WSAA Product Appraisal 1405 Issue 2 1 COPYRIGHT All Pumps Sales and Service PRODUCT APPRAISAL REPORT 1405 Issue 2 FRP Packaged Pump Stations (PPS) and Emergency Storage Tanks (EST) WSA 129:2011 - Industry Standard for Plastics Collection Tanks for Pressure and Vacuum Sewers AS 2634:1983 - Chemical plant equipment made from glass-fiber reinforced plastics (GRP) based on thermosetting resins BS 4994:1987 - Specification for design and construction of vessels and tanks in reinforced plastics ASME RTP-1 – Reinforced Thermoset Plastic Corrosion-Resistant Equipment AWWA C950 - Buried Structural Design AS 1546:1983 - Underground Tank Design AS 1770:1981 - Loading Code Issue 1 Publication Date: 20 August 2015 Issue 2 Publication Date: 11 July 2017
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All Pumps Sales and Service · AWWA C950 - Buried Structural Design AS 1546:1983 - Underground Tank Design AS 1770:1981 - Loading Code Issue 1 Publication Date: 20 August 2015
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WSAA Product Appraisal 1405 Issue 2 1
COPYRIGHT
All Pumps Sales and Service PRODUCT APPRAISAL REPORT 1405 Issue 2
FRP Packaged Pump Stations (PPS) and Emergency Storage Tanks (EST)
WSA 129:2011 - Industry Standard for Plastics Collection Tanks for Pressure and Vacuum Sewers
AS 2634:1983 - Chemical plant equipment made from glass-fiber reinforced plastics (GRP) based on thermosetting resins
BS 4994:1987 - Specification for design and construction of vessels and tanks in reinforced plastics
The following information indicates the changes made to this document.
Date Version File Location
11/07/2017 1:06:00 PM Peer Review Draft
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1405 Gebel - FRP Pumping Stations and Emergency Storage Tanks\Report Final\Publication
20/08/2015 Publication Issue 1
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1405 Gebel - FRP Pumping Stations and Emergency Storage Tanks\Report Final\Publication Version\PA 1405 Gebel_FRP PS and EST final 20-8-15.docx
11/7/2017 Publication Issue 2
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1405 Gebel - FRP Pumping Stations and Emergency Storage Tanks\Issue 2\PA 1405 All Pumps FRP PPS and EST Issue 2 10-7-17.docx
Peer Reviewers
Name/Title Organisation Date
Adam Glasson, Technical Officer Goulburn Valley Water 10/06/2015
David Moore, Manager Design City West Water 18/05/2015
Carl Radford, Product Appraisal Manager WSAA 21/04/2015
Mohamed Yoosuf, Senior Standards Engineer City West Water 21/04/2015
Peter Pittard, WSAA Contractor WSAA 11/7/2017
Appraised
Name/Title Signature Date
Carl Radford, Product Appraisal Manager WSAA 20/08/2015
Carl Radford, Product Appraisal Manager WSAA 11/7/2017
WSAA Product Appraisal 1405 Issue 2 3
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Overview of WSAA
The Water Services Association of Australia (WSAA) is the peak industry body representing
the urban water industry. Our members provide water and sewerage services to over 20
million customers in Australia and New Zealand and many of Australia's largest industrial
and commercial enterprises.
Based around our vision of 'customer driven, enriching life', WSAA facilitates collaboration,
knowledge sharing, networking and cooperation within the urban water industry. We are
proud of the collegiate attitude of our members which has led to industry-wide approaches
to national water issues.
WSAA can demonstrate success in the standardisation of industry performance monitoring
and benchmarking, as well as many research outcomes of national significance. The WSAA
Executive retains strong links with policy makers and legislative bodies and their influencers,
to monitor emerging issues of importance to the urban water industry.
WSAA was formed in 1995 as a non-profit organisation to foster the exchange of information
between industry, government and the community, and to promote sustainable water
resource management.
The urban water industry is committed to anchoring its services to customers' values, and
to enrich communities where water services have broad economic, environmental and social
values. In line with this our main activities focus on four areas:
1. influencing national and state policies on the provision of urban water services and
sustainable water resource management
2. promoting debate on environmentally sustainable development and management of
water resources and the community health requirements of public water supplies
3. improving industry performance and establishing benchmarks and industry leading
practices for water service processes; and
4. fostering the exchange of information on education, training, research, water and
wastewater management and treatment and other matters of common interest.
Copyright
This document is copyrighted. Apart from any use as permitted under the Copyright Act
1968, no part of this document may be reproduced or transmitted in any form or by any
means, electronically or mechanical, for any purpose, without the express written permission
of Water Services Association of Australia Limited.
2 THE APPLICANT........................................................................................................................................ 8
3 THE PRODUCT .......................................................................................................................................... 8
6.1.2 Wet-well and valve pit access covers suppliers ............................................................................................ 17
6.2 COMPLIANCE WITH PERFORMANCE REQUIREMENTS ................................................................................ 19
6.2.1 FRP Material Components ............................................................................................................................ 20
6.2.2 Type and Batch Release Tests ..................................................................................................................... 25
6.2.3 FRP Packaged Pump Station – Buoyancy Consideration ............................................................................. 27
8.3 TRAINING REQUIREMENTS ............................................................................................................................. 45
13.5 WELL WASHERS ............................................................................................................................................. 48
16.1 ISSUE OF REPORT .......................................................................................................................................... 50
16.2 LIMITS ON RELIANCE ON INFORMATION AND RECOMMENDATIONS ....................................................... 51
16.2.1 Disclaimer of Liability .................................................................................................................................. 51
16.2.2 Intellectual Property and other rights .......................................................................................................... 51
16.2.3 Need for Independent Assessment ............................................................................................................. 51
16.3 NO UPDATING ................................................................................................................................................. 52
16.4 NO WARRANTY ............................................................................................................................................... 52
APPENDIX A – TECHNICAL MANUAL....................................................................................................... 53
APPENDIX B - QUALITY ASSURANCE CERTIFICATES .......................................................................... 54
APPENDIX C – DIAGRAMS FOR A FLANGED AND PVC SPIGOT JOINT TO FRP BARREL ................ 56
APPENDIX D – ALL PUMPS STANDARD ALUMINIUM COVER SPECIFICATION. ................................. 57
APPENDIX E – ENGINEERING DESIGN BY A FULLY CERTIFIED THIRD-PARTY COMPOSITE ENGINEER .................................................................................................................................................. 67
APPENDIX F – INSPECTION AND TEST PLAN (ITP) VERIFICATION STATEMENT ISSUED BY THE COMPOSITE ENGINEER ........................................................................................................................... 72
APPENDIX G – STANDARD SPECIFICATION FOR ALL PUMPS FRP PUMP STATION STRUCTURES ..................................................................................................................................................................... 76
APPENDIX H – FINAL INSPECTION BY A FOURTH PARTY ENGINEER ............................................... 77
APPENDIX I – LAMINATE TESTING REPORTS ....................................................................................... 78
APPENDIX J – LETTER OF APPROVAL ALL PUMPS FRP EMERGENCY STORAGE TANK ................ 85
APPENDIX K – BALLAST CALCULATIONS (WORST CASE SCENARIOS) ............................................ 86
APPENDIX L - WSAA PRODUCT SPECIFICATION .................................................................................. 92
APPENDIX M – PACKAGING AND TRANSPORTATION .......................................................................... 93
APPENDIX N –ALL PUMPS WARRANTY .................................................................................................. 95
APPENDIX O - SUPPLIER CONTACTS ..................................................................................................... 96
APPENDIX P – DENMAN CASE STUDY ................................................................................................... 97
WSAA Product Appraisal 1405 Issue 2 6
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1 EXECUTIVE SUMMARY
This second issue of PA 1405 recognises a change of brand name from Gebel FRP
Engineering to All Pumps Sales and Service (All Pumps) as a result of an amalgamation
between the two businesses. There has been no change to the manufacturing processes or
installation procedures. Quality certification, documentation and references contained within
this report have been updated to replace the Gebel brand with All Pumps, however the
documentation in Addendum 1 currently retains the Gebel brand name as many of the
documents are historic. The Manuals included in Addendum 1 were in the process of being
amended at the time of this report update. Where All Pump branded manuals are required
these may be obtained directly from All Pumps.
