Joint Waste Disposal Force Main and Sludge Transfer Stations
Location: Elgin, Ill.
Client: City of Elgin and Fox River Water Reclamation District
Completion Date: Design: 2007, 2009; Construction: 2009, 2010
Burns & McDonnell provide design and construction phase services for installation of:
- Approximately 25,000 linear feet of 14-inch diameter lime sludge disposal main for the City of Elgin, extending from the Riverside Water Treatment Plant to the McLean Avenue Sludge Lagoons
- Approximately 15,000 linear feet of 8-inch diameter sludge transfer main for the the Fox River Water Reclamation District, extending from the North Plant to a 24-inch interceptor manhole on the south side of U.S. Route 20 at the Elgin Sports Complex
- Approximately 1,000 linear feet of 8-inch diameter ductile iron sludge transfer main for the the Fox River Water Reclamation District and 500 linear feet of 4-inch diameter ductile iron pressure regulation main for the the Fox River Water Reclamation District, all within the North Plant
- Construction phase services
Both force mains were installed through a combination of directional drilling, open cut trench, and jacking and boring. In shared locations, both pipes were installed in either the same bore hole, trench or casing pipe. Where the jacking and boring was performed, guided boring was used to keep the augers on the correct plane.
Improvements to the City of Elgin's sludge transfer pump station were also made. This included piping and valve improvements to allow for use of the new sludge transfer main. Pump testing and commissioning support of the improvements to the transfer station and new sludge transfer main were included.
Burns & McDonnell was also contracted independently by the Fox River Water Reclamation District to design and provide construction services for a new sludge transfer station at the district's North Plant. The purpose of the new transfer station is to allow for pumping of sludge from the North Plant to the District's South Plant. This will eliminate the need for trucking the sludge from the North Plant to the South Plant.
Prior to this project, the Fox River Water Reclamation District had to transfer sludge from the North Plant to the South Plant via 6,500 gallon tanker trucks traveling over City of Elgin streets. This process severely limited the amount of sludge that could be transferred and treated in one day as well as presented a traffic safety hazard due to the lack of signalized intersections along the route.
The new 8-inch diameter sludge transfer main was connected to an existing 8-inch diameter HDPE main that was installed as part of a joint effort with the City of Elgin. In addition to this main, Burns & McDonnell designed process improvements to the sludge handling system at the North Plant to automate the sludge transfer process. These improvements included a new primary sludge lift station with two chopper pumps, re-piping of the basement of the sludge transfer building, installation of motorized actuators on the primary sludge tank valves, air line modifications to improve the aeration system, installation of a pneumatic tank to regulate pressure within the sludge transfer main, new sludge transfer pumps capable of pumping sludge from the North Plant to the South Plant, and a new SCADA system tied to the system at the South Plant.
- Sludge handling system process improvements
- Pneumatic tank
- Actuated valves
- Aeration system improvements
- Preparation of plans and specifications
- Utility conflict resolution
- Bidding assistance
- Shop drawing review
- On-site construction inspection
- Stakeholder coordination with:
- Illinois Department of Transportation
- Union Pacific Railroad
- Metra Railroad
- Army Corps of Engineers
- Wing Park Golf Course
- Highlands Golf Course
- Multiple contractors on separate City of Elgin projects that were impacted by the route and timeline of the installation of the force mains