LIFT STATION

DESIGN & CONSTRUCTION

GUIDELINES

March 2011

OPERATIONS & MAINTENANCE ENGINEERING

2800 U.S. Hwy.281
San Antonio, TX 78212
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 SAN ANTONIO WATER SYSTEM
LIFT STATION DESIGN GUIDELINES
TABLE OF REVISIONS

Section Revision Date

A. General Requirements 2. Updated to reflect new TCEQ Chapter 217 and latest SAWS 11/22/2010
Utility Service Regulations.
3. Modified wording to require submersible type lift stations, but 11/22/2010
self priming and package lift stations will be evaluated by SAWS
on a case-by-case basis. Updated Table 1.
4. Added requirement for lift station design to comply with NEC 11/22/2010
2008, NESC 2007 and OSHA 2007, or latest editions. Made
reference to standard drawings for location of the required
grades.
5. Updated TCEQ reference Chapter 213, Subchapter A 11/22/2010
§213.5(c)(3)(C) for design of lift stations located over EARZ.
6. Updated the requirement for the lift station firm pumping 11/22/2010
capacity to be at least 1.5 times greater than the expected peak
wet weather flow.
12. Added the requirement for the wet well hatch to be anti-slip 11/22/2010
surface type. Added requirement for safety grate gaps to be 4-
inch or less. Added requirement for safety grate to be flushed
with wet well top slab. Added requirement of black and yellow
paint strips around wet well hatch and “Do Not Step” sign.
17. Updated canopy dimensions to extend 5.0 feet to the front 12/13/2010
and 3.5 feet to the back. Added requirement of structural
requirement for canopy to withstand winds of up to 90 MPH.
22. Added requirement of service pole to be located within lift 11/22/2010
station site. Added requirement for electric overhead for not
crossing over the lift station site, nor to be near the SCADA
tower structure.
23. Added requirement for lift stations to be protected from 11/22/2010
storm runoffs.
B. Wet Well Design 1. Clarified that wet well level control device will not be blocked 11/22/2010
by gravity invert pipe, discharge pipes and pipe supports. Added
requirement for wet well bottom to be between 5 and 7 feet
below gravity invert pipe.
2. Clarified that the spill level elevation is determined by wet 11/22/2010
well top elevation or the manhole with the lowest top elevation,
whichever is lower.
5. Updated requirement for baffles for peak wet weather flows of 11/22/2010
3 MGD or greater.
19. Added requirement for distance between wet well bottom and 11/22/2010
gravity invert pipe to be between 5 and 7 feet.
21. Added wet well testing requirement and test criteria. 11/22/2010
Section Revision Date
C. Pumping Equipment 1. Added reference for table 3 for minimum number of pumps 11/22/2010
Design required and minimum sphere pass required. Clarified that
semi-chopper, vortex or grinder pumps might be accepted on
case-by-case basis. Clarified that 2-pole motors will be reviewed
and approved by SAWS. Added Table 3 to show the required
number of pumps according to peak wet weather flow
magnitude.
2. Added requirement for pump duty point to be within +/-20% 11/22/2010
range of pump flow at Best Efficiency Point (BEP). Clarified
that this condition shall be satisfied for one and two pumps in
operation. Added figure.
3. Updated Table 4 referring to wet well cycling. 11/22/2010
4. Clarified paragraph. 11/22/2010
6. Updated submersible pump requirements. 11/22/2010
7. Updated self priming pump requirements. Added requirement 11/22/2010
of prime loss protection via vacuum switches.
8. Updated package lift station requirements. 11/22/2010
D. Station Piping 1. Clarified if self priming pumps are approved. 11/22/2010
6. Updated requirement for suction flow velocity to be within 3.0 11/22/2010
and 4.0 feet per second.
E. Station Valves 2. Added requirement of check valve on by-pass quick connector. 11/22/2010
4. Added requirements for air release valves. 11/22/2010
5. Added requirements for pressure relief valves. 11/22/2010
F. Force Main 1. Updated requirement for force mains to be buried at least 4 11/22/2010
feet below ground.
2. Added requirement of detector tape. 11/22/2010
5. Added requirement of air release valves on all high points, 11/22/2010
minimum size of 2 inches, rated for sewage.
6. Updated force main discharge requirement to be via drop 11/22/2010
manhole to minimize turbulence.
7. Clarified that minimum force main size to be 4-inch (except 11/22/2010
for grinder pumps), force main velocity to be within 3.0 and 4.0
feet per second, and the allowance of flow velocities of up to 2.0
feet per second as long as a flushing velocity of 5.0 feet per
seconds can be generated with two or more pumps in operation.
8. Added requirement for HDPE force mains to be DIPS size. 11/22/2010
9. Added requirement for double barrel force mains. 11/22/2010
10. Added requirement for force mains to withstand the surge 11/22/2010
pressure generated by instantaneous pump stoppage under
maximum pumping conditions.
11. Added requirement of average flush time analysis. 11/22/2010
12. Added requirement of force main surge control measures. 11/22/2010
13. Added requirements of air release valves. 11/22/2010
14. & 15. Added force main testing requirements. 11/22/2010
Section Revision Date
G. Electrical Equipment 1. Added requirement for motor control panel to be double door 11/22/2010
and separation of 120V and 480V loads within enclosure. Also
added requirement for conductor color code for different voltage
systems.
2. Added requirement for conductor size for motor controls and 11/22/2010
SCADA panels.
3. Added junction boxes. 10/12/2006
6. Clarified that receptacles and light switches shall be weather 01/19/2011
proof “in-use” type with clear cover.
8. Updated pipe supports of mounting racks to be square 4” x 4” 11/22/2010
x ½” hot dip galvanized structural square steel tube.
9. Clarified when generator is not required, and depending on 11/22/2010
electric load.
10. Emphasized the preference for diesel generators. Added 12/16/2010
requirement for diesel tank. Add requirement for generator load
analysis. Added requirement for fuel tank float switch device.
14. Updated requirement for exposed conduits to be rigid 11/22/2010
aluminum and added requirement for conduits to be embedded
in concrete to avoid tripping hazards.
16. Clarified the requirement of the Hand-Off-Auto selector 11/22/2010
switches. Added requirement for self priming pumps to have a
local non-fused disconnect with auxiliary contacts at motor per
NEC.
19. Remarked the requirement of alternating controls, the 11/22/2010
separation of 120V and 480V loads, added the criteria for
establishing when soft starters are required, soft starter
operation requirements and cooling unit requirement for panel.
21. Added requirements for the grounding system. 11/22/2010
H. Station Controls, 1. Added the preference for submersible pressure transmitters, 11/22/2010
Instrumentation and but ultrasonic level transmitters may be used if approved by
Monitoring SAWS. Added criteria for submersible level transmitters.
2. Added the requirement of a true scaled analysis of the wet 11/22/2010
well interior to verify that the wet well level control device does
not interfere with anything within the wet well.
4. Clarified that pressure transmitter must have an LCD display 11/22/2010
and must be calibrated to read the operating and surge
pressures and must display the pressure in psi.
5. Made reference to Table 3. Clarified that the example 12/16/2010
described is for a duplex lift station.
6. Made reference to new Table 3. Clarified that the example 11/22/2010
was for a 2 pump type lift station, but the logic applies for 3 or
more pump type lift stations.
10. Added requirement for an explosion proof float switch for 02/18/2011
generator diesel fuel tank. Clarified that float switch shall send
signal when fuel tank reaches ¼ full.
Section Revision Date
I. SCADA 1. Added requirements of radio path study. 11/22/2010
2. Added procedure to follow if a straight radio path is not 11/22/2010
achievable directly from the lift station.
3. Updated SCADA alarms. 11/22/2010
4. Added requirement of interposing or isolation relays within 11/22/2010
the SCAD panel.
5. Added the requirement for the radio to be located within the 11/22/2010
SCADA panel and be two way communication type.
6. Added the requirement for monitoring the SCADA panel 11/22/2010
internal temperature via SCADA.
7. Added the requirement for the SCADA panel to be climate 11/23/2010
controlled with AC and heater units.
8. Added requirements for tower location, accessibility and 11/23/2010
clearance of electric overheads.
9. Added requirements for uninterruptible power supply. 11/23/2010
J. Emergency Provisions 1. Made reference to Section I, paragraph 3. 02/22/2011
1.a. Clarified paragraph. 02/23/2011
2. Added requirement for check valve on emergency by-pass 01/06/2011
coupling.
K. Safety Requirements 1. Added requirement of overhead lines clearance. 11/23/2010
2. Added the requirement of eliminating tripping hazards. 11/23/2010
3. Added the requirement of arc flash analysis. 11/23/2010
4. Moved the requirement of bollards from General 11/23/2010
Requirements to Safety Requirements.
5. Added requirement of provisions for installation of portable 11/23/2010
handrails around wet well hatches.
6. Added requirements for dry vaults. 11/23/2010
J. Submittal 1. Added the requirement of calculations for NPSH and total 11/23/2010
Requirements suction lift.
2. Added formulas for calculations of total suction lift and 11/23/2010
definition of total suction lift.
12. Added formulas and example of force main flush time 02/24/2011
calculations.
 SAN ANTONIO WATER SYSTEM
LIFT STATION DESIGN GUIDELINES
TABLE OF CONTENTS

SECTION PAGE

A. General Requirements .....................................................................................................1

B. Wet Well Design .............................................................................................................5

C. Pumping Equipment ........................................................................................................9

D. Station Piping Design....................................................................................................13

E. Station Valves ................................................................................................................14

F. Force Main .....................................................................................................................15

G. Electrical Equipment .....................................................................................................16

H. Station Controls, Instrumentation and Monitoring .......................................................19

I. Supervisory Control And Data Acquisition (SCADA)………………………………...21

J. Emergency Provisions ....................................................................................................22

K. Safety………………………………………………………………………………….24

L. Submittal Requirement ..................................................................................................24

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LIFT STATIONS

A. General Requirements

1. As required by Section 11.4.2 of the San Antonio Water System Utility Services Regulations
(USR), a consultant or developer who proposes to construct a lift station and force main system
shall prepare a present value analysis of the cost of constructing gravity mains compared to the
cost of the lift station/force main system. This analysis shall show that the lift station installation
cost plus 30 years of operational and maintenance expenses would be less than the cost of the
gravity mains. Lift stations will only be considered a viable option if the cost analysis clearly
shows that the gravity sewers are not economically feasible. Lift stations will not be allowed
where an acceptable alternative gravity route exists.

2. Design the lift station to consider the potential for expansion to build-out densities. The
design of the lift station shall incorporate a wet well sized for the ultimate capacity of the water
shed. The lift station design shall consider both the total number of acres and number of
Equivalent Dwelling Units (EDU) to be developed, as stated in the Water and Sewer
Commitment submitted to SAWS. The flow capacities are determined in accordance with
applicable chapters and sections of Texas Commission on Environmental Quality (TCEQ)
Chapter 217 “Design Criteria for Sewerage Systems” dated August 28th 2008 or the latest
edition thereof, and in accordance with the assumptions and requirements of San Antonio Water
System Utility Service Regulations, January 6th 2009 or the latest edition thereof.

