March 2016 INSTALLATION INSTRUCTIONS FOR FURTHER QUESTIONS, PLEASE CALL 775 440 2025 JENSEN WATER RESOURCES 521 Dunn Circle, Sparks, NV 89431 JensenPumps.com
Figure 1: This illustration shows a complete pump station material delivery as arranged on one flat bed truck. Installation Instructions Page 2
Table of Contents Lift Station Identification Bracket Orientation Bracket Installation Base Elbow Orientation Base Elbow Installation Station Layout Identification Mechanical Joint Sleeve Installation Force Main Installation Intermediate Guide Rail Bracket Installation Pipe Bracing Installation Pump Installation Electrical Cable Management Control Panel Installation 4 5 6 7 8 9 10 11 12 13 14 15 16 Appendix A Junction Box Installation Appendix B Pre commissioning Check List 18 20 Installation Instructions Page 3
JENSEN PUMP STATION SYSTEM IDENTIFICATION DRAWING 5.) WET WELL RIM ELEVATION SINGLE DOOR HATCH 4.) FINISH GRADE ELEVATION DOUBLE DOOR HATCH FORCE MAIN LENGTH 3.) DISCHARGE STRUCTURE 1.) WET WELL 2.) VALVE VAULT 10.) OUTFALL ELEVATION 11.) DRAIN PIPE 6.) GRAVITY INLET INVERT 9.) PUMP FORCE MAIN 7.) SUBMERSIBLE PUMP 8.) BASE ELBOW FOR AUTOCOUPLING SYSTEM PUMP STATION IDENTIFICATION 1. WET WELL: WET UTILITY STRUCTURE WHICH CONTAINS PUMPS, SLIDE RAIL SYSTEM, AND LEVEL SENSORS. 2. VALVE VAULT: DRY STRUCTURE WHICH CONTAINS VALVES, PIPING AND FITTINGS. 3. DISCHARGE STRUCTURE: UPSTREAM LOCATION AT WHICH THE PUMP FORCEMAIN ENDS AND SYSTEM TURNS TO GRAVITY, TYPICALLY A MANHOLE. 4. FINISH GRADE ELEVATION: ELEVATION OF GROUND LEVEL AFTER PROJECT COMPLETION. 5. WET WELL RIM ELEVATION: ELEVATION OF TOP OF WET WELL AFTER PROJECT COMPLETION. TYPICALLY EQUAL TO FINISH GRADE. 6. GRAVITY INLET INVERT ELEVATION: ELEVATION OF INLET PIPE TO THE PUMP STATION. TYPICALLY FROM A GRAVITY PIPE, BUT CAN BE A FORCEMAIN IF COMING FROM A PRESSURIZED SOURCE SUCH AS A PUMP STATION. 7. SUBMERSIBLE PUMP: PUMP IN WET WELL THAT WILL BE SUBMERGED DURING NORMAL OPERATION. 8. BASE ELBOW: PERMANENT BASE IN WET WELL WHICH ALLOWS FOR PUMP COUPLING WHEN PUMP IS PLACED IN WET WELL. 9. PUMP FORCEMAIN: PRESSURIZED PIPE THAT CARRIES WATER FROM PUMP TO DISCHARGE STRUCTURE. 10. OUTFALL ELEVATION: ELEVATION OF FORCEMAIN PIPE TERMINATION AT THE DISCHARGE STRUCTURE. 11. DRAIN PIPE: DRAIN FROM VALVE VAULT TO WET WELL, PREVENTS WATER BUILD UP IN VALVE VAULT. Copyright Information 2011 Jensen Precast All Rights Reserved. All materials appearing as Jensen Precast documents and the like are propriety work product and are protected under U.S. copyright and other laws. Unless in conjunction with business conducted with Jensen Precast, any use of Jensen Precast work product without express, written consent is prohibited and recipient is prohibited from distributing any and all work product to non-approved third parties under penalty of civil action. PROJECT: STATION IDENTIFICATION DETAIL DRAWING DATE: DRAWN BY: SHEET NO: MARCH 2016 BP 1 of 1 PUMP STATIONS 521 DUNN CIRCLE, SPARKS, NV 89431 JensenPumps.com (855) 468-5600 C:\Vault\Jobs\Standard Details\Installation Procedures\Identification Sheet\Station ID Assembly.iam
PART LIST 1 PART DESCRIPTION 1 PRECAST CONCRETE FLAT TOP 2 PRECAST CONCRETE TOP BARREL 3 UPPER GUIDE RAIL ASSEMBLY 4 FLOAT BRACKET ASSEMBLY 5 CAST IN HATCH 6 FACTORY INSTALLED NUTRAIL 5 1 4 3 2 6 Figure 2: This image shows upper guide rail bracket orientation when the flat top includes a single door hatch. Figure 3: Shown here is the upper guide rail bracket orientation when the flat top has a double door hatch. 3 4 Figure 4: The flat top must be oriented such that the long axis of the access hatch is perpendicular to the direction of the force main. Installation Instructions Page 5
