherein said valve chamber is positioned entirely within said footprint of said precast concrete bottom section; and wherein said valve chamber is positioned in an upper 33% of said precast concrete enclosure as measured between said concrete base slab and said top slab.

2. The enclosure of claim 1, wherein a lower end of said wall of said bottom section is thicker than an upper end of said wall.

3. The enclosure of claim 1, wherein said enclosure further comprises a first riser section comprising vertically extending sidewalls and arcuate end sections, wherein said first riser section is positioned between said upper section and said bottom section to selectively alter a height of said precast concrete enclosure.

4. The enclosure of claim 3, further comprising a second riser section comprising vertically extending sidewalls and arcuate end sections, wherein an upper surface of said second riser section is sealingly engaged to a lower surface of said first riser section, wherein a lower surface of said second riser section is interconnected to an upper surface of said wall of said bottom section, wherein said first riser section has a third height and said second riser section has a fourth height, and wherein said third height is not equal to said fourth height.

5. The enclosure of claim 3, wherein said top slab, said first riser section, and said bottom section are precast of wet cast self-consolidating concrete.

6. The enclosure of claim 1, wherein said valve chamber comprises a valve assembly, and wherein said valve assembly comprises at least one of a water meter, a backflow preventer valve, and a pressure reducing valve.

7. The enclosure of claim 1, wherein the concrete is at least partially comprised of an antimicrobial admixture.

8. The enclosure of claim 1, further comprising a discharge line extending from said water collection chamber through an aperture in said vertical partition wall through said valve chamber and out said outlet.

9. A below-grade pumping station for collecting and moving liquids, comprising: a height-adjustable, precast concrete enclosure comprising: a top slab having a substantially planar upper surface, arcuate ends, and at least one access opening; a monolithic, precast concrete upper section comprising a first vertically extending sidewall, a second vertically extending sidewall, a first arcuate end section, a second arcuate end section, a vertical partition wall extending from said first vertically extending sidewall to said second vertically extending sidewall, a horizontal floor extending from said first arcuate end section to said vertical partition wall, a portion of a collection chamber positioned on one side of said vertical partition wall; and a valve chamber positioned on the other side of said vertical partition wall and above said horizontal floor, wherein said upper section is interconnected on an upper end to said top slab; an inlet positioned proximate to said internal collection chamber, wherein said inlet allows fluid to enter said collection chamber; an outlet positioned proximate to said valve chamber; a monolithic, precast concrete bottom section further defining said collection chamber, said bottom section comprising: a base slab having a lower surface, an upper surface, and a perimeter edge; a perimeter wall extending upwardly from said upper surface of said base slab and positioned within said perimeter edge, and said perimeter wall positioned directly below said first and second vertically extending sidewalls and said first and second arcuate end sections of said upper section; an interior junction between said perimeter wall and said upper surface of said base slab; a beveled corner section extending at least partially around said interior junction; and a sloped floor section positioned proximate said upper surface of said base slab, wherein said sloped floor section extends from an arcuate end of said perimeter wall toward an opposing arcuate end of said perimeter wall to promote drainage of the liquids; a pump; a discharge line interconnected on a first end to said pump and interconnected on a second end to said outlet, wherein said discharge line extends through an aperture in said vertical partition wall and through said valve chamber; a valve assembly positioned within said valve chamber and interconnected to said discharge line; at least one of a float switch and a level sensor; and a vent.

10. The below-grade pumping station of claim 9, further comprising one or more intermediate riser sections comprising vertically extending sidewalls and arcuate end sections, wherein said one or more intermediate riser sections are positioned between said upper section and said bottom section to selectively alter a height of said precast concrete enclosure.

11. The below-grade pumping station of claim 9, wherein said monolithic bottom section is precast of wet cast self-consolidating concrete.

12. The below-grade pumping station of claim 9, further comprising a second access opening in said top slab, wherein said second access opening provides access into said valve chamber, wherein said perimeter wall of the monolithic, precast concrete bottom section extends upwardly from said base slab above said beveled corner section and said sloped floor section and comprises a lower portion proximate the base slab and an upper portion positioned above said lower portion, and wherein said lower portion of said perimeter wall is thicker than said upper portion of said perimeter wall.

13. The below-grade pumping station of claim 9, wherein said valve assembly comprises a check valve.

14. The below-grade pumping station of claim 9, wherein an upper surface of said vertical partition wall is in direct contact with a lower surface of said top slab.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description given above and the detailed description of the drawings given below, serve to explain the principles of these embodiments.

(2) FIG. 1 is a rear perspective view of an embodiment of a pump station body;

(3) FIG. 2 is a cross-sectional front elevation view of an embodiment of a water pumping station;

(4) FIG. 3 is a top plan view of an embodiment of a water pumping station;

(5) FIG. 4 is an exploded rear perspective view of an embodiment of a water pumping station comprised of multiple sections; and

(6) FIG. 5 is a cross-sectional elevation view of a section of an embodiment of a wet well collection chamber.

