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

WSAA Product Appraisal 1405 Issue 2 1

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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

http://www.saiglobal.com/online/Script/Details.asp?DocN=stds000003906

http://www.saiglobal.com/online/Script/Details.asp?DocN=stds000003906

http://www.saiglobal.com/online/Script/Details.asp?DocN=BSI003372_3703

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Document History

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




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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.

© Copyright 2017 by WATER SERVICES ASSOCIATION of Australia Limited All rights

reserved.


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CONTENTS

1 EXECUTIVE SUMMARY ............................................................................................................................ 6

1.1 RECOMMENDATIONS ........................................................................................................................... 7

2 THE APPLICANT........................................................................................................................................ 8

3 THE PRODUCT .......................................................................................................................................... 8

3.1 FRP VESSEL ...................................................................................................................................................... 14

3.2 FRP VESSEL MANUFACTURING METHOD ..................................................................................................... 14

3.3 THICKNESS OF THE CORROSION BARRIER TO FRP EXPOSED SURFACES ............................................. 15

3.4 JOINTING OPTIONS .......................................................................................................................................... 15

3.5 ACCESS COVERS AND SAFETY GRATES ...................................................................................................... 15

4 SCOPE OF THE APPRAISAL .................................................................................................................. 16

5 APPRAISAL CRITERIA ............................................................................................................................ 16

5.1 QUALITY ASSURANCE REQUIREMENTS ........................................................................................................ 16

5.2 PERFORMANCE REQUIREMENTS ................................................................................................................... 16

5.2.1 Product manufacturing standards ................................................................................................................. 16

6 COMPLIANCE WITH APPRAISAL CRITERIA ......................................................................................... 17

6.1 COMPLIANCE WITH QUALITY ASSURANCE REQUIREMENTS ..................................................................... 17

6.1.1 FRP Vessel Supplier ..................................................................................................................................... 17

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

6.2.3.1 Ballast Layout .......................................................................................................................................... 29

6.2.4 Attachments .................................................................................................................................................. 29

6.2.5 Review of documentation .............................................................................................................................. 29

7 WSAA NETWORK REQUESTS ............................................................................................................... 30

8 INSTALLATION, REPAIR, MAINTENANCE AND TRAINING ................................................................. 44

8.1 REPAIR PROCEDURE ....................................................................................................................................... 44

8.2 MAINTENANCE PROCEDURE .......................................................................................................................... 45

8.3 TRAINING REQUIREMENTS ............................................................................................................................. 45

8.4 BACKFILL REQUIREMENT ................................................................................................................................ 45

9 PRODUCT MARKING .............................................................................................................................. 45

10 PACKAGING AND TRANSPORTATION ............................................................................................... 46

11 PRODUCT WARRANTY ........................................................................................................................ 46

12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT .................. 46

13 DISCUSSION ......................................................................................................................................... 48

13.1 PIPEWORK ....................................................................................................................................................... 48


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13.2 VALVING ........................................................................................................................................................... 48

13.3 INLET VALVES ................................................................................................................................................. 48

13.4 GUIDE RAILS .................................................................................................................................................... 48

13.5 WELL WASHERS ............................................................................................................................................. 48

13.6 LADDERS ......................................................................................................................................................... 49

13.7 INLET BASKETS AND GRINDER GUIDE RAILS ............................................................................................. 49

13.8 PUMPS .............................................................................................................................................................. 49

13.9 LEVEL CONTROL OPTIONS ............................................................................................................................ 49

14 LIFE EXPECTANCY UNDER VARIOUS OPERATIONAL CONDITIONS ............................................. 49

15 FUTURE WORKS .................................................................................................................................. 50

16 DISCLAIMER .......................................................................................................................................... 50

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


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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


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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

reinforced plastics; and

ASME RTP-1 Reinforced Thermoset Plastic Corrosion-Resistant Equipment

All Pumps packaged pump station and emergency storage tanks have been assessed in line

with WSA 129:2011 Industry Standard for Plastics Collection Tanks for Pressure and

Vacuum Sewers, AS 2634:1983, BS 4994:1987 and ASME RTP-1.

Two types of joints to external services are used:

Socket connections for PVC-U fittings; and

Flange connections for all other materials.

Design, verification and final inspection of the product is carried out by qualified composite

and structural engineers. See Section 6.2.

Appendix E includes the following two documents:

a) Design Methodology for FRP Pump Station Laminate Design, and

b) Engineer’s design calculation for a 4 m dia x 10 m high FRP pumping station.

Appendix K provides ballast calculations for five worst case scenarios:

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

The requirements of this appraisal have now been met with respect to general design

requirements, product type testing, auditing of production quality control systems, review of

documentation and guidance for designers, installers and operatives and the products are

seen as 'fit for purpose'.