3. All sanitary sewer lift stations shall be submersible type. Suction lift self primer and package
type lift stations could be approve by SAWS on a case-by-case basis depending on station
size/capacity, wet well depth, head requirements and motor horsepower. Table 1 outlines the
allowable design criteria for each type of pump station:

TABLE 1
PUMPING STATION DESIGN CRITERIA
Maximum Motor
Station Type Maximum Wet Well Depth
Horsepower
Suction-lift/Self-priming* 17 feet, with gravity invert
(If approved on a case-by- No restrictions 5 feet above Wet Well
case basis) bottom
Wet Well bottom to be 5
Submersible** No restrictions
feet below gravity invert
Packaged Lift Stations
(If approved on a case-by- 5 HP 13 feet
case basis)

* Design Engineer will evaluate Total Suction Lift and NPSH values at all different
operating points (i.e. one pump running, two pumps, three pumps and so) to ensure the
pumps will not cavitate in all scenarios. Maximum wet well depth shall not exceed 17
feet. Total suction pipe length shall not exceed 22 feet.
** The 5 feet distance could be greater depending on pump size and SAWS approval.

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4. All lift stations shall be designed to meet the requirements of TCEQ 217.60, 213 Subparts A
and B (for lift station over Edwards Aquifer Recharge, Transition or Contributing Zones), 2008
National Electrical Code (NEC), 2007 National Electrical Safety Code (NESC), Occupational
Safety and Health Administration (OSHA) 2007 or latest editions, and contemporary industry
practices. An application or submittal for a lift station shall satisfy all State requirements, which
include final construction plans and a design report prepared by or under the direct supervision
of and signed, sealed and dated by a Texas Licensed Professional Engineer. The lift station site
layout shall show the proposed grades. See SAWS Standard Lift Station Drawings for location of
required proposed grades.

5. Lift stations located over the Edwards Aquifer recharge, contributing and transition Zone
shall be designed and constructed to ensure that bypassing of any sewage does not occur (TCEQ
Chapter 213, Subchapter A §213.5(c)(3)(C)). All lift stations shall be designed to meet the
requirements of these Design Guidelines and SAWS Standard Design Drawings; and meet or
exceed TCEQ Chapter 217, Subsection C from §217.59 to §217.68. A lift station application
shall include final construction plans, a design engineering report prepared by or under the direct
supervision of a Texas Licensed Professional Engineer. All design information shall be signed,
sealed, and dated by a Texas Licensed Professional Engineer.

6. The firm pumping capacity of all lift stations shall be such that the expected peak flow can be
pumped to its desired destination. Firm pumping capacity is defined as total station, maximum
pumping capacity with the largest pumping unit out of service, or with either one or two pumps
out of service, depending on magnitude of flow (see Table 3). The firm pumping capacity shall
be at a minimum 1.5 times greater than the expected Peak Wet Weather Flow.

7. Lift Station site layouts shall consider clearances for unimpeded maintenance operations. The
paved area surrounding the lift station components including, but not limited to, the wet well,
pump and motor slabs, valve slabs, generator, electric service rack and tower shall be large
enough to permit heavy equipment and vehicles ample room to maneuver. The lift station site
shall be designed to allow maintenance vehicles to have direct access to the wet well, electric
controls, generator and tower.

8. Access Road Design in Residential or Commercial Developments: The lift station shall
have an access road, either temporary or permanent, located in a dedicated right-of-way or
permanent easement. The access road surface, either temporary or permanent, shall have a
minimum width of 16 feet and shall be paved with asphalt. Crushed stone, flexible base or
similar materials will not be accepted. The access road surface, either temporary or permanent,
shall be designed to be above the water level caused by a 25-year storm event. The design of the
access road, either temporary or permanent, shall include plan, section and profile sheets of the
access road and drain pipes, details and engineering calculations. The design shall limit the slope
to no more than 8 percent (8%) and grade break to 3 percent (3%) and provide soil erosion
protection to prevent collection of sedimentation along the access road. Inside the boundary of a
proposed residential development, design of the access road, either temporary or permanent,
shall minimize turns and achieve the straightest possible alignment. If a straight access road is
not provided, SAWS will determine whether or not an adequate turn around is required to allow
a 55 foot 18 wheeler tanker truck to safely turn around depending on wet well size, influent flow
and site location. In a phased development, a temporary access road alignment shall be reviewed

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and approved by SAWS prior to the initial phase of development. SAWS written approval is
required prior to any modifications to the temporary access road. Inside the boundary of a
proposed commercial development, the lift station will be accepted by SAWS for operation and
maintenance only if there is an exclusive driveway and paved access road that will be for SAWS
use only. Design of access road inside the boundary of the proposed commercial development
shall be a straight horizontal alignment, paved and inaccessible to the public. The paved access
road shall be a minimum of 16 feet wide without any interference with, but not limited to
vehicles, landscape, curbs, posts, bollards, fences, parking stalls, striping, and above grade
appurtenances, etc. If these design conditions can not be satisfied, then the lift station shall be
private and maintenance of all sewer facilities within the commercial boundary shall be
maintained by the property owner or a legally designated association.

9. Provide 2-8 foot gates for a 16-foot clearance to allow access by large maintenance
equipment. Turnarounds may be required for stations constructed along heavily traveled streets.
Allow sufficient space for large maintenance vehicles to have unhindered access to the wet well,
generator and tower. Entries located parallel to the roadway should also be considered. Lift
stations are not allowed within the street right-of-way.

10. The lift station, including all electrical and mechanical equipment, shall be protected from a
100-year flood event including wave action, and remain fully operational during such event.
Provide a letter dated, signed and sealed by a Texas Professional Engineer certifying the site is
protected from such an event. Attach drainage calculations if required by SAWS.

11. Provide protection of the lift station, including mechanical and electrical equipment, from
access by any unauthorized person. The lift station shall be enclosed within an intruder resistant
fence or located entirely within a lockable structure. An intruder resistant fence shall consist of a
chain link fence 6 feet minimum in height, with a 1-foot section above consisting of 3 strands of
barbed wire “up-riggers.” Privacy fences shall be analyzed in a case by case basis.

12. One or more lockable aluminum hatch covers with anti-slip top surface shall be installed in
the wet well cover for access to the wet well and pump(s). Minimum hatch dimensions shall be
3 feet by 4 feet, or large enough to allow plentiful room for removal of submersible pumps and
access to wet well. Hatch safety grate shall be installed to provide fall protection and shall
consist of aluminum material. Safety Grate shall be designed to have gaps of mot more than 4
inches, and to be flush with concrete slab. Black and yellow strips shall be painted around
access hatch using thick coating system. Also a “Do Not Step” sign shall be painted around
hatch. Coating requirements shall be in accordance with Manufacturer’s recommendations.

13. Provide a reinforced concrete base slab, or other appropriate feature, sized adequately to
counteract buoyancy, and provide supporting design calculations. The concrete slabs of top of
wet well, electrical rack, tower foundation and generator (when required) shall be 4” minimum
and 6” maximum higher than the finished pavement.

14. The lift station site shall be completely paved. The pavement section shall be either concrete
or asphalt pavement and the design shall be prepared by a Texas Professional Engineer. The
design and construction shall be in accordance with all applicable City of San Antonio’s
Pavement Specifications for Construction, and if needed, includes additional reinforcement of

3
the subgrade and base. The pavement design shall consider loading exerted by a 55 foot, 18
wheeler, and 80,000 pound tanker truck. The pavement shall be shaped to the lines, grades, and
typical sections that are on the approved construction plans. If trees exist, leave a circular
pervious area with a minimum 12-inch clearance around tree.

15. Design shall provide for 3/4-inch minimum freeze proof water service with hose bib vacuum
breaker attached to the hose connection. It shall be located near the wet well.

16. Design shall include a freeze proof emergency eyewash and shower station located near the
wet well.

17. Design shall provide for a galvanized steel supported canopy that will provide a minimum
7.0 foot vertical clearance, and 5 feet front span and 3.5 feet back span horizontal from the face
and rear of the panel rack respectively. Design engineer must perform a structural analysis to
determine the structural requirements for the canopy to withstand winds of up to 90 MPH.

18. Provide calculations (in engineering report) to determine potential for hydrogen sulfide
suppression in force main and wet well, and provide recommendations. If the development is
phased, this analysis shall be made for both initial and final phases.

19. All exposed pipe, valves, and fittings outside the wet well shall receive after installation a
100% solids epoxy coating system with a top coat system of urethane, suitable for the
environment. Prior to application, prepare surfaces in accordance with manufacturer’s
instructions and any reference to cleaning in the manufacturer’s instructions shall be understood
to refer to the applicable SSPC specifications. Thickness, mixing and application shall be in
accordance with manufacturers instructions. Apply finish coat in accordance with the color-
coding set forth in Table 2, below. Approved manufacturers are Tnemec, Carboline, Sherwin-
Williams, PPG, and M.A.B. Paints.

20. All pump discharge pipe and fittings within wet well, except SS 316 and PVC, shall receive
after installation, a 100% solids coal tar epoxy coating system. Thickness, mixing and
application shall be in accordance with Manufacturers instructions. Prior to application, prepare
surfaces in accordance with manufacturer’s instructions, and any reference to cleaning in the
manufacturer’s instructions shall be understood to refer to the applicable SSPC specifications.
Approved manufacturers are Tnemec, Carboline, Sherwin-Williams, PPG, and M.A.B. Paints.

21. For appropriate landscaping of the Lift Station Site (outside the fence), comply with the UDC
Section 35-510 as it may apply.

22. Service pole shall be located within lift station site in a place that electric overhead wires do
not cross over the lift station site, nor located near the SCADA tower structure.

23. Lift station site shall be designed in a manner that will be protected from storm runoff
entering the lift station site, but will allow storm water to drain away from lift station site.

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 TABLE 2
SAN ANTONIO WATER SYSTEM LIFT STATION COLOR CODES

TYPES OF EQUIPMENT COLOR

1. Pump Suction Piping (if required) Gray – Pantone Number 431 U

2. Header and Force Main Piping Gray – Pantone Number 431 U
3. Pump/Motors and Mounts (if apply) Gray – Pantone Number 431 U
4. Potable Water Line Avalon Blue – Pantone Number 558 C
5. Compressed Air Line (where used) Green – Pantone Number 349
6. Power Conduit Orange – Pantone Number 166
7. Control/Instrumentation Conduit Yellow – Pantone Number 109
8. Recycle water pipe Purple – Pantone Number 521 C

B. Wet Well Design

1. Dimensions: Minimum 72” in diameter or larger as necessary to accommodate submersible

pumping equipment, gravity invert drop, discharge pipes and pipe supports without interfering
with wet well level control device. Depth of wet wells on submersible lift stations shall consider
adequate submergence of the pumps and emergency storage requirements. Fiberglass reinforced
polyester (FRP) wet wells shall be installed for diameters up to 18 feet, unless prior
arrangements have been made and approved by SAWS to install precast wet well. Prior
arrangements shall be made for SAWS to consider and approve any proposed Dry Vaults.

