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Growing Pains or Growing Old Pains – What best describes your old gravity sewer?

What happens when your sewerage network gets too old? Your old clay pipes have cracked or are filled with roots, every time it rains it seems like its a direct line from the clouds to the Treatment Plant. People in the community start asking why you are spending a load of money on treating rainwater instead of just sewerage.

If you are part of a coastal community it could be worse, your old broken  pipes could be letting seawater into the system every time there is a high tide or major storm. Salt water can cause major problems at the Treatment Plant. For communities like Miami Beach who get storm surges flooding their sewers and closing their beach on an increasingly regular basis it can cause major economic and health risks. Santa Pola in the Alicante area of Spain found that the impact of global warming and rising sea levels caused a complete failure of their old sewer system.

The town of Santa Pola with over 10,000 homes replaced their whole gravity sewer system with a Flovac vacuum sewerage system. As vacuum mains are laid in shallow trenches it was possible to skirt around, above and below exiting infrastructure and eventually replace the network. You can read more about that project here.

It could be that the old gravity sewer system with large heavy pipes just wasn’t suited to the ground conditions that are often found near the coast or in swampy area’s and that over time they no longer have the correct grade to remove the sewage or have pipes that continually break allowing ground water into the system as well as blockages. This occurred at Hope Island on Queensland’s famous Gold Coast.  Gold Coast Council have developed a Master Plan and slowly replaced a number of area’s with vacuum sewers. When the original gravity sewer was laid, there was no choice, developers were racing to put up houses and council at that stage had no experience with vacuum sewers and so deep gravity mains were installed. Almost immediately problems were noticed as the ground subsided in different area’s. Sewage backed up in pipes and was unable to flow as the grades first allowed for in the networks were no longer the same.

When looking at upgrading a gravity sewer, pipe relining can be an option, but in many cases this becomes an ongoing expensive option and be too difficult in a large network. Some utilities just look to replace the old pipework, but in most communities this is just not practical. This could mean uprooted gardens, roads out of use for a number of months, noise, dust and a huge cost.

For many communities it is the size of the town that has changed dramatically over the years. In most cases this has meant an increase in the population as people move from the city to the coast. Developers move into the fringes of the town. Planning regulations change allowing for sub dividing of the old large land blocks or height and density changes. This puts pressure on existing sewers that are already not coping due to age and lack of maintenance. This has happened, not only in small coastal towns but in larger developed cities like Abu Dhabi and New Delhi. Vacuum sewers can be used to supplement the towns aging sewer system, loads can be taken off the main system by a series of collection pits and shallow pipework.

Flovac vacuum sewers have shown time and again, their versatility. This means either their ability to handle density changes or climate changes. It might even mean changes in ground conditions as happened in Christchurch New Zealand when they suffered from a terrible earthquake. The old gravity sewers in the city and surrounding suburbs broke and left residents with no service for months. Vacuum sewers have now replaced a large portion of the gravity sewers in Christchurch and although difficult has proved to be a better long term  solution for the residents and operators. Christchurch systems

Vacuum sewers should not be looked at as the only solution in many of these towns. In some cases a combination of grinder pumps, gravity and vacuum is going to be the better result for the community. Whether the problem is growing pains, or growing old pains a vacuum solution might offer the versatility that you need.

The Hidden Costs of Gravity Sewers versus Vacuum Sewers

When looking at what sewage infrastructure to use in a difficult area, most consultants will do a study which compares gravity sewers with vacuum sewer technology. In some smaller communities they may also do a comparison showing a low pressure or grinder pump system.

These costs are usually split between the Capital Cost of the Project and the Whole of Life costs. In some countries the consultant will also do a carbon footprint study to look at the environmental impact of the new infrastructure.

When looking at the Capital Cost for a sewerage infrastructure project engineers look at the following major items.

  • Pump Station Costs
  • Cost of Pipe in the Ground
  • Manholes or collection Pits
  • Property Connection costs to the Collection point
  • Rising Main Cost to the Treatment Plant

Will this information give a municipality or developer the full picture? What is being left off this analysis?

Pump Station Costs   – In a gravity system, multiple gravity pump stations may be required (up to 18) where one vacuum station will handle the flow. Is the cost of the land taken into account? How about the impact of a properties value if situated next to a gravity station?

Pipe Installation Cost – Usually the consultant will look at the price of pipe per metre installed in the ground, but how about how long the construction period is to install pipe in difficult ground where dewatering may be required. The gravity project in the photo  required 2 weeks per every 100 metres of pipe being laid. Some area’s with very hard rock may take longer. If dewatering what is the cost of disposing of the water? If requiring new fill from somewhere else to embed the pipe, what is that cost?

Impact on Community, Trade and House Sales. – If a project takes a long time to be installed then a municipality may not allow a developer to commence the sale of houses until all houses are connected to the sewer. If commercial area’s or shops cannot be accessed for extended periods this may have a financial impact on the project. If homeowners cannot access their homes then what is the political cost?

