JPS Install Instructions V3.2016

March
2016
INSTALLATION INSTRUCTIONS
FOR FURTHER QUESTIONS, PLEASE CALL 775‐440‐2025
JENSEN WATER RESOURCES
521 Dunn Circle, Sparks, NV 89431
JensenPumps.com
Figure 1: This illustration shows a complete pump station material delivery as arranged on one flat bed truck.
Submersible Pump Station
Installation Instructions Page 2
Table of Contents
• Lift Station Identification 4
• Bracket Orientation 5
• Bracket Installation 6
• Base Elbow Orientation 7
• Base Elbow Installation 8
• Station Layout Identification 9
• Mechanical Joint Sleeve Installation 10
• Force Main Installation 11
• Intermediate Guide Rail Bracket Installation 12
• Pipe Bracing Installation 13
• Pump Installation 14
• Electrical Cable Management 15
• Control Panel Installation 16
• Appendix A – Junction Box Installation 18
• Appendix B – Pre‐commissioning Check List 20
JENSEN PUMP STATION
SYSTEM IDENTIFICATION DRAWING
5.) WET WELL RIM ELEVATION
4.) FINISH GRADE ELEVATION DOUBLE DOOR

SINGLE DOOR HATCH HATCH 3.) DISCHARGE
STRUCTURE
FORCE MAIN
LENGTH
1.) WET WELL 2.) VALVE VAULT
10.) OUTFALL ELEVATION
11.) DRAIN PIPE
6.) GRAVITY INLET

INVERT 9.) PUMP FORCE MAIN
7.) SUBMERSIBLE
PUMP 8.) BASE ELBOW FOR
AUTOCOUPLING SYSTEM
PUMP STATION IDENTIFICATION

1. WET WELL: WET UTILITY STRUCTURE WHICH CONTAINS PUMPS, SLIDE RAIL SYSTEM, AND LEVEL SENSORS.
2. VALVE VAULT: DRY STRUCTURE WHICH CONTAINS VALVES, PIPING AND FITTINGS.
3. DISCHARGE STRUCTURE: UPSTREAM LOCATION AT WHICH THE PUMP FORCEMAIN ENDS AND SYSTEM TURNS TO GRAVITY,
TYPICALLY A MANHOLE.
4. FINISH GRADE ELEVATION: ELEVATION OF GROUND LEVEL AFTER PROJECT COMPLETION.
5. WET WELL RIM ELEVATION: ELEVATION OF TOP OF WET WELL AFTER PROJECT COMPLETION. TYPICALLY EQUAL TO FINISH
GRADE.
6. GRAVITY INLET INVERT ELEVATION: ELEVATION OF INLET PIPE TO THE PUMP STATION. TYPICALLY FROM A GRAVITY PIPE,
BUT CAN BE A FORCEMAIN IF COMING FROM A PRESSURIZED SOURCE SUCH AS A PUMP STATION.
7. SUBMERSIBLE PUMP: PUMP IN WET WELL THAT WILL BE SUBMERGED DURING NORMAL OPERATION.
8. BASE ELBOW: PERMANENT BASE IN WET WELL WHICH ALLOWS FOR PUMP COUPLING WHEN PUMP IS PLACED IN WET WELL.
9. PUMP FORCEMAIN: PRESSURIZED PIPE THAT CARRIES WATER FROM PUMP TO DISCHARGE STRUCTURE.
10. OUTFALL ELEVATION: ELEVATION OF FORCEMAIN PIPE TERMINATION AT THE DISCHARGE STRUCTURE.
11. DRAIN PIPE: DRAIN FROM VALVE VAULT TO WET WELL, PREVENTS WATER BUILD UP IN VALVE VAULT.
Copyright Information 2011 Jensen PROJECT:

Precast All Rights Reserved. All
materials appearing as Jensen Precast
documents and the like are propriety STATION IDENTIFICATION
work product and are protected under
U.S. copyright and other laws. Unless
in conjunction with business conducted
DETAIL DRAWING PUMP
with Jensen Precast, any use of
Jensen Precast work product without STATIONS
express, written consent is prohibited
and recipient is prohibited from 521 DUNN CIRCLE, SPARKS, NV 89431
distributing any and all work product to DATE: DRAWN BY: SHEET NO:
non-approved third parties under JensenPumps.com
penalty of civil action. MARCH 2016 BP 1 of 1 (855) 468-5600
C:\Vault\Jobs\Standard Details\Installation Procedures\Identification Sheet\Station ID Assembly.iam