(7) To assist in the understanding of the embodiments of the present invention the following list of components and associated numbering found in the drawings is provided herein:

(8) TABLE-US-00001 Component No. Component 2 pumping station 4A-F float switches 6 collection chamber (wet well) 10 pump station body 12 vertical side (of pump station body) 14 end (of pump station body) 16 valve vault chamber 18 valve vault assembly 20 top slab (of pump station body) 22 pump 24 top surface 26 bottom surface (of top slab) 28 thickness (of top slab) 30 base (of pump station body) 31 base slab 32 access opening 34 access frame 36 access cover 36A grate (access cover) 38 perimeter wall 40 riser (of pump station body) 40A bottom riser (of base) 42 sloped floor 44 access ladder (into valve vault) 46 upper section (of pump station body) 48 beveled corner section 50 wall (of riser) 52 inlet 54 control panel 56 vent 58 inner surface (of riser) 58A inner surface (of base riser) 60 junction box 62 outlet 62A outlet - optional location A 62B outlet - optional location B 64 bypass valve 66 transducer 68 valve vault floor drain 70 guide rails 72 pump discharge line 74 pump power wire 76 pump control wire 78 sealing section 80 interconnection point 82 trash basket assembly 84 vertical partition wall 86 horizontal partition wall (valve chamber floor)

(9) It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

(10) Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. Also note that the scale for each figure is different. Thus, the scale for FIG. 1 is different from the scale of FIG. 2, etc.

(11) FIG. 1 shows one embodiment of a pump station body. In the embodiment shown, the pump station body 10 comprises a top slab 20, a top surface 24, outlets 62A, 62B, two access covers 36, risers 40, a base 30, and a base slab 31. Two optional locations for an outlet 62 are shown in FIG. 2: optional location A for the outlet 62A and optional location B for the outlet 62B, both of which are positioned proximate to the valve vault chamber. Typically, only one outlet 62A or 62B will used in a pumping station. However, more than one outlet 62A, 62B is possible in alternative embodiments. Additionally, some embodiments may include and overflow outlet and line to the main pumping system or to an overflow tank. An overflow outlet and line will typically be positioned such that water can exit the wet well if both pumps fail or if both pumps cannot hand the incoming water load. Thus, the overflow outlet will be positioned in the wet well collection chamber. The risers 40, when assembled, create a generally elongated shaped structure with planar vertical sides 12 and arcuate ends 14. The pump station body may, in alternate embodiments, have an elongated pill shape. Thus, the one or more risers 40 are generally oval shaped. In another embodiment, the risers 40 are rectangular in shape having rounded corners, resulting in a generally pill-shaped riser 40. In still further embodiments, the pump station body 10 may be manufactured in a variety of shapes, including but not limited to a parallelogram, rectangle, rhombus, square, trapezoid, cylinder, sphere, or box. In various embodiments, no matter the shape of the structure 10, each riser 40 has a continuous vertical planar wall 50 to form a ring with a wall height and thickness. The riser wall height is typically greater than 6 and the riser wall thickness is typically greater than 4. In some embodiments, the riser wall height is at least one of 6, 1, 2, 3, and 4. In various embodiments, the wall thickness is at least one of 4, 5, 6, 7, 8 or 9.

(12) In one embodiment, the pump station body 10 is manufactured from precast concrete. In an additional embodiment, the pump station body 10 is constructed with precast, reinforced concrete sections. In other embodiments, other materials may be used to manufacture the pump station body 10 including but not limited to plastic, polymer concrete, other materials known in the art. In additional embodiments, the pump station body 10 is manufactured of materials and composition mixes having various combinations of ingredients such as those found in the manufacture of concrete, plastics, polymers, cement, water, cementitious materials, chemical and/or mineral admixtures, and coloring agents, which when combined may create the concrete material. Various embodiments may include a wide variety of different finishes, colors, and textures, such as those commonly utilized in the architectural and stone industries.

(13) In one embodiment, an antimicrobial admixture may be added to the concrete mix to prevent the formation of hydrogen sulfide gas. In additional or alternative embodiments, other added mixtures such as waterproofing materials (e.g., a crystalline waterproofing additive, such as XYPEX Admix C-1000 manufactured by XYPEX Chemical Corporation) are used to seal the concrete against the penetration of liquids from any direction and protect the concrete from deterioration due to harsh environmental conditions. Although the pumping station is designed for water-tightness without exterior coatings or additives, additional coatings may be applied to either internal or external surfaces in some embodiments. For example, Karnak #83 AF fibered damp proofing asphalt compound can be applied to the pump station body at the rate of about 25 sf/gal.

(14) In some embodiments, the structures are designed to prevent flotation without requiring surface resistance (skin friction) or the weight of mechanical equipment when the ground water level is at finished ground surface. The factor of safety against uplift is calculated as a ratio of the total resisting force (excluding skin friction and the weight of the equipment) to the total hydrostatic uplift force, and may be at least 1.15 in some embodiments. The net uplift force may be transferred to the anti-buoyancy collar.