2. Emergency Storage: Includes additional volume within the wet well as excluding the
capacity of sanitary collection system upstream from the lift station. Emergency storage capacity
shall be supported by calculations in the engineering report. Design wet well emergency storage
for the following capacities, using Average Daily Flows (ADF): 1) 60-minutes with generator for
lift stations within Edwards Aquifer Recharge Zone, or 2) For lift stations over the Edwards
Aquifer Contributing and Transition Zones SAWS staff will evaluate the site location, water
stream proximity, remoteness, and geographical features to determine if the lift station site shall
be treated as if it were over the EARZ or 3) For lift stations outside the Edwards Aquifer
Recharge, Contributing and Transition Zones 60-minutes with generator or 120 minutes without
generator. For calculation purposes, the wet well emergency storage level begins at the Lead
Pump On level until wet well level is at least 3 feet below spill elevation. Spill elevation is
determined by the wet well top slab elevation, or by the manhole upstream of wet well with the
lowest top elevation, whichever is lower.

3. The lift station design shall minimize odor potential. Locate incoming well gravity pipes to
reduce turbulence. Minimize detention times in wet well during all phases of development. If
detention times are greater than 180 minutes, SAWS may require odor control measures based
on evaluation of, but not limited to phasing, prevailing wind direction, and proximity to
neighborhoods. If odor control measures are needed, odor control shall consist of the chemical
drum scrubber with top mounted blower to absorb odorous compounds for oxidizing. The drum

5
scrubber shall be designed to operate at 99.5% gas removal. The design specification shall be
prepared by the drum scrubber and media supplier. Approved manufacturer is Purafil, or an
approved equal.

4. No fixed ladders are permitted in the wet well; however when used elsewhere, ladders shall
be aluminum with non-skid rungs and must comply with all other of OSHA 1910.27, Fixed
Ladders.

5. The wet well floors shall have a minimum of 10 percent slope to the pump intakes and have a
smooth finish. There shall be no wet well projections that will allow deposition of solids under
normal operating conditions. Include anti-vortex baffling on all lift stations with greater than 3
MGD (2,083 gpm) Peak Wet Weather Flow.

6. If permission is provided by SAWS, construction of concrete wells shall include a full

monolithic structure or a precast structure with monolithic base. The minimum wall thickness
shall be 8 inches for all wet wells. The minimum base thickness shall be 12 inches. The top slab
shall have a minimum thickness of 10 inches.

7. Line interior of concrete wet well with either a 100% solids epoxy or urethane coating
system. Surface preparation, thickness, mixing and application shall be in accordance with the
manufacturer’s instructions. Wet well joints shall be sealed per the manufacturer’s
recommendations. Approved manufacturers are Raven, Tnemec, Belzona, Carboline-Polybrid,
and Madison. Alternatively, a high-density polyethylene (HDPE) and Polypropylene Copolymer
(PPR) thermal plastic liner installed at the foundry as an integral part of the concrete casting
process, as manufactured by AGRU Sure Grip is also approved.

8. The exterior of concrete wet well, shall be coated with a coal tar epoxy system. Coating shall
be continuous, free of “pin holes” and/or voids, and it’s to be applied in accordance with
manufacturer instructions. After wet well top slab, base and all sections have been permanently
set in place, seal outside with a chemically compatible non-shrink grout prior to exterior
application of protective coal tar coating. Approved manufacturers are Koppers, Tnemec, and
Sherwin-Williams.

9. The bottom of the excavation for the wet well structure shall be a level subgrade
approximately 18 inches of crushed stone below the bottom of the wet well structure and native
soils shall be compacted with excavation equipment for the installation of 6 inches of flexible
base to support the base of the structure. Compaction of native soil and flexible base shall
achieve minimum ninety-eight (98%) of the maximum dry density as determined by the TXDOT
testing method Tex 113-E.

10. Concrete subgrade filler shall also be installed between the wet well and the excavation to an
elevation of 1/3 the total depth of the structure, as measured from the well bottom. The
remaining 2/3 shall be backfilled with ½-inch crushed stone compacted a minimum of 98% as
described in item 9 above. Wet well manufacturer shall design the wet well thickness if concrete
or flowable fill are used to backfill the entire wet well excavation.

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11. Use 316 Stainless Steel screens on passive ventilation, gooseneck type or turbine, to prevent
the entry of birds or insects into the wet well. If passive ventilation is provided for the wet well,
any mechanical and electrical equipment in the wet well shall be of explosion-proof construction.
Size the passive ventilation to vent at a rate equal to the maximum pumping rate of the station
and not exceed 600 fpm through the vent pipe. The minimum air vent size shall be 4-inch
diameter, and it shall be made of stainless steel 316. Vent outlets shall be at least 1 foot above
the 100-year flood elevation.

12. If explosion proof mechanical and electrical equipment is not provided throughout the wet
well, use continuous mechanical ventilation to ventilate the wet well. Size the ventilation
equipment for 12 air changes per hour and construct of corrosion resistant material. In residential
areas, there may be a need for reducing potential odors from the ventilated wet well.

13. Provide permanent mechanical ventilation for dry wells located below the ground surface and
for wet wells having screens or mechanical equipment requiring regular maintenance and
inspection.

14. Connection between wet well and dry well ventilation systems is not allowed.

15. Provide multiple air inlets and outlets in dry wells over 15 feet deep. Do not use dampers on
exhaust or fresh air ducts. Avoid screens that are finer than #10 sieve or other obstructions within
air ducts to prevent clogging.

16. Provide manual lighting/ventilation switches to override automatic controls installed for any
intermittently operated lighting/venting equipment. The location of these switches will be at the
Wet/Dry Well entrance.

17. Incorporate hoisting equipment, or access for hoisting equipment, for removal of pumps,
motors, valves, etc. into the design. SAWS will determine if hoisting equipment shall be
included in the design, depending on size of equipment.

18. All accessory hardware in wet well including but not limited to chains, cables, bolts, nuts,
fasteners, brackets, anchor bolts, washers, cable holders and slide rails, shall be 316 stainless
steel.

19. The distance between the bottom of the wet well and the bottom of the gravity invert pipe
shall be between 5 and 7 feet.

20. Fiberglass reinforced polyester (FRP) wet wells shall be manufactured from commercial
grade polyester resin or vinyl ester resin, with fiberglass reinforcements. The wet well shall be
manufactured in one-piece including body, bottom and top, and it shall be sit over a concrete slab
design to counteract buoyancy forces. Design engineer shall design the top concrete slab.
Approved manufacturers are L.F. Manufacturing, and Containment Solutions or approved equal

a. The resins used shall be a commercial grade unsaturated polyester resin.

b. The reinforcing materials shall be commercial Grade "E" type glass in the form of mat,
continuous roving, chopped roving, roving fabric or a combination of the above, having a

7
 coupling agent that will provide a suitable bond between the glass reinforcement and the
resin.

c. If reinforcing materials are used on the surface exposed to the contained substance, it
shall be a commercial grade chemical-resistant glass that will provide a suitable bond
with the resin and leave a resin rich surface.

d. Fillers, when used, shall be inert to the environment and wetwell construction. Additives,
such as thixotropic agents, catalysts, promoters, etc., may be added as required by the
specific manufacturing process to be used. The resulting reinforced plastic material shall
meet the requirement of this specification.

e. The exterior surface shall be relatively smooth with no sharp projections. Handwork
finish is acceptable if enough resin is present to eliminate fiber show. The exterior
surface shall be free of blisters larger than 1/2 inch in diameter, delamination and fiber
show.

f. The interior surface shall be resin rich with no exposed fibers. The surface shall be free of
grazing, delamination, and blisters larger than 1/2 inch in diameter, and wrinkles of 1/8
inch or greater in depth. Surface pits shall be permitted up to 6 square feet if they are less
than 3/4 inch in diameter and less than 1/16 inch deep.

g. The bottom to be fabricated using fiberglass material. Bottom to be attached to wet well
pipe with fiberglass layup to comply with A.S.T.M.-D3299 specifications.
Reinforcement, if needed, shall be fiberglass channel laminated to wet well bottom per
A.S.T.M.-D3299.

h. The fiberglass wet well top shall be fabricated using fiberglass material. Top to be
attached to wetwell pipe with fiberglass layup to comply with A.S.T.M.-D3299
specifications. Reinforcement, if needed, shall be fiberglass channel laminated to wetwell
bottom per A.S.T.M.-D3299.

i. Influent pipe shall be Kor-N-Seal or Inserta-Tee (refer to standard drawings for details).
Sleeve shall be either PVC or Fiberglass Pipe, and it shall be installed and tested by the
manufacturer. Alternative methods are grouted PVC sewer pipe, or link seal FRP sleeve
with a reinforced wall. Installation of stubouts to be fiberglass layup to comply with
A.S.T.M.-D3299 specifications.

j. The complete wet well shall have a minimum dynamic-load rating of 16,000 ft-lbs. To
establish this rating, the complete wetwell shall not leak, crack, or suffer other damage
when load tested to 40,000 ft-lbs and shall not deflect vertically downward more than 1/4
inch at the point of load application when loaded to 24,000 lbs.

k. The (FRP) wet well shall be installed in strict accordance with the wetwell manufacturer
recommendations.

l. Each wetwell shall be marked with the following information.

8
 (1) Manufacturer's name or trademark
(2) Manufacturing special number
(3) Total length and nominal diameter

21. Wet Well Testing. An Exfiltration test must be performed immediately after the wet well has
been backfilled and compacted. Exfiltration shall not exceed 0.0142 gal/hr per foot diameter
per foot depth. The test must be done by plugging the gravity invert and filling up the wet
well with water to either 1-foot below the wet well top slab, or up to the manhole lid with the
lowest elevation below top slab. (This level must be clearly marked in the wet well internal
wall). Once the wet well is filled, it must be left for stabilization for 48 hours minimum prior
to beginning the Exfiltration test. After the stabilization period, the wet well must be refilled
up to the mark to begin the test. The test will be done for two hours, and no water must be
added to the wet well during the test period. The Exfiltration test must be determined by
measuring the amount of water required to raise the wet well level back to the mark at the
end of the test period. The maximum allowable water loss to pass the test is determined by
the following equation:
Water Loss (gallons) = 0.0142

Where:
t = test time period (2 hours)
D = wet well diameter (in feet)
h = water level depth within wet well (in feet)

If the Exfiltration test fails the Design Engineer must work with the Contractor to determine
all the necessary corrective actions to reduce the exfiltration. Once the repairs are completed
the test will be repeated. The wet well will pass the test until the exfiltration is equal or less
then the allowable water loss. SAWS Inspector, contractor and design engineer will witness
the complete Exfiltration test. Design engineer will provide a certified letter showing the
results of the exfiltration test to SAWS inspector. The certification letter will include a
description of all steps taken to complete the exfiltration test, including water loss, wet well
level mark, and any corrective actions taken if a prior test failed.

