Front Royal Wastewater Treatment Plant Influent Pump Station Upgrade

Key Accomplishments

Johnston Construction Company and B & R Electrical Contractors

• JCC’s scope included construction coordination, sequencing, demolition, pump installation, pump foundation work, piping and valve replacement, removal of failed concrete grout, installation of new concrete grout layer, spiral staircase replacement, electric manhole drainage, site excavation, stormwater ditch grading, closeout, training, and turnover.
• The project required maintaining the influent pump station in operation during construction, with only one pump allowed to be shut down at a time.
• Each pump, foundation, valving, electrical components, and piping had to be removed and replaced in sequence before the next pump could be taken out of service.
• The work included coordination with the Town and Engineer for inspection of each completed pump installation before the pump was placed back into service.
• Johnston Construction Company completed the Upgrade of Influent Pump Station at the Town of Front Royal Wastewater Treatment Plant in Front Royal, Virginia. The project was performed for the Town of Front Royal, Virginia and designed by Potesta & Associates, Inc.
• The project consisted of upgrades to the existing influent lift station at the wastewater treatment plant. The work included installation of replacement wastewater pumps, pipe fittings, valves, associated appurtenances, concrete foundations, concrete grout replacement, wet-well HVAC equipment, wet-well level sensors, spiral staircase replacement, electric manhole drainage, and site restoration.
• JCC coordinated the overall construction effort, including sequencing, submittals, work planning, demolition, protection of existing utilities and structures, pump removal and installation, foundation work, piping and valve installation, wet-well equipment replacement, dewatering, storm drainage improvements, cleanup, closeout, and owner training.
• A major part of the project included maintaining the influent pump station in operation throughout construction. Work was sequenced so that only one pump could be shut down at a time. Once flow was shut off to a pump, the pump, foundation, valving, electrical components, and piping were removed and replaced before the pump was inspected and placed back into service. This process was repeated until all four pump assemblies and related components were replaced.
• The project included transporting and installing four Town-purchased Xylem Flygt wastewater pumps. Because of limited 36-inch floor openings in the lift station, each pump had to be separated from its sled and rotating assembly from the volute so it could be lowered through the opening using the existing 3,000-pound monorail and hoist.
• JCC’s work also included removal of the existing failed concrete grout layer, installation of replacement concrete grout layer, removal and replacement of pump foundations, pipe fittings, valves, wet-well ventilation equipment, stack motors, electrical components, bubbler level sensor controls, and related station appurtenances.
• The project included replacement of the existing spiral staircase and platform. JCC coordinated removal of the deteriorated spiral stair and installation of the new fabricated spiral stair, platform, railings, anchors, fittings, brackets, and associated appurtenances.
• The electric manhole drainage work included dewatering the manhole, installing pipe, fittings, conduits, and associated appurtenances to allow drainage, and excavating, grading, and compacting the stormwater drainage ditch. Site work included dewatering, trenching, backfilling, compacting, earthwork, erosion and sediment control, storm drainage, utility protection, restoration, and cleanup.
• Johnston Construction Company and B & R Electrical Contractors, Inc. completed the Upgrade of Influent Pump Station at the Town of Front Royal Wastewater Treatment Plant.
• The project included influent lift station improvements, pump replacement, piping, valves, concrete grout replacement, wet-well ventilation equipment, wet-well level sensors, electrical equipment, controls, spiral staircase replacement, electric manhole drainage, and site restoration.
• JCC coordinated the overall project delivery, including sequencing, demolition, pump installation, foundation and grout work, piping, valves, spiral stair replacement, electric manhole drainage, dewatering, excavation, backfill, stormwater ditch grading, restoration, training, and closeout.
• BRE performed electrical, controls, VFD, motor control center, switchboard, pump wiring, wet-well level sensor, and startup support work.
• The work required maintaining the influent pump station in operation during construction, with only one pump allowed to be shut down at a time.
• Each pump, foundation, valving, electrical component, and piping assembly was removed and replaced in sequence, inspected by the Engineer and Town, and placed back into service before the next pump was taken offline.
• Johnston Construction Company and B & R Electrical Contractors, Inc. completed the Upgrade of Influent Pump Station at the Town of Front Royal Wastewater Treatment Plant in Front Royal, Virginia. The project was performed for the Town of Front Royal, Virginia and designed by Potesta & Associates, Inc.
• The project consisted of improvements to the existing influent lift station, including installation of wastewater pumps, valves, piping, concrete foundations, concrete grout layer, wet-well ventilation HVAC equipment, wet-well level sensors, spiral staircase replacement, electric manhole drainage, and related site improvements.
• JCC led the overall construction effort, including project sequencing, submittals, demolition, pump removal and installation, piping and valve replacement, foundation work, failed concrete grout removal, concrete grout replacement, spiral staircase replacement, manhole dewatering, drainage improvements, excavation, grading, compaction, restoration, training, and closeout.
• BRE performed the electrical and controls portions of the work, including disconnecting and replacing pump-related electrical components, coordinating pump control wiring, supporting upgraded electrical equipment, motor control center, switchboard, VFD equipment, wet-well level hydrostatic sensors, and startup support for each pump installation.
• The Town had previously purchased four Xylem Flygt wastewater pumps for the project. The work required coordinating pickup, protection, transportation, and installation of the pumps at the treatment plant. Due to the 36-inch-wide floor openings in the lift station, each pump had to be separated from its sled and the rotating assembly from the volute so it could be lowered through the openings using the existing 3,000-pound monorail and hoist.
• Mechanical and process work included removal and installation of wastewater pumps, pipe fittings, valves, foundations, wet-well ventilation equipment, stack motors, wet-well level sensors, and related appurtenances. The work also included removal of existing bubbler level sensor controls and installation of new wet-well hydrostatic level sensors connected and sequenced with the existing controls.
• The project also included removal and replacement of the existing spiral staircase and platform, including fabricated spiral stair components, platform, railings, anchors, fittings, brackets, and associated appurtenances.
• The electric manhole drainage scope included dewatering the electric manhole, installing pipe, fittings, conduits, and appurtenances to allow drainage, and excavating, grading, and compacting a stormwater drainage ditch. Site work included dewatering, trenching, backfilling, compacting, earthwork, erosion and sediment control, storm drainage, utility protection, restoration, cleanup, and closeout.