(15) In one embodiment, all pump station 2 exterior walls below finished grade can be designed for a fluid pressure of 90 psf per foot of depth caused by saturated earth pressure. The top of the pressure diagram is assumed to originate at finished grade. In addition to the soil pressure, a two-foot live load surcharge shall be applied to a depth of eight feet.

(16) FIG. 2 shows one embodiment of a water pumping station 2 with an integral valve vault 16. Specifically, FIG. 2 shows the internal components of the pumping station 2. The water pumping station 2 generally comprises a pump station body, a wet well collection chamber 6, a valve vault chamber 16, a valve vault assembly 18, an inlet 52, an outlet 62 (which is shown in position 62A per FIG. 1), a pump discharge line 72, and one or more submersible pumps 22. Additionally, the system design flow rate may determine the interior piping size, valve size, and force main size.

(17) In some embodiments, piping and fittings are ductile iron, polyvinyl chloride (PVC), or galvanized steel pipe. In one embodiment, piping and fittings supplied with the pumping station are ductile iron class 53. The standard pipe and fittings may be cement lined to the thickness as specified ANSI A26.51 and ANSI A21.4 and may be interior and/or exterior asphalt seal coated by the pipe manufacturer. In one embodiment, the piping and fittings are factory coal-tar epoxy coated. In one embodiment, the piping and fittings are factory epoxy Hi-Build Epoxoline (Tnemec N-69) coated.

(18) In some embodiments, the structural design calculations for the pumping station 2 with an integral valve vault chamber 16 may be prepared and stamped by a registered professional engineer in the project state, and may be submitted for approval prior to fabrication or for record purposes as project time allows. The structural design may take into account discontinuities in the structure produced by the openings for the inlet 52, outlet 62, vent 56, and access opening(s) 32. In one embodiment, the access opening is 3048. In another embodiment, the access opening is 3654. In a further embodiment, the access opening is 3036.

(19) In various embodiments, all pipe penetrations for the water pumping station 2 may utilize cored openings with flexible manhole boots and stainless strap anchors. Pipe penetrations may include: inlet(s) 52, discharge piping 72 from pumps 22 and common discharge exiting the station, and station venting 56. These pipe penetrations may be cast in during manufacturing.

(20) Some embodiments of the piping station 2 include vertical discharge piping 72 from the pump base elbows. This discharge piping can be additionally supported to the wet well 6 structure in intermediate locations utilizing stainless steel structural angles and stainless steel U-bolts, especially when the pump station height exceeds 15 feet.

(21) Typical embodiments include two pumps 22, but the second pump is not viewable in FIG. 2 because it is positioned behind the first pump 22. In some embodiments, the pumping station 2 may have one, two, three, or more pumps 22. If the pumping station 2 has two or more pumps 22, then the pumps may either be arranged in parallel such that the second pump has a higher flow with equal head (i.e., head or lifting force) to the first pump. Otherwise, the pumps 22 could be arranged in series such that the two or more pumps have the same amount of flow, but one pump will have a larger amount of head.

(22) Critical pumping station elevations include Top Of Structure (TOS), grade elevation (also called finished grade elevation because it is the height or level of the ground surrounding the pump station after surrounding ground is set in its final position), inlet invert elevation, floor elevation of structure, and discharge elevation. TOS is usually set at grade elevation or at least 6 above grade elevation.

(23) The inlet invert elevation is site-dependent and is determined from the slope of the pipe coming into the pumping station. Determining the pumping station inlet location is a critical part of the design. The elevation above the inlet is unusable space. A portion of the pump station space below the inlet invert is the working volume of the pumping station 2 and, as such, sets the minimum depth of the pumping station 2. The floor elevation for the pumping station 2 and the pumping station's total height is determined by the lowest inlet invert elevation, the system's reserve and working volumes, and the TOS. Once the inlet invert elevation is determined, reserve and working volumes are determined based on the volume per foot values for the pumping station. Then a minimum floor elevation of the pumping station 2 can be calculated. The pumping station discharge elevation is usually a minimum of four feet below grade, even when the TOS is set 6 above grade. Should a deeper discharge elevation be required, optional risers 40 (which are two feet or four feet tall in some embodiments) can be added to produce additional earth cover.

(24) The pump station body comprises a top slab 20, multiple risers 40 (each with a riser wall 50 having an inner surface 58), and a base 30 having a slab 31 and a perimeter wall 38, which can also be an oval-shaped bottom riser. The top slab 20 of the pump station body has a top surface 24, a bottom surface 26, and a thickness 28. In one embodiment, the pump station body also comprises a sloped floor 42, which is sloped toward the pump(s) 22 such that water and debris are directed toward the pump(s) 22. In some embodiments, the perimeter wall 38 of the base 30 is not positioned on the perimeter of the base slab 31. Therefore, a section of the base slab 31 extends outwardly in a horizontal direction from the perimeter wall 38. This outwardly extending section, which may be called a lip herein, prevents floatation of the pumping station because the soil backfilled around the pumping station will provide a downward force on the lip. In some embodiments, the base 30 is monolithic, precast concrete and includes a sloped floor 42 and a beveled corner 48 positioned between the base slab 31 and an inner surface of the perimeter wall 38. The sloped floor 42 and beveled corner section 48 promote drainage of the water and debris to the pumps.