1.1 RECOMMENDATIONS

It is recommended that WSAA members, subject to any specific requirements of the member,

accept or authorise the All Pumps range of FRP Packaged Pumping Stations and Emergency

Storage Tanks, as detailed in this report for use in sewerage networks and alternative water


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supply (i.e. stormwater) provided pipeline design, installation, acceptance testing and

commissioning are in accordance with relevant WSAA Codes, WSAA Member Integrated

Codes, and the manufacturer's requirements.

2 THE APPLICANT

The original manufacturer of FRP packaged pumping stations and emergency storage tanks,

Gebel FRP Engineering, has been operating since 1972. In 2013 Gebel joined with ‘The All

Pumps Group’ which has resulted in a recently implemented name change for the Gebel

range of products.

All Pumps Sales and Service is an Australian based solution provider for fluid handling,

providing customised pumps and packaged pumping solutions for the civil and building

industries. It is also a market leader in odour control, FRP pressure vessels and associated

stormwater and wastewater equipment. Its products also include clarifiers, degassing and

aeration towers, filter media, pressure vessels, rainwater harvesting, FRP filtration and

process tanks and insulated pressure vessels.

3 THE PRODUCT

All Pumps markets a range of FRP Packaged Pumping Stations and Emergency Storage

Tanks as follows:

FRP Pumping Stations from 1,000 mm to 4,000 mm in diameter and from 1 m to 12 m in

depth as a single unit (pumping station with an integral valve pit) or as separate wet well

and valve chamber; and

FRP Emergency Storage Tanks from 1,000 mm to 4,000 mm in diameter and from 3 m

to 25 m in length.

Each FRP product is tailored for specific site conditions rather than a ‘one size fits all’

standard solution. Each unit is individually designed by All Pumps in house engineers and

verified by a third-party composite engineer. All units are designed for total submergence in

flooded soil, with the type of soil and depth being taken into consideration in the design. All

Pumps offers support to consultants and contractors on all aspects of design, supply,

installation and maintenance.

The FRP Sewage Pumping Station consists of the following components:

FRP wet well and valve chamber as an integral or two separate units;

Access covers for wet well and valve chamber. Each station can be designed to accommodate

a multipart cast iron Class B or Class D (solid-top or concrete infill) cover or fabricated

aluminium covers.

Each pump station is usually supplied to include fit-out with a range of optional accessories

including pumps and valves installed with either polyethylene or ductile iron pipe work, well

washers, ladders, platforms and stainless steel adjustable brackets. Adaptors to suit non-

standard pumps can also be provided. Electrical controls including main switchboard and level

controls can be supplied by All Pumps to Water Agency specification, if specified.

All Pumps FRP pump stations are light, easy to handle and easy to install. The smooth

internal moulded finish provides protection against scum build up. They are not susceptible

to rust, exhibit excellent corrosion resistance and have a life expectancy of 150 years.

The FRP Emergency Storage Tank consists of the following components:

FRP vessel of appropriate size

Vertical risers; one or two depending on vessel size and depth for tank maintenance and

ventilation


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Horizontal incoming and outgoing pipes

Grade 316 stainless steel access ladder

Light service aluminium or cast iron heavy duty access covers

Level sensor (stilling well)

All Pumps mechanical anchoring straps (supplied on a case by case basis as there is an option

for concrete ballast poured on the top of the vessel)

Table 1 shows the product sizing and configurations of All Pumps FRP Pumping Station and

Emergency Storage Tank range.


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TABLE 1: ALL PUMPS FRP PUMP STATION AND EMERGENCY STORAGE TANK – SIZING AND CONFIGURATIONS WITH MODEL

Model Pump Station Vessel (Vertical)

Valve Pit Dimensions (mm x mm)

Emergency Storage Tank (Horizontal)

Dia (mm) Depths (mm)

PS Series 1,000

1,000 to 12,000

(FRP Pump Station) 1,200

This is a vertical

fibreglass in-ground

pump well.

1,500

1,850

2,200

2,470

3,000

3,500

4,000

PSV Series 1,000

1,000 to 12,000

600 x 900

(FRP Pump Station 1,200 900 x 900

With Valve Pit) 1,500 1,200 x 1,200

This is a PS series

with an additional

separate or

integrated valve pit

1,850 1,500 x 1,500

2,200

Custom size

2,470

3,000

3,500

4,000

Dia (mm) Length (mm)

HPS Series 600 x 900 1,000 3,000

(FRP Horizontal 900 x 900 1,200

Pump Station) 1,200 x 1,200 1,500

This is the ideal

solution for situations

where depth is a problem, e.g. rock.