B & R Electrical Contractors

• B & R Electrical Contractors performed electrical work for the Front Royal Wastewater Treatment Plant Influent Pump Station Upgrade project in Front Royal, Virginia.
• The project included electrical support for upgrades to the influent lift station at the Town of Front Royal Wastewater Treatment Plant.
• BRE’s scope included conduit, wiring, electrical connections, electrical demolition, panelboard demolition, temporary power, VFD installation, switchboard installation, disconnect installation, motor starter installation, transducer conduit, electrical testing, arc flash support, startup, and closeout.
• Major electrical equipment included two 100 HP VFDs, two 75 HP VFDs, one 600A switchboard, two 200A disconnects, two 125A disconnects, and two fan disconnects / motor starters.
• BRE provided electrical demolition and make-safe work to support demolition of mechanical equipment by Johnston Construction Company.
• BRE furnished and installed conduit, wire, and connections in accordance with the electrical and instrumentation drawings.
• BRE provided temporary power required to swap the new panelboard / switchboard SB.
• BRE performed electrical testing, including arc flash-related testing and project startup support.
• The work required coordination with Johnston Construction Company, Town of Front Royal, Potesta & Associates, equipment suppliers, instrumentation and controls providers, electrical inspections, temporary power requirements, and the overall influent pump station upgrade sequence.
• B & R Electrical Contractors performed the electrical subcontract scope for the Front Royal Wastewater Treatment Plant Influent Pump Station Upgrade project in Front Royal, Virginia. The work was completed under subcontract to Johnston Construction Company for Job No. 2023-10.
• The overall project consisted of upgrades to the influent pump station at the Town of Front Royal Wastewater Treatment Plant. The project included replacement of wastewater pumps, pipe fittings, valves, pump foundations, concrete grout layer, wet-well ventilation equipment, wet-well level sensors, spiral staircase and platform, electric manhole drainage, and related appurtenances.
• The work was performed at an active wastewater treatment plant facility. The project required the influent pump station to remain in operation during construction, with only one pump shut down at a time. Each pump, foundation, valving, electrical components, and piping were required to be removed and replaced in sequence before the next pump could be taken out of service.
• BRE’s electrical scope included furnishing material, labor, tools, equipment, supervision, and coordination necessary to complete the electrical work in accordance with the subcontract documents, contract plans, specifications, addenda, electrical drawings, instrumentation drawings, and project requirements.
• Electrical demolition work included demolition and make-safe work for mechanical equipment demolition by Johnston Construction Company. BRE also performed demolition of electric panelboards required for the pump station upgrade.