(25) In some embodiments, the valve vault chamber 16 is precast with the pump station body or is precast with a section of the pump station body, meaning the valve vault chamber 16 is cast in as a part of the precast pump station body or upper section 46 of the pump station body. In various embodiments, the valve vault chamber 16 is formed by a substantially vertical partition wall 84 and a substantially horizontal partition wall (also called the valve vault chamber floor) 86. In one embodiment, the wet well 6 is also cast in as a part of the pump station body. In alternate embodiments, the wet well 6 is formed from multiple sections, e.g., the base 30, base slab 31, bottom riser, one or more risers 40, an upper section 46, and a top slab 20.

(26) In some embodiments, the pumping station 2 further comprises a vent 56, guide rails 70 for the pump(s) 22 to slide down and up for insert and removal, and one or more access openings 32. Each access opening can have an access frame 34 and/or an access cover 36. The pump 22 is designed to slide down and up the guide rails 70. When inserting the pump 22, the pump is slid down the guide rails 70 and positioned such that the pump 22 sits on the base elbows, which are anchored to the base slab 31 of the pump station. The weight of the pump 22 against the seal on the base elbow and the pressure from the pump pushing water through the discharge line 72 provides the required water-tight connection between the pump 22 and the discharge line 72. When a pump 22 needs servicing, the pump 22 is lifted, via a lifting chain or cable, off of the base elbow, up the guide rail 72 system, and out of the pump station 2 through the access opening 32. In one embodiment the base elbow is bolted to the discharge line 72. The base elbow and discharge line 72 remain in the pump station 2 when the pump 22 is removed for servicing.

(27) In one embodiment, the pumping station includes a passive wet well vent assembly 56. The vent assembly 56 can be a standard four-inch vent fashioned from Sch80 PVC piping and fittings. Alternatively, the vent 56 can be a PVC pipe with a curved end to allow air to exit the pump station 2 such that a backpressure is not created because a backpressure would inhibit water from entering the pump station 2. In one embodiment, the vent assembly 56 ends with a gooseneck downward tuning outlet and stainless steel insect screen, positioned approximately three feet above the TOS elevation. The vent assembly 56 may be factory assembled and side-mounted to the exterior of the pump station body 10, then removed and shipped separately to the job site for field installation. If vent piping runs underground elsewhere on the site, the pump station body 10 may have a cored opening with a manhole boot positioned below grade, rather than the vent assembly 56 shown, for use when site-venting is installed. In one embodiment, the vent assembly 56 includes a 4 carbon canister with carbon refill rather than the gooseneck and insect screen.

(28) The interior of a sewage pumping station is a dangerous place. Poisonous gases, such as methane and hydrogen sulfide, can accumulate in the wet well. Any entry into the wet well requires the correct confined space entry method for a hazardous environment. To minimize the need for entry, the pumping station 2 is normally designed to allow pumps and other equipment to be removed from outside the wet well 6. Thus, in various embodiments, the pumping station 2 may be supplied with stainless steel pump-removal guide-rail systems. The guide rails 70, which are appropriately sized for the pumps 22 of the pumping station 2 (i.e., to 2 diameter), extend from the pump base elbows to the stainless steel upper guide brackets in the hatchway area. The guide rails 70 may be composed of 304 grade stainless steel, schedule 40. The guide rails 70 may be supported at intermediate locations with stainless steel brackets, as dictated by the pump manufacturer. The pump guide-rail system is designed to easily allow the submersible pumps 22 to be removed from the pumping station 2 via a lifting chain or cable located at grade elevation and allow all pump service to be performed from outside of the pumping station 2.

(29) In one embodiment, the discharge gauge assembly option may be selected for factory installation of a pressure discharge gauge and related accessories on each pump discharge line 72 as the pipe 72 enters the valve vault (set of two gauges total). The discharge pressure gauges allow the owner to accurately assess down-stream force main pressure conditions and test pumping conditions with select discharge isolation valves. In one embodiment, the discharge gauge assembly comprises a discharge pipe saddle, brass piping and isolation or bleed-off ball valves, a gauge seal fitting, and a liquid-filled pressure gauge with a 0-30 psi, 60 psi, or 100 psi gauge-range readout, depending on the pump and system requirements.

(30) In some embodiments, the valve vault chamber 16 houses a valve vault assembly 18. The valve vault assembly 18 may include a bypass valve 64. Further, the valve vault chamber can comprise a floor drain 68 to allow water in the valve vault to drain to the wet well 6. In additional embodiments, the pumping station 2 includes adjustable, floor-mounted, galvanized pipe stands, which support piping in the center of the valve vault chamber 16. In one embodiment, standard aluminum wall-mounted support brackets with stainless steel U-bolts may be supplied in three locations where the piping penetrations enter and exit the valve vault chamber 16. In an alternate embodiment, stainless steel floor-mounted supports are used.