C. Pumping Equipment Design

1. Provide the required number of pumps, and adequate controls to alternate all pumps (See
Table 3 for minimum number of pumps required). All pumps, regardless of station design, shall
be electric, centrifugal non-clogging units capable of passing incompressible spheres as
indicated in Table 3 (Minimum Sphere Pass), and shall have no less than 4-inch diameter suction
and discharge openings. Semi chopper, vortex or grinder pumps might be accepted on case-by-
case basis. Self priming pumps (if approved) shall include inspection and cleanout plates,
located both on suction and discharge sides of each pump to facilitate locating and removing
blockage-causing materials unless the pump design accommodates easy removal of the rotation
elements. Specify pumps and motors suitable for continuous operation and inverse duty type
(suitable for soft starters and variable frequency drives) at full nameplate load while the motor is
completely submerged, partially submerged, totally non-submerged for submersible pumps. 2-
Pole motors will be reviewed and approved by SAWS.

9
 TABLE 3
MINIMUM NUMBER OF PUMPS REQUIRED
Minimum
Peak Wet Weather Flow Minimum Number of Pumps
Sphere Pass
500 gpm or less ● 2 Pumps: 1 Lead, 1 Standby † 3-inch
Between 500 and 1200 gpm ▲ 3 Pumps: 1 Lead, 1 Lag, 1 Standby † 3-inch
Between 1200 and 3000 gpm ▲ 4 Pumps: 1 Lead, 1 Lag, 2 Standby ‡ 4-inch
Over 3000 gpm ■ 5 Pumps: 1 Lead, 2 Lag, 2 Standby ‡ 4.5-inch
NOTES: All pumps including Standby must alternate constantly.
● Lead Pump will discharge at least 1.5 times the Peak Wet Weather Flow.
▲ Lead Pump with Lag Pump will discharge at least 1.5 times the Peak Wet Weather Flow.
■ Lead Pump with Lag Pumps will discharge at least 1.5 times the Peak Wet Weather Flow.
† One standby pump required only.
‡ Two standby pumps required due to magnitude of flow.

2. Pumps shall be capable of meeting all system hydraulic conditions without overloading the
motors. In addition, a minimum of 5-hp motor is required, unless prior arrangements have been
made and approved by SAWS. Submit pump head capacity and system curves to SAWS, along
with the lift station plans. Base the curves on the total of static head, friction losses through force
mains, headers and pump risers. Pump duty point shall be within +/-20% range of pump’s flow
at Best Efficiency Point (B.E.P). This condition shall be satisfied for at least one and two pumps
in operation.

B.E.P

Head

-20% +20%
Flow
FIGURE 1: PUMP DUTY POINT BETWEEN +/-20% RANGE OF FLOW AT B.E.P.

10
3. Based on peak flow, pump cycle time shall not be less than those in Table 4.

TABLE 4
MINIMUM WET WELL CYCLING
Minimum Wet Well Cycling Minimum Wet Well Cycling
Pump Horsepower
Using Peak Wet Weather Flow Using Average Daily Flow
Less than 30 10 minutes: 3 Fill, 7 Empty 13 minutes: 10 Fill, 3 Empty
Between 30 and 75 17 minutes: 6 Fill, 11 Empty 22 minutes: 17 Fill, 5 Empty
Over 75 25 minutes: 8 Fill 17 Empty 32 minutes: 25 Fill, 7 Empty
NOTE:
• Wet well cycling is determined by the wet well internal volume established by the wet well internal
diameter, and the distance between Pump On and Pump Off levels.
• Fill time is the time that takes the wet well level to rise from Pump Off to Pump On.
• Empty time is the time that takes a pump to drop the wet well level from Pump On to Pump Off. (Pump
Run Time).

4. All lift stations shall operate automatically based on the water level in the wet well. Locate
wet well level control device so that is unaffected by currents, rags, grease, pumps, pipes, wet
well wall or other wet well internal components. All level control devices shall be fully
accessible without entering the wet well.

5. Contractor shall submit minimum 3 hard copies and an electronic copy of the Operation and
Maintenance Manuals to the Inspector. Operation and Maintenance Manuals shall detail the
following, but not limited to technical data, performance levels, specifications, parts description,
installation, operation and maintenance of electrical, mechanical, and instrumentation
components.

6. Submersible Pumping Stations.

a. The lift station shall consist of submersible centrifugal sewage pumps, stainless steel 316
guide rail system, wet well access, discharge seal and elbow, motor control center,
starters, liquid level control system, SCADA monitoring system, and all hardware
necessary to make a complete working system. Every integral component of the guide
system shall be stainless steel 316, which includes the following but not limited to: guide
rails, brackets, fittings, bolts, nuts, fasteners, adapters, attachments, etc. Flanged
discharges are not allowed.
b. Impellers shall consist of cast stainless steel or ductile iron. Mechanical Seals shall
consist of Tungsten Carbide or Silicon Carbide.
c. Motor insulation shall be rated at Class H, inverted duty.
d. Pump duty point shall be within +/-20% range of pump’s flow at Best Efficiency Point
(BEP) for one and two pumps in operation as to achieve the maximum efficiency
possible, and no substitutions will be accepted after SAWS approval of the Lift Station
construction plans and Engineering report. Designer shall consider different combinations
of pumps, impellers and pipe sizes including discharge and force main piping in order to
achieve the pump operating criteria and maximum efficiency. The Utility Services
Regulations, Section 11.4.4 requires Energy Calculations which mean the engineering
report shall prove the proposed pump is the most efficient option. Exemptions may be

11
 considered on a case-by-case. Approved pump manufacturers are ITT Flygt, Hydromatic,
ABS and KSB.
e. Sealing of the pump unit to the discharge connection shall be a machined metal to metal
water tight contact.
f. The proposed elevation of all critical components shall be shown in the drawings
including, but not limited to pump intake line inverts, control and alarm levels, top of the
wet well, top of the dry well, influent line invert(s).
g. Pumps shall be readily removable and replaceable without dewatering the wet well or
disconnecting any piping in the wet well.
h. All electrical equipment/panels and controls shall be above ground.

7. Non-packaged Suction Lift/Self-priming Stations. (If Approved)

a. Suction lift stations shall meet all applicable requirements in this standard, as well as
those required by TCEQ Chapter 217. The lift station shall consist of self-priming,
horizontal, centrifugal, sewage pumps, wet well access, discharge seal and elbow, motor
control center, starters, liquid level control system, SCADA monitoring system and all
hardware necessary to make a complete working system. Supply and warranty will be
through a single company. Approved pump manufacturers are Hydromatic, and Gorman
Rupp.
b. Impellers shall consist of ductile iron or cast stainless steel. Mechanical seals shall consist
of Tungsten Carbide or Silicon Carbide.
c. Pump duty point shall be within +/-20% range of pump’s Best Efficiency Point (BEP) for
both one and two pumps in operation as to achieve the maximum efficiency possible, and
no substitutions accepted after SAWS approval of the Lift Station construction plans and
Engineering report. Designer shall consider different combinations of pumps, impellers
and pipe sizes including discharge and force main piping in order to achieve the pump
operating criteria and maximum efficiency. The Utility Services Regulations, Section
11.4.4 requires Energy Calculations which mean the engineering report shall prove the
proposed pump is the most efficient option. Exemptions may be considered on a case-
by-case.
d. Suction-lift pump stations using dynamic suction lifts exceeding the limits outlined in the
following paragraphs will not be approved. Detailed calculations shall include static
suction lift as measured from the “lead pump off” elevation to the centerline of the pump
suction, friction and other dynamic head losses altitude correction, required net positive
suction head and a safety factor of 4 feet.
e. The pump equipment pad or compartment shall be above grade or slightly offset and shall
be physically located either on top of or as close as possible to the wet well to prevent the
humid and corrosive atmosphere from entering the compartment. Wet well access shall
be provided through another opening on the wet well cover, 3 feet x 4 feet minimum
dimensions.
f. Self-priming pumps shall be capable of priming and repriming at the “lead pump on”
elevation. Self-priming and repriming shall be automatically accomplished within 60
seconds under design operating conditions. Vacuum switches rated for raw sewage and
weather proof shall be installed at the suction pipes. Vacuum switches will have
adjustable vacuum operating points, and will be wired to the SCADA monitoring system
to indicate that a pump has lost prime. A timer will be incorporated in the control

12
 diagram to allow the pump to reprime within 20 minutes. If at the end of the 20 minutes
the pump hasn’t reprimed, the timer will take the pump out of service, but only in the
automatic mode. The control diagram shall allow any pump to run manually regardless
of the prime condition, vacuum switch condition or timer condition.
g. Discharge piping shall not exceed the size of the pump suction and shall not exceed 15
feet in total vertical lift with zero horizontal suction pipe length. Wet well slab design
shall consider structural loading due static and dynamic loading exerted by the pump and
any deadweight. Request to design a separate slab for the pump shall be reviewed by
SAWS and considered for approval on a case by case basis. The total of the dynamic
suction lift at the “pump off elevation” and required net positive suction head at design
operating conditions shall not exceed 20 feet.
h. Use “T” fittings on the individual suction lines, instead of 90-degree elbows, at the last
turn before the pumps, to facilitate suction line cleaning.
i. A ¾-inch bleeder valve and piping shall be installed on the discharge side of the pump
housing and terminate back into the top of the wet well for priming and cleaning of the
pumps. Piping shall be schedule 40 PVC
j. Use flanged fittings for piping at the pumps to facilitate pump removal.
k. Provide heavy duty and supported pulley guards.
l. Electric motors shall be in compliance with the NEMA Premium Efficiency specification.
m. Electric motor shall be totally enclosed, fan cooled.
n. Pump and motor configuration shall be belt drive with drive end of motor (rotating
counter clock-wise) opposing driven end of pump (rotating clock-wise), and motor
located above pump on adjustable hinged mounting base allowing access to pump.
Minimum number of belts is 2 for motors up to 10 HP, 3 belts for motors larger than 10
HP and up to 30 HP, 4 belts for motors larger than 30 HP.
o. Motor base shall be hinged, bolt adjustable and manufactured as a primed single
frame. Motor base size shall accommodate NEMA mounting dimensions. The motor and
base fit shall provide tolerance for alignment, ease of belt adjustment and tensioning
without removal of guards, as well as simple removal and replacement of
belts, shieves, and pumps. Equipment shall be supported by concrete or steel frame
support bases used as part of the noise and vibration isolation of the equipment. Motor
manufacturer shall furnish the support bases and properly size them for the
mounted motor and base and grout as necessary for stable footing.

8. Packaged Lift Stations (If Approved).

a. Approved manufacturers are ITT Flygt, Hydromatic, Gorman-Rupp, KSB
b. Station design shall satisfy all the requirements listed in this guideline Check with SAWS
for possible exemptions.
c. All pumps, motors, internal valves and piping, level indicators, control switches, SCADA
monitoring system, ladder, alarms, blower and dehumidifier shall be manufactured and
assembled as a package unit. Supply and warranty will be through one company.

13
D. Station Piping

1. Each non-submersible pump shall have a separate suction pipe. Eccentric reducers shall be
used on suction pipes in lieu of a concentric reducer (if self priming pumps are approved). Pipes
in wet wells of suction lift pumps shall be equipped with a turndown type flared intake and
consist of ductile iron or SS 316.

