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3 Julie Avenue and Hoeschler Drive Lift Stations Evaluation City of Sparta TABLE OF CONTENTS Page CHAPTER 1 GENERAL INFORMATION Scope of Lift Station Evaluation... 1 CHAPTER 2 LIFT STATIONS Julie Avenue Lift Station Julie Avenue Existing Conditions Service Area Pump Sizes / Run Times Flow rates Hoeschler Drive Lift Station Hoeschler Drive Existing Conditions Service Area Pump Sizes / Run Times Flow rates... 9 CHAPTER 3 RECOMMENDATIONS Julie Avenue Lift Station Recommendations Hoeschler Drive Lift Station Recommendations LIST OF APPENDICES Appendix A Service Areas Appendix B Cost Estimates Appendix C Calculations October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

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5 Lift Station Evaluation Chapter 1 - General Information City of Sparta, Wisconsin October 2017 CHAPTER 1 GENERAL INFORMATION 1.1 SCOPE OF LIFT STATION EVALUATION The City of Sparta has experienced significant residential development in the southwest corner of the City. The wastewater collection system in this area is served by the Julie Avenue and Hoeschler Drive Lift Stations. The growth of the areas served by the lift stations has begun to test the capacities of the stations. The stations are struggling to keep up with the increased wastewater flows. The City has hired MSA Professional Services, Inc. to evaluate the Julie Avenue and Hoeschler Drive Stations regarding their capacities with current flows experienced. MSA will provide recommendations to correct any capacity deficiencies found and other improvements to the system to increase reliability. Project No Page 1 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

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7 Lift Station Evaluation Chapter 2 - Lift Stations City of Sparta, Wisconsin October 2017 CHAPTER 2 LIFT STATIONS 2.1 JULIE AVENUE LIFT STATION The Julie Avenue Lift Station is located on Julie Avenue approximately mid-block between Sugarberry Boulevard and Terry Court. The station is a duplex submersible lift station constructed of a precast reinforced concrete structure. The station currently has 240 volt, single-phase electrical service at the panel JULIE AVENUE EXISTING CONDITIONS Julie Avenue Lift Station The station has two surface hatches. One side enters the wet-well portion of the structure where the wastewater enters the station and is stored until pumped. The pumps are also located in the wet-well. The wet-well is a 6-foot diameter structure that is approximately 31-feet deep. The wet-well did not show any signs of infiltration and appeared to be in good shape. However, there was some debris build-up on the upper ledge. The opposite hatch enters into the valve vault, which houses check valves and isolation valves. The valve vault sits on top of a portion of the wet-well structure. There is also piping within the valve vault to allow for bypass pumping of the station. The valve vault was in good condition, and did not show any signs of infiltration. The check valves had recently been replaced. The station also has a newer pad mounted 25KVA natural gas backup generator. Project No Page 2 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

8 Lift Station Evaluation Chapter 2 - Lift Stations City of Sparta, Wisconsin October 2017 Julie Avenue Station Wet-Well Julie Avenue Station Valve Vault Project No Page 3 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

9 Lift Station Evaluation Chapter 2 - Lift Stations City of Sparta, Wisconsin October 2017 Once wastewater leaves the station it is pumped through a 4-inch force main east along Julie Avenue, then south on Terry Court to a sanitary manhole in the intersection of Terry Court and Linda Lane. From there the flow enters the gravity collection system, which ultimately discharges into the Hoeschler Drive Lift Station SERVICE AREA The Julie Avenue Station serves a large residential area in the City of Sparta located west of HWY 27 and South of HWY 16. The station also receives wastewater from a station located in the Riverwood Subdivision on the end of Hanson Place. The entire area served by the Julie Avenue Station is approximately 192 acres with a total of about 320 residential lots and 83 mobile homes. This equates to roughly 930 residents served by the station. The original lift station 20-year service area was 45 acres with a total of 327 residents PUMP SIZES / RUN TIMES The original design report for the station called for pump sizes of 80 gallons per minute (GPM) with a pump cycle time of approximately 20 minutes. In 2007, the pumps were upsized to 150 GPM. In 2014 the impellers of the pumps were upsized from 6.62-inches to 7.0-inches, which results in a flow rate of approximately 180 GPM. On August 29, 2017, MSA worked with City wastewater staff to perform some pump run times analysis. At the time of the tests, the pump cycles were closer to 1.5 minutes. Short cycles are hard on pumps, as they cause the pumps to turn on and turn off in very short periods of time. This can lead to a shortened life for the pump, or require maintenance on the pumps more regularly. It appears from the run-times collected in the field that the floats which control the on-off cycle of the pumps may be set approximately only 4-inches apart. The original design of the station had a separation of 3-feet. Setting the floats closer to the original set points will allow for longer cycle times, which should be easier on the pumps FLOW RATES During the pump run-time analysis performed by MSA and City staff, incoming flow rates were approximately 140 GPM. A typical residential household will contribute approximately 100 gallons per capita per day (GPCD) of wastewater. Based upon the service area contribution of 920 residents this station should experience an average flow of 92,000 gallons per day or approximately 64 GPM. Based on run times of the pumps provided by City staff, the station in July and August of this year averaged about 81,000 gallons per day or 56 GPM pumped. However, wastewater flows are not consistent and can fluctuate greatly throughout the day. A service area of this size can experience peak flows that are approximately four times the average flow. DNR standards require pumps sized for lift stations to be sized to accommodate the peak flows which the system will experience. The peak flows at the Julie Avenue Lift Station are expected to be more in the 240 GPM range. The future 20-year service area for this lift station is estimated to include another Project No Page 4 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