(31) 3, 4, and 6 pump isolation plug valves with non-lubricated eccentric type plugs may be used in one embodiment and provide a minimum port opening of 80% in order to assure minimum turbulence and minimum pressure drop. Valves may be rated for 175 psi working pressure and cast of ASTM A126 Class B cast iron. Valve flanges meet ANSI B16.1, Class 125 flange specifications. Valves may have a balanced plug, coated with Buna-N (Neoprene) resilient seating surfaces to mate with the body seat. All plug valves may be supplied with lever operators and may be epoxy coated as supplied by the valve manufacturer.

(32) The pumping station according to one embodiment has at least one 3, 4, or 6 check valve. The check valve may be a full-opening swing type check valve with an all-iron body and a bronze seat. The check valve may also have a resilient disc. The check valve should comply with AWWA Standard C-508 and the flanges should meet ANSI B16.1, Class 125 flange specifications. The check valve may be supplied with adjustable outside lever and weight (L&W), epoxy coated, and a standard color or materials, as supplied by the valve manufacturer. In one embodiment, the lever and air cushion check valves with L&W are used.

(33) The pump station body 10 comprises a top slab 20, a base 30, and one or more riser portions 40. The top slab 20, which may be oval shaped, may comprise a generally planar horizontal top surface 24 and a bottom surface 26 with a thickness 28 of approximately 4 to 9, one or more generally rectangular access openings 32, one or more access frames 34, and one or more access covers 36. Alternatively, the top slab 20 may be rectangular in shape and have rounded corners, resulting in a generally pill-shaped top slab 20 when viewed from the top.

(34) In one embodiment, the pumping station 2 comprises a valve vault access ladder 44, which can be aluminum, wall-mounted, and/or properly sized to meet OSHA Standard 1910.27. In an additional embodiment, the pumping station 2 also comprises an aluminum ladder-up, access-assist assembly.

(35) In some embodiments, the base 30 comprises a riser section cast into a base slab 31 resulting in a monolithic base 30 with the slab 31 extending out past the riser walls 50. In one embodiment, the slab 31 extends outwardly beyond the riser walls 50 a distance approximately equal to the thickness of the riser walls 50. The monolithic base 30 further embodies a sloped floor that extends upward from the top surface of the base slab 31 to the interior surface of the riser wall 50 at an angle, thereby creating a non-horizontal floor. In some embodiments, the pump station body 10 is constructed with a reinforced concrete slab 31.

(36) In one embodiment, the pumping station 2 comprises one or more float switches 4A-F on a bundle of wires. Alternatively, a level sensor (not shown) may be used rather than multiple float switches. The level sensor is known in the art and perform a similar function as the float switches. When the wet well collection chamber 6 fills with water and the water reaches a level equal to or above float switch 4A, the float switch sends a signal to the control panel (shown in FIG. 3) that the lead pump 22 should now be turned on. If the water continues to rise above float switch 4A to float switch 4B, then float switch 4B sends a signal to the control panel that the lag pump (not visible in FIG. 2) should now turn on. Under normal conditions, the lead and lag pumps 22 will pump water through the discharge line 72 and out the outlet 62. Thus, the water level in the wet well 6 will decrease. When the water level decreases below float switch 4C, float switch 4C sends a signal to the control panel that one of the pumps 22 can now be turned off. As the water level continues to decrease and falls below float switch 4D, float switch 4D sends a signal to the control panel that the second pump 22 should now be turned off. If the water level ever rises above float switch 4E, then float switch 4E (also called the high level alarm float) sends a signal to the control panel that the high water alarm should be sounded to notify a worker that the water has risen above a normal working level. If the water continues to rise and rises to float switch 4F, then float switch 4F (also called the high high level alarm float) sends a signal to the control panel that the high high water alarm should be sounded.

(37) In some embodiments, the high water alarm float 4E and the high high level alarm float 4F eliminates the requirement that an overflow outlet and line be included in the pump station. Crews are often on alert with portable pumping equipment if the pumps cannot handle the water load or if either the high water alarm sounds or the high high water alarm sounds. In further embodiments, a bypass valve 64 and piping may be utilized when both submersible pumps 22 are out of commission at the same time. Thus, temporary portable bypass piping equipment, including portable pumps, could be employed to collect water from the pumping station working volume area and discharge the water through the bypass valve 64 and into the dedicated bypass force main. The bypass piping size and material options include: 2 PVC, 3 PVC, 3 ductile iron (DI), and 4 DI. This scenario, although unlikely, may also be required by the local municipal authority for back-up emergencies.

(38) In embodiments where a level transducer 66 is used, a cable runs uncut to the control panel and no junction box 60 is required. Available site power (voltage and phase) is critical information required for pump and control selection.