2. The design shall consider surge effects and provide protection where necessary. Surge relief
shall be contained in the system. If a surge relief valve is needed, it shall be installed in the exact
position shown in the standard drawings.

3. All main piping shall have manual vents and drains to allow draining of sewage prior to
piping disassembly.

4. Floor drains from valve vaults to wet wells shall be designed to prevent gas from entering the
valve vault. Such designs shall include flap valves, "P" traps, submerged outlets, or a
combination of these devices. Sumps pumps are acceptable in lieu of floor drains.

5. Provide reinforced concrete or metal manufactured supports for pipes between wet well and
drywell or pump pad, where appropriate.

6. Lift station piping shall be D.I. and shall have flanged connections to allow for removal of
pumps and valves without interruption of the lift station operations. Wall penetrations shall be
designed to allow for pipe flexure while excluding exfiltration or infiltration. Pipe suction
velocities (if self priming pumps are approved) shall be between 3.0 and 4.0 feet per second.

7. Use forty-five (45) degree cast iron elbows for pump discharge piping turns where the force
main bends toward the ground.

E. Station Valves

1. Gate Valves: Install a gate valve on the upstream side of the check valve. Gate valves shall
be resilient wedge, flanged joints. All resilient wedge gate valves shall conform to the applicable
requirements of ANSI/AWWA C509, and shall be handled and installed in accordance with the
recommendations set forth in the appendix to ANSI/AWWA C509 and the recommendations of
the manufacturer. All interior and exterior ferrous metal surfaces of valves and accessories shall
be shop coated for corrosion protection. Approved manufacturers are Clow F-6102, Mueller A-
2360, Kennedy 4561/4701, and American Flow Control – Series 2500

2. Check Valves: A FL. X FL. check valve shall be installed on the discharge side of each pump
and on the by-pass quick connector, followed by a full-closing isolation valve on each pump.
Check valves shall be swing type with an external lever and minimum pressure rating of 250 psi.
If the full-closing valve is other than a rising stem gate valve, the valve shall include a position
indicator to show its open or closed position. Approved check valve manufacturers are Clow
Style 106LW, Mueller #2600-6-01, Kennedy IBBM Swing Check Valve, American “50” Line
with Weight and Lever.

14
3. Butterfly valves, tilting disc check valves, or other valves utilizing a tilting disc in the flow
line are not allowed.

4. Air Release Valves: Shall be mounted on common header and all high points along force
mains. Air release valves shall be rated for raw sewage, have a minimum 2” inlet, and be
provided with flush ports. Air release valves shall be mounted on isolation valves. The air
release pipe shall be a minimum of 1-inch PVC Sch. 40, and it shall be installed in a manner that
doesn’t represent a tripping hazard, and it shall be solidly fastened; unless embedded in
concrete slab, and shall discharge into wet well. Liquid shall not accumulate within air release
pipe. Air release valves shall have a PVC body and allow both air and vacuum release.
Approved manufacturer is A.R.I Model S-020 or equivalent.

5. Surge Relief Valves: Size shall be selected based on Firm Pumping Capacity flow. It shall be
rated for raw sewage service, and it shall have isolation valve on the inlet side. Opening setting
shall not exceed 5 psi above normal operating pressure of the system at header when firm
pumping capacity flow is being discharged. Surge relief pipe shall be routed back to either wet
well or manhole next to wet well. Engineering report must include analysis and reference
information showing how the valve was selected. Valve specifications shall be included in the
book of specifications. Design engineer must include in plans surge relief valve detail, and fill
data in the blank spaces. See standard drawings. When the analysis shows dangerous surge
pressure at firm pumping capacity, a surge relief valve will be included in the design in addition
to the soft starters.

F. Force Main

1. Install the Force Main at least 4 feet below finished ground surface, and higher than the
gravity inlet line elevation.

2. Detector Tape must be laid in the same trench as the force main. The detector tape must be
located above and parallel to the force main. The detector tape must bear the label
“PRESSURIZED WASTEWATER” continuously repeated in at least 1.5-inch letters.

3. Provide plan and profile of the force main in plans.

4. Install an isolation gate valve on all force mains, located immediately before they turn toward
the underground.

5. Minimize the number of peaks and valleys along the Force Main profile to limit the
accumulation of gases. All high points shall have 2-inch minimum air and vacuum release valves
rated for raw sewage. Plans must include the air release valve installation detail. See standard
drawings.

6. Force Mains shall transition into a gravity line within a manhole via drop manhole as to
minimize agitation of sewage. The crowns of the force main and outlet gravity line shall match
where possible, with bench grouting installed to direct flow into the outlet with a minimal change
in the gravity flow angle to minimize turbulence.

15
7. Minimum force main size will be 4-inch (except for grinder pumps); however, size Force
Mains so that flow velocity is between three (3.0) and four (4.0) feet per second (velocities
slightly above 3 feet per second are preferred) with one pump in operation. For lift stations with
more than 2 pumps, flow velocities may be as low as two (2.0) feet per second with one pump in
operation, but when two or more pumps operate a flow velocity of five (5.0) feet per second must
be generated.

8. All Force Main pipe material shall consist of HDPE, and shall be Ductile Iron Pipe Size.
Pipe shall consist of HDPE solid wall referred as to Drisco 1000, Drisco 8600, Quali Pipe, Poly
Pipe, and Plexco Pipe that is in compliance with ASTM F714. All pipe and fittings shall be high
density polyethylene pipe and made of virgin material, and shall have a minimum working
pressure rating of 150 psi. The liner material shall be manufactured from a High Density High
Molecular weight polyethylene compound which conforms to ASTM D 1248 and meets the
requirements for Type III, Class C, Grade P-34, Category 5, and has a PPI rating of PE 3048.
Solid wall pipe shall be produced with a plain end construction for heat-joining (butt fusion)
conforming to ASTM D 2657; no flanged or slip-on joints will be accepted. See SAWS Standard
Specifications for Construction, Item No. 900: “Reconstruction of Sanitary Sewer by Pipe
Bursting/Crushing Replacement Process”, Section 900.2.1. No PVC force main piping will be
allowed.

9. Double barrel force main will be required for all lift stations with either Peak Wet Weather
Flows of 1,200+ gpm, force main lengths of 5,000+feet or located over Edwards Aquifer
Recharge Zone. (Edwards Aquifer Contributing and Transition Zones will be evaluated and
SAWS will determine if double barrel force mains are required). The force mains will be split at
the common header, and they shall be provided with isolation gate valves that will allow the
pumps to discharge through either force main or both if required (depending on number of
pumps and magnitude of firm pumping capacity).

10. Force mains must withstand the pressure generated by instantaneous pump stoppage due to
a power failure under maximum pumping conditions.

11. A force main average flush time analysis must be included in the engineering report.

12. Force main design must include surge control measures to manage pressures due to water
hammer that may exceed the working strength of a force main pipe. This analysis must consider
the worst case scenario, which is a power outage while pumping at Firm Pumping Capacity.

13. Combination Air/Vacuum Release Valves must be installed in a dry vault with a minimum
inner diameter of 6 feet and with a minimum 30-inch access opening. Location of force main and
air release valve within dry vault must be in a manner that will provide safe working space and
safe access. See standard drawings.

14. Force mains must be tested by filling with water and pressurizing to 50 psi above force main
rated pressure. Force main must hold the test pressure for 4 hours.

15. A leak test must be also performed, and the leakage rate must not exceed 10 gallons per inch
diameter per mile of pipe per day.

16
G. Electrical Equipment

1. Electrical service shall be 277/480-volt, 3-phase, and 4-wire, unless otherwise approved by
SAWS. Minimum service size shall be 200 amps. General lighting and power transformer shall
be 10KVA, minimum and shall be housed with load center in a separate stainless steel enclosure.
Request for smaller electrical service shall be reviewed by SAWS and considered for approval
on a case by case basis. All electrical enclosures shall be rated NEMA 4X, NEMA 3R stainless
steel 304 with lever type door closures. Pump control enclosure shall be double door type as to
locate all 480V equipment on the right side and all 120V equipment on the left side. Single-phase
systems are not allowed. Use the following color scheme:

480Y/277 Volts 120/240Volts 3P4W 24Vdc

Phase A: Purple Phase A: Black Positive: Red
Phase B: Brown Phase B(High): Red(Orange) Negative: Blue
Phase C: Yellow Phase C: Blue Ground: Green
Neutral: White Neutral: White
Ground: Green Ground: Green

2. Wire size for controls shall be #14 AWG copper stranded rated for 90 ºC. Wire size for
SCADA controls shall be #16 AWG copper stranded rated for 90 ºC.

3. Due to the potential presence of hydrogen sulfide and other corrosive gases, greases, oils, and
other constituents frequently present in sewage, all mounting hardware shall be Type 304
Stainless Steel and install seal-offs in conduit leading into the pump control panel and junction
boxes. All enclosures shall be Type 304 Stainless Steel, and disconnects shall be FRP-NEMA
4X. All enclosures and disconnects shall be lockable with a padlock.

4. Main electrical disconnect shall be housed in either a separate NEMA 4X, stainless steel
enclosure and shall be equal to Square D, Class 3110, 600-volt class, heavy duty, service rated
safety switch, NEMA 4X, with all copper current carrying parts, Model H36_DS. Provide with
fusing class size based on the characteristics of the motor loads served and the available fault
current. Main electrical disconnect shall be time delay fuse or time delay circuit breaker. Provide
a surge arrestor in a separate enclosure attached to the back of the main electrical disconnect
enclosure. Approved Manufacturers: Square D, Siemens, General Electric, and Cutler-Hammer.

5. Electrical equipment shall comply with the National Electrical Code (NEC) requirements for
Class 1, Group C and D, Division 1 locations. Additionally, equipment located in wet wells shall
be suitable for use under corrosive environments. Each flexible cable shall be provided with a
watertight seal and separate strain relief. High water float switch shall be normally open and non
mercury type.

6. Free-standing electrical service and transfer switch shall be housed in heavy-duty electrical
weatherproof, NEMA 4X, stainless steel enclosures securely mounted onto the rack a minimum
of 24” above the ground. Provide 120-volt, 20-amp duplex, GFI, receptacle in an “in-use”
weatherproof box with clear cover. Light switches shall also be installed in a weatherproof box
with an “in-use” clear weatherproof cover.

17
7. All electrical equipment shall be protected during a 100-year flood event and be protected
from potential flooding from the wet well. If the electrical equipment is raised significantly to be
above the 100-year flood event, then a platform shall be constructed with rails and adequate
working clearance in front of the electrical equipment, with permanent ladder or steps for access.
As a minimum, Motor Control Centers shall be mounted on a 4-inch tall concrete housekeeping
pad. All electrical equipment and connections in wet wells and dry wells shall be explosion proof
unless continuous ventilation is provided.

8. All enclosures, panels, and boxes housing electrical, communication, control and
instrumentation components shall be mounted on a single rack under the Canopy as detailed in
the standard drawings. Mounting rack shall be constructed of type 304 stainless steel strut, 1-1/2”
minimum, mounted on 4”x 4”x ½” hot dip galvanized structural square steel tube. See
mounting rack layout and structural details on the standard drawings. Approved manufacturers:
UNISTRUT, Kindorf, and B-Line. Touch up any scratches where coatings are applied. Close all
exposed tube ends with proper size PVC plug caps. Do not use the electrical service pole as one
of the supports.