PART LIST 2 PART QTY DESCRIPTION 1 N.A. FACTORY INSTALLED NUT RAIL 2 5 SS CHANNEL NUT 3 2 UPPER GUIDE RAIL BRACKET 4 5 SS HEX BOLT 5 4 GUIDERAIL PIPE 6 1 SSFLOAT BRACKET 7 2 OPTI FLOAT LEVEL SENSOR 8 1 PRESSURE TRANSDUCER 1 2 3 4 1 2 6 5 7 Figure 5: Upper guide rail bracket installation. 8 Figure 6: Float bracket installation. STEPS FOR PART LIST 2 1. Install upper guide rail bracket on the force main side of wet well. a) Leave the SS Hex Head bolts loose. 2. Install float bracket on opposite side of access hatch. 3. If there is no nut rail installed, make sure that all brackets are installed no farther than 6 down the skirt of the frame. IMPORTANT! Pressure transducer handling: The pressure transducer is to be kept in a moisture free environment until it can be installed and pulled directly to the control panel. Please do not splice the cable and/or install in junction box! If a longer cable is needed, contact us at 775 440 2025. A stilling well may be used; consult Jensen Pump Stations before installing the stilling well pipe. Installation Instructions Page 6
PART LIST 3 PART DESCRIPTION 1 UPPER GUIDE RAIL BRACKET 2 CORE HOLE (FORCE MAIN DISCHARGE) 3 PLUMB BOB 4 PUMP BASE ELBOW 5 SS WEDGE ANCHOR 2 4 Figure 7 *Double door hatch orientation see page #3* 1 2 DISCHARGE FLANGE OF PUMP BASE ELBOW MOUNTING HOLES FOR GUIDE RAIL 3 5 Figure 8 Figure 9 STEPS FOR PART LIST 3 1. Align the center of the discharge flange of the pump base elbow, the upper guide rail bracket, and the center of the core hole for the force main discharge. (Figure 7 on this page) 2. Using a plumb bob, align the upper guide rail grommets with the mounting holes for the guide rail in the base elbow. (Figure 8 on this page) 3. Figure 9 is described further on the following page. Installation Instructions Page 7
Figure 10 STEPS FOR FIGURE 10 1. Drill hole for wedge anchors with Roto Hammer. a) WARNING: Take care to not drill all the way through the concrete base. 2. Install wedge anchors. 3. Install base elbows. 4. Tighten wedge anchor hex head. Installation Instructions Page 8
*Single door hatch orientation see page 3.* 6 9 7 8 5 4 2 3 Figure 11: Typical station layout PART LIST 4 PART DESCRIPTION 1 PUMP BASE ELBOW 2 STAINLESS STEEL GUIDE RAIL PIPE 3 FLANGE X PLAIN END PIPE, CUT TO LENGTH IF NEEDED 4 RESTRAINED FLANGE COUPLING ADAPTER (RFCA) 5 FLANGED 90 ELBOW 6 STAINLESS STEEL UPPER GUIDE RAIL BRACKET 7 MEGALUG 8 MECHANICAL JOINT SLEEVE (LONG) 9 PRE ASSEMBLED VALVE VAULT 1 DUCTILE IRON FLANGE: TORQUE SPECIFICATIONS Pipe Diameter Torque Value (ft lbs) 3 80 4 90 6 90 8 90 10 90 12 90 14 110 Figure 12: Bolt tightening sequence Installation Instructions Page 9
MECHANICAL JOINT SLEEVES PRE ASSEMBLED VALVE VAULT Figure 13: MJ Sleeve installation STEPS FOR FIGURE 13 1. Slide the Mega Lugs and the Joint Sleeves onto the plain ends of the pipes coming out of the valve vault. 2. Once the pipes from the wet well are placed (see Page 9), center the sleeves between the connection and tighten the bolts. Installation Instructions Page 10
STEPS FOR PART LIST 4 (from Page 7) 1. In the wet well, install boots into core holes for force main discharge. 2. Install horizontal force main pipe (flange X plain end) through boots. 3. Install vertical force main pipe (can be flange X flange and/or flange X plain end depending on the total well depth). 4. Bolt flanged 90 elbow to RFCA. 5. Slide RFCA onto plain end of vertical force main pipe. Leave loose. 6. Bolt flanged 90 elbow to horizontal force main pipe. 7. Refer to installation instructions provided with RFCA to tighten. 8. Remove the upper guide rail brackets in order to install the guide rails in the base elbow mounting holes (see Fig. 9, page 5), then replace them back on the hatch nut rail. 9. Refer to Fig. 18 on p. 10 for installation of intermediate guide rail brackets for deep wells. *Single door hatch orientation see page 3.* Figure 14: Step 1 Figure 15: Step 2 *Double door hatch orientation see page 3.* STEP 4 STEP 8 STEP 5 STEP 3 STEP 6 Figure 17: Step 6 & Step 8 Figure 16: Step 3 Step 5 Installation Instructions Page 11
*Note: Not all stations require intermediate brackets. The following instructions are specifically for stations that are provided with this hardware. Figure 18: Intermediate guide rail bracket installation illustration. STEPS FOR FIGURE 18 1. With the guide rail pipe provided, measure out the sections. Guide rails are provided in 20 sticks, and quantity depends on the total depth. The guide rails may need to be field cut due to exact well depth. a) For example: If the well is 15 deep, place the intermediate bracket no more than 10 from the floor. This allows for two ~10 sections and two ~5 sections for each pump. 2. Loosely attach the U bolt to the bracket and slide the bracket down the discharge pipe to where the first section of guide rail pipe ends. If flanges do not allow sliding the bracket down the discharge line, remove the U bolt and reconnect it where the first section of the guide rail pipe ends. 3. Connect the next section of guide rail pipe directly on top of the intermediate bracket and tighten the U bolt nuts. Installation Instructions Page 12