(39) In some embodiments, the pumping station 2 includes an interior junction box 60 for the pump power cables 74 and pump control cables 76 and the level control float cables. The control panel is typically remote-mounted elsewhere, such as adjacent to the pumping station 2 or within a nearby weatherproof structure or facility. The conduits and conductors between the pump control panel and the junction box 60 inside the pumping station 2 may be field supplied and installed by third parties. In one embodiment, the pump power and control cable junction box 60 is Nema 7 explosion-proof and the float cable box (not shown) is polypropylene because it is intrinsically safe. In one embodiment, the interior junction box 60 includes an RGS conduit and stainless steel supports.

(40) In some embodiments, the pumping station may be offered with an exterior junction box (not shown), for example, the Nema 4X, with a divided interior for power and control voltages. The junction box may be mounted to the exterior of the pumping station 2 approximately two feet above TOS. The conduits and conductors between the pump control panel and the exterior junction box may be field supplied. A junction box, RGS conduit and seal-offs between the junction box and station, and stainless steel supports may be supplied in some embodiments. When a level transducer 66 is used, the cable runs uncut to the control panel and may not be routed through the exterior junction box.

(41) In other embodiments, pump station junction boxes are not used and pump cables run uncut to the control panel, no matter the location of the pump control panel. In these embodiments, float junction boxes 66 are usually required. An intrinsically safe float junction box 66, RGS conduit, and stainless steel supports may also be used.

(42) In embodiments where a transducer 66 is required for primary control, the transducer cable and each float cable may be suspended individually from supports inside the hatchway for easy access. In one embodiment, four or five float switches operate with stainless steel chain tree and weight assemblies. In an additional embodiment, a primary level transducer 66 with a two-float emergency back-up is used. In an alternate embodiment, a primary level transducer 66 with four or five float switches 4A-F for secondary operation are used. In some embodiments, float switches 4A-F and transducers 66 may be supplied with the pump control panel, and as such, site mounting and wiring is expected to be performed.

(43) In various embodiments, the pump control panel is supplied with float switches 4A-4F, a submersible transducer 66, or a combination of both. The float switches 4A-F are level control devices and operation is dictated by the owner and/or local rules. When multiple float switches 4A-F for primary operation are required (four to six float switches), the pump station body 10 can include a stainless steel chain tree and weight assembly for standard float switch positioning. The stainless steel chain and weight assembly with attached floats may hang from a support in the hatchway for easy access and removal for adjustment outside of the pumping station 2.

(44) The pumping station 2 disclosed herein allows for a variety of piping, valve sizing, and materials. Examples of piping, valve sizing, and material varieties include: (1) 2 PVC piping and valves to 2 PVC common force main (FM) discharge; (2) 3 PVC piping and valves to 3 PVC common FM discharge; (3) 3 ductile iron (DI) discharge piping and valves to 3 DI common FM discharge; (4) 4 DI discharge piping and valves to 4 DI common FM discharge; and (5) 6 DI discharge piping and valves to 6 DI common FM discharge.

(45) Various dimensions of the pump station body are used according to various embodiments. For example, the interior width of the pump station body can be between about 4 and 7, or more specifically between about 5 and 6. In additional embodiments, the interior width is either about 5 or 6. The interior width is the distance between the inner surfaces 58 of the two vertical walls 12. Additionally, the interior length of the pump station body can be between about 8 and 12, or more specifically between about 9 and 11. In additional embodiments, the interior length is either about 9 or 11. The interior length is the distance between the inner surfaces 58 of the two ends 14. The height of the pump station body can be between about 10 and 25, or more specifically between about 10-10 and 24-10. In additional embodiments, the height is either about 10-10, 12-10, 14-10, 1610, 18-10, 20-10, 22-10 or 24-10. The height of the pump station body is the distance from the top surface of the base slab 31 to the T.O.S. In some embodiments, the thickness of the pump station body walls is between about 6 and 10, and more specifically between about 7 and 9. In additional embodiments, the wall thickness is either about 7 or 9. In some embodiments, the valve vault chamber 16 walls (floor and partition wall) are 3 to 8 thick. In a preferred embodiment, the valve vault chamber partition wall is about 4 thick and the valve vault chamber floor is about 6 thick at the end interconnected to the body's 10 exterior wall and the floor tapers to between 4 and 5 thick at the point interconnected to the partition wall. The valve vault chamber floor may taper and slope toward the valve vault floor drain such that water will flow toward the drain 68. In further embodiments, the thickness of the base slab 31 is the same as the body wall thickness. In other embodiments, the base slab 31 is a different thickness, for example 8 thick. In some embodiments, the thickness 28 of the pump station body top slab 20 is between about 10 and 14, and more specifically about 12. Pumping stations 2 are available in a variety of configurations including dry pit sewage stations, round submersible stations, and innovative oval-shaped stations. Pumping stations 2 according to the present disclosure and according to the dimensions given above typically replace conventional pump stations having a 6 diameter, an 8 diameter, and a 10 diameter.