All Pumps, previously Gebel, specialises in the manufacture and supply of Fibre Reinforced
Plastic (FRP) packaged pumping stations (PPS) and emergency storage tanks (EST) and
services for individual Council or Water Agency requirements across Australia.
The original manufacturer, Gebel FRP Engineering, has been manufacturing FRP tanks and
process equipment since 1972. In 2013 Gebel joined with ‘The All Pumps Group’. All Pumps
Sales and Service is a solution provider for fluid handling, providing customised pumps and
packaged pumping solutions for the civil and building industries. All Pumps is also a market
leader in odour control, FRP pressure vessels and associated stormwater and wastewater
equipment.
The All Pumps FRP Pumping Stations are available in sizes from 1,000 mm to 4,000 mm in
diameter and from 1 m to 12 m in depth. The All Pumps Emergency Storage Tanks are
available in sizes from 1,000 mm to 4,000 mm in diameter and from 3 m to 25 m in length.
Multiple tanks can be installed in series if required.
All Pumps FRP pumping stations and FRP emergency storage tanks are built with stiffening
ribs. The design thickness and manufacturing process are supplied by All Pumps composite
engineer. The use of ribs provides increased stiffness resulting in:
Longevity due to reduced flexural loads on the FRP wall from active soils;
Reduced point loading from the ballast on a single locking ring; the ballast will lock onto
more than two ribs; and
Increased tank stiffness for active conditions such as installations beside roadways,
where increased lateral loads can be experienced.
Each FRP pump station or emergency storage tank is a single unit (i.e. wet-well with an
integral valve chamber) or as separate wet-well and valve chamber. All Pumps endeavour
to supply all of their pump stations and emergency storage tanks as completely assembled
items, direct to site as packages, tailored for specific site conditions. All joining of internal
components is carried out as part of the manufacturing process. No onsite joining or sealing
is required as the pump station or emergency storage tank is a one-piece construction, fully
pre-packaged and delivered to site ready for placement into excavation.
The project consultant and/or Water Agency is responsible for determining the suitability of
the station design for local ground conditions. All Pumps offers support to the consultants
and contractors on all aspects of design, supply, installation, maintenance and
commissioning.
To meet customers’ special needs, All Pumps can supply socketed joints for assembly of
several FRP vessel segments, on tight sites or on tanks too large to shift or transport
according to traffic regulations. These FRP vessel segments are placed together as spigot-
socket joints and laminated together in accordance with the relevant standard and engineer’s
WSAA Product Appraisal 1405 Issue 2 7
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procedures. These will all be set out on a drawing that is delivered to site along with all
installation instructions.
A range of options and accessories (offered at fit out) are outlined in this appraisal to
demonstrate product versatility but are not intended to be included in the appraisal. The
project constructor will need to ensure that the specifications for access covers, pumping
equipment, electrical controls and cubicles comply with relevant project documentation,
based upon the individual Council or Water Agency standards. Each station can be designed
with single or multi-part cast iron covers Class B, D or G or aluminium covers.
The FRP vessels are designed to meet the requirements of:
AS 2634:1983 Chemical Plant Equipment made from Glass-Fibre Reinforced Plastics
(GRP) based on thermosetting resins;
BS 4994:1997 Specification for design and construction of vessels and tanks in
10.2.2, 10.2.3 and 11 of WSA 129 shall be applied, noting that FRP chamber being assessed
is not a pressure vessel (i.e. pressure or vacuum sewer).
All Pumps uses the following as minimum Standards in the design and construction of their
FRP vessels:
a) BS 4994:1987 Specification for design and construction of vessels and tanks in
reinforced plastics
b) AS 2634:1983 Chemical plant equipment made from glass-fibre reinforced plastics (GRP)
based on thermosetting resins
c) ASME RTP-1 Reinforced thermoset plastic corrosion-resistant equipment
d) AWWA C950 Buried structural design
e) AS1546:1983 Underground tank design
f) AS1770:1981 Loading code
The following Product Specification is also relevant to this application:
WSA PS-402 - Collection Tanks for Pressure and Vacuum Sewerage.
A copy of the above Product Specification can be found in Appendix L or downloaded from
the WSAA website.
A geotechnical report prepared with information determined from soil samples taken at the
Pumping Station or Emergency Storage Tank site is requested by All Pumps in order to verify
the structural integrity of the design of the FRP Pumping Station or Emergency Storage Tank.
As a minimum, the geotechnical report shall contain soil classification, information on the
water table location, the soil bearing capacity and the lateral earth pressure coeffic ients.
6 COMPLIANCE WITH APPRAISAL CRITERIA
6.1 COMPLIANCE WITH QUALITY ASSURANCE REQUIREMENTS
6.1.1 FRP Vessel Supplier
All Pumps manufacture and supply the FRP vessels for their range of FRP Pumping Stations
and Emergency Storage Tanks.
Manufacturing of the FRP Sewage Pumping Stations and FRP Emergency Storage Tanks
follows the certified ITP (Inspection and Test Plan) that forms the quality insurance system
for the manufacturing process.
All Pumps operates under an ISO 9001 Quality Management System licenced by Qual-Safe
Management Systems.
6.1.2 Wet-well and valve pit access covers suppliers
Cast Iron cover options:
Bolt down secure covers
Concrete infill
Solid surface
Grates
Multi-part
Brass or stainless-steel surrounds for tiled areas (shopping centres etc.) are all available on enquiry
Certified Standards
Products designed to meet and exceed AS3996:2006 - Access Covers and Grates
Comprehensive range of sizes and load classes from Class B and D; right through to Class E, F and G
Ductile iron: Grade 600/3 castings to AS1831
Precision machined to gas, air and water tightness (sealed as per AS3996)
WSAA Product Appraisal 1405 Issue 2 18
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Australian Standard lifting keyholes: safe lifting with non-rotating keyways
Non-rocking of cover in frame with machined drawcut/undercut profiles
Covers are neatly ribbed to provide maximum strength and an aesthetic appearance
“T” and cellular style frames designed to anchor the frame into position
Custom cover options:
Lockable cast iron Gatic covers.
Lockable, gas tight covers constructed from mild steel galvanised, stainless steel and aluminium.
Lockable safety grates constructed from mild steel galvanised, stainless steel and aluminium.
FRP covers.
Grates with Fall Protection and customised openings to access control and monitoring.
Custom designed covers to meet customer specifications.
All Pumps supply multi-part solid-top or concrete infill cast ductile iron access covers and
frames Class B, D or G. All Pumps purchases these covers and frames from accredited
suppliers whose products comply with AS 3996:2006 Access covers and grates and/or WSA
132 Industry Standard for Ductile Iron Access Covers for water supply and sewerage .
In trafficable areas, Class D covers and frames shall be provided to access points. In non-
trafficable areas, Class B access covers hinged to frames can be provided to access points.
In heavy duty areas such as airport taxiways and aircraft standing areas Class G can be
provided to access points.
All Pumps also supply lockable aluminium hinged lids, including the aluminium swing up
safety grate as fall protection as per the requirements of individual water agency or local
council.
Aluminium covers are manufactured with the higher grades of Aluminium, 6061 T6 for
Structural Sections and 5086 for the cover plate. All the design, welding and inspection is to
AS 1664:1979 Rules for the use of aluminium in structures or better.
Hinged safety grates are mounted below the cover to prevent operators accidentally falling
into the wet-well or valve pit. The individual covers are opened only during pump removal.
The covers are sized to suit the pump and valve access requirements and the hinge
assemblies and step-down frame is cast into the cover slab.
All Pumps assembles an EPDM rubber odour seal to the frame edging under the cover. Gall
Pumps advises that their aluminium covers are water and gas tight. The use of the foam seal
and the locking system sizing to suit the size of the padlocks used by the various Water
Authorities is designed to press the aluminium access covers down and compress the foam
to give a water and gas tight seal.
The cover slab is set above ground level if rainwater surface infiltration is likely. The height
of the cover slab above ground level is specified on the Project Drawings to conform to the
Water Agency requirements.
All Pumps has indicated that aluminium post inserts for corner posts for rail safe telescopic
guardrail system can be cast into the cover slab or mounted underneath the cover.
The aluminium cover design allows the cover to be opened fully and laid flat or stands
vertical. All Pumps recommends safety grates as fall protection measure for valve pit depths
greater than 1.5 m.
All Pumps have advised that in line with current trends, pumping stations are rarely located
in trafficable areas and ductile iron covers are therefore not normally fitted. All Pumps
advises that some ductile iron covers exceed OHS maximum lifting limits and pose other
safety risks to service personnel.