1,500 x 1,500 1,850

Custom size

2,200 to

2,470

3,000

3,500

4,000 25,000

PSVE Series 1,000 600 x 900 1,000 3,000

(FRP Pump Station 1,200 900 x 900 1,200

with Valve Pit 1,500 1,200 x 1,200 1,500

And Emergency 1,850 1,500 x 1,500 1,850

Storage Tank) 2,200

Custom size

2,200 to

This combines the

PSV series with an emergency storage tank (HPS Series)

2,470 2,470

3,000 3,000

3,500 3,500

4,000 4,000 25,000


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1. PS Series - FRP Pump Station

Fully engineered and manufactured to be fully

submerged in the harshest environments.

This model offers the following options:

• Single, dual or triplex pump setups.

• Free standing or guiderail pump setups.

• PVC, PE, cast iron pipe work systems.

• Brass, cast iron, bronze or stainless steel

valving.

• FRP pipework supports.

• Float or probe hooks.

• All auxiliary connections (penetrations) as

per customer specifications.

• Galvanised or stainless chain setups.

• Aluminium, cast iron or fibreglass access

covers.

• FRP inlet stilling tubes.

• Knife gate valves on inlet with risers and

valve stop box.

2. PSV Series - FRP Pump Station with Valve Pit

One of the most crucial benefits of a valve pit is

increased safety. Servicing a pump station

ordinarily involves some risk as one has to

reach inside the pit to turn off the valves. A

valve pit eliminates the need to reach into an

open pit.

This model offers the following options:

• Single, duel or triplex pump setups

• Free standing or guiderail pump setup





valving.




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• All auxiliary connections (penetrations) as

per customer specifications.


• Aluminium, cast iron or fiberglass access

covers.



valve stop box.

• Inlet grinder guide rails.

• Duckbill check valve on valve pit

3. HPS Series - FRP Horizontal Pump Station

Includes all the features of the standard

vertical pump station, yet with only a fraction

of the depth required for the equivalent

volume tank.

Fully engineered and manufactured to be

fully submerged in the harshest

environments, this model offers the following

options:





valving.


• All auxiliary connections (penetrations)

as per customer specifications.


• Galvanized or stainless chain setups.

• Aluminium, cast iron or fibreglass access

covers.



valve stop box.


• Valve pits (integrated or separate).


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4. PSVE Series - FRP Pump Station with Valve Pit & Emergency Storage

These features provide a much needed

back up in the case of a serious electrical

failure or pump failure




• Brass, cast iron, bronze or stainless

steel valving.



• All auxiliary connections (penetrations)

as per customer specifications.


• Aluminium, cast iron or fiberglass

access covers.



valve stop box.


• Valve chamber drain.

All Pumps FRP Pump Stations are designed to meet the needs of pumping of:

Sewerage

Ground Water

Storm Water Retention

Collection and Pumping for Large Water Features

All Pumps Emergency Storage Tanks are specifically designed to meet the needs of:

Emergency storage for wastewater during power outages

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


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3.1 FRP VESSEL

The design, construction and appropriateness of design methodology of all All Pumps FRP

structures is designed and verified to be within the bounds of AS 2634:1983 and BS 4994.

Each pump station has a smooth moulded resin rich corrosion barrier inner layer and an

external resin rich water penetration barrier. Monitoring the manufacturing process with a

digital read out system, the resin rich layer and main laminate resins are kept within

specification parameters, thus minimizing human error.

Quality control procedures require each tank to be inspected and tested using equipment

such as ultrasonic thickness testers. Material weights and other data are recorded against

each pump station’s unique serial number.

The general construction of the station is as follows:

a) Internal Corrosion Barrier Contact Moulded: 0.5mm “C” Glass Veil Surface layer with

Hetron 922 (or equivalent) Vinyl Ester Resin

b) Internal Corrosion Barrier Backing Layers: 2.5mm ‘E’ Glass Chop Strand tie layer with

Hetron 922 (or equivalent) Vinyl Ester Resin

c) Structural Laminate: ‘E’ Glass reinforcement in chopped and continuous strands.

Minimum glass content 50% (Thickness according to Design requirements)

d) Structural Stiffeners: Polyurethane Foam rib former overlaid with ‘E’ Glass reinforcement

in chopped and continuous strands. Minimum glass content 50% (Size and Thickness

according to Design requirements)

e) External Surface - Final Surface: 0.5mm “C” Glass Veil Surface layer with Hetron 922 (or

equivalent) Vinyl Ester Resin

f) External Surface – Sealer: Pigmented ISO/NPG Flowcoat for external protection

All laminates are rolled to get complete wet out of all glass fibres and to remove all bubbles

and air voids through the thickness of the laminate.

3.2 FRP VESSEL MANUFACTURING METHOD

All Pumps FRP vessels are manufactured by the chop hoop filament winding process on

collapsible mandrels with computer controlled equipment.

The chop hoop filament winding process produces not only circumferential strength as found

in helical wound pump stations, but also longitudinal strength. The inter-laminar shear

strength permits pump stations to be cut for access man ways and pipe work without any

undue loss of integral strength.