(46) Because the dimensions of the pump station body are variable in various embodiments, the volume of the pump station body varies with varying embodiments. In one embodiment, the volume of the pump station body (measured in gal/vertical foot) is between about 250 gallons and 500 gallons. In a preferred embodiment, the volume of the pump station body (measured in gal/vertical foot) is between about 295 gallons and 470 gallons. In a more preferred embodiment, the volume of the pump station body (measured in gal/vertical foot) is either 297 gal., 310 gal., 436 gal., or 466 gal.

(47) FIG. 3 shows an embodiment of a pumping station from a top plan view. The pumping station includes one or more access covers, which are hatch covers 36A in the embodiment shown, with embedded frames 34, a top slab 20, an outlet 62, a vent 56, and a control panel 54. The hatch covers 36 may be of safety grates 36A in one embodiment. The access covers may be manufactured in a variety of shapes (e.g., circular, square, etc.) and sizes to meet application needs. In one embodiment, the pump station access cover and hatch loading is 300 lb pedestrian loading or AASHTO H-20 or HS-20 vehicle loading. When TOS is set at grade elevation, the H-20 and HS-20 structural loading and hatches should be strongly considered, especially if accidental vehicle wheel loading can be foreseen. Typically, when the TOS is set 6 above grade, 300 lb pedestrian structural loading and hatches may be utilized.

(48) In one embodiment, access hatches 36 for the water pumping station may be manufactured from a variety of materials, for example, metals (such as aluminum, steel, stainless steel, copper, or iron), plastics, polymers, and other materials known in the art.

(49) In some embodiments, the access cover or hatch 36 on the wet well 6 side of the pumping station is equipped with an angle frame 34 and skit to full precast cover height. In one embodiment, the frame 34 is tar coated where the aluminum comes in contact with the precast concrete. In an additional embodiment, the access cover 36 comprise a slam lock and removable key operator, a recessed padlock hasp, a lift assist, and an OSHA safety grate 36A that is permanently attached to the hatchway inner frame 34. The safety grate 36A is hinged and lockable.

(50) In other embodiments, the valve vault access opening 32 is aluminum and includes a single door, flush with precast cover, with stainless steel hardware. The access cover 36 can be a diamond plate with a stainless steel slam lock and weather plug, a lift handle that sits flush with cover, a recessed pad lock clip (pad lock by others), a hold open arm to lock cover 36 in 90-degree position, and heavy duty stainless hinges. The access frame 34 can be a channel style with 1 NPT drain port in the bottom of the channel, a continuous 1 anchor flange, and a full slab-height skirt to show no exposed concrete when the opening 32 is open. The access frame's 34 exterior surfaces in contact with concrete can have one coat of bituminous paint. The access opening 32 can be supplied with a heavy duty, stainless steel pneu-spring, for ease of operation when opening the cover 36.

(51) In some embodiments, the access cover or hatch 36 on the valve vault 16 side of the pumping station 2 is equipped with a channel frame 34 and skit to full precast cover height. In one embodiment, the frame 34 is tar coated where the aluminum comes in contact with the precast concrete. The frame 34 may also comprise a slam lock and removable key operator, a recessed padlock hasp, and a lift assist.

(52) In one embodiment, the precast pumping station is designed to support its own weight as well as at least one superimposed load selected from the group comprising a top slab, a top slab 20, a live load (AASHTO H-20 and/or HS-20), a base slab 31, live load of 200 psf, exterior walls (vertical and lateral earth loads), and the water table load due to the water table depth. All exterior walls of the pumping station that are below finished grade can be designed for an equivalent fluid pressure of 90 psf caused by saturated earth pressure. The top of the pressure diagram is assumed to originate at finished grade. In addition to the soil pressure, a live load traffic surcharge shall be applied according to the AASHTO specification. In additional embodiments, all additional equipment is accounted for in the design of the elements.

(53) In some embodiments, the pump control panel 54 is mounted to the exterior of the pump station body at approximately two feet to six inches above TOS. The connecting RGS conduit, external seal-off fittings, and stainless steel unistrut framework support between the control panel 54 and the pumping station are also included in one embodiment.

(54) In some embodiments, the control panel 54 is mounted and wired to the pump station. In one embodiment, the control panel 54 is shipped mounted to the pump station. In another embodiment, after factory mounting of the pump control panel 54 to the pump station body and conduit work, the control panel 54 and supports and conduit may be disassembled at the conduit unions and at the support-mounting locations such that the control panel 54 can be shipped separately, due to trucking height restrictions. Thus, the control panel 54 is shipped loose for mounting onto the pump station upon delivery or on-site and minimal reassembly effort will be required on-site. Final wiring and filling of conduit seals (pumps to control panel and level devices to control panel) are performed on-site.