Refer to Appendix D for All Pumps Standard Aluminium Cover specification.
WSAA Product Appraisal 1405 Issue 2 19
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6.2 COMPLIANCE WITH PERFORMANCE REQUIREMENTS
All Pumps manufactures solid FRP wall pump stations that do not require attachment of
external strengthening ribs.
The FRP vessels are designed to meet the requirements of:
AS 2634:1983 Chemical Plant Equipment made from Glass-Fibre Reinforced Plastics
(GRP) based on thermosetting resins; and
BS 4994:1997 Specification for design and construction of vessels and tanks in
Reinforced Plastic
All Pumps performs the following steps to ensure the FRP vessels are constructed in line
with the above Standards:
a) Design: All Pumps employs the services of a fully certified third-party composite engineer
(e.g. Dennis Southam & Associates Pty Ltd, New Port SA 5015) who provides the factory
with comprehensive design calculations and manufacturing processes. These
calculations are done for every new size or change of conditions. The results from these
calculations are set out on the QA paperwork that follows the pump station or emergency
storage tank through the factory processes and assembly. The Actual results are
recorded against the design requirements.
b) Design Verification: Where requested or required the design calculations are checked
by a verifying composite engineer who is unconnected with the actual designer, such as
‘Oceania Composite Engineering Pty Ltd’ whose Principal, Mike Leggett, is a registered
Professional Engineer in QLD. This ensures the design is impartial and without problems
and allows All Pumps to supply their equipment with total confidence as nearly all of their
designs have, at some stage, been verified and checked.
Mike Leggett provides a verification statement for each completed FRP vessel based on
a comprehensive review of an Inspection & Testing Plan (ITP), working drawings, the
finished product inspection and the finalised specifications. Refer to Appendix F for a
copy of the design verification statement and for the Inspection and Test Plan (ITP).
c) Final Inspection: Where required customers can have a final inspection by a 4 th party
engineer (e.g. Kneebone, Bretta & Hall Pty Ltd, Penrith NSW 2750) to ascertain their
pump station or emergency storage tank have been made in accordance with all
engineering documentation, procedures and applicable standards. Refer to Appendix H
for a copy of this report.
d) To ensure quality of raw materials used the following laminate tests are conducted:
Tensile Testing
Lap Shear Strength Testing
Fibre Fraction Test
Burn-Off Test (samples from the FRP vessel to ensure the “resin to fibre percentage” complies with AS2634)
Refer to Appendix I for copies of test results.
a) At completion of each FRP vessel, a quality inspection is performed by All Pumps in-
house engineer using a quality checklist that ensures the vessel meets all required
design standards.
b) Pressure tests are performed on the internal pipe work and fittings of each completed
pumping station and emergency storage tank.
c) All Pumps conducts ‘type and performance tests’ in line with WSA 129 as detailed in
Tables 2, 3, 4 and 5.
WSAA Product Appraisal 1405 Issue 2 20
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6.2.1 FRP Material Components
The FRP vessels have been assessed in line with WSA 129:2011 Industry Standard for
Plastics Collection Tanks for Pressure and Vacuum Sewers . Refer to Table 2.
TABLE 2: FRP MATERIAL COMPONENTS
Materials WSA 129 Clauses Remarks
5.2.1 - Resin (Glass Fibre Reinforced Plastics)
The resin shall be polyester, vinyl ester or equivalent resin that
(a) has a minimum heat distortion temperature of 60°C when tested in accordance with ISO 75-3 and is capable of being used in the manufacture of a laminate that complies with Clause 9.2.2;
(b) will cure at ambient or higher temperature with the addition of an initiator (catalyst) and, if necessary, promoters or accelerators used in accordance with the manufacturer’s or supplier’s recommendations; and
(c) Contains:
(i) Not less than 50% w/w of non-volatile materials;
(ii) No pigment or fillers; and
(iii) Not more than 2% w/w of thixotropic agents.
All Pumps Response
Resins are high grade polyesters and Vinyl esters and comply with the following:
(a) The minimum heat distortion temperature of any resin used by All Pumps is 65 deg C when tested in accordance with ISO 75-3 and is capable of being used in the manufacture of a laminate that complies with Clause 9.2.2;
(b) All resins will cure at ambient or higher temperature with the addition of an initiator (catalyst) and, if necessary, promoters or accelerators used in accordance with the manufacturer’s or supplier’s recommendations; and
(c) All resins contain: (i) Not less than 50% w/w of non-volatile materials; (ii) No pigment or fillers; and
(iii) Not more than 2% w/w of thixotropic agents.
Comply
WSAA Product Appraisal 1405 Issue 2 21
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Materials WSA 129 Clauses Remarks
5.2.2 Reinforcement (Glass Fibre Reinforcement)
5.2.2.1 Glass-fibre
The reinforcing material shall be a suitable grade of glass fibre having a glass finish compatible with the resin used and complying with BS 3396 Part 3, EN 14118-1, 2 and 3 or BS 3749, as appropriate.
Gall Pumps Response
All Reinforcing glass both Continuous rovings and chopped strands, used by All Pumps, have finishes which are compatible with all resins used. All Glass complies with BS 3396 Part 3, EN 14118-1, 2 and 3 or BS 3749 as required by design or customer.
Comply
5.2.3 Resin coatings (Polyester and vinyl ester)
5.2.3.1 Polyester and vinyl ester
Polyester or vinyl ester resins used for resin-rich internal layers shall be a suitable chemical resistant resin with a minimum heat distortion temperature of 60o C when tested in accordance with ISO 75-3.
Polyester and vinyl ester resins shall comply with the following requirements, as appropriate:
(a) Internal resin-rich layer:
Internal resin-rich layers shall cure with the addition of an initiator and if necessary, promoters or accelerators used in accordance with the manufacturer’s or supplier’s recommendations.
The resin-rich layer shall be free of any pigment or filler.
Thixotropic agents of up to 3% w/w are permitted.
The resin-rich layer shall be a minimum of 0.4mm thick.
(b) External flowcoat
External flowcoats shall cure with the addition of an initiator and, if necessary, promoters or accelerators or waxes used in accordance with the manufacturer’s or supplier’s recommendations.
The flowcoat for the tank and cover may contain up to 10% w/w pigment paste.
The cured flowcoat shall be from cracks, pinholes and surface defects and shall not be less than 0.4 mm thick.
All Pumps Response
Polyester or vinyl ester resins used for resin-rich internal layers by All Pumps are required to be suitably chemical resistant for the service required with a minimum heat distortion temperature of 65o C when tested in accordance with ISO 75-3.
Polyester and vinyl ester resins used by All Pumps in the manufacturing of FRP vessel comply with the following requirements, as appropriate:
(a) Internal resin-rich layer:
Internal resin-rich layers cure with the addition of an initiator and if necessary, promoters or accelerators used in accordance with the manufacturer’s or supplier’s recommendations.
The resin-rich layers are free of any pigment or filler in All Pumps manufacture.
Thixotropic agents of no more than 3% w/w are used.
The resin-rich layer on all All Pumps vessels is a minimum of 0.5mm thick.
(b) External flowcoats
External flowcoats applied by All Pumps cure with the addition of an initiator and, if necessary, promoters or accelerators with waxes used in accordance with the manufacturer’s or supplier’s recommendations.
The flowcoat for the tank and cover contains no more than 10% w/w pigment paste.
The cured flowcoat on All pumps tanks are free from cracks, pinholes and surface defects and are not less than 0.5 mm thick.
Comply
5.2.3.3 Resistance to strain corrosion
The strain corrosion resistance of fibre-reinforced plastics shall be determined using the requirement and the procedure described in Clause 5.4.2 or Clause 5.4.3 of ISO 10467:2004, whichever the manufacturer decides.
All Pumps Response
The strain corrosion resistance of fibre-reinforced plastics for the manufacture of All Pumps equipment is determined using the requirement and the procedure described in Clause 5.4.3 of ISO 10467:2004.and design constraints of BS4994.
Comply
WSAA Product Appraisal 1405 Issue 2 22
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FRP Design
Materials WSA 129 Clauses Remarks
6.2 GRP Plastics Tanks
The design of glass fibre-reinforced plastic tanks shall be in accordance with BS 4994.
All Pumps Response
All Pumps vessels are designed in accordance with BS 4994.