10 Lift Station Evaluation Chapter 2 - Lift Stations City of Sparta, Wisconsin October acres of land of roughly 150 residential lots; 350 people. The estimated service area population is 1,270 residents, and will require an estimated design flow rate of 360 GPM. This flow rate could be controlled by extending the future force mains to the interceptor sewer mains on Hoeschler Drive of STH 27, thus bypassing the Julie Avenue Lift Station. 2.2 HOESCHLER DRIVE LIFT STATION The Hoeschler Drive Lift Station is located at the southeast corner of Hoeschler Drive and Industrial Drive. The station is a duplex submersible lift station constructed of a precast reinforced concrete structure HOESCHLER DRIVE EXISTING CONDITIONS The Hoeschler Drive station consists of a 6-foot diameter precast concrete tank wet-well which houses two submersible pumps. There is a separate precast concrete structure, which houses check valves and isolation valves. The station has a pad mounted natural gas backup generator. The wet-well did not show any signs of infiltration. However, there was a significant build-up of grease. The grease was thick enough to support the weight on the end of the float chain as it was lowered into the wet-well. Project No Page 5 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

11 Lift Station Evaluation Chapter 2 - Lift Stations City of Sparta, Wisconsin October 2017 Hoeschler Drive Wet-well Project No Page 6 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

12 Lift Station Evaluation Chapter 2 - Lift Stations City of Sparta, Wisconsin October 2017 Hoeschler Drive Valve Vault The valve vault appeared to be in good condition, and there were no signs of infiltration. Once wastewater leaves the station it is pumped a short distance to a manhole on the lift station site. The wastewater then enters the gravity collection system through an 8-inch pipe, which ultimately discharges into the City wastewater treatment facility. Project No Page 7 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

13 Lift Station Evaluation Chapter 2 - Lift Stations City of Sparta, Wisconsin October 2017 Discharge Manhole SERVICE AREA The Hoeschler Drive Station serves a large residential area along with commercial and industrial development. The Station also receives wastewater flow from the Julie Avenue Station. In total this station serves an area of approximately 492 acres. Approximately 200 acres of this is industrial/commercial development with the remaining 292 acres being residential. The original design report for the station is not available so it is unknown what the original design service area was intended to be PUMP SIZES / RUN TIMES It is not known what the flow rates of the pumps from the original design of the station were intended to be. New submersible pumps were installed into the station in Information provided by the supplier indicates that the pumps were rated for 400 GPM. On August 29, 2017, MSA worked with City wastewater staff to perform some pump run times analysis. Based on the draw down tests at the station it is believed that the pumps are running closer to 340 GPM. At the time of the tests, the pump cycle times were between 2-3 minutes. Short cycles are hard on pumps as they cause the pumps to turn on and turn off in very short periods of time. This can lead to a shortened life for the pump or require maintenance on the pumps more regularly. Project No Page 8 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

14 Lift Station Evaluation Chapter 2 - Lift Stations City of Sparta, Wisconsin October FLOW RATES During the pump run-time analysis performed by MSA and City staff, incoming flow rates were calculated to be an average of 195 GPM. A typical residential household will contribute approximately 100 gallons per capita per day (GPCD) of wastewater. It was also assumed that the industrial / commercial properties in the service area would average approximately 10 employees per acre, and the contribution would be 30 gallons per employee per day (GPED). The service area also has an industry, Century Foods, which would be considered a heavy water user. The average water use for the business was added to the flow calculations. Based upon the above assumptions an average daily flow of approximately 274,400 gallons or 190 GPM was calculated. The City staff provided flow rates based on run times of the pumps in July and August of this year, and the station averaged about 240,000 gallons per day pumped or 167 GPM. The existing flows are assumed to be lower than the estimated flows because the existing service area is not fully developed. For the purposes of estimating future peak flows, a current average flow of 274,400 gallons per day will be used. Wastewater flows are not consistent and can fluctuate greatly throughout the day. A service area of this size can experience peak flows that are approximately four times the average flow. DNR standards require pumps sized for lift stations be sized to accommodate the peak flows which the system will experience. The current estimated peak flows at the Hoeschler Drive lift station are in the 680 GPM range. The future 20-year service area for this lift station will include another 150 acres of residential development, increasing the lift station 20-year peak flow rate to approximately 950 GPM. Project No Page 9 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