Refer to Appendix A for ‘All Pumps Xtream packaged FRP Pump Stations and Emergency

Storage Tanks Brochure’ which sets out the detail of this construction.

The FRP vessel shell is a one piece homogenous composite which is joined with the base

and the roof. These joins are the only joins in the construction of the pump well or emergency

storage tank.

The base and top are manufactured to BS 4994 by the chopped strand method to ensure

there are no PVA binders that can invoke the production of Osmotic blistering.

The thicknesses and weights of these parts are checked and recorded on All Pumps quality

documentation before the pump well or emergency storage tank is assembled.

These automated machines manufactured by Magnum Venus dispense resin and catalyst at

a pre-determined mix for perfect catalysation and thus full molecular bonding.


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The glass is weighed as it is applied so a ratio that is set by engineering design is reached

and held.

All Pumps manufacturing procedures are set out in All Pumps ITP (Inspection and Test Plan)

Document No. GEB-DOC.027-REV.3 as shown in Appendix F. This document has been

verified by a Composite Engineer (Mike Leggett) to be within the scope and intent of BS

4994. Refer to Appendix F for verification statement of the composite engineer.

3.3 THICKNESS OF THE CORROSION BARRIER TO FRP EXPOSED SURFACES

A minimum of 3 mm thickness is required as a corrosion barrier and this is reinforced with a

product called Veil to prevent any cracking of the Vinyl Ester Hetron 922 resin.

Refer to Appendix A9 – All Pumps FRP Vessel Chemical Resistance Manual (Addendum

No. 1 to this main report) for tables showing chemical resistance of resin to various

chemicals.

3.4 JOINTING OPTIONS

The FRP packaged pump station is supplied as a complete unit. 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 is a one-piece construction, fully pre-packaged and delivered

to site ready for placement into excavation.

Two types of joints to external services are used:

Socket connections for PVC-U (Series 1 & 2 and DWV) fittings; and

Flange connections for all other materials such as polyethylene (PE), polypropylene (PP),

DICL, Stainless Steel and GRP.

The following jointing options are available for PVC-U DWV, PE, PP, DICL, Stainless Steel

and GRP pipework:

a) PVC-U DWV spigots and sockets are compatible with glass resins, so inlet/outlet using

this pipe material is installed as per the clients’ requirements.

b) PE, PP, DICL or any steel items are not compatible with glass resins for a number of

reasons, especially the different rates of expansion and contraction of these materials,

causing cracking around the joint over time and allowing the connection to leak. To

overcome this potential problem, All Pumps installs FRP flange pipe sections either as

flange/spigot or flange/flange sections to suit the application required.

c) GRP pipe work can be built-in within the FRP barrel.

Refer to Appendix C for schematic diagrams of a flange and PVC spigot joints to FRP barrel.

3.5 ACCESS COVERS AND SAFETY GRATES

All pumps standard access covers are manufactured from 6 mm checker plate using

aluminium marine grade 5052 in H32 temper with triple grip finish with recessed hinges and

lifting handles that are light to lift and cannot fall into the wet-well or valve pit.

The covers can be padlocked shut and fitted with an optional step down aluminium safety

grates to allow inspection and hose down or even float switch replacement without risk to

service personnel. The covers are sized to suit the pump and valve access requirements

and the hinge assemblies and step down.

The access covers and safety grates shall comply with specific requirements of some water

agencies to be allowed for use in their licensed area such as City West Water Supplementary

Manual to the WSAA Sewage Pumping Station Code (WSA 04-2005:2.1) Version 2.4.

Refer to Appendix D for All Pumps Standard Aluminium Cover Specification.


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4 SCOPE OF THE APPRAISAL

The scope of this appraisal is limited to the range of All Pumps FRP Packaged Pumping

Stations and Emergency Storage Tanks referenced in Section 3 with associated valve

chambers and covers.

The range of optional accessories (fit-out) are discussed in Clause 7.2.4 and 14 to

demonstrate product versatility but not intended to be included in the appraisal as they are

usually supplied to individual water agency specification.

All Pumps offers an extensive range of optional accessories, offered at fit-out. The extensive

range of optional accessories includes mechanical, electrical and SCADA equipment which

can initially be reviewed by individual water agency on a case by case basis. These options

are not included in this assessment.

This appraisal covers FRP packaged pump stations and emergency storage tanks used in

alternative water supply (stormwater) and sewer networks.

5 APPRAISAL CRITERIA

Appraisal criteria is determined by the WSAA Infrastructure Products and Materials Network

and regularly reviewed to ensure that the criteria reflect the requirements of WSAA members.

The FRP pump station has been assessed in line with WSA 129:2011 Industry Standard for

Plastics Collection Tanks for Pressure and Vacuum Sewers which is based on AS

2634:1983.