Comply
Dimensions and Tolerances
Dimensions and Tolerances
WSA 129 Clauses Remarks
7.1 Dimensions
All dimensions shall be taken at the time of manufacture with the tank in the operating upright position, unfilled. Tank dimensions shall represent the exterior measurements.
The dimensions (wall thickness, diameters, tapers, lengths and lengths of engagement) of tank components, including spigots and sockets for pipe connections, shall not be less than those specified in the relevant Australian Standard for a fitting or component of the same material and nominal diameter, e.g. AS/NZS 1260 for PVC-U.
All Pumps Response
At All Pumps all dimensions are taken at the time of manufacture with the tank in the operating upright position, unfilled. Tank dimensions represent the exterior measurements, unless otherwise requested by the customer.
The dimensions (wall thickness, diameters, tapers, lengths and lengths of engagement) of tank components, including spigots and sockets for pipe connections, are not less than those specified in the relevant Australian Standard for a fitting or component of the same material and nominal diameter.
Comply
7.2 Tolerances
7.2.1 Outside dimensions
The tolerance for outside dimensions, including out of roundness, shall be ±3% of the specified outside dimensions. The tolerances of dimensions (wall thickness, diameters, tapers, lengths and lengths of engagement) of tank components, including spigots and sockets for pipe connections, shall not be less than those specified in the relevant Australian Standard for a fitting or component of the same material and nominal diameter, e.g. AS/NZS 1260 for PVC-U.
All Pumps Response
All tolerances for outside dimensions at All Pumps, including out of roundness, are no more than ±3% of the specified outside dimensions. The tolerances of dimensions (wall thickness, diameters, tapers, lengths and lengths of engagement) of tank components, including spigots and sockets for pipe connections, are not be less than those specified in the relevant Australian Standard for a fitting or component of the same material and nominal diameter.
Comply
7.2.2 Tank wall and roof thickness
Wall and roof thickness shall be the design thickness −10%, +unlimited. The total amount of surface area with a thickness below the design thickness shall not exceed 10% of the total surface area, and an individual area shall not exceed 0.10 m2. Where wall and roof thicknesses are measured using ultrasonic equipment, this equipment shall be capable of measuring to an accuracy of 0.1 mm.
All Pumps Response
At All Pumps, the wall and roof thickness are built to the design thickness −5%, +unlimited. The total amount of surface area with a thickness below the design thickness does not exceed 5% of the total surface area, and an individual area does not exceed 0.10 m2. All thicknesses are measured using ultrasonic equipment, this equipment is capable of measuring to an accuracy of 0.1 mm.
Comply
WSAA Product Appraisal 1405 Issue 2 23
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Fittings WSA 129 Clauses Remarks
8 FITTINGS
8.1 General The suitability of fabricated fittings, gaskets and other fitting accessories intended for use in tanks shall be based on product data, or advice obtained from the fitting supplier. Fittings shall be compatible with the tank and catchment system materials.
All Pumps Response
At All pumps the suitability of fabricated fittings, gaskets and other fitting accessories intended for use in tanks is based on product data, or advice obtained from the fitting supplier as well as experience gained over the 40 years of manufacturing. Fittings are compatible with the tank and catchment system materials.
Comply
8.2 Fittings and Flanges
Inlet and outlet fittings may be installed either by the manufacturer prior to delivery of the tank or by the constructor at the time of installation of the tank. Flanges and fittings integral to the tank shall make a leak proof seal with the tank. Threads shall not be tapped directly into the tank wall unless the thread depth is greater than or equal to the relevant fitting spigot thread length. Threaded sockets formed in the tank wall during the moulding process shall be acceptable. Where required, connecting flanges should comply with AS 4087 and connecting threads should comply with AS 1722.1 or AS 1722.2.
NOTE: Threads on connecting fittings are often made undersize to ensure they fit a wide range of products with nominally similar threads. A check should be made of the fastening and sealing capability of the tank connecting thread with the fitting intended to connect to it.
All Pumps Response
Inlet and outlet fittings are installed either by All Pumps prior to delivery of the tank or by the contractor at the time of installation of the tank. All Flanges and fittings integral to the tank made by All Pumps are made with leak proof seal with the tank to BS4994. Threads are not tapped directly into the tank wall unless the thread depth is greater than or equal to the relevant fitting spigot thread length. Threaded sockets are formed in the tank wall during the moulding process. Where required, connecting flanges comply with AS 4087 and connecting threads comply with AS 1722.1 or AS 1722.2.
Comply
FRP Manufacture
Manufacture WSA 129 Clauses Remarks
9.1.1 Surface finish:
At the time of manufacture, the finished tank surface, when viewed without magnification, shall be smooth, clean and free from grooving, blistering, visible impurities or pores and any other surface irregularity likely to prevent their conformity with this standard or impair serviceability.
An internal surface with both high gloss and discolouration shall not be acceptable.
NOTE: Due to differences in resins and in moulding conditions, the interior surface characteristics may vary.
For glass fibre-reinforced plastics acceptance of surface defects shall be in accordance with Appendix ZC of AS 3571.1:2009.
All Pumps Response
At the time of manufacture, the finished tank surface of all All pumps equipment, when viewed without magnification, is smooth, clean and free from grooving, blistering, visible impurities or pores and any other surface irregularity likely to prevent their conformity with the WSA 129 standard or impair serviceability.
With All Pumps glass fibre-reinforced plastics equipment acceptance of surface defects is in accordance with Appendix ZC of AS 3571.1:2009.
Comply
9.1.2 Colour Tanks if manufactured in layers shall have their surfaces coloured throughout. The internal surfaces of tanks shall be a light colour to permit condition assessment of the tank by CCTV inspection.
All Pumps Response
This does not apply to FRP manufacture. The colour is applied after the tank or vessel is complete leaving visual inspection unimpeded.
Comply
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Figure 1: FRP Station operating in action for the past couple of years (i.e. Clean
walls without any stain)
Manufacture WSA 129 Clauses Remarks
9.1.3 Assemblies Components of tank assemblies can be a combination of two or more of the specified materials, which may also be used for different components of the same fitting.
All Pumps Response
Where different types of materials are used All Pumps uses its expertise and the suppliers knowledge to use the correct process to install or bond the unit to the tank or vessel.
Comply
9.1.4 Inlet and outlet holes
Tank fittings inlet and outlet holes shall be cut or formed in the tank wall prior to the tank leaving the manufacturer’s premises. Tank fittings inlet and outlet holes ends shall be cleanly cut and square with the axis of the ends and within any cutting zone provided by the design.
All Pumps Response
Holes are cut and sealed as per WSA129 when needed. The hole is compensated for loss of strength where engineering design requires it.
Comply
9.2 GLASS FIBRE REINFORCED PLASTICS TANKS
9.2.1 General The method for the manufacture of components for glass fibre-reinforced plastics tanks shall be by:
(a) The even application of resin and glass to the mould;
(b) Rolling the lay-up to achieve:
(i) Complete wetting of the fibres;
(ii) Removal of air bubbles and voids throughout the thickness of the laminate; and
(c) Rounding of all internal corners with a radius of not less than 6 mm;
The mass of glass rovings, if filament winding is used, shall be determined continuously as the material is applied.
All Pumps Response
All Pumps manufactures to this Standard.
Comply
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(a) The process is machine operated giving you even application of resin and glass. (b) Rolling the lay-up is done thoroughly to achieve:
(i) Complete wetting of the fibres; (ii) Removal of air bubbles and voids throughout the thickness of the laminate.
(c) Rounding of all internal corners is done with all moulds having radius of more than 6mm.
At All Pumps the mass of glass roving in the filament winding process is weighed continuously to record the material as it is applied.
9.2.2 Laminate and thickness
The composition and thickness of the laminate shall be as follows:
(a) Tank
The laminate shall contain not less than 30% glass. No pigments shall be included in the laminate. The thickness of the laminate shall be not less than 4 mm. The thickness shall be increased to be not less than 6 mm for a distance of not less than 40 mm from all edges of openings and the edges of upstands for access and inspection covers. Changes in thickness shall be by smooth transitions. The external surface of the tanks shall be coated with either a clear layer of initiated (catalysed) resin or an external flowcoat as defined in Clause 5.2.3.1(b), of not less than 0.4 mm thick.
(b) Access opening cover and top of vertical tanks.