9. Provide connector for emergency generator with manual transfer switch (when generator is
not required). Generator connectors shall be Crouse-Hinds, cam-lok, E1016 or 1017 Series
(depending on electric load), male type. 5 connectors – 3-phases, ground and neutral, shall be
mounted in a panel adjoining the manual transfer switch. The manual transfer switch shall be
equal to Square D, Class 3140, 600-volt class, double throw, non-fused safety switch, NEMA
4X, Model 8234_DS. Size the transfer switch to handle the entire load of the lift station.
Approved Manufacturers: Square D, Siemens, General Electric, and Cutler-Hammer.

10. If a generator is required, the transfer switch shall be automatic. The generator shall be
fueled by diesel, or it may be fueled by natural gas if feasible. If the generator is fueled by diesel,
the containment tank shall be double wall type and sized to run the generator for around 10 hrs
continuously at 100% load. The generator shall have a 4-foot clearance all around, and it shall be
provided with noise control package. Noise Control Package Specification for Generator shall be
residential rated. Sound attenuation includes enclosure and exhaust muffler package. Sound
attenuation system performance shall result in measured sound levels not to exceed 78 dB @ 7
meters (23 feet), 60 Hz. Design engineer shall perform different load analysis and the sequence
of motor starting in order to know the motor starting loads and the motor running loads. The
generator shall have a motor starting kVA capacity at least 1.5 times greater than the worst case
motor starting kVA load conditions to limit generator voltage dips to no more than 25% during
such motor starting conditions. Fuel tank shall be provided with an explosion proof float switch
device to indicate when fuel tank level is ¼ full. Approved manufacturers are Kohler, Onan,
Caterpillar and Generac or approved equal.

11. Provide terminal blocks and panel wiring for future remote start and stop contacts.

12. If a dry well is used, consider it a confined space, and provide explosion proof dry well
lighting adequate to illuminate the ladder and the floor of the dry well.

13. All underground electrical conduits shall be grey, rigid nonmetallic conduit (RNC). Field
manufactured bends are not permitted. Only factory fabricated conduit bends are allowed.

18
Buried conduit shall have a cover depth of 18 to 24 inches beneath the finished surface. Conduit
shall comply with minimum NEC bend radius and not burned or kinked.

14. All exposed pipe shall be rigid aluminum conduit. To avoid tripping hazards, conduits must
be embedded in concrete slabs.

15. Provide general illumination of 1.0 foot-candle (average) on the lift station equipment areas.
Use Metal Halide fixtures for general illumination. Mount task lighting to the canopy as detailed
in the standard drawings.

16. Provide ability to operate station with one pump removed for maintenance, by utilizing a
Hand-Off-Auto switch and control logic that keeps alternating all the remaining pumps in
service and no parallel switching in order to allow for proper lockout procedures. For self
priming pumps, provide local non-fused disconnect with auxiliary contacts at motor per NEC.

17. Provide explosion proof local control in dry well, when one is used, to operate pumps for
testing.

18. Install all conduit runs in initial construction sized to meet ultimate electrical and
instrumentation needs.

19. The pump controller shall be provided with alternating lead-lag controls within a NEMA 4X
enclosure. The pump control enclosure shall have two doors (480V equipment installed on the
right side, 120V equipment installed on the left side), and shall also contain the motor disconnect
circuit breaker, motor starters, Milltronics, and soft starters. Soft Starters must include by-pass
mode capability, and will be required for either motor sizes of 50+ HP, force mains of 5,000+
feet long, flow velocities of 5+ feet per second (firm pumping capacity), or static heads of 60+
feet. Soft starters must be rated for operation at 50 ºC. Soft starter shall be capable of allowing
accelerating and decelerating ramps of 60 seconds without de-rating the soft starter capacity;
however accelerating and decelerating ramps will be easily programmable to lower values.
When soft starters are required, the pump control panel must be insulated and provided with a
closed-loop climate controlled unit of 3,000 BTU (minimum) operating at 120 V. Approved
manufacturer is Kooltronics model KNA4C3P21L or approved equal. See standard drawings for
details.

20. Special considerations for submersible stations:

a. Design electrical supply, control and alarm circuits to allow for disconnection outside the
wet well. Terminals and connectors shall be protected from corrosion by location outside
the wet well in a NEMA 4X stainless steel enclosure.
b. Locate the motor control center outside the wet well, readily accessible and protected by
conduit seals, to meet the requirements of the national Electrical Code to prevent the
atmosphere of the wet well to enter the control center. The seal shall be so located that
the motor may be electrically disconnected without disturbing the seal.
c. Pump motor cables shall meet the requirements of the National Electrical Code for
flexible cords in wastewater pumping stations. Power cord terminal fittings shall be

19
 corrosion-resistant and constructed in a manner to prevent entry of moisture into the
cable, and shall be provided with strain relief appurtenances.

21. Grounding system shall have a maximum ground resistance of 10 Ohms. Design engineer
will incorporate special soils such as graphite compounds to improve the ground resistance
properties. A 1-inch PVC Sch. 80 pipe with perforated holes of 1/8-inch diameter will be
buried vertically one foot away from the ground resistance. The bottom of the pipe will have
a glued cap with a drilled hole at the bottom to allow full drain. The top of the pipe will be
protected with a 6-inch diameter ductile iron cap, and the pipe top end will be provided with
a threaded cap. The function of this pipe is to inject water during dry weather to moisture the
soil and maintain the quality of the ground resistance.

H. Station Controls, Instrumentation and Monitoring

1. Primary level monitoring and pump control must be of the submersible level transmitter
type, but may also be ultrasonic or radar type. Accepted manufacturers are Siemens (Milltronics
HydroRanger 200), Greyline Instruments, and Drexelbrook. If approved by SAWS a submersible
level transmitter can be used. Approved manufacturer is Mercoid model PBLT2 or equivalent.
An equivalent unit must be of equivalent design and weight at least 4 pounds. Submersible level
sensors must include a 10 pound weight made of carbon steel, and the instrument shall be solidly
fastened to the weight to prevent the instrument from being dragged into a pump intake. A
stainless steel 316 stranded cable must be solidly fastened to the instrument for removal ease. A
24Vdc power supply shall be included in the pump control panel to feed the submersible or
ultrasonic level transmitters. Feeding the submersible or ultrasonic level transmitters of the
24Vdc power supply from the SCADA Panel is not acceptable. Instrument wiring (shielded
cables) shall be free of splices, no exceptions.

2. Design engineer must perform a true scale graphical analysis of the wet well interior
equipment, parts and appurtenances to ensure the submersible level transmitter is located away
from wet well inflow currents, pump intakes, etc.; or the ultrasonic beam cone projection of the
ultrasonic level transmitter has a clear and uninterrupted path from top to bottom of wet well. If
the ultrasonic beam cone touches anything along the way from wet well top to bottom, the wet
well diameter must be increased until the cone beam has uninterrupted path from top to bottom.
Lowering the ultrasonic transmitter is not acceptable. Ultrasonic transmitter must be always at
top of wet well as shown in standard drawings. Different level transmitters project ultrasonic
beams at different cone angles. Design engineer must be sure to specify the cone angle in the
specifications to ensure the level ultrasonic transmitter will work properly and accurately.

3. The pressure transmitter shall have a 150 psi pressure range, but it must be calibrated to
read the operating and surge pressures. It shall operate at 24 Vdc, 4-20 mA output, and it shall
be located before the last valve as shown in the standard drawings. It shall be provided with an
isolation ball valve and freeze protection. Approved manufacturer is Rosemount model
2088G2S22A1B4E5M5 or approved equal. Pressure transmitter will have a LCD display and
will display the measured pressure in psi. Pressure transmitter will be powered from the 24Vdc
power supply located within the SCADA panel.

20
4. Place the wet well level transmitter and high level float switch in an area of the wet well
which is removed from the effects of the influent flow(s) being received. The wet well level
transmitter junction box, and a separate junction box that houses both the pump/motor splice and
the high level float, shall be located on top of the wet well and made of SS316.

5. Lift station shall be capable of discharging all anticipated peak wet weather flow as
indicated in Table 3. The “lead” pump is turned on at the first “on control elevation” and the
“lag” pump will start with a rising liquid level at the “second on control elevation.” The “lead”
and “lag” pumps will continue to operate until the “pump off control elevation” is reached. The
“lead” and “lag” shall automatically alternate between the two pumps at the completion of each
pumping cycle. (This example is for a 2-Pump type lift station, but the same logic shall be
applied for 3-Pump, 4-Pump and 5-Pump type lift stations)

6. Install a pressure gauge rated for corrosive service that meets the following specifications:
4.5” Dial, Grade 1A, ASME B40.100, ±1% full scale accuracy, liquid filled, type 316 stainless
steel bourdon tube, glass safety lens, full blowout protection, weatherproof, hermetic seal and
with a standard ¼ inch NPT. Pressure gauge shall be provided with an isolation ball valve. The
installation and location of the pressure gauge shall be as indicated in the standard drawings.
Design engineer must make sure the pressure gauge rating is 3 times greater than the operating
pressure at firm pumping capacity at the location of the gauge. Install vacuum gauges on each
suction pipe of self priming pumps. Vacuum gauges shall meet the same specifications of the
pressure gauges.

7. Install elapsed time meters and overload reset with metal extension and plastic cap on the
inner panel (Dead Front) of the pump control enclosure. Meters shall be five digit, indicates
tenths of hours and be non-resetting. Operating power shall be 120 volt. Approved
manufacturers are Cramer, Hobbs, Honeywell, and Redington

8. Provide structural support of the mounting rack that houses electrical, communication,
control, and instrumentation components as detailed in the standard drawings.

9. If specifically required by SAWS, provide flow-measuring devices with instantaneous rate

indicators, totalizers and recorders designed specifically for sewage force mains on the discharge
side of the pump station. Meters, Flowtronics or approved equal, shall be in an approved vault.
Flow display to be installed at lift station electrical/controls rack. In this case the header must
provide a minimum horizontal distance equivalent to 30 pipe diameters of straight pipe for
installation of ultrasonic flowmeters.

10. When a diesel generator is required, an explosion proof float switch shall be installed and
wired to SCADA system to send a signal when the fuel tank level reaches ¼-tank full.

I. Supervisory Control And Data Acquisition (SCADA)

1. Design engineer must include a radio path study report in the lift station engineering report.
The radio path study must be done physically and computer simulated. Both the report and
the plans must include the GPS coordinates of the proposed lift station site. The Radio Path
Study report must show a communication solution that will ensure a clear and steady quality

21
 radio signal is achieved from the proposed lift station site to one of SAWS existing facilities
with SCADA radio repeater.