5.1 QUALITY ASSURANCE REQUIREMENTS

The WSAA Infrastructure Product and Materials Network accept FRP components

manufactured and supplied under cover of a certified ISO 9001 management system.

The scope of the certification shall include “Manufacture and supply of FRP to AS 2634:1983

(or similar)”.

5.2 PERFORMANCE REQUIREMENTS

5.2.1 Product manufacturing standards

There is no specific Australian or International product standard that provides manufacturers,

designers and installers with a document that outlines the specific criteria applicable to the

scope of products (i.e. FRP chambers for alternative water supply or sewerage applications)

covered by this appraisal.

WSA 129:2011 is a WSAA Industry Standard that specifies the design, manufacturing and

performance requirements for manufacturers of plastics collection tanks for storage of

sewage in pressure and vacuum sewerage systems which are specifically designed for

buried installation. This standard specifies performance requirements for glass fibre-

reinforced plastics as the material for collection tank.

Until such time as an appropriate Industry Standard, Australian or International Standard is

developed which specifies the:

a) requirements of FRP chambers;

b) the minimum requirements for the materials to be used in the manufacture of controlled

quality FRP chamber components; and

c) descriptions of methods of sampling and testing of components;

the performance criteria defined in Sections 5.2.1, 5.2.2, 5.2.3, 6.2, 7.1, 7.2.1, 7.2.2, 8.1,

8.2, 9.1.2, 9.1.3, 9.1.4, 9.2.1, 9.2.2, 10.1.1, 10.1.2, 10.1.3, 10.1.4, 10.1.5, 10.1.6, 10.2.1,


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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)


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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.


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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.


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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


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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


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FRP Design


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


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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


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


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.

OH&S Quick installation thus minimum ground opening time. Light weight thus reduction of OH&S risks.

Long assembly time thus leaving more scope to OH&S Risk. Heavy Handling thus increases OH&S risk.

Time Quick installation and light weight resulting in cost savings.

Long assembly time thus high crane and labour costs.

Weight Light weight reduces OH&S risk. Heavy handling increases OH&S risk.

Corrosion Corrosion resistant integral construction. Need to coat inside surface for corrosion resistance.

Engineered Engineered for maximum strength allows for ground movement with no structural fatigue.

Ground movement can cause cracks and can break seals between sections.

Life Expectancy

150-year life expectancy. Often needs to be repaired or refurbished due to early failure from corrosion.

Warranty 75-year warranty. Guarantees with warranties of no more than five years.

Maintenance Minimum maintenance smooth internal walls stay cleaner longer.

Rough walls need more frequent cleaning.

Reinforcement No metal reinforcement to cause rust and concrete erosion.

Metal reinforcement corrosion and concrete spalling thus erupting the lining which will require confined space entrance and further costs in repairs.

Leakage No leaks, homogenous sealed unit External leaking from osmosis through the concrete structure.

Question 7: Do you have any project reference to demonstrate your capability of

constructing FRP pump stations of dia up to 4 m and depth up to 10 m as mentioned in your

product sizing and configurations with model numbers. What is the maximum size of FRP

Pump Station (in terms of dia and depth) undertaken by All Pumps so far? Do you have any

restriction or experienced any issues with State Authorities in transporting such large FRP

structures?

Answer 7: All Pumps has a project reference of a 3.5 m dia x 9.9 m deep FRP Pump station

for Denman Town Sewage Pump Station and a 4 m dia x 6.8 m deep for Windsor NSW STP.

So, a 4 m dia and 10 m deep pumping station would follow the same design process and

engineering to ensure the design strengths are maintained.


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In terms of transportation a 4 m dia x 18 m deep could be delivered Australia Wide with ease.

(4.5 m dia x 18 m deep would be possible)

Question 8: Please describe the installation process for a FRP Pump Station if the bottom

portion of the proposed pit is in a rocky environment and submerged in water.

Answer 8: For installation in a wet rocky environment, the station can be designed with a

bottom skirt, FRP I beams and reo installed for a total support for any uneven ground or rock

in a wet hole. The concrete mix, as per our Cassion Wall mix, must be used to get total flow

of concrete under the base. See figures 2 and 3 below.

This is poured into the wet hole to ensure the station has full concrete support under the

unit; the reinforcement is already in place under the floor, from installation in the factory. The

well is then placed into the concrete and filled with water till it settles to the level needed to

match the inverts required.

The concrete is then pumped around the cassion wall running through the open holes to fill

the benching void and construct the retaining ring. The concrete is poured to meet the ballast

required as supplied by All Pumps.

All difficult installations will be discussed and install method agreed open with customer.

This will entail the development of engineering calculations and drawings to allow the

installer to perform his job with excellence.

Figure 2: All Pumps Concrete Mix being poured into wet well hole before Well is installed.