Access, inspection covers and tops of tanks shall contain not less than 30% chopped glass strands. The thickness of the laminate shall be not less than 4 mm. This shall be increased to 6 mm within 40 mm of any edge.
All Pumps Response
The composition and thickness of the laminate on All Pumps tanks is as follows:
(a) Tank
The laminate contains not less than 30% glass. No pigments are included in the laminate. The thickness of the laminate is never less than 5 mm. The thickness is increased to be not less than 8 mm for a distance of not less than 40 mm from all edges of openings and the edges of upstands for access and inspection covers. Changes in thickness are by smooth transitions. The external surface of the tanks are coated with either a clear layer of initiated (catalysed)waxed resin or an external flowcoat as defined in Clause 5.2.3.1(b), of not less than 0.5 mm thick.
(b) Access opening cover and top of vertical tanks
All Pumps access, inspection covers and tops of tanks contain not less than 30% chopped glass strands. The thickness of the laminate is never less than 5 mm. This is increased to 8 mm within 40 mm of any edge.
Comply
6.2.2 Type and Batch Release Tests
All Pumps FRP vessel complies with most of the type tests as shown in Table 3 and Batch Release Tests as shown in Table 4, in compliance with WSA 129 clauses 10.1 and 10.2 respectively.
TABLE 3: TYPE TESTS
Type Tests WSA 129 Clauses Remarks
10.1.1 General
All tanks shall comply with the type test requirements of Clauses 10.1.2 to 10.1.5 inclusive. These tests may be combined by applying the lateral and top loads to a tank before conducting the water tightness test. In addition, glass fibre-reinforced plastics tanks shall comply with Clause 10.1.6.
All Pumps Response
All Pumps tanks have been designed and tested to meet this requirement.
Comply
10.1.2 Water tightness
When an assembled tank including access openings and covers, inlet fittings and outlet fittings is tested in accordance with the hydrostatic pressure test of AS/NZS 1462.10, at an internal pressure of 85 +5, −0 kPa for 60 +5, −0 min., the assembled tank shall not leak.
All Pumps Response
All Pumps tanks are tested to this Standard before dispatch and are water tight on test. This is recorded on our Final Inspection and test certificate.
Comply
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10.1.3 Liquid infiltration test
When an assembled tank including access openings and covers, inlet fittings and outlet fittings is tested in accordance with AS/NZS 1462.8, is subjected to an internal vacuum or external hydrostatic pressure, resulting in a pressure differential of 80 +5, −0 kPa, for 60 +5, −0 min, the assembled tank shall not leak.
All Pumps Response
All Pumps tanks are designed and tested to meet this requirement.
Comply
10.1.4 Resistance to lateral loads
When tested in accordance with EN 1277 Condition A for 100 h at 23±2°C with an internal negative pressure of 300 +5, −0 kPa, the assembled tank shall not suffer any damage to its structure that could be deemed to impair its function. Following the application of lateral loads, each tank shall pass the water tightness test in accordance with Clause 10.1.2.
All Pumps Response
All Pumps tanks are designed and tested to meet this requirement.
Comply
10.1.5 Resistance to top load
Following the application of a top load in accordance with Appendix G of AS/NZS 1546.1:2008, each tank shall pass the water tightness test in accordance with Clause 10.1.2.
All Pumps Response
All Pumps tanks are designed and tested to meet this requirement.
Comply
10.1.6 Glass fibre-reinforced plastics tanks
10.1.6.1 Test specimens
All test specimens shall be prepared in accordance with ISO 1268-1.
All Pumps Response
All pumps conforms to this requirement. See test results from independent laboratory submitted with WSAA appraisal submission.
Comply
10.1.6.2 Flexural strength and modulus of elasticity
When tested in accordance with ISO 178, the flexural strength and modulus of elasticity of each test specimen shall be not less than 110 MPa and 4830 MPa, respectively.
All Pumps Response
All Pumps conforms to this requirement. See test results from independent laboratory submitted with WSAA appraisal submission.
Comply
10.1.6.3 Impact resistance
When tested in accordance with ISO 179-2, the test specimen shall have no surface cracks visible to normal or corrected normal vision.
All Pumps Response
All Pumps conforms to this requirement. See test results from independent laboratory submitted with WSAA appraisal submission.
Comply
10.1.6.4 Hardness When tested in accordance with Appendix J of AS/NZS 1546.1:2008, the Barcol hardness number of each test specimen and any part of each test rainwater tank shall be not less than 35.
All Pumps Response
All Pumps Barcol hardness tests all equipment to ensure this requirement is reached.
Comply
10.1.6.5 Water absorption
When tested in accordance with ISO 62, the amount of water absorption of each test specimen shall be not greater than 0.75%.
All Pumps Response
All Pumps conforms to this requirement. Only resins are used that will meet this requirement. Testing has proved that this is so.
Comply
10.1.6.6 Glass fibre content
When tested in accordance with ISO 1172, the glass content of each test specimen shall be not less than 30% w/w. The test specimens shall be through-thickness to exclude the resin-rich internal layers being measured on their own.
All Pumps Response
The Test results submitted with the WSAA appraisal shows that All Pumps performs beyond this requirement.
Comply
10.1.6.7 Tensile strength
When tested in accordance with ISO 527, the tensile strength shall not be less than 63 MPa.
All Pumps Response
As submitted all All Pumps laminate is beyond this requirement.
Comply
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Type Tests WSA 129 Clauses Remarks
10.1.6.8 Tensile Elongation
When tested in accordance with ISO 527, the tensile elongation shall not be less than 1.5% minimum.
All Pumps Response
All Pumps complies with this as all tested laminates are well below this requirement.
Comply
TABLE 4: BATCH RELEASE TESTS
Batch Release Tests
WSA 129 Clauses Remarks
10.2.1 General
Each batch of tanks shall comply with the test requirements of Clauses 10.2.2 to 10.2.4 as appropriate before release.
10.2.2 Vacuum test – all tank materials
When tested in accordance with Appendix B, a sample from each production batch of tanks, and for cast in-situ concrete tanks each tank, shall not leak, collapse, buckle or delaminate.
All Pumps Response
No All Pumps tank has under test or in situ been known to collapse buckle or delaminate. If a leak occurs it is repaired according to BS4994.
Comply
10.2.3 Glass fibre-reinforced plastics tanks
The following tests shall be conducted on each batch of tanks:
a) Thickness of laminate (Refer to #Clause 7.2.2 below).
b) Thickness of internal resin-rich layer at time of application (Refer to Clause 5.2.3).
c) Hardness (Refer to Clause 10.1.6.4).
d) Reinforcing fibre content (Refer to Clause 10.1.6.6).
All Pumps Response
At the All Pumps manufacturing plant all these tests are carried out and recorded on our QA job sheet record, which is kept with the paperwork of the job for traceability.
Comply
TABLE 5: MARKING
Marking WSA 129 Clauses Remarks
11 Marking Tanks shall be legibly and permanently marked on the tank wall or roof as follows:
(a) Manufacturer’s name or registered trademark.
(b) Date (month and year) of manufacture.
(c) Material identification e.g. PE.
(d) Useable volume in litres.
(e) Safe installation depth in metres*.
(f) Number of this Standard.
NOTE: * Based on any limitations, if applicable, nominated in the installation instructions
All Pumps Response
All Pumps tanks have the markings as required by this standard securely attached.
Comply
6.2.3 FRP Packaged Pump Station – Buoyancy Consideration
All Pumps has submitted guideline/parameters for ballast calculations to prevent hydrostatic
uplift of FRP vessel. These guidelines are site specific and are provided with each pump
station.
Refer to Appendix K for five worst case scenarios ballast calculations providing guidance to
the Installers on:
a) Station Parameters;
b) Concrete Ballasts;
c) Backfill Ballasts; and
d) Roof Slab.
The worst-case scenarios are as follows:
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a) FRP pump station with concrete ballast 4 m dia x 10 m high
b) FRP pump station with concrete ballast 4 m dia x 10 m high with 2.4 m x 2.4 m x 1.8 m
high valve pit
c) FRP horizontal emergency storage tank (no concrete ballast) 4m dia x 20 m length
d) FRP horizontal emergency storage tank (with ballast slab at top of tank) 4m dia x 20 m
length
e) FRP horizontal emergency storage tank (with some concrete ballast) 4m dia x 20 m
length
All Pumps calculations have been checked and approved by Consulting Engineering
companies such as Dennis Southam & Associates Pty Ltd, Oceania Composite Engineering
Pty Ltd and Kneebone, Bretta & Hall Pty Ltd.