*Note: Not all stations require pipe bracing. The following instructions are specifically for stations that are provided with this hardware. Figure 19: Typical pipe bracket by Placer Waterworks Inc. Figure 20: Shown above is an example of the pipe bracket installation, with a close up of the wedge anchor placement. STEPS FOR FIGURE 20 1. Loosely install the U bolts on the discharge pipes and extend the bracket tubing on each side to reach the inner walls of the well. 2. Drill hole for wedge anchors with Roto Hammer. a) WARNING: Take care to not drill all the way through the wall. 3. Install wedge anchors. 4. Place bracket angles on each side. 5. Tighten wedge anchor hex heads, tighten U bolt hex heads. Installation Instructions Page 13
Figure 21: Pump is lowered onto base elbow via guide rails. STEPS FOR FIGURE 21 1. Lower pumps down guide rails onto base elbows. a) Lifting chain with shackles are supplied with the pump station materials. 2. The weight of the pumps creates a water tight seal to the base elbow. a) There is a gasket between the guide claw and base elbow. 3. THERE IS NO BOLTING REQUIRED to connect pumps to the base elbows. *Double door hatch orientation see page 3* Note: The hoist shown on this page is not always included. Use the proper lifting equipment to lower the pumps into the well and to raise the pumps out of the well. Figure 22: Pump is lowered onto base elbow via guide rails. Installation Instructions Page 14
Figure 23: The above illustration is an example of electrical cable management. ELECTRICAL CABLE MANAGEMENT NOTES It is essential to utilize proper cord separation techniques when hanging electrical cables. The electrical contractor is responsible for conduit installation. Jensen Pump Stations recommends 2 minimum conduit for both high and low voltage. Pumps typically have two cables exiting the casing. Refer to the installation instructions provided by the pump manufacturer to identify the low voltage and high voltage cables (typically, the high voltage cables have a larger diameter). All low voltage and high voltage cords MUST be ran in separate conduits to the control panel. If low voltage and high voltage cables are placed in the same conduit, a current can be induced in the low voltage cables and create false seal fail alarms. See the following page for continued information. Installation Instructions Page 15
UNISTRUT RAIL CONDUIT PIPE Figure 24: Typical control panel installation. CONTROL PANEL INSTALLATION NOTES The location and installation of the control panel is the responsibility of the installing contractor or electrical contractor. Jensen Pump Stations recommends that the panel is mounted as close to the wet well as possible to avoid voltage loss and make start up and continued maintenance more convenient. The panel enclosure may be mounted on a nearby wall or within a nearby structure. Please pull all cables to the control panel. If the control panel is too far to use factory connections, contact JPS (775 440 2025) for longer cables. If a junction box is ABSOLUTELY necessary, take note of Pressure Transducer Handling instructions on page 4. It is crucial that the junction box is completely watertight. See Appendix A for junction box installation recommendations. Leave all excess cable coiled within the control panel. A JPS pump technician will make the electrical connections at time of start up/commissioning. Installation Instructions Page 16
Please contact Jensen Pump Stations with any questions about the equipment, installation, or commissioning services. PumpSupport@JensenPrecast.com (775) 440 2025 A completed pre commissioning check list (see Appendix B) is required in order to schedule start up and training services. Please send a copy of this form completed to PumpSupport@JensenPrecast.com and call (775) 440 2025 to schedule the date with one of our Pump Technicians. Please allow us 2 weeks notice to plan the commissioning of the station. Installation Instructions Page 17