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Figure 3: Lowering pump well into position (Showing openings in Cassion construction) reinforcement can be seen through holes.


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Full Cassion Wall Systems are available for area where high surface loads are implied (See

Pictures below).

The units are supplied to site complete with all steel reinforcement to engineers’

requirements.

The three photos below show the cross section of cassion construction.

Figure 4: FRP Well inside with external FRP shutter wall


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Figure 5: Pouring Concrete in Caisson Design

Figure 6: Free Flowing All Pumps Concrete Mix

Question 9: What is the maximum size of inlet pipe that a 4 m dia FRP wet well could be

built-with and how such inlet pipe is maintained in place under normal operating condition

(i.e. are there any external support?).

Answer 9: A 2.5 meter dia inlet would be able to be installed in a 4m dia Station the Design

would need to take into account the required compensation to allow for the removed section.

The largest size that we have actually fitted is an 1850 mm dia pipe section. It was a FRP

socket joint.


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These sockets and flanges are glassed in with the required compensation as requested by

our engineers. Normally gussets are not needed unless there is some additional stra in

applied to the pipe system such as an internal Knife gate valve which increases the peel

strain due to the additional cantilevered weight

Figure 7: Typical FRP Sockets Laminated Into well walls.

Figure 8: Combined 1850 mm dia Emergency storage tank fitted into side of Pump well at Lionco at Penrith NSW.


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Figure 9: Replacing leaking concrete pump stations below.

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

Retail Water Agencies):

http://mrwa.com.au/Documents/Standards/MRWA_Backfill_Specification_04-03.2.pdf

9 PRODUCT MARKING

All Pumps tankage comes with its own individual Serial Number on a plaque which includes:

The Manufacturers name

Date it was manufactured

Material it is constructed from

Usable volume (litres)

Safe installation depth

Standards to which the vessel is made

Each tank is provided with a full set of installation instructions in English including signage

that entry into the tank is into a confined space and that ventilation and gas testing is needed

before any entry of personnel is undertaken.

http://mrwa.com.au/Documents/Standards/MRWA_Backfill_Specification_04-03.2.pdf


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10 PACKAGING AND TRANSPORTATION

All Pumps is responsible for packaging and delivery of FRP vessels and associated

components. Products are customised engineering units and are transported as fully

assembled. The units are of robust construction and do not need additional packaging. Refer

to Appendix M.

11 PRODUCT WARRANTY

All Pumps sets out 75 year warranty of their products which includes FRP Pump Stations

and Emergency Storage Tanks and standby their products in every way, providing training

and guidance from inception of the project to final installation and commissioning. Refer to

Appendix N for All Pumps warranty statement.

12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING

REPORT

All Pumps have supplied in excess of 10,000 pump stations in Australia since 1972. Some

examples of these pump stations and their contacts are shown in the next page.


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13 DISCUSSION

Although computations and detailed drawings are available for various types of FRP pump

stations and emergency storage tanks differing in wet-well diameter, depth and valve pit

size, All Pumps has advised that site specific calculations can be done if there is a

requirement for a deeper chamber or a chamber location is specified under severe adverse

conditions.

The All Pumps range of packaged FRP Pumping Stations and Emergency Storage Tanks

incorporates a range of optional items beyond the reasonable scope of this appraisal. The

many variations result in an adaptable product designed to satisfying the requirements of

water agencies for Sewage Pumping Stations and Emergency Storage Tanks in this size

range.

The optional items available but not included in this appraisal are:

13.1 PIPEWORK

All Pumps has a large range of pipework options available in various sizes, designs and

materials. Every application requires pipework that is suited to the nature of the fluid being

pumped, the pressures and the flows. All pumps can help with a design to meet your

specifications. The pipework range includes PVC, Polyethylene, Cast iron, FRP and

Stainless steel. All bolting is with 316 stainless steel and insulating washers are used

between dissimilar metals.

13.2 VALVING

All Pumps has a large range of valves available in various sizes, designs and materials.

Pump stations can be fitted with different types of valves to suit your application. As a

standard, bronze valves are used up to DN80 and cast iron thereafter. Available sizes (in

mm): 40, 50, 80, 100, 150, 200, 300, or larger where required. Available materials: Brass,

Bronze, Cast Iron and Stainless Steel. Valves can be installed within the Pump Station or

can be fitted in an integrated or separate valve pit.

13.3 INLET VALVES

Many applications require inlet valves, a safety device which allows the isolation of the inlet

flow in emergency or service conditions. Inlet valves are mainly setup with a riser spindle to

the finish surface to allow zero access to the station for shut off.

13.4 GUIDE RAILS

All Pumps installs a pump pedestal integrated with the pump station. We also supply and fit

guide rails in all types of materials; galvanised, stainless steel and FRP, thus supplying a

complete package. Many other options are also available. Call us with your requirements

and we can tailor a solution for your application.