All underground structures are potentially subject to hydrostatic loading from ground water
should it be present. Where this loading is greater than the self-weight of the structure it is
possible the structure could move due to buoyancy forces. There are numerous ways the
potential movement due to buoyancy can be eliminated. These include:
a) Placement of backfill material either concrete, soil or a combination of both over or
around the structure to act as ballast against the uplift forces;
b) Anchoring the structure to concrete deadman, hold-down slabs or surrounding strata
should suitable material, such as high strength rock, be present;
c) Increasing the dead weight of the structure; and/or
d) Decrease the hydrostatic loading by either removing or lowering the level of ground water
around the structure.
For its Packaged Pump Stations, All Pumps recommends the ballasting method to resist
buoyancy forces. As part of the installation instructions provided with each station, a
recommendation is included of the ballast required for its safe installation. In determining
the ballast required for a FRP Packaged Pump Station, a worst-case scenario is considered
based on the following conditions:
a) The surrounding soil is completely saturated to the surface level resulting in hydrostatic
loading of the station for its full depth;
b) In determining the self-weight of the station, it is assumed any removable equipment
including the pumps are not in place;
c) The station is completely empty with no water or sewage present to provide downward
loading;
d) Backfill materials are cohesionless with no soil friction present; and
e) Weight of ballast material is adjusted to take into account the hydrostatic loading on it.
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The ballast calculations are based on parameters as detailed in Table 6:
TABLE 6: PARAMETERS FOR BALLAST CALCULATIONS
Parameter Value
Density of water 9.81 kN/m3
Concrete density
Submerged concrete density
23.5 kN/m3
13.69 kN/m3
Backfill density
Submerged backfill density
19.6 kN/m3
9.79 kN/m3
Factor of Safety 110%
6.2.3.1 Ballast Layout
Bottom of All Pumps pumping station has a hold down flange which has to be designed in
line with specific site conditions. The net weight of the ballast material is to be greater than
the buoyancy forces on the structure less its dead weight plus the required Factor of Safety.
The FRP packaged pump station is manufactured with external ribs, onto which a concrete
ballast slab is poured. The shape of the slab is either round or square, the selection of which
is dependent on the size of the station and the surrounding conditions. The minimum depth
of this slab is sufficient for the transfer of ballast loading to the ribs without the need for
reinforcing steel. The overall depth of the concrete slab is dependent on the ballast loading
required.
Above the ballast slab, compact fill is placed. The weight of material directly above the
concrete slab is only considered for ballast calculation purposes.
Concrete roof slabs are recommended for all stations and the weight of these are included
in the ballast calculations.
For shallow FRP structures such as standard alone valve pits, the weight of the roof slab
generally provides sufficient ballast loading. Where additional ballast is required, thickened
edge beams to the roof slab are recommended.
6.2.4 Attachments
All Pumps pump stations can be shop fitted with FRP, stainless steel or galvanised ladders.
The ladders can be fitted with extension handles. The stations can be fitted also with
handrails, platforms and fall safety nets to suit Water Agency Specification.
NOTE: The above items are not included in this appraisal.
6.2.5 Review of documentation
All Pumps provides customers with documents for submission of their pump station or
emergency storage tank requirements, plus diagrams for customers/designers to nominate
pipe positions for factory cored apertures. Also provided to customers is a list of items
required to be completed prior to installation and/or commissioning of the pump station or
emergency storage tank.
For further information refer to Section 8.
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7 WSAA NETWORK REQUESTS
Question 1: Several concerns have been raised on resistance to flotation when FRP vessels
are installed in water charged ground. How do you address the potential buoyancy forces in
the design calculation? Do you assume the groundwater level to exist at the surface of the
pumping station as a worst-case scenario? To provide additional resistance to buoyant
forces, do you provide a concrete ring beam cast in situ in the base configuration? Do you
undertake any additional precautions against flotation such as increasing weight of precast
concrete cover slab by increasing its thickness?
Answer 1: When we design ballast for any pump station we allow for the worst-case
scenario, i.e. total immersion - ground water level at the top of the station.
The Engineering calculations take into account the uplift forces including wall buckling load,
floor deflection etc. in the shell design.
To provide resistance to buoyant forces All Pumps designs a ring beam cast in situ as per
our installation instructions M200 as shown in Appendix A6 (Addendum No. 1 to the main
report).
We supply calculations that can be verified by on site civil engineer. Refer to Appendix K for
typical calculations sheet.
Question 2: The All Pumps FRP packaged pumping station and emergency storage tank is
a turn-key product. The civil contractor's main responsibilities are; installation of FRP wet
wells and valve pits, excavation, trenching and backfill works, water supply and site
restoration. The turn-key scope of works also includes the mechanical and electrical fit-out
and overall supervision of the project from geotechnical testing of site, material delivery,
attending site during installation, testing, commissioning and hand over.
Which parts of the above package does All Pumps take responsibility for? How long the
Packaged FRP Pump Stations / Emergency Storage Tanks are warranted from the date of
installation and who provides such warranty?
Answer 2: All Pumps supply a fully designed product to comply with the customer’s
specifications as well as meeting full Composite Design Engineering.
We can supply a turnkey project including all fit out, electrical design, pump supply and
excavation and installation.
We supply many contractors who wish to do the install and part of the supply. We are flexible
in this regard and offer full supervision as and when the unit is installed with new installers.
Commissioning, handover etc. is all in the turnkey project supply unless otherwise agreed
with customer and contractor.
As far as warranty is concerned All Pumps takes full responsibility and provides warranty on
all sections of any contract taken up. Refer to Appendix N for the All Pumps warranty.
Question 3: How many FRP Packaged Pumping Stations / Emergency Storage Tanks have
All Pumps supplied? Please provide a list in a tabular form indicating detai ls of those pump
stations (dia & depth) and customers.
Answer 3: All Pumps have supplied in excess of 10,000 pump stations in Australia since
1972. A list of a small portion of this vast volume of units has been submitted for WSAA’s
record.
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Question 4: Is it possible for liquid to leak out of the pumping station or for groundwater to
ingress?
Answer 4: It is not possible for liquid to transfer in either direction as all fittings are laminated
into the shell making the unit one homogenous assembly. Many installations in high water
table areas have been installed for many years with no leakage in either direction.
Below photos show the wells beside sea level that are subjected to changing external forces
at from high to low tide.
Question 5: Does All Pumps offer a pump station design and drafting services of project
specific drawings and hydraulic calculations? Or such services are done by another party?
Answer 5: All Pumps has employees with the skill sets to provide complete drawings,
Hydraulic, civil and Mechanical calculations, and is able to offer these services to our clients.
Often a customer will request third party verification of design and we have the needed
expertise in place to offer this further service.
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Question 6: What are the advantages of FRP Sewage Pump Stations?
Answer 6: All Pumps FRP sewage pumping stations and emergency storage tanks are
manufactured from high quality resins and have proven themselves with over 40 years of
service. FRP is the only answer for the elimination of structural degradation resulting from
corrosive substances or contaminated fluids in the pump well.
TABLE 7: ADVANTAGES OF FRP SEWAGE PUMP STATIONS
Attributes FRP - No corrosion Concrete - Corrosion
Package Delivered as one complete, homogeneous unit- no assembly on site fully fitted out, thus no need to enter the tank once installed.
Comes in sections to be joined on site or poured on site then fitting out will need access to a confined space. This will not be required when installing All pumps Pump Station.
Figure 10: Pump Station showing Sockets laminated into FRP Wells
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Figure 11: Unit above shows flanges and electrical sockets
Question 11: Your product sizing for FRP pump station shows dia from 1 m to 4 m and
depths from 1 m to 10 m; please clarify the maximum dia 4 m is for internal or external dia
of FRP vessel, and if it is external do you have any restriction in transport from State
authorities like in QLD? In one of the WSAA assessments for FRP pump station we limited
the internal dia to 3.75 m because of transport restriction? From our today’s telephone
conversation we understand All pumps can fabricate FRP vessels deeper than 10m,
although the maximum depth mentioned in your brochure is 10 m? Is it true, if so please
elaborate how this can be done, if possible giving reference to any previous projects where
deeper than 10m depth station was installed.