2. If a clear and steady quality radio signal cannot be achieved between the proposed lift
station and any existing SAWS facility with SCADA radio repeaters, the design engineer will
evaluate other existing SAWS facilities not set up as SCADA radio repeaters near the
proposed lift station in order to ensure a clear and steady quality radio signal is achieved as
follow: from the proposed lift station to the existing SAWS non-repeater facility to an existing
SAWS SCADA radio repeater facility. The design engineer must include in the lift station
design and the engineering report a section that show the design required to convert the
existing SAWS non-SCADA radio repeater facility into a SCADA radio repeater. If a steady
quality radio signal cannot be achieved through any existing SAWS non-repeater facilities,
the design engineer and developer must provide a new site for a radio repeater station in
order to achieve a steady quality radio signal from the proposed lift station to any existing
SAWS SCADA radio repeater facility. See standard drawings for repeater station details and
requirements. New radio repeater stations will comply with all access and site requirements
for lift station site as described in this guidelines.

3. SCADA system shall monitor all the following, but not limited to: Pump #1 Hand, Pump #2
Hand, Pump #1 Auto, Pump #2 Auto, Pump #1 Run, Pump #2 Run, Pump #1 Stator Leak,
Pump #2 Stator Leak, Motor #1 High Temp, Motor #2 High Temp, Motor #1 Overload,
Motor #2 Overload, Low Level Alarm, High Level Alarm, Loss of Echo, Utility Power On,
Generator Power On, Generator Fuel Tank Low, Transfer Fail, Force Main Pressure, Wet
Well Level and SCADA Panel Internal Temperature. For stations with more than two pumps,
alarm signals shall be expanded to include all pumps. See standard drawings for correct I/O
Input wiring order.

4. SCADA panel must include isolation relays for all digital inputs. Isolation relays must be
located within the SCADA panel to separate 120Vac circuits or others from SCADA 24Vdc.

5. Radio must be located within SCADA panel, and be able to communicate in two ways.

6. A temperature transmitter must be included within the SCADA panel and wired to the PLC
analog input board for internal panel temperature monitoring through SAWS Control
Center.

7. SCADA Panel must be climate controlled by including both a 200 Watt minimum space
heater and an A/C unit rated for 3,000 BTU minimum and operating at 120Vac. Design
engineer must have caution with the minimum clearance around heater.

8. Tower used to mount the antenna shall be free stand type and design to withstand wind gusts
of 90 MPH. The tower height will be determinate by the radio path study. Design engineer
will select the adequate tower and foundation according to the required height. Tower will
be located within lift station site in a place where maintenance vehicles have straight access.
See standard drawings. Tower structure will be away from electric overhead wires. Minimum
separation between tower and electric overhead will be 40ft.

22
9. SCADA Panel will be provided with an uninterruptible power supply of 24Vdc. The power
supply will provide reliable power for a minimum of 2 hours. Power supply will be used
exclusively for the 24Vdc loads within the SCADA panel and pressure transmitter located in
the header. The wet well level controller and any other 24Vdc load located within the Pump
Control Panel and automatic transfer switch (if any) will not be powered by the SCADA
power supply.

J. Emergency Provisions

1. Design Lift Stations to prevent overflow from the lift station due to loss of power or
mechanical failure within the operating time frames defined in this section. An audio-visual
alarm system (red flashing light and horn) shall be provided for all lift stations. All alarm
conditions shall be transmitted, through use of a SCADA telemetering system, to a location(s)
where 24-hour assistance is available. The alarm system shall be activated for all the alarms
described in Section I, paragraph 3 of this document. In addition to the alarms and telemetering
requirements, all lift stations shall be provided with service reliability based on the options
detailed in paragraphs a-c, below:

a. The retention capacity of lift stations not over the Edwards Aquifer recharge, transition,
and contributing Zone shall have the wet well and incoming gravity sewer lines designed
to insure that no discharges of untreated wastewater will occur at the station or any point
upstream for a period of time equal to 120 minutes or the longest electrical outage
recorded during the past 24 months, whichever is greater. If no records are available, the
designer shall use 120 minutes of Average Daily Flow (ADF) to calculate required
retention capacity. SAWS may allow a minimum of a 60-minute retention time if a stand-
by generator is included in the design. Power outage records shall be on the utility
company letterhead, bear the signature of a utility representative, identify the location of
the lift station, list the total number of outages that have occurred in the past 24 months,
and indicate the duration of each power outage. For calculation purposes, the start of the
outage period or mechanical failure shall begin at the wet well elevation at which the last
normally operating pump, excluding the standby pump, has just begun to operate.

The retention capacity of lift stations over the Edwards Aquifer recharge Zone shall have
the wet well and incoming gravity sewer lines designed to insure that no discharges of
untreated wastewater will occur at the station or any point upstream for a period of time
equal to 60 minutes. In addition to the 60-minute retention capacity requirement,
emergency power shall be provided by on-site, stand-by generator and automatic transfer
switch sized to operate 100% of lift station electric loads. See Section G, paragraph 10
and standard drawings for generator requirements. In addition force mains shall be
double barrel, and the pumps shall be able to discharge at firm pumping capacity
through a single force main without generating dangerous surge pressures and
maintaining pump duty points within specified range. See Section C, paragraph 2.

The retention capacity of lift stations over the Edwards Aquifer transition and
contributing Zone shall be determined by SAWS staff at the outcome of an evaluation of
the site location, water stream proximity, remoteness, and geographical features to decide

23
 if the site shall be treated as if it were over the EARZ. SAWS will make a written
determination prior to design after receiving a written request from an engineer.

b. The lift station may meet the emergency power requirement by arranging for the facility
to receive electrical service through either two separate electrical distribution circuits or
from separate power companies which have a fully automatic switch over capability
designed to assure continuous service. The two distributions lines shall be physically
separated, not carried on the same pole, and obtain their power from different substations.
If separate distribution circuits originate from the same substation, overall substation
reliability shall be demonstrated.

c. The use of a spill containment structure as a means of providing service reliability is

prohibited. Spill containment structures may be used in addition to one of the service
reliability options detailed in this section, provided a detailed management plan for
cleaning and maintaining the spill containment structure is discussed in the final
engineering design report. Additionally, any spill containment structures shall be fenced
with a six-foot fence which has a minimum of 3 strands of barbed wire and which has a
locked gate. Spill containment structures shall not be used to reduce other power
reliability requirements in any way.

2. Emergency (quick-connection) pump by-pass system shall be provided at all lift stations.
Connection shall be sized according to station and header pipe size, and shall consist of a gate
valve, adapter flange with “quick-disconnect” male fitting with dust cap. Provide a check valve
to allow flow only in the direction of Force Main.

K. Safety Requirements

1. Overhead Wires. Do not run overhead wires over lift station site. Overhead wires include,
but are not limited to, primary and secondary electric lines, electric service drop, and cable
and telephone lines. If a secondary overhead electric service drop is required to feed the lift
station, the service pole must be located in a place where the service drop will be at least: 10
feet away from canopy, 20 feet away from wet well, header piping and generator, and 40
feet away from SCADA tower structure.

2. Electric Conduits and Small Pipes. Eliminate tripping hazards from electric conduits and
small pipes across the surface of the lift station. They must be buried or embedded in
concrete.

3. Arc Flash Analyses. Include an Arc Flash Analysis in engineering report. Reduce arc flash
Hazard/Risk Rating to Category 2 if they originally are Category 3 or 4 by making
adjustments to circuits. Electric panels must include proper warning labels.

4. Bollards. Install bollards to protect equipment located at the end of driveways, or in tight
locations. If lift stations are adjacent to streets of driveways, install bollards between the
equipment and the street. Removable bollards in buried sleeves are acceptable.

24
5. Handrails. Install removable handrails around wet well openings and dry vault openings.
Portable handrails must slide into sleeves embedded in the concrete slabs. Surface-mounted
brackets are not acceptable.

6. Enclosed Dry Vaults (if approved).

a. Install blowers and lights so they won’t become confined spaces. Circulation of
fresh air in vaults would have to be complete and deliver at least 6 air changes per
hour.
b. Locate access covers and ladders so personnel entering the vault land on flat
surface, rather than on top of pipes, valves or other equipment.
c. Provide at least 28” clearance around pipes and mechanical structures and at least
36” for all electrical equipment and panels for employee access.
d. Ladders (if used) follow the SAWS production vault engineering standards.

L. Submittal Requirements

1. An engineering design report that include Construction feasibility and site analysis, a
present value analysis with detailed cost estimate, flow development for initial and final phases
of the development, wet well design, wet well detention time and force main flush time for both
initial and final phases, system curves, pump curves and head calculations (Total Head including
Static Head, Friction Losses, Minor Losses, NPSH, Total Suction Lift (when applicable)).
Calculations and system curves at both minimum (all pumps off) and maximum (last normal
operating pump on) static heads and for a C value of both 100 and 140 shall be provided for each
pump and for the combination of pumps (modified pump curves). Buoyancy calculations for the
wet well in order to design a concrete slab heavy enough to keep the wet well in place. Energy
consumption calculations shall be presented comparing different pumps, impellers and pipe sizes
in order to select the most efficient pump. Where a suction lift is required, the report shall
include a calculation of the available net positive suction head (NPSH) and a comparison of that
value to the required NPSH for the pump(s) selected, as well as calculations for the total suction
lift. The overall layout of the development and the development master plan shall be submitted
for SAWS review.

2. The engineering design report shall be presented in the following format, although the
designer is not required to use the same formulas:

A. TITLE PAGE - Title page should include the project name, date, developer/owner’s name
and engineering firm preparing plans.

B. SEWER SYSTEM INFORMATION

1. Introduction
a) Type, location and size of development
b) Number of and range in size of lots or buildings to be serviced
2. Existing Sewer System
a) Location and type of gravity system the force main will discharge into.
b) State whether the entire development will be serviced by the proposed phase or if
several phases will be involved.

25
 c) State the number of lots this phase will encompass initially and finally if future
phases are to be constructed.

C. PUMP STATION AND FORCE MAIN DESIGN CALCULATIONS

(The following formulas are provided as guidelines. The design engineer can use other
formulas, of preference, to achieve the same results.)

1. Site Characteristics, and allowances, to Calculate Flows (SAWS Utility Service

Regulations 11.3.1):
a) Residential EDUs @ 240 gals/day per EDU
b) Commercial SF @ 0.07 gals/day per SF
c) Multi-family Units @ 0.70 EDUs per Unit
d) Peaking Factor - Sect 11.3.1 SAWS USR
e) Inflow and Infiltration (I/I) Allowance of 300 GPD/acre.