PART LIST 1
PART DESCRIPTION
1 PRECAST CONCRETE FLAT TOP
2 PRECAST CONCRETE TOP BARREL
3 UPPER GUIDE RAIL ASSEMBLY
4 FLOAT BRACKET ASSEMBLY
5 CAST‐IN HATCH
6 FACTORY INSTALLED NUTRAIL
3 6
4 2
Figure 2: This image shows upper guide rail bracket Figure 3: Shown here is the upper guide rail bracket
orientation when the flat top includes a single door hatch. orientation when the flat top has a double door hatch.
Figure 4: The flat top must be oriented such that the
long axis of the access hatch is perpendicular to the
direction of the force main.
PART LIST 2
PART QTY DESCRIPTION
1 N.A. FACTORY INSTALLED NUT RAIL
2 5 SS CHANNEL NUT 3 4
3 2 UPPER GUIDE RAIL BRACKET 2
1
4 5 SS HEX BOLT
5 4 GUIDE RAIL PIPE
6 1 SS FLOAT BRACKET
7 2 OPTI‐FLOAT LEVEL SENSOR
8 1 PRESSURE TRANSDUCER
2 6
1
7
Figure 5: Upper guide rail bracket installation.
STEPS FOR PART LIST 2

1. Install upper guide rail bracket on the force
main side of wet well.
a) Leave the SS Hex Head bolts loose.
2. Install float bracket on opposite side of access
8 hatch.
3. If there is no nut rail installed, make sure that
all brackets are installed no farther than 6”
down the skirt of the frame.
Figure 6: Float bracket installation.
IMPORTANT!
Pressure transducer handling:
• The pressure transducer is to be kept in a moisture free environment until it can be
installed and pulled directly to the control panel.
• Please do not splice the cable and/or install in junction box! If a longer cable is needed,
contact us at 775‐440‐2025.
• A stilling well may be used; consult Jensen Pump Stations before installing the stilling well
pipe.
PART LIST 3
PART DESCRIPTION
1 UPPER GUIDE RAIL BRACKET 2
2 CORE HOLE (FORCE MAIN DISCHARGE)
3 PLUMB BOB
4 PUMP BASE ELBOW 4
5 SS WEDGE ANCHOR
Figure 7
*Double door hatch
orientation – see page #3*
DISCHARGE
FLANGE OF PUMP MOUNTING
1 BASE ELBOW HOLES FOR
2 GUIDE RAIL
5
Figure 8
Figure 9
STEPS FOR PART LIST 3

1. Align the center of the discharge flange of the pump base elbow, the upper guide
rail bracket, and the center of the core hole for the force main discharge. (Figure 7
on this page)
2. Using a plumb bob, align the upper guide rail grommets with the mounting holes
for the guide rail in the base elbow. (Figure 8 on this page)
3. Figure 9 is described further on the following page.
Figure 10
STEPS FOR FIGURE 10