APPENDIX A Installation Instructions Page 18
PUMP HIGH VOLTAGE CONDUIT (1.5" MINIMUM DIAMETER) B JENSEN PRECAST HT1730 TRAFFIC BOX PUMP LOW VOLTAGE CONDUIT (1.5" MINIMUM DIAMETER) 2'-6" TO CONTROL PANEL LEVEL SENSOR CONDUIT (1.5" MINIMUM DIAMETER) B 1'-5" PLAN SECTION NOT TO SCALE ISOMETRIC VIEW W/ COVER REMOVED NOT TO SCALE RIM/FINISH GRADE 2.5' MIN 1'-0" TYP. ELECTRICAL CONDUIT DESIGN AND MATERIAL BY OTHERS LOW VOLTAGE NEMA 4X ELECTRICAL JUNCTION BOX LOW VOLTAGE NEMA 4X ELECTRICAL JUNCTION BOX HIGH VOLTAGE NEMA 4X ELECTRICAL JUNCTION BOX SEAL CONDUIT WITH DOTTIES DUCT SEAL PUTTY OR EQUAL PRODUCT (SEWER APPLICATIONS REQUIRE GAS TIGHT CONDUIT SEAL) PUMP STATION MANHOLE 2" PVC SCH40 DRAIN LINE 2" PVC SCH40 CHECK VALVE 3" TYP. DRAIN ROCK DESIGN AND COMPACTION BY OTHERS 2" 1" UNISTRUT RAIL SUPPORT FOR JUNCTION BOXES SECTION B-B NOT TO SCALE TYPICAL SYSTEM LAYOUT NOT TO SCALE Jensen Pump Stations does not make any claim that this detail is compliant with the NEC or any other jurisdictional electrical codes or regulations. Copyright Information 2011 Jensen Precast All Rights Reserved. All materials appearing as Jensen Precast documents and the like are propriety work product and are protected under U.S. copyright and other laws. Unless in conjunction with business conducted with Jensen Precast, any use of Jensen Precast work product without express, written consent is prohibited and recipient is prohibited from distributing any and all work product to non-approved third parties under penalty of civil action. PROJECT: TRAFFIC RATED JUNCTION BOX STANDARD DETAIL DATE: DRAWN BY: SHEET NO: MARCH 2016 NEC 2 of 2 PUMP STATIONS 521 Dunn Circle, Sparks, NV 89431 JensenPumps.com (855) 468-5600 C:\Vault\Jobs\Standard Details\Installation Procedures\Junction Box\JENSEN JUNCTION.iam
APPENDIX B Installation Instructions Page 19
521 Dunn Circle Sparks, NV 89431 (855)468-5600 PRE-COMMISSIONING CHECK LIST Please complete prior to scheduling a Jensen Engineered Systems representative for commissioning services. DATE REQUESTED FOR STATION COMMISSIONING: TODAY S DATE: PROJECT ADDRESS: REQUESTED BY: PROJECT NAME: Name: Phone #: Cell Phone #: Company: NUMBER OF STATIONS REQUIRING COMMISSIONING: GENERAL Has all mechanical equipment been installed? Yes or No Is there an acceptable water source available for commissioning? Yes or No *Acceptable water source is a water truck or fire hose connection w/ hose. Garden hose is not acceptable. Will a lifting device to remove pumps be available during commissioning? Yes or No Have the wet well and all piping been cleared of debris? Yes or No Has any of the equipment been exposed to sewage? Yes or No Have appropriate parties been scheduled for training immediately following commissioning? Yes or No ELECTRICAL Is high voltage/low voltage wires in separate conduit? Yes or No Has electrical conduit been sealed? Yes or No Have the electrical leads for the pumps been landed in control panel? Yes or No Have the leads for the level detection devices been landed in control panel? Yes or No Has power been provided to the control panel? Yes or No Is there a main disconnect panel prior to the pump station panel? Yes or No Is a junction box used? Yes or No Verify in line voltage L1/L2 = L2/L3 = L1/L3 =
521 Dunn Circle Sparks, NV 89431 (855)468-5600 STATION DESIGNATION: *If there are multiple stations on a single job, submit a copy of this sheet for each station. PUMPS PUMP # 1 PUMP #1 PUMP #2 PUMP #2 PUMP #3 Select One: DUPLEX PUMP STATION TRIPLEX PUMP STATION Refer to tag information on the side of the pump to collect the following information: Pump # Serial Number Model Number 1 2 3 PHOTOS Photos are very helpful for the Jensen Engineered Systems technician to review prior to visiting the project site for commissioning. If time permits, please submit pictures showing the overall site, the control panel with door open, and the inside of the wet well. Photos can be emailed to PumpStations@JensenPrecast.com (please put the project name in the subject line).