St. Charles Pumping Station 3B Equipment Upgrades – Phase 2

Key Accomplishments

Johnston Construction Company

• JCC’s scope included furnishing and installing two submersible pumps with associated VFDs and retrofit breakers, one emergency generator with day tank and load connection box, one 10 MGD sewage grinder with controls, new instrumentation, and related control panel modifications.
• The work included building modifications, roofing repairs for the new exhaust thimble and exhaust pipe, ductwork modifications for the new generator installation, painting of generator exhaust piping, and touch-up of affected work.
• The project required temporary generator backup power while the permanent generator replacement was ongoing, along with new generator conduit and wiring, load connection box connection, and equipment grounding.
• Johnston Construction Company performed the St. Charles Pumping Station 3B Equipment Upgrades project for St. Charles Community, LLC in Charles County, Maryland. The project was designed by Whitman, Requardt and Associates, LLP and performed under Contract No. S-245 / PGM #VR 06-0118.
• The work consisted of equipment upgrades at the existing Pumping Station 3B facility. JCC provided labor, materials, tools, equipment, supervision, bonds, submittals, coordination, and installation services required to complete the pump station upgrade work.
• Major pumping equipment work included furnishing and installing two submersible pumps with associated variable frequency drives and retrofit breakers. The project also included installation of a new 10 MGD sewage grinder with controls to match the existing grinder system.
• The emergency power scope included a new emergency generator with day tank and load connection box. The work also included generator conduit and wiring, load connection box connection, new equipment grounding, and temporary generator support to maintain backup power while the generator replacement work was ongoing.
• Instrumentation and controls work included two new pressure switches for the added pumps, two new wet well floats, one auxiliary secondary control panel, field modifications to the existing secondary control panel, and integration of additional input/output points into the existing PLC panel.
• Building modification work included roofing repairs required for installation of the new exhaust thimble and exhaust pipe, ductwork modifications for the new generator installation, painting of the generator exhaust pipe, and general touch-up painting of affected work.
• The project was scheduled to start on August 15, 2023, with substantial completion scheduled for March 1, 2024.

B & R Electrical Contractors

• B & R Electrical Contractors performed electrical work for the St. Charles Pumping Station 3B Phase 2 Upgrades project in Waldorf, Maryland.
• The project included electrical support for upgrades to the St. Charles Communities Pumping Station 3B wastewater pumping station.
• BRE’s scope included electrical demolition, conduit, wiring, electrical connections, VFD installation, instrumentation installation, grounding, electrical permitting, testing, startup, and record drawings.
• Major demolition work included demolition of existing generator feeders and demolition of the existing load connection box with feeders.
• BRE disconnected and reconnected the fuel tank and motor-operated dampers on the west side wall at the fuel tank.
• BRE provided electrical support for temporary generator setup, including one electrician for one week to assist with temporary generator setup.
• BRE installed grinder electrical work and connected the grinder to the existing MCC bucket.
• BRE installed VFDs provided by others and installed instrumentation furnished by others.
• BRE grounded new equipment to the existing grounding system and coordinated electrical field acceptance testing, including insulation resistance testing, conductor connection testing, and operating tests.
• The work required coordination with Johnston Construction Company, St. Charles Community, Charles County requirements, electrical inspections, equipment suppliers, VFDs and breakers furnished by others, instrumentation furnished by others, testing services, and overall pump station upgrade sequencing.
• The overall project involved upgrades to St. Charles Communities Pumping Station 3B in Charles County, Maryland. The original pump station project included maintaining the continuous operation of existing pumping facilities, performing field investigations, coordinating with the local electrical utility, constructing and testing the wastewater pumping station, completing site and utility work, pigging force mains, and coordinating bypass pumping or pump-and-haul during shutdowns.
• BRE’s electrical scope included furnishing labor, materials, tools, supervision, and electrical services necessary to complete the electrical work for the Pumping Station 3B Phase 2 Upgrades in accordance with the subcontract documents, contract documents, Division 16 requirements, project drawings, and electrical code requirements.
• Electrical demolition work included demolition of existing generator feeders and demolition of the existing load connection box with feeders. BRE coordinated demolition work with Johnston Construction Company, field conditions, existing station operations, and the overall upgrade sequence.
• BRE’s new electrical work included furnishing and installing conduit, wire, and electrical connections required for the upgraded pump station systems. The work also included installation of VFDs provided by others and installation of instrumentation furnished by others.