13.5 WELL WASHERS

All Pumps offer a complete range of well washers to suit each tank application. The 316

Stainless Steel Rotary Tank Cleaner is available in 4 sizes, so we can offer the exact unit to

suit your application.

Eliminates fat build-up on wet well walls.

Uses as little as 100 litres of water per day.

Reduces odours, hydrogen sulphide and increases life of the infrastructure.

Reduces maintenance costs and confined space entries for cleaning.

Cleaner and odour free wet wells, resulting in a healthier environment.


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13.6 LADDERS

Our pumps 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 platforms

and fall safety nets.

13.7 INLET BASKETS AND GRINDER GUIDE RAILS

The grinder guide rails can be set up with quick removal of the grinder and side screens to

allow water to flow during high flow conditions, but stopping large solids from escaping.

Inlet baskets can be set up on guide rails, baskets can be set up on the high flow by pass

from the inlet grinder.

Baskets and Grinders are mainly used in jails, correction centres, and other industrial

applications

13.8 PUMPS

All Pumps offers a large range of pumps available in various sizes, designs and materials.

Pump stations can be fitted with a large range of submersible and above ground pumps to

suit the customer’s needs. Varying heads, volumes and liquids call for different pumps in

almost every application. We use quality pumps from all major suppliers such as ABS, Xylem,

Mono, Grundfos and many more.

13.9 LEVEL CONTROL OPTIONS

All Pumps offer float switches as well as probes for level control. Multitrode units, Vega

Probe, Vega Radar are just a few that are available. All Pumps can source the unit that best

suits the customer’s requirements. All level controls are installed as per clause 21.10.2 of

the Sewage Pumping Station Code of Australia, WSA 04:2005-2.1.

14 LIFE EXPECTANCY UNDER VARIOUS OPERATIONAL CONDITIONS

All Pumps FRP Pump Stations and Emergency Storage Tanks are built to BS 4994 using the

highest quality resins and reinforcements to give a 150 year plus life expectancy. All Pumps

has developed processes to ensure this life expectancy is met.

These processes are provided as below for review:

All Pumps has been manufacturing FRP Vessels since 1972 and has supplied over

10,000 units Australia wide. There is no recorded failure of any of these units and site

visits confirm excellent condition on the oldest install.

Resin:

a) All resins used are of the highest quality Vinyl esters and isophthalic polyesters to provide

the 150-year life expectancy that we design for.

b) No fillers are used in any resins used for construction at All Pumps.

c) All resins are checked and quality Certificate of Conformance is procured from the

manufacturer for each batch purchased.

d) Chemical resistance charts are available for all resins used. A copy is attached in the

Addendum No. 1 to this main report in Appendix A9.

e) All resins used are recorded with its batch number on each QA job sheet that

accompanies the tank through the factory in its manufacture. Thus, each vessel

manufactured has full traceability regarding materials used.


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Reinforcements

a) All Pumps uses E-glass and ECR-glass hoop and chop roving for manufacturing all their

equipment that is done by machines.

b) Hand work uses E-glass woven rovings, uni-directional and some chopped strand mat

(CSM). Note: No CSM is used in corrosion barriers. (It has been shown that the use of

CSM with PVA binders cause osmotic reactions and blistering in some areas. Thus All

Pumps do not use it in corrosion barriers)

c) All Glass is checked by All Pumps QA department and a quality Certificate of

Conformance is procured from the manufacturer for each batch purchased.

d) All glass used are recorded with its batch number on each QA job sheet that accompanies

the tank through the factory in its manufacture. Thus, each vessel manufactured has full

traceability regarding materials used.

15 FUTURE WORKS

There are no future works items.

16 DISCLAIMER

This Product Appraisal Report (Report) is issued by the Water Services Association of

Australia Limited on the understanding that:

This Report applies to the product(s) as submitted. Any changes to the product(s) either

minor or major shall void this Report.

To maintain the recommendations of this Report any such changes shall be detailed and

notified to the Product Appraisal Manager for consideration and review of the Report and

appropriate action. Appraisals and their recommendations will be the subject of continuous

review dependent upon the satisfactory performance of products.

WSAA reserves the right to undertake random audits of product manufacture and installation.

Where products fail to maintain appraised performance requirements the appraisal and its

recommendations may be modified and reissued. Appraisal reports will be reviewed and

reissued at regular intervals not exceeding five (5) years.

The following information explains a number of very important limits on your ability to rely on

the information in this Report. Please read it carefully and take it into account when

considering the contents of this Report.

Any enquiries regarding this report should be directed to the Program Manager, Carl

Radford, Phone: 03 8605 7601 email [email protected].

16.1 ISSUE OF REPORT

This Report has been published and/or prepared by the Water Services Association of

Australia Limited and nominated Project Manager and peer group of technical specialists

(the Publishers).