Answer 11: All our dimensions for diameters are inside dimensions. Up till now we have had
no problems shifting diameters up to 4 metres ID, this is an overall maximum OD of 4.3
metres. This may involve the use of pilot cars which to date has caused us no problems. We
have the ability to build pump wells to depths which are greater than 10 metres. The structure
is designed by our composite engineers to handle the loads and verified by a third party.
All Pumps has built units to 9.8 m depth x 3.5 m dia which is shown in our Denman Case
Study. Refer to Appendix Q.
Question 12: To comment on the application of your below range of FRP products:
(a) All Pumps FRP Pump Stations are designed to meet the pumping needs of:
Sewage
Ground Water
Storm Water Retention
Collection and Pumping for Large Water Features
(b) All Pumps Emergency Storage Tanks are specifically designed to meet the needs of:
Emergency storage for wastewater during power outages
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Backup storage for wastewater during peak or seasonal demands
Potable water supply storage
Stormwater retention storage
Buffer storage for Stormwater Harvesting
Sewerage eduction holding vessel
Answer 12: All Pumps FRP Pump Stations are designed to meet the needs of pumping of:
a) Sewage – All Pumps pump stations have been designed to efficiently pump sewage from gravity system networks in municipal, mining and private subdivision situations. The units are also used to pump industrial waste to the sewer networks.
b) Ground Water – All Pumps pump stations are also used to move groundwater from areas where the salt water table has risen and the salt laden water is pumped away to evaporation ponds or rivers at controlled rates to reduce the rising salt levels. The FRP construction provides the resistance to corrosion that is needed in these circumstances.
c) Storm Water Retention – With the increase of urban development and the reduction of absorption areas All Pumps pump stations provide the answer to retain Stormwater and pump it away at controlled rates. Drainage to remove troublesome underground waters is solved by installation of All Pumps Stormwater pump wells and retention tanks.
d) Collection and Pumping for Large Water Features – On many occasions All Pumps has supplied pump wells to collect water from water features and pump via All Pumps filtration and sterilization back to the display or feature at the required pressure.
All Pumpos Emergency Storage Tanks are specifically designed to meet the needs of:
a) Emergency storage for wastewater during power outages – All Pumps FRP emergency overflow tanks are designed to handle specific volumes that drain back to the Pump well to handle the needs of any particular venue or area when there is a power outage . This reduces the chances of sewer overflows which are detrimental to the health of local inhabitants and the environment, such as creeks and rivers.
b) Backup storage for wastewater during peak or seasonal demands - Many areas which have major fluctuations in flows due to incoming tourists or due to high peak flows over short times such as mining camps use All Pumps emergency storage tanks to overcome these problems. Each situation is taken on its own merit and designed accordingly to give the capacity that is needed to avoid major problems.
c) Potable water supply storage – All Pumps FRP underground horizontal tanks are used as potable water storage tanks in remote areas as well as break tanks and storage where the supply cannot handle peak demands. These units are fitted to comply with local water authority requirements. Potable water tanks are also used for firefighting water storage. This has the added advantage of being underground and no chance of fire damage, thus a continuity of water supply. All potable water tanks are built from resins made from ingredients approved by the FDA for potable water use.
d) Stormwater retention storage – All Pumps FRP Horizontal Storage tanks are used in many situations in Stormwater control, treatment and harvesting. In retention use the tank is fitted with either a control orifice for discharge at set rates according to the site design or pumps that pump out at a set rate. Many of the pumped systems use half the volume of the tank for retention and the other half for water harvesting making a highly economic installation. Stormwater harvesting is complimented by All Pumps filtration and sterilization systems.
e) Buffer storage for Stormwater Harvesting – All Pumps supply FRP underground buffer tanks for the water harvesting industry. To reduce flooding at times of high rainfall our
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Buffer tanks take the excess water which is used first to be ready again for the next high level incident.
f) Sewerage eduction holding vessel – All Pumps Sewage Holding Vessels are supplied with aeration equipment to stop the waste turning anaerobic while it waits to be pumped to the main at low flows or into a sewage treatment plant. These vessels are also used for underground sewage treatment in anaerobic, aerobic, settlement and membrane processes.
Question 13: The following questions have been raised by David Moore at City West Water
in Melbourne in his review of the All Pumps FRP Pump Station and Emergency Storage
Tank:
Q 13.1: I like the idea of FRP SPS’s and storage tanks and would like to see this get up. In
summary, they include:
Suggest the Water agency will usually require the design calculations for most Sewage
Pumping Stations (SPS).
A 13.1: Each pump station is pre-designed with engineering calculations that can be
provided with each pumping station, once the design drawing is complete with thicknesses
and design requirements it is submitted to a third-party engineer for verification. So, this
check not on the engineering calculations but also the fabrication drawings the factory works
off. This all can be provided to the Authority.
Q 13.2: I have used FRP storage tanks at South East Water Ltd (SEWL) and they worked
well.
A 13.2: This is the response from all authorities with whom we have worked with.
Q 13.3: 150-year life expectancy is a positive;
A 13.3: FRP in an underground situation.
Q 13.4: CWW has used another brand of FRP SPS's and it was very successful. The
installation was very straightforward and I believe easier than concrete precast wells. There
is no reason the All pumps product would not be as successful;
A 13.4: All Pumps product is manufactured as a one-piece design with external ribs,
increasing stiffness and anti-floatation.
Q 13.5: I may have missed it but the locking mechanism on the covers is to be recessed to
avoid being a trip hazard.
A 13.5: The padlock mechanism is recessed and the lid is 100% flat with nothing extruding
the lid surface. (as shown in Figure 12 below)
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Figure 12: Locking mechanism on the covers is recessed to avoid potential trip hazard.
Q 13.6: All Pumps takes full responsibility and provides warranty on all sections of the
contract – does this include installation by a contractor?
A 13.6: All contractors are issued with a site-specific installation drawing, if all aspects are
adhered to; All Pumps carries all warranties around the tank installation.
Q 13.7: Suggest All Pumps consider providing on-site support for contractors for all projects
initially. If just one SPS goes off the rails they will have a hard job selling more.
A 13.7: All Pumps provides on-site support for:
Site Installation support
Site Commissioning
These services are offered with each project.
Q 13.8: All Pumps has a selection of valves available. Are they approved?
A 13.8: All Pumps preferred supplier is AVK; all valves used in each project are according
to the specification provided by the client or Consultant.
Q 13.9: Galvanised ladders generally not acceptable in SPS environments;
A 13.9: All Pumps only supply what is specified by the Client or Consultant, some water
Authorities request Galvanised when the stations are used for Stormwater applications.
Q 13.10: Ladders may not be required by all Water Agencies but they are required by some.
Some of these arrangements make no allowance or have no room for ladders.
A 13.10: All Pumps only supply what is specified by the Client or Consultant.
Q 13.11: Some of the valve pits look extremely tight for a safe work place – something we
can discuss.
A 13.11: Each pumping station is designed around the information given to All Pumps by the
client or consultant, many applications have very large valve pits and All Pumps can
manufacture the Valve pit size to suit the Authorities requirements.
Q 13.12: Some access for the storage tanks looks rather narrow and high for safe man
access. Can we get more details please?
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A 13.12: Each storage tank is designed around the information given to All Pumps by the
client or consultant, many applications have very large manholes and All Pumps can
manufacture the manhole size to suit the Authorities requirements
Question 14: Adam Glasson at Goulburn Valley Water, VIC raised the following questions
in his review:
Q 14: The issues that we found generally related to the company (All Pumps) and things not
being checked on departure such as, lids supplied did not fit the well, cut outs appeared to
be of a poor quality and in wrong position, poor quality of the finish of the product, late
delivery (delivery driver said they were still working on it when he was to pick it up), parts
going missing in transit and required remanufacturing, the vent stack did not fit the supplied
base etc. these all required extra time and money to fix onsite.
A 14: The above issues are correct. The FRP tank was supplied in record time as we didn’t
receive the signed drawing until a week prior to the delivery. The outsourced products such
as the Vent base and covers were supplied directly to the site and placed All Pumps in a
position where trial fitting wasn’t an option. This was a disaster but All Pumps believe the
net result was good.
8 INSTALLATION, REPAIR, MAINTENANCE AND TRAINING
All Pumps provides customers with proforma documents for submission of their pumping
station requirements plus diagrams for customers/designers to nominate inlet/outlet
pipelines from FRP barrel. There are also documents for the customer to complete advising
All Pumps of the required delivery dates and programmed commissioning dates. All Pumps
also provides a checklist of items required to be completed prior to commissioning of the
pumping station.
The pumping station is delivered as a complete unit ready to install into the excavation with
instructions for installation for the civil contractor. All Pumps requires that installation should
be undertaken by experienced civil contractors. If required, All Pumps can also supply onsite
supervision and technical assistance through to complete pumping station installation and
commissioning contracts in most regional areas via their network of affiliated companies and
authorised distributors.
At the completion of commissioning All Pumps provide the Asset Owners with Operation and
Maintenance Manuals in accordance with the specified requirements.
8.1 REPAIR PROCEDURE
Fibreglass Reinforced Plastics are now one of the most popular materials for building tanks and vessels of almost every type. One of the main advantages of these materials is their high strength coupled with light weight, but it is, nevertheless, possible for an FRP tank or vessel to be damaged accidentally.
Even when damage does occur, FRP still has advantages over other building materials. Firstly, such damage will be localised around the point of impact, and secondly, in the majority of cases, it is possible for the average tradesperson to carry out a speedy, safe and effective repair. The raw materials for an average repair are relatively inexpensive and it is not necessary to own a specialised kit of tools. And All Pumps are always willing to sell the necessary small quantities of materials to persons who need to carry out repair work.
By repairing damage to his FRP tank the owner can also make considerable cash savings. Typically, a repair by the owner will cost approximately 20% of a professional job by All Pumps.
This manual will give the owner guidance on carrying out repair and maintenance work on
his FRP tank. The basic skills required are simple and easily acquired, and tank builders or
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raw material suppliers are always willing to give advice on the best way to overcome any
problems which may arise.
Refer to Appendix A8 – All Pumps Repair Manual for FRP tanks and vessels (Addendum
No. 1 to this Main Report).
8.2 MAINTENANCE PROCEDURE
All Pumps FRP stations require very little maintenance. All Pumps services a number of local
stations on a six-monthly basis. The FRP components never need any work and are only
hosed down with a garden hose to wash down any dust or dirt that has accumulated around
the access openings. It is the pumps and electrical equipment that requires the maintenance.
8.3 TRAINING REQUIREMENTS
All Pumps offers training for the civil installer, if required. If All Pumps have any doubt about
a particular installer’s ability or his record of poor quality work, then All Pumps
representative(s) will visit the site when the station is being installed to make sure the work
is carried out as per All pumps detailed Installation Instruction sheets.
Registered Training Organisations (RTOs): Currently no RTOs are available to provide a
training program for the installation of FRP pump stations. All Pumps has a training
procedure that they employ when required to check and train a new installer.
8.4 BACKFILL REQUIREMENT
All Pumps recommends the consulting engineer conducts a site investigation to establish
indicative subsurface conditions prior to the commencement of construction.
All Pumps has submitted backfill requirements and construction notes for correct installation
procedures as detailed in Appendix A6 – All Pumps FRP Pump Station Installation Manual
M200 and Appendix A7 – All Pumps FRP Emergency Storage Tank Installation Manual M600
which are included to the Addendum No. 1 to this appraisal report.
The Construction Notes are based on normal site conditions which are free of groundwater
and apply to installations in cohesive and non-cohesive soils. Sites which have ground water
will need dewatering for construction purposes.
In addition to All Pumps recommendation, the installation works shall comply with
specification and standards of individual water company or local council. Refer to below link
to access a sample Backfill Specification 04.03.2 published in 2013 by MRWA (Melbourne
Refer to Addendum No. 1 to this main report to access the below appendices:
Appendix A1 Kemsey Jail Case Study
All Pumps FRP Pump Station Photos
Appendix A2 Townsville Port Authority FRP Sewage Pump Station Case Study
All Pumps FRP Vessel construction photos and design calculations by Dennis Southam & Associates Pty Ltd
Appendix A3 Tolga Tablelands Regional Council FRP Sewage Pump Station Case Study
Appendix A4 Nambucca Shire Council NSW Case Study
All Pumps Emergency Storage Tank Photos
Appendix A5 Wannon Water Mahoney’s Road Case Study
All Pumps FRP Emergency Storage Tank Photos
Appendix A6 All Pumps FRP Pump Station Installation Manual M200
Appendix A7 All Pumps Emergency Storage Tank Installation Manual M600
Appendix A8 All Pumps FRP Vessel Repair Manual
Appendix A9 All Pumps FRP Vessel Chemical Resistance Manual
Appendix A10 All Pumps FRP Operation & Maintenance Manual
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APPENDIX B - QUALITY ASSURANCE CERTIFICATES
TABLE B1: ALL PUMPS SALES AND SERVICE – MANAGEMENT SYSTEMS
Applicant’s Business Address: 27 Coombes Drive, Penrith, NSW. 2750
Quality Systems Standard ISO 9001:2008
Certification licence no. APQ170501
Certifying agency Qual-Safe Management Systems
First date of certification 17 June 1996
Current date of certification 1 May 2017
Expiry date of certification 1 May 2018
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All Pumps Sales and Service
100 Silverwater Road, Silverwater NSW 2128
The procurement, warehousing, production, assembly and
repair of pumping equipment and associated products
01/05/2018
APQ170501 01/05/2017
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APPENDIX C – DIAGRAMS FOR A FLANGED AND PVC SPIGOT JOINT TO FRP BARREL
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APPENDIX D – ALL PUMPS STANDARD ALUMINIUM COVER SPECIFICATION.
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APPENDIX E – ENGINEERING DESIGN BY A FULLY CERTIFIED THIRD-
PARTY COMPOSITE ENGINEER
This appendix includes the below two documents:
Design Methodology for FRP Pump Station Laminate Design : Design methodology
applied to the design of pump stations, with a range of pump pit diameters and depths,
for All Pump FRP Engineering. The adopted design methodology is based on
AS2634:1983 and ASME RTP-1 where applicable, with all other design considerations
based on good engineering practice.
Engineer’s design calculation for a 4 m dia x 10 m high FRP pumping station: The
first two pages of a latest 26 pages report dated 10/11/2014 for a worst-case scenario
(i.e. FRP pump station 4 m dia x 10 m high) design calculation by the Engineer ‘Dennis
Southam & Associates Pty Ltd are shown. The remaining 24 pages consist of detailed
calculations are “Commercial-In-Confidence” hence not shown.
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APPENDIX F – INSPECTION AND TEST PLAN (ITP) VERIFICATION
STATEMENT ISSUED BY THE COMPOSITE ENGINEER
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APPENDIX G – INSPECTION AND TEST PLAN (ITP) VERIFICATION STATEMENT ISSUED BY THE COMPOSITE ENGINEER
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APPENDIX G – STANDARD SPECIFICATION FOR ALL PUMPS FRP PUMP
STATION STRUCTURES
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APPENDIX H – FINAL INSPECTION BY A FOURTH PARTY ENGINEER
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APPENDIX I – LAMINATE TESTING REPORTS
This appendix consists of the following four reports:
Tensile Testing Report
Lap Shear Strength Testing Report
Fibre Fraction Test Report
Burn-Off Test Report
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APPENDIX J – LETTER OF APPROVAL ALL PUMPS FRP EMERGENCY
STORAGE TANK
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APPENDIX K – BALLAST CALCULATIONS (WORST CASE SCENARIOS)
Design calculations for below five worst case scenarios are shown in the following pages:
f) FRP pump station with concrete ballast 4 m dia x 10 m high
g) FRP pump station with concrete ballast 4 m dia x 10 m high with 2.4 m x 2.4 m x 1.8 m
high valve pit
h) FRP horizontal emergency storage tank (no concrete ballast) 4m dia x 20 m length
i) FRP horizontal emergency storage tank (with ballast slab at top of tank) 4m dia x 20 m
length
j) FRP horizontal emergency storage tank (with some concrete ballast) 4m dia x 20 m
length
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APPENDIX L - WSAA PRODUCT SPECIFICATION
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APPENDIX M – PACKAGING AND TRANSPORTATION
Due to the high strength-to-weight ratio of a FRP pump station or FRP emergency storage tank, the process of loading, transport and unloading is simple.
There are no weight issues with FRP as with pump stations manufactured out of other materials.
Special equipment such as low loaders and overweight floats are unnecessary. Only standard transport/lifting equipment is required.