Easement Requirements – When looking at a low pressure pump scheme where pumps are required on private properties has the cost of an easement been built into the estimate? When looking at Whole of Life costs does it include washing down the sewage off people’s yards after repairs have been made to the pumps?

Treatment Plant Impact  – If designing a gravity sewer where infiltration will need to be accommodated will the Treatment Plant need to be upgraded and what is the impact of the increased  discharge?

Operational Costs and Risks. –  Health and Safety of operators, Odour, gas explosions, fatbergs, wet wipes clogging pumps, exfiltration damage. None of these are adequately covered in assessments.

Energy Costs – Does the community count the cost of the extra energy costs when it is only homeowners paying the cost with grinder pumps or do you need to look at the cost to the town. When infiltration occurs how much extra power will that consume at pump stations and at the treatment plant.

Increased Risk – is there an assessment given over possible EPA or environmental fines if a gravity system or low pressure system discharges sewerage into a sensitive area. What happens in a tourism area if the sewage overflows? How about in a fishery habitat?

There are many other hidden costs and many more long term costs to be taken into account, This is especially true when trying to repair a leak in a pipe 10 metres (30′) under the highway. I am sure you can think of other costs that have impacted on projects you have done in the past, If so, we would love to hear about your experiences.

Santa Pola resolves odours and overflows with a Flovac system

The Flovac vacuum system is one of the most innovative and longest in Spain – The vacuum system installation, executed over the past 8 years have allowed prevention of salinity problems in the town. With this system, the City of Santa Pola collected wastewater generated for 12,900 homes for later use mainly on irrigation

Vacuum Pump Station

Vacuum Pump Station

Spains largest vacuum system is near completion. It is a technological solution to solve the problems the utility in Santa Pola were suffering as it was built on a cattle farm located on salt marshes , which has a subsoil of sand.

This caused problems of infiltration and unstable ground conditions. Seawater infiltration resulted in increased salinity of the water, which greatly impaired the biological process of purification of the wastewater.

To solve this problem the city has installed a Flovac vacuum sewerage system. Flovac installed pipes up to 315 mm diameter, inside which is a constant vacuum of -0.5 and -0.6 atmosphere is maintained by vacuum pumps.

Vacuum valves are opened by the difference in air pressure automatically and take in  the wastewater from pits. No electricity at the pips is required. The pressure differential allows sewage to flow into the vacuum station and then it is pumped to the Treatment Plant.

There were a number of benefits to the community and to the operators with reduced construction costs and impact on businesses and residents. Operators, who use the monitoring system, note reduced blockages and odours and time at site.

The monitoring system allows operators to know exactly when they are needed and where to go.

A number of other towns with similar problems and now talking to Flovac.

Earthquake Sewer System for Christchurch NZ

Vacuum Sewers prove to be the best Earthquake sewer system for Christchurch Shirley vacuum sewer a first for the South Island.

SCIRT partner McConnell Dowell is more than halfway through a big project to build a Flovac vacuum wastewater system in the Christchurch residential suburb of Shirley – the first area of the South Island to use such technology.

The catchment includes about 750 houses, with 7km of vacuum main pipes in streets as well as lateral/ side connecting pipes to homes and businesses. About 6km of mains and 150 out of 195 collection chambers have been built, with a pump station and lateral pipes still in progress. It will take just over a year to complete the project, which began April 2013.

The area targeted for the Flovac vacuum system was badly affected by earthquakes with lateral spread and land-level changes. Previously, the city’s wastewater network has relied totally on a gravity system with pipelines at a gradient to support downhill flow.

After the earthquakes, the slope changed in many parts of the city, so wastewater was running in the wrong direction. The Flovac vacuum system will offer much greater resilience if there are further large earthquakes, especially in areas considered prone to liquefaction.

A further reason for using vacuum in Shirley was to keep excavation depths to a minimum because of the high ground water table and running sand. The system allowed McConnell Dowell to lay the pipes mostly at depths between one and 1.5 metres deep.

This is shallow compared to the traditional gravity system which has pipes plunging to several metres deep to maintain the gravity-feedwhich takes a lot longer to access for maintenance or repair work with subsequent traffic and residential disruption.

Wastewater will arrive at the Shirley catchments new pumping station, on Golf Links Road, from small collection chambers, usually located on the grass berm of a street, each serving up to four properties. The only visible parts in most streets will be collection chamber lids and man-holes at ground-level, while vent stacks will sit against property boundaries.

Like in other parts of the city, wastewater from the new pumping station will go via the normal gravity system southeast to the wastewater treatment plant at Bromley.Shirley NZ Flovac Project

Residents will not notice any change

Shirley residents will not notice any difference when they flush their toilets or see their kitchen and bathroom wastewater draining to the collection chamber on the street via the gully trap/ lateral pipe. There is no additional cost to them for becoming part of this modern system.