15 Lift Station Evaluation Chapter 3 - Recommendations City of Sparta, Wisconsin October 2017 CHAPTER 3 RECOMMENDATIONS 3.1 JULIE AVENUE LIFT STATION RECOMMENDATIONS Based on the findings in the report it is recommended that the City perform the following actions: 1. Replace the existing 4-inch force main with a new 8-inch diameter force main to accommodate higher flows. Estimated Cost: $94, Replace the existing pumps and controls with the new equipment sized to match the estimated 20-year peak flow rate for the lift station of about 360 gallons per minute. This will include a new duplex submersible pump system, basin mixer, control panel with VFD s, pressure transducer and backup float for level controls, PLC with touch screen, and SCADA with a transmitter back to the WWTF master SCADA system. Estimated Cost: $170, Replace the existing engine generator set and automatic transfer switch if the existing engine generator set is not of adequate size to power the proposed lift station equipment. Estimated Cost: $44, Consider adding a pump-mate above-ground valve structure to eliminate the confined space entry concerns with below grade valves. Estimated Cost: $50, Consider extending three-phase power to the lift station if a larger pump motor is needed. Estimated Cost: $75, HOESCHLER DRIVE LIFT STATION RECOMMENDATIONS Based on the findings of this report; it is recommended that the City perform the following actions: 1. Replace the existing 8-inch gravity sewer main from the Hoeschler Drive Lift station to the existing manhole, about 275 feet east of Hoeschler Drive lift station, with a new 10-inch force main. Estimated Cost: $86, Replace the existing pumps and controls with the new equipment sized to match the estimated 20-year peak flow rate for the lift station of about 950 gallons per minute. This will include: a new duplex submersible pump system, above ground pump-mate valve structure, basin mixer, control panel with VFD s, pressure transducer and backup floats for level controls, PLC with touch screen, and SCADA with a transmitter back to the WWTF master SCADA system. Estimated Cost: $220, Replace the existing engine generator set and automatic transfer switch if it is not of adequate size to power the new lift station. Estimated Cost: $44,000 Project No Page 10 October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

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17 Lift Station Evaluation Appendices City of Sparta, Wisconsin October 2017 Appendix A Service Areas Project No October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

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19 10" GENEVA DR 10" FAITH AVE HANOVER RD HAMMOCK RD LIFT STATION SERVICE AREA Unknown ST ANNE ST ST ANNE ST ST HWY 16 HAMMOND AVE Unknown HANOVER RD HAMLET AVE JULIE AVE LINDA LA " LINDA LA RIVER RD 10" A " 10" LEGEND HANSON PL SERVICE AREA JULIE AVE SERVICE AREA!2 Manhole, GPS!( Manhole, No GPS!< Control Valve!( System Valve [ä Lift Station 3Q Treatment Plant Gravity Main Force Main Lateral Line City Limits EM_Railroads EM_AllRoads Hydrology LCD_MonroeCo_hydro_rivers Tax Parcel PRIVATE ST E BASE DATA PROVIDED BY MONROE COUNTY CITY OF SPARTA MONROE COUNTY, WISCONSIN Feet ,200 Printed By: crooyakkers, File: P:\50s\51\ \GIS\LiftStation Service Area.mxd Print Date: 9/7/2017

20 HANOVER RD FAITH AVE HAMMOCK RD LIFT STATION SERVICE AREA Unknown ST ANNE ST ST ANN E ST LEGEND HOESCHLER DR SERVICE AREA HAMMOND AVE 22.7 HANOVER RD HAMLET AVE ST H JULIE AVE " " LINDA LA Lift Station 3 Q Treatment Plant Gravity Main Hydrology LCD_MonroeCo_hydro_rivers LINDA LA [ ä Tax Parcel System Valve (! EM_AllRoads Control Valve EM_Railroads " ! < City Limits WY 1 Manhole, No GPS Lateral Line 10" 22.52! ( Force Main Manhole, GPS !! " A " RIVER RD GENEVA DR PRIVATE ST Unknown BASE DATA PROVIDED BY MONROE COUNTY E CITY OF SPARTA MONROE COUNTY,WISCONSIN 0 Printed By: crooyakkers, File: P:\50s\51\ \GIS\LiftStation Service Area.mxd Feet 1,200 Print Date: 9/7/2017

21 Lift Station Evaluation Appendices City of Sparta, Wisconsin October 2017 Appendix B Cost Estimates Project No October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

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23 DATE COMPLETED: 10/5/2017 CITY OF SPARTA JULIE AVENUE LIFT STATION PRELIMINARY COST ESTIMATE Oct-17 ESTIMATE YEAR: CONSTRUCTION YEAR: DESCRIPTION QTY. UNIT UNIT PRICE TOTAL PRICE LIFT STATION IMPROVEMENTS NEW DUPLEX PUMP PUMP SYSTEM 1 LS $57,000 $57,000 CONTROLS WITH SCADA 1 LS $45,000 $45,000 NEW BASIN MIXER 1 EA $10,000 $10,000 PUMPMATE VALVE STRUCTURE 1 LS $35,000 $35,000 STANDBY ENGINE GENERATOR SET 1 EA $34,000 $34,000 3 PHASE POWER TO SITE 1 EA $75,000 $52,000 FORCEMAIN FORCEMAIN, 740 LF $60 $44,400 TRAFFIC CONTROL, EROSION CONTROL, AND TURF RESTