Building a Pump Station on the Water April 20 th 2016 DESIGN AND CONSTRUCTION CHALLENGES FOR A RAW W ATER INTAKE A T LAKE CONROE
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Building a Pump Station on the Water
April 20th 2016
DESIGN AND CONSTRUCTION CHALLENGES FOR A
RAW WATER INTAKE AT LAKE CONROE
Agenda
• Introductions
• Project Overview
• Design Challenges Encountered
• Construction Challenges Encountered
• Q&A
2
Surface Water Facilities Program Project Overview
• Supply 24 MGD Surface Water to Montgomery County
• $480 Million Total Cost– $191 Million for SWF
• Treated Surface Water Delivery by January 1, 2016
3
Surface Water Facilities Program Project Overview
• Lake Conroe Surface Water Facilities– Raw Water
Intake and Pump Station
– Surface Water Treatment Plant
– High Service Pump Station
4
Surface Water Facilities Program Project Overview
• Successful SWF Project Team– SJRA
– Three Engineers
– Construction Manager at Risk
– Construction Inspection
– 36 Contractors
– 350 Peak Workforce
5
Raw Water Intake and Pump Station Project Overview
• Located near the dam
• 300 feet long bridge– Access deep water
• Initial Capacity of 47 MGD– Planned expansion of 3 pumps
6
Design Challenges Encountered Under-Slab Items
• Pump Room Challenge– Open floor plan, accessible for O&M equipment
– Exposed platform over lake, vulnerability to weather and vandalism
• Solution– Hardened electrical conduit
7
Design Challenges Encountered Under-Slab Items
8
Design Challenges Encountered Under-Slab Items
9
Design Challenges Encountered Under-Slab Items
10
Design Challenges Encountered Pump/Barrel Design
• Vertical Turbine Pumps Challenges– Variable Intake Elevations
– Wave Forces on Pump Columns
• Solution– Enclosed Barrels with Three Gates
11
Design Challenges Encountered Pump/Barrel Design
12
Design Challenges Encountered Pump/Barrel Design
13
Design Challenges Encountered Pump/Barrel Design
14
Construction Challenges Encountered Pump/Barrel Installation
• Construction Challenge– Installation of Pumps and Barrels
• Solution– CMAR involvement/input during design phase
– Pre-work planning with CMAR
15
Construction Challenges Encountered Pump/Barrel Installation
16
Construction Challenges Encountered Pump/Barrel Installation
17
Construction Challenges Encountered Pump/Barrel Installation
18
Construction Challenges EncounteredDrilled Shafts over Water
• Construction Challenge– Drilled shaft installation over water
• Solution– Work from inland “flexi-float” barges
– Extensive pre- and post-installation testing
19
Construction Challenges EncounteredDrilled Shafts over Water
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20
Construction Challenges EncounteredDrilled Shafts over Water
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21
Construction Challenges EncounteredDrilled Shafts over Water
22
Construction Challenges EncounteredDrilled Shafts over Water
23
Construction Challenges EncounteredInstalling Pipes through Dam
• Construction Challenge– Install raw water line, fire protection line, sample/chemical lines, electrical
duct bank through dam embankment
• Solution– Work with CMAR to schedule work outside of hurricane season
– Extensive planning and contingencies
24
Construction Challenges EncounteredInstalling Pipes through Dam
25
Construction Challenges EncounteredInstalling Pipes through Dam
26
Construction Challenges EncounteredInstalling Pipes through Dam
27
Construction Challenges EncounteredInstalling Pipes through Dam
28
Construction Challenges EncounteredInstalling Pipes through Dam
29
Construction Challenges EncounteredPump Startup
• Construction Challenge– Starting up pumps without treatment plant online
• Solution– Bypass flows to lake
30
Construction Challenges EncounteredPump Startup
31
Q&A
32
Contacts
• Shane Porter, PE– [email protected]
• Sam Meisner, PE– [email protected]
• Jason Ward, PE– [email protected]
33
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