1. Drill hole for wedge anchors with Roto‐Hammer.
a) WARNING: Take care to not drill all the way through the concrete base.
2. Install wedge anchors.
3. Install base elbows.
4. Tighten wedge anchor hex head.
*Single door hatch
orientation – see page 3.*
9
6
7 8
2
Figure 11: Typical station layout
3
1 DUCTILE IRON FLANGE:
TORQUE SPECIFICATIONS
Pipe Torque Value
Diameter (ft‐lbs)
3” 80
PART LIST 4 4” 90
PART DESCRIPTION 6” 90
1 PUMP BASE ELBOW 8” 90
2 STAINLESS STEEL GUIDE RAIL PIPE 10” 90
3 FLANGE X PLAIN END PIPE, CUT TO LENGTH IF 12” 90
NEEDED 14” 110
4 RESTRAINED FLANGE COUPLING ADAPTER
(RFCA)
5 FLANGED 90 ELBOW
6 STAINLESS STEEL UPPER GUIDE RAIL BRACKET
7 MEGALUG
8 MECHANICAL JOINT SLEEVE (LONG)
9 PRE‐ASSEMBLED VALVE VAULT
Figure 12: Bolt tightening sequence
MECHANICAL
JOINT SLEEVES
PRE‐ASSEMBLED
VALVE VAULT
Figure 13: MJ Sleeve installation
STEPS FOR FIGURE 13
1. Slide the Mega Lugs and the Joint Sleeves onto the plain ends of the pipes coming out
of the valve vault.
2. Once the pipes from the wet well are placed (see Page 9), center the sleeves between
the connection and tighten the bolts.
STEPS FOR PART LIST 4 (from Page 7)
1. In the wet well, install boots into core holes for force main discharge.
2. Install horizontal force main pipe (flange X plain end) through boots.
3. Install vertical force main pipe (can be flange X flange and/or flange X plain end
depending on the total well depth).
4. Bolt flanged 90 elbow to RFCA.
5. Slide RFCA onto plain end of vertical force main pipe. Leave loose.
6. Bolt flanged 90 elbow to horizontal force main pipe.
7. Refer to installation instructions provided with RFCA to tighten.
8. Remove the upper guide rail brackets in order to install the guide rails in the base elbow
mounting holes (see Fig. 9, page 5), then replace them back on the hatch nut rail.
9. Refer to Fig. 18 on p. 10 for installation of intermediate guide rail brackets for deep wells.
*Single door hatch
orientation – see Figure 14: Step 1 Figure 15: Step 2
page 3.*
*Double door hatch
orientation – see page 3.*
STEP 4 STEP 8
STEP 5
STEP 3
STEP 6
Figure 17: Step 6 & Step 8
Figure 16: Step 3 – Step 5
*Note: Not all stations require intermediate brackets. The following
instructions are specifically for stations that are provided with this hardware.
Figure 18: Intermediate guide rail bracket installation illustration.
STEPS FOR FIGURE 18
1. With the guide rail pipe provided, measure out the sections. Guide rails are provided in
20’ sticks, and quantity depends on the total depth. The guide rails may need to be field
cut due to exact well depth.
a) For example: If the well is 15’ deep, place the intermediate bracket no more than
10’ from the floor. This allows for two ~10’ sections and two ~5’ sections for each
pump.
2. Loosely attach the U‐bolt to the bracket and slide the bracket down the discharge pipe to
where the first section of guide rail pipe ends. If flanges do not allow sliding the bracket
down the discharge line, remove the U‐bolt and reconnect it where the first section of
the guide rail pipe ends.
3. Connect the next section of guide rail pipe directly on top of the intermediate bracket
and tighten the U‐bolt nuts.
*Note: Not all stations require pipe bracing. The
following instructions are specifically for stations
that are provided with this hardware.
Figure 19: Typical pipe bracket by Placer Waterworks Inc.
Figure 20: Shown above is an example of the pipe bracket installation, with a close up of the wedge anchor placement.
STEPS FOR FIGURE 20
1. Loosely install the U‐bolts on the discharge pipes and extend the bracket
tubing on each side to reach the inner walls of the well.
2. Drill hole for wedge anchors with Roto‐Hammer.
a) WARNING: Take care to not drill all the way through the wall.
3. Install wedge anchors.
4. Place bracket angles on each side.
5. Tighten wedge anchor hex heads, tighten U‐bolt hex heads.
Figure 21: Pump is lowered onto base elbow via guide rails.
STEPS FOR FIGURE 21 *Double door
hatch orientation
1. Lower pumps down guide rails onto – see page 3*
base elbows.
a) Lifting chain with shackles are
supplied with the pump
station materials.
2. The weight of the pumps creates a
water tight seal to the base elbow.
a) There is a gasket between the
guide claw and base elbow.
3. THERE IS NO BOLTING REQUIRED to
connect pumps to the base elbows.
Note: The hoist shown on this page is not
always included. Use the proper lifting
equipment to lower the pumps into the
well and to raise the pumps out of the
well.
Figure 22: Pump is lowered onto base elbow via guide rails.
Figure 23: The above illustration is an example of electrical cable management.
ELECTRICAL CABLE MANAGEMENT NOTES
• It is essential to utilize proper cord separation techniques when hanging electrical
cables.
• The electrical contractor is responsible for conduit installation. Jensen Pump Stations
recommends 2” minimum conduit for both high and low voltage.
• Pumps typically have two cables exiting the casing. Refer to the installation
instructions provided by the pump manufacturer to identify the low voltage and high
voltage cables (typically, the high voltage cables have a larger diameter).
• All low voltage and high voltage cords MUST be ran in separate conduits to the control
panel.
• If low voltage and high voltage cables are placed in the same conduit, a current
can be induced in the low voltage cables and create false seal fail alarms.
See the following page for continued information.
UNISTRUT
RAIL
CONDUIT
PIPE
Figure 24: Typical control panel installation.
CONTROL PANEL INSTALLATION NOTES
• The location and installation of the control panel is the responsibility of the installing
contractor or electrical contractor.
• Jensen Pump Stations recommends that the panel is mounted as close to the wet well
as possible to avoid voltage loss and make start up and continued maintenance more
convenient.
• The panel enclosure may be mounted on a nearby wall or within a nearby structure.
• Please pull all cables to the control panel. If the control panel is too far to use factory
connections, contact JPS (775‐440‐2025) for longer cables. If a junction box is
ABSOLUTELY necessary, take note of Pressure Transducer Handling instructions on
page 4. It is crucial that the junction box is completely watertight.
• See Appendix A for junction box installation recommendations.
• Leave all excess cable coiled within the control panel. A JPS pump technician will make
the electrical connections at time of start‐up/commissioning.
Please contact Jensen Pump Stations with any questions about the
equipment, installation, or commissioning services.
PumpSupport@JensenPrecast.com
(775) 440 ‐ 2025
• A completed pre‐commissioning check list (see Appendix B) is required in order to
schedule start‐up and training services. Please send a copy of this form completed to
PumpSupport@JensenPrecast.com and call (775) 440 ‐ 2025 to schedule the date with
one of our Pump Technicians. Please allow us 2 weeks’ notice to plan the commissioning
of the station.
APPENDIX A
JENSEN PRECAST
B HT1730 TRAFFIC BOX
PUMP HIGH VOLTAGE CONDUIT
(1.5" MINIMUM DIAMETER)
PUMP LOW VOLTAGE CONDUIT