(55) FIG. 4 is an exploded perspective view of an embodiment of a body for a water pumping station comprised of multiple sections. The pump station body comprises a top slab 20; one or more access covers 36; an upper section 46 with a valve vault chamber 16, the top of the wet well chamber 6, and an outlet 62; one or more risers 40 with inner surfaces 58; a base 30 with a base slab 31; a bottom riser 40A having a perimeter wall 38 and an inner surface 58A; and sealing sections 78 on upper and lower surfaces of the risers 40, 40A, 46. The upper section 46 can have a vertical partition wall 84 extending from an inner surface of a first sidewall of the upper section 46 to an inner surface of a second sidewall of the upper section 46 such that the vertical partition wall 84 is substantially perpendicular to the first and second sidewalls. The vertical partition wall 84 separates the valve vault chamber 16 from the wet well chamber 6. The floor of the base 30 includes a sloped portion 42 proximate one arcuate end of the bottom riser 40A and extending toward a center of the base 30. The base 30 also included a beveled corner section 48 positioned between the floor (i.e., upper surface of the base slab 31) and the inner surface 58A of the perimeter wall 38. In some embodiments, the beveled corner section 48 extends around the entire perimeter of the inner surface 58A of the perimeter wall 38.

(56) One embodiment of the pump station body 10 can utilize stock prefabricated structural components for ease of production and/or reduced production costs. In various embodiments, the pump station base 30, two-foot risers 40, three-foot risers 40, four-foot risers 40, an integral valve vault chamber 16, and access covers 36 with or without hatches are all stock components that can be inventoried at the production facility for ultimate cost savings and a reduction in product assembly time. Also, the use of stock structural components reduces the time required for project submittals. All stock structural components are designed and PE stamped for final installation. Additionally, precast concrete sections may conform to the latest requirements of ACI 350.

(57) In various embodiments the precast components (e.g., bottom riser, risers, upper section, and top slab, etc.) are fabricated on steel forms with machined rings to form accurate bell and spigot joint surfaces to ensure water-tightness. All horizontal joints between precast sections may be sealed with a vulcanized butyl rubber joint material conforming to AASHTO M-198 or a similar standard. In one embodiment, the joint material is Conseal CS-102 as manufactured by Concrete Sealants. In alternate embodiments, the joints or interconnection points 80 are comprised of other configurations including O-ring joints and wedge gasket joints, as well as other joints known in the art.

(58) In one embodiment, the height and depth of the valve vault chamber is adjustable. Accordingly, the upper section 46 of the pump station body 10 comprises a shelf upon which the valve vault chamber 6 can be set. Thus, the divider between the wet well chamber 16 and the valve vault chamber 6 shown in FIG. 4 would not be a part of the upper portion 46 according to this embodiment because the valve vault chamber 6 set into the pump station body 10 could comprise this divider. In one embodiment, the shelf could be monolithic and cast in with the precast body section (e.g., the upper section 46 or a riser 40). In some embodiments, the valve vault chamber 6 is also precast and positioned on the shelf upon installation. In an alternate embodiment, a riser 40 may comprise the shelf upon which the valve vault chamber 6 will be placed. According to this embodiment, the height of the upper section 46 could vary depending on the desired depth of the valve vault chamber 6. In an alternative embodiment, a valve vault riser with a partition wall is placed above the upper section 46 and below the top slab 20 such that the height of the valve vault chamber 16 is increased.

(59) FIG. 5 is a cross-sectional elevation view of a section of an embodiment of a wet well collection chamber. In the embodiment shown, the pumping station is supplied with a trash basket straining system 82 mounted on an aluminum rail guide system for easy extraction from grade elevation, similar to the pumps. Because the wet well hatch is set in size and location, the inlet pipe to the pumping station should come in through an end wall, perpendicular to and in the center of the end wall, which will position the interior trash basket centrally relative to the wet well hatch above. Based on the pumping equipment size, the trash basket sitting above the pumps may interfere with the removal of the pump and as such the trash basket may have to be removed first, prior to the pump removal.

(60) One embodiment of a trash basket assembly 82 comprises a trash basket with low-flow, that is light-weight, and that has a thin-profile, and perforated holes. An alternate embodiment comprises a trash basket with higher flow, a larger profile, and a heavy-duty bar screen construction. In one embodiment, a stainless steel trash basket assembly is used. The trash basket and rail system may also be composed of stainless steel materials.

(61) In some embodiments, the pump station is supplied with portable hoisting equipment for pump and trash basket removal. The hoisting equipment will utilize exterior wall mounted sockets which are permanently mounted to the pump station structure. The hoist and wall mounts can be constructed of 304 stainless steel. The winch is hand-operated and the hoist reach is adjustable from 24 to 36. In embodiments where a portable hoist option is selected, dedicated lifting cables will be provided for each pump and trash basket option (if selected). The dedicated lifting cable is designed to mesh with the winching equipment provided and is expected to be coiled and stored in the hatchway when not in use. Hoisting capacity options include a 300 lb. lifting capacity and a 1000 lb. lifting capacity.

(62) The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more embodiments for the purpose of streamlining the disclosure.

(63) Moreover, though the present disclosure has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the disclosure, e.g. the use of a certain component described above alone or in conjunction with other components may comprise a system, while in other aspects the system may be the combination of all of the components described herein, and in different order than that employed for the purpose of communicating the novel aspects of the present disclosure. Other variations and modifications may be within the skill and knowledge of those in the art, after understanding the present disclosure. This method of disclosure is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.