2. Average Dry Weather Flow (ADF): This is the flow developed without the maximum
flow peaking factor. This flow is used to determine the average detention time in the wet
well.

a) ADF (GPD) = Residential (single and multi-family) + Commercial GPDs

b) ADF (GPM) = ADF (GPD) / 1440 (Min/Day)

3. Peak Dry Weather Flow (PDWF) (SAWS Utility Service Regulation 11.3.1): This flow is
used to determine pipe size in the collection system.

a) Peaking Factor = 2.5 for Proposed Residential Development, SAWS USR

b) PDWF (GPD) = PF * ADF
c) PDWF (GPM) = PF * ADF (GPM)

4. Peak Wet Weather Flow (PWF): This flow is used to determine the lift station design
capacity. All lift stations shall be designed to handle the maximum wet weather flow for
its service area.

a) Inflow and Infiltration (I/I): Total Development Acreage * 300 GPD/acre

b) PWF (GPD) = PDWF (GPD) + I/I (GPD)
c) PWF (GPM) = PWF (GPD) / 1440 (Min/Day)

5. Minimum Dry Weather Flow (MDWF): This is used to determine the maximum
detention time in the wet well.

MDWF = (0.2* (0.0144 * ADF) 0.198) * ADF

6. Minimum Pump Requirements (Peak Wet Weather Flow, PWF):

a) For two-pump stations, size each pump to handle PWF.
b) Calculate Total Dynamic Head (TDH):

26
 1) Static Head (Hs)
Eh = Maximum force main elevation
E1 = Wet well low water elevation
Hs = Eh – E1
2) Loss (Lf) due to friction in force main
Length = Total equivalent length of force main and piping on station
Lf = Length x Friction Factor
(Use Hazen-Williams C of 100 and 140 for friction losses)
3) TDH = Hs + Lf
c) Plot System Curve on Pump Curve and determine operating point to select proper
pump sizes.

7. Net Positive Suction Head: For suction lift stations, compare the net positive suction
head (NPSHR) required by the pump with the net positive suction head available
(NPSHA) in the system, at the operating point. The NPSH available shall be greater than
the NPSH required.

NPSHA (suction lift) = PB + HS – PV - Hfs

Where;
PB = barometric pressure in feet absolute, use 33.4 feet
HS = minimum static suction head, in feet
PV = vapor pressure of liquid in feet absolute, use 1.4 feet
Hfs = friction loss in suction, in feet

a) Velocity Produced in Force Main with one pump in operation. 3 to 4 fps for lift
stations with two pumps ;may be as low as 2 fps for lift stations with three or more
pumps:

Vfm = 0.4087099 * (Q / d2)

Where;
Q = Actual flow for selected pump(s)
d = Force Main interior diameter, inches

8. Total Suction Lift:

a) When apply a total suction lift calculation must be performed. The total suction lift
is the addition of the static suction lift plus the friction losses along the suction
pipe. The static suction lift is the distance between the wet well level elevation at
All Pumps Off and the elevation of the impeller eye.

Total Suction Lift = Static Suction Lift + Friction Losses along Suction Pipe

Static Suction Lift = Impeller eye elevation – elevation of wet well level at All
Pumps Off

27
9. Storage Requirements:
a) Required Wet Well Volume (volume between “pump on” and “pump off”
elevation):

Vr (Gals) = Pump GPM * T (Minimum Cycle Time, Table 3)

4

b) Volume of Storage (Vs)

• Not over the Edwards Aquifer recharge, transition and contributing Zone:
Vs (Gals) = ADF (GPD) * [(1hr. minimum/2 hr. maximum storage) / 24 hours per
day]
Vs (CF) = Vs (Gals) / 7.481 CF per Gal
• Over the Edwards Aquifer recharge, transition and contributing Zone:
Vs (Gals) = ADF (GPD) * [(1hr.storage) / 24 hours per day]
Vs (CF) = Vs (Gals) / 7.481 CF per Gal

c) Dimensions of Storage Facility

1) Use Table 2 for Wet Well diameter, minimum 72-inch diameter

2) Wet Well Depth = _________4 * Vs (CF)_________
PI() * (Wet Well diameter)2

10. Buoyancy Checks: A buoyancy check shall be performed for the pump station wet well
and the retention chamber.

11. Water Hammer Calculations: Calculate surge pressures and compare to the pressure
rating of the force main pipe to determine the need for a surge relief valve.

P = (a)*(V)/(2.31)*(g) + operating pressure

Where:
P = water hammer pressure
a = pressure wave velocity
V = flow velocity in the pipe
g = acceleration of gravity (32.2 ft/sec2)

12. Force Main Flush Time Calculations: Calculate force main average flush time.

Instructions:

1. Basic Information Required.

1.1. Wet Well Diameter (D)
1.2. Distance between All Pumps Off and Lead Pump On (∆hOn-Off)
1.3. Wet Well Inflow (Qi)
1.4. Pumped Flow (Qo)
1.5. Force Main Length (L)

28
2. Basic Calculations Required
2.1. Wet Well Filling Time (WWFT)
The wet well filling time is the time that takes to raise the wet well level from All
Pumps Off to Lead Pump On.
2.2. Pump Running Time (PRT)
The pump running time is the time that takes to drop the wet well level from Lead
Pump On to All Pumps Off.
2.3. Wet Well Detention Time (WWDT)
The wet well detention time is the addition of the wet well filling time plus the
pump running time.
2.4. Flushing Cycles (FC)
The cycles to flush are the number of cycles required to flush the force main.
2.5. Flush Time (FT)
The flush time is the time that takes to flush the force main completely.

3. Formulas

3.1. Equation 1: Wet Well Filling Time (WWFT)

3.2.
7.481πD 2 (∆hOn−Off )
WWFT =
4Qi
Where:
D is the Wet Well Diameter in feet.
∆hOn-Off is the distance in feet between Lead Pump On and All Pumps Off.
Qi is the wet well inflow in gal/min.
WARNING!
Use Average Daily Flow to calculate Average Wet Well Filling Time.

3.3. Equation 2: Pump Running Time (PRT)

7.481πD 2 (∆hOn−Off )
PRT =
4(Qo − Qi )
Where:
D is the Wet Well Diameter in feet.
∆hOn-Off is the distance in feet between Lead Pump On and All Pumps Off.
Qi is the wet well inflow in gal/min.
Qo is the pumped flow in gal/min.
WARNING!
Average Daily Flow to calculate Average Pump Running Time.

3.4. Equation 3: Wet Well Detention Time (WWDT)

WWDT = WWFT + PRT

Where:
WWFT is the wet well filling time in minutes.
PRT is the pump running time in minutes.
WARNING!
Use average wet well filling time and average pump running time to calculate average wet well detention
time.

29
 3.5. Equation 4: Flushing Cycles (FC)

L
FC =
60v( PRT )
Where:
L is the force main total length in feet.
V is the flow velocity within the force main in ft/s.
PRT is pump running time in minutes.
WARNING!
Use average pump running time to calculate average flushing cycles.

IMPORTANT!
Normally the flushing cycles are composed by whole and decimal numbers. It is required to separate the
whole part from the decimal part in order to be used in the following equation.

3.6. Equation 5: Flushing Time (FT)

FT = ( FCW )(WWDT ) + ( FC D )( PRT )

Where:
FCW is the whole part of the flushing cycles.
WWDT is the wet well filling time in minutes.
FCD is the decimal part of the flushing cycles.
PRT is the pump running time.
WARNING!
Use average flushing cycles, average wet well detention time and average pump running time to calculate
average force main flushing time.

4. Example:
A lift station with a 12-foot diameter wet well has a 3000-foot force main. The average daily
flow is 150 gal/min. The distance between Lead Pump On and All Pumps Off is 2 feet. The
pumps discharge 600 gal/min, and the flow velocity within the force main is 3.25 ft/s.
Calculate the average force main flush time.

Procedure

Step 1: Calculate average wet well filling time with equation 1 as follows:

7.481π ( D ) 2 (∆hOn − Off ) 7.481π (12)2 (2)

WWFT = ⇒
4Qi 4(150)

The Average Wet Well Filling Time is 11.28 minutes.

Step 2: Calculate average pump running time with equation 2 as follow:

7.481πD 2 (∆hOn − Off ) 7.481π (12)2 (2)

PRT = ⇒
4(Qo − Qi ) 4(600 − 150)

The Average Pump Running Time is 3.76 minutes.

30
 Step 3: Calculate average wet well detention time with equation 3 as follow:

WWDT = WWFT + PRT ⇒ 11.28 + 3.76

The Wet Well Average Detention Time is 15.04 minutes.

Step 4: Calculate average flushing cycles with equation 4 as follow:

L 3000
FC = ⇒
60v( PRT ) 60(3.25)(3.76)
The Average Flushing Cycles are 4.09 cycles.

Step 5: Calculate average force main flush time with equation 5 as follow:

FT = ( FCW )(WWDT ) + ( FC D )( PRT ) ⇒ (4)(15.04) + (0.09)(3.76)

The Average Force Main Flush Time is 60.49 minutes.

Step 6: Summary Table. Make a table showing all the results of the calculations as
follow:

Table1: Average Flush Time Results

Wet Well Diameter 12.00 Average Wet Well Filling Time 11.28
Distance between Lead Pump On and All
2.00 Average Pump Running Time 3.76
Pumps Off
Average Daily Flow 150.00 Average Wet Well Detention Time 15.04
Pumped Flow 600.00 Average Flushing Cycles 4.09
Force Main Length 3000.00 Average Force Main Flush Time 60.49
Flow Velocity Within Force Main 3.25

D. CYCLE TIMES. Calculate detention times (Td) for Average Daily Flow, Peak Wet Weather
Flow, and Minimum Dry Weather Flow.

Td = Tf + Te
Where;
Tf = time to fill wet well in minutes = Vr / i
Te = time to empty wet well in minutes = Vr / (Q – i)
Vr = Required Wet Well Volume, 8.a
i = Flow into the station for given condition
Q = Pump capacity in gpm

1. Average Detention Time (based on Average Dry Weather Daily Flow):

a) Tf = Vr /ADF (GPM)
b) Te = Vr / (Q – ADF)

31
 c) Td (ADF) = Tf + Te

2. Maximum Detention Time (based on Minimum Dry Weather Flow):

a) Tf = Vr /MDWF (GPM)
b) Te = Vr / (Q – MDWF)
c) Td (MDWF) = Tf + Te

If detention times exceed 180 minutes, SAWS may require the design and installation
of a chemical drum scrubber with top mounted blower for odor control. See Section
B(3) for details.

3. Total Cycle Times:

Pump ON for Te
Pump OFF for (2) Tf + Te

The pump is on for one pumping cycle of Te and off for 2 storage cycles of Tf plus one
pumping cycle of Te because pumps alternate

E. LISTING OF RESULTS FROM THE DESIGN CALCULATIONS TO BE

PRESENTED IN THE FOLLOWING ORDER:

1. Number of Lots or Buildings

2. Population Equivalent
3. Average Daily Flows in GPM
4. Peak Daily Flows in GPM
5. The Volume of the Retention Chamber
6. Static Head
7. Total Dynamic Head
8. The Pump Selected (including type manufacturer, model number, size, Hp, RPM, phase
and GPM)
9. Net Positive Suction Head Available (NPSHA) for suction pumps
10. Total Detention Times for, Maximum Dry Weather Flow, and Average Dry Weather
Flow.
11. Total Cycle Times for, Maximum Dry Weather Flow, and Average Dry Weather Flow.
a) Number of Minutes ON (Pumping Time)
b) Number of Minutes OFF (Fill Time)
12. Size and Length of Force Main
13. Velocity Maintained in Force Main
14. Force Main Retention Time (at initial flows and at design flows)
15. Wet well buoyancy calculations.

F. COST EFFECTIVENESS ANALYSIS

As required by the San Antonio Water System Utility Services Regulations.

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