(1.5" MINIMUM DIAMETER) 2'-6"
TO CONTROL PANEL
LEVEL SENSOR CONDUIT

(1.5" MINIMUM DIAMETER)
B
1'-5"
PLAN SECTION
NOT TO SCALE
ISOMETRIC VIEW W/ COVER REMOVED

NOT TO SCALE
2.5' MIN
RIM/FINISH GRADE
LOW VOLTAGE NEMA
LOW VOLTAGE NEMA 4X ELECTRICAL
1'-0" TYP. HIGH VOLTAGE NEMA
ELECTRICAL 4X ELECTRICAL JUNCTION BOX
4X ELECTRICAL
CONDUIT DESIGN JUNCTION BOX JUNCTION BOX
AND MATERIAL
BY OTHERS
SEAL CONDUIT WITH DOTTIES
DUCT SEAL PUTTY OR EQUAL
PRODUCT (SEWER APPLICATIONS
REQUIRE GAS TIGHT CONDUIT SEAL)
PUMP STATION MANHOLE

2" PVC SCH40 3" TYP.
DRAIN LINE
2" 1" UNISTRUT RAIL SUPPORT
DRAIN ROCK DESIGN AND
FOR JUNCTION BOXES
2" PVC SCH40 COMPACTION BY OTHERS
CHECK VALVE
SECTION B-B
NOT TO SCALE
Copyright Information 2011 Jensen PROJECT:

Jensen Pump Stations does not make Precast All Rights Reserved. All
materials appearing as Jensen Precast
documents and the like are propriety TRAFFIC RATED JUNCTION BOX
TYPICAL SYSTEM LAYOUT any claim that this detail is compliant work product and are protected under
U.S. copyright and other laws. Unless
STANDARD DETAIL PUMP
in conjunction with business conducted
NOT TO SCALE with the NEC or any other with Jensen Precast, any use of
Jensen Precast work product without STATIONS
express, written consent is prohibited
jurisdictional electrical codes or and recipient is prohibited from
distributing any and all work product to DATE: DRAWN BY: SHEET NO:
521 Dunn Circle, Sparks, NV 89431
JensenPumps.com
regulations. non-approved third parties under
penalty of civil action. MARCH 2016 NEC 2 of 2 (855) 468-5600
C:\Vault\Jobs\Standard Details\Installation Procedures\Junction Box\JENSEN JUNCTION.iam

