Are you looking for streamlined solution from one supplier that includes project management services for you and value-engineering capabilities to eliminate scope gaps, accelerate project timeline, and minimize risk throughout the project? If so, a prefabricated packaged pump station is the way to go. It’s the most efficient way to get your pump station in the ground, tested, and running smoothly. Working with the same organization that designs, manufactures and delivers your pump station, you can be assured that your packaged pump station will have an efficient and desired result.
The entire pump station is delivered from a single source which will minimize scope gaps, reduce installation risk and exposure to items being missed in the bid. Excel Fluid Group uses Solidworks to design our pump stations, along for thorough checking of design interferences digitally before our prefabricated pump stations are manufactured and sent to site. These scope gaps and minimized risks are summed up by Dan, a project manager experienced with the packaged pump station solution:
“Your [Excel Fluid Group] drawings were perfect and depicted exactly what we ended up receiving and installing in the field."
Once the pump station submittal has been approved, the factory preassembled method brings all components into a quality-controlled environment where they are assembled and tested as a turnkey system, prior to being shipped to the jobsite. This approach ensures there are no onsite installation delays due to components not functioning as designed. The factory preassembled pump station is delivered to the job-site for the contractor’s team to install into the excavation. Having the same team that designed and manufactured the station on site during install will ensure that all the components of the pump station integrate and work properly making a low stress install for you and your team.
When purchasing a packaged pump station there are a variety of add-ons that can make maintaining your pump station a lot easier. We work to design a pump station that will leave our customers with not only a pump station that is easy to install but also a hassle-free experience to maintain. This is done by including the right add-ons for your specific requirements in your packaged pump station.
Trash Basket
If your pump station deals with a lot of non-organic waste, a trash basket is a good investment to decrease the risk of your pumps clogging. The basket will be located over the inlet pipe and collects trash before it can enter the pump preventing any pump damage or clogging.
Extendable Wet Well Ladder
In times when you need to enter the well, an extendable ladder can be pre-installed to make this process a lot safer. With designs available in wall mount and floor mount, our custom fit wall mounted standoffs can fit any wet well sizes you need.
Lifting Hoist
Confined space entry can be minimized with lifting hoist options above grade to avoid going down in the wet well by ladder. Available in our enclosures the electric hoist comes standard with an 120V electric marine grade brake winch with a hand held remote pendulum. Manual hand crank options are also available for external station designs with embedded or floor mounted hoist sockets. This, along with an optional boom extension, allow for safer lifting of pumps out of the wet well.
An odor control system can be included to reduce the odor that pump stations often produce. They aggressively aerate and mix wet well influent. Continual microbial activity combined with constant agitation stimulates growth of aerobic microbes in wastewater, digests organic wastes throughout the system, prohibits the ability to H2S to form, and prevents FOG formation in the wells.
Having a backup plan for your pump station is a good investment when power outages are frequent. We can design bypass piping which will help with a simple hook up during an emergency that will keep the pump station online.
Prefabricated Buildings
Above-ground enclosures and buildings are used for housing electrical components and above ground piping and valves. Our prefabricated enclosures or buildings arrive fully assembled as we pre-install and test pump station equipment in our factory before it arrives on site. These buildings are typically adjacent to the wet wells and provide ample walk-in space for easy service and maintenance access. There are three main structural options; precast concrete, structural steel, and fiberglass.
NoVault ™Pump Station Design
The EXCEL NoVault™ pump station is the “Next Generation” in municipal wastewater collection system management. Our design team can modify standard construction features to fit almost any job specific requirement. All NoVaults are built with rugged aluminum and feature packed for operational convenience. The NoVault™ pump station is, by design, one of the most versatile units on the market today.
NoVault Types | NV2 | NV3 | NV4 | |||
Discharge Pipe and Valve Fittings: |
Duplex: 2 in. to 4 in. |
Triplex: Unavailable |
Duplex: 2 in. to 4 in. |
Triplex: 4 in. |
Duplex: 8 in. to 12 in. |
Triplex: 6 in. |
Standard Layout: | 4 in. Ductile Iron | 6 in. Ductile Iron | Used in custom layouts only | |||
Typical Uses: | Lift station designs with a wet well | Lift station designs with a wet well | Water Booster layouts and more |
When it comes to the controls or electrical components of a pump station, there can be a plethora of choices. There are a variety of electrical add-on options to make maintaining your station a more pleasant experience. The main three additional components we would recommend include SCADA, Generators, and Power Pedestals.
SCADA
Control panel and telecommunication systems can be preprogrammed to minimize third party integrations. This allows you to monitor your pump stations remotely and get any alarm alerts or notifications when needed. While you might not be able to remove a clog remotely, you can monitor, control, and manage your pump station as you see fit.
Generators
When pump stations are needed most, it is crucial that they have power to do the job they were designed for. Unfortunately, the most likely time for the power to fail is in the middle of a storm when a pump station is vital to handling the incoming precipitation or combined wastewater. A portable generator is a good temporary solution to have when a pump station is without power during an emergency. A generator that is permanently installed as part of the pump station’s design is the peace of mind, hands free approach to having an emergency power supply. While we recommend CAT or Cummins, we can provide any brand generator with our pump stations. Check out our emergency power supply blog to determine what options would be best for your system.
Power Pedestals
Power Pedestals are pad-mounted, weather-resistant electrical enclosures consisting of a utility pull section with optional meter socket and a customer section containing distribution and control equipment. Commercial pedestals are an attractive, secure, easy-to-install and cost-effective solution when underground remote site power distribution and control requirement is required, replacing unsightly and inefficient strut and backboard structures.
Every engineer and contractor knows mechanics play a huge role in the overall performance of the pump station. These include the gauges, valves, flow meters, and more.
Air Release Valve
Within the mechanics of your pump station, we recommend adding an air release vacuum/valve. We recommend a short body design that automatically and efficiently release air and gas that have collected in the discharge piping while under pressure and operation. Typically installed at high points where air and gas naturally collect, the valve opens when sufficient air and gas has accumulated in the valve and closes tightly after the air has been released.
Flow meters help indicate the amount of waste-water moving through the station as precisely as possible. It does this with a flow tube mounted seamlessly in the design. There are three typical types that we recommend for pump stations. The control panel mount style is designed to fit into a control panel and monitor flow rates. The wall or pipe mount style meter can simply be mounted to a pipe or wall. Lastly the direct mount style will reduce the potential for temperature variation. Depending on your design our experts will work with you to determine what style of flow meter will best suit your pump station’s design.
Pump Station Gauges
Like flow meters, Excel has a wide range of gauges to choose from. Ring gauges, isolator ring gauges, digital pressure gauges, liquid-filled case pressure gauges are just a few out of the many gauges that we can include. Depending on your design, each will provide simple and accurate readings on the pressures in your system.