The Report has been prepared for use within Australia only by technical specialists that have

expertise in the function of products such as those appraised in the Report (the Recipients).

By accepting this Report, the Recipient acknowledges and represents to the Publisher(s)

and each person involved in the preparation of the Report that the Recipient has understood

and accepted the terms of this Disclaimer.

mailto:[email protected]


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16.2 LIMITS ON RELIANCE ON INFORMATION AND RECOMMENDATIONS

16.2.1 Disclaimer of Liability

Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s)

any liability for any loss or damage suffered by any person however caused (including

negligence or the omission by any person to do anything) relating in any way to the Report

or the product appraisal criteria underlying it. This includes (without limitation) any liability

for any recommendation or information in the Report or any errors or omissions.

16.2.2 Intellectual Property and other rights

The Water Services Association of Australia Limited does not undertake any assessment of

whether the importation, manufacture, sale or use of the Product the subject of this Report

infringes the intellectual property rights or proprietary rights of any person. Recipients of the

report should undertake their own assessment of whether (as relevant) the importation,

manufacture, sale or use of the relevant Products infringe the intellectual property rights or

other proprietary rights of any person. If the Product infringes intellectual property rights or

other proprietary rights there is potential for the supply of the Products to be interrupted.

From time to time the Water Services Association of Australia Limited and the other

Publishers may receive notice of allegations that the importation, manufacture, sale or use

of the Product infringes intellectual property rights or other proprietary rights. The Water

Services Association of Australia Limited's policy is to not refer to such allegations in its

reports or take any other steps to put Recipients on notice of such allegations, unless and

until it is aware that the allegations have been admitted or proved in Court. As such,

Recipients acknowledge, agree and accept that the Water Services Association of Australia

Limited may have information in its possession about intellectual property rights infringement

allegations or other infringement allegations in relation to the Product which are not referred

to or disclosed in this Report and which are not otherwise communicated to Recipients.

16.2.3 Need for Independent Assessment

The information and any recommendation contained (expressly or by implication) in this

Report are provided in good faith (and subject to the limitations noted in this Report).

However, you should treat the information as indicative only. You should not rely on that

information or any such recommendation except to the extent that you reach an agreement

to the contrary with the Publisher(s).

This Report does not contain all information that a person might require for the purposes of

assessing any product discussed or appraised within it (Product). The product appraisal

criteria used in preparing this Report may not address all relevant aspects of the Product.

Recipients should seek independent evidence of any matter which is material to their

decisions in connection with an assessment of the Product and consult their own advisers

for any technical information required. Any decision to use the Product should take into

account the reliability of that independent evidence obtained by the Recipient regarding the

Product.

Recipients should also independently verify and assess the appropriateness of any

recommendation in the Report, especially given that any recommendation will not take into

account a Recipient’s particular needs or circumstances.

WSAA has not evaluated the extent of the product liability and professional indemnify

insurance that the provider of the product maintains. Recipients should ensure that they

evaluate the allocation of liability for product defects and any professional advice obtained

in relation to the product or its specification including the requirements for product liability

and professional indemnity insurance.


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16.3 NO UPDATING

Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have]

any obligation to notify you of any change in the information contained in this Report or of

any new information concerning the Publisher(s) or the Product or any other matter.

16.4 NO WARRANTY

The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit

the accuracy or completeness of the information in this Report, or the accuracy,

completeness or reasonableness of any recommendation in this Report.


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APPENDIX A – TECHNICAL MANUAL

1. All Pumps Product Range

https://www.allpumps.com.au/applications/pump-stations

2. All Pumps Xtream packaged FRP Pump Stations and Emergency Storage Tanks

Brochure

https://www.allpumps.com.au/applications/pump-stations/psve-series-frp-pump-station-

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.

Figure 1 Packaging and transport of FRP Vessels


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Figure 2: Installation of FRP pump station


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APPENDIX N –ALL PUMPS WARRANTY


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APPENDIX O - SUPPLIER CONTACTS

All Pumps Sales and Service

100 Silverwater Rd., Silverwater. NSW 2128

P.O. Box 7138, Silverwater. NSW. 1811

Tel. 02 9630 0369

Contact: James Hales

Email. [email protected]

All Pumps Sales and Service Plant

26 Coombes Drive, Penrith. NSW. 2750

P O Box 7051, South Penrith, LPO, NSW. 2750

Email: [email protected]

Tel. 02 8705 0205




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APPENDIX P – DENMAN CASE STUDY


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Melbourne Office

Level 8 | Suite 8.02 | 401 Docklands Drive | Docklands | VIC | 3008

Sydney Office

Level 9 | 420 George Street | Sydney | NSW | 2000

GPO Box 915 | Sydney | NSW | 2001

www.wsaa.asn.au

http://www.wsaa.asn.au/