APPENDIX B
521 Dunn Circle
Sparks, NV 89431
(855)468-5600
PRE-COMMISSIONING CHECK LIST

Please complete prior to scheduling a Jensen Engineered Systems representative for commissioning services.
DATE REQUESTED FOR STATION COMMISSIONING:

TODAY’S DATE:
PROJECT ADDRESS:
REQUESTED BY: Name:

Phone #:
Cell Phone #:
Company:
PROJECT NAME:
NUMBER OF STATIONS REQUIRING COMMISSIONING:
GENERAL
Has all mechanical equipment been installed? □ Yes or □ No
Is there an acceptable water source available for commissioning? □ Yes or □ No
*Acceptable water source is a water truck or fire hose connection w/ hose. Garden hose is not acceptable.
Will a lifting device to remove pumps be available during commissioning? □ Yes or □ No

Have the wet well and all piping been cleared of debris? □ Yes or □ No
Has any of the equipment been exposed to sewage? □ Yes or □ No
Have appropriate parties been scheduled for
training immediately following commissioning? □ Yes or □ No
ELECTRICAL
Is high voltage/low voltage wires in separate conduit? □ Yes or □ No
Has electrical conduit been sealed? □ Yes or □ No
Have the electrical leads for the pumps been landed in control panel? □ Yes or □ No
Have the leads for the level detection devices been landed in control panel? □ Yes or □ No
Has power been provided to the control panel? □ Yes or □ No
Is there a main disconnect panel prior to the pump station panel? □ Yes or □ No
Is a junction box used? □ Yes or □ No
Verify in line voltage ______________________ L1/L2 = ________ L2/L3 = ________ L1/L3 = ________
521 Dunn Circle
Sparks, NV 89431
(855)468-5600
STATION DESIGNATION:
*If there are multiple stations on a single job, submit a copy of this sheet for each station.
PUMPS
PUMP #1 PUMP #1
PUMP #2 PUMP #2
PUMP #3
Select One: □ DUPLEX PUMP STATION □ TRIPLEX PUMP STATION
Refer to tag information on the side of the pump to collect the following information:
Pump # Serial Number Model Number
1
2
3
PHOTOS
Photos are very helpful for the Jensen Engineered Systems technician to review prior to visiting the
project site for commissioning. If time permits, please submit pictures showing the overall site, the
control panel with door open, and the inside of the wet well. Photos can be emailed to
PumpStations@JensenPrecast.com (please put the project name in the subject line).

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March

5.) WET WELL RIM ELEVATION

4.) FINISH GRADE ELEVATION DOUBLE DOOR

1.) WET WELL 2.) VALVE VAULT

10.) OUTFALL ELEVATION

11.) DRAIN PIPE

6.) GRAVITY INLET

PUMP STATION IDENTIFICATION

Copyright Information 2011 Jensen PROJECT:

C:\Vault\Jobs\Standard Details\Installation Procedures\Identification Sheet\Station ID Assembly.iam

STEPS FOR PART LIST 2

STEPS FOR PART LIST 3

STEPS FOR FIGURE 10

PUMP LOW VOLTAGE CONDUIT

LEVEL SENSOR CONDUIT

ISOMETRIC VIEW W/ COVER REMOVED

PUMP STATION MANHOLE

Copyright Information 2011 Jensen PROJECT:

C:\Vault\Jobs\Standard Details\Installation Procedures\Junction Box\JENSEN JUNCTION.iam

PRE-COMMISSIONING CHECK LIST

DATE REQUESTED FOR STATION COMMISSIONING:

REQUESTED BY: Name:

Will a lifting device to remove pumps be available during commissioning? □ Yes or □ No

Select One: □ DUPLEX PUMP STATION □ TRIPLEX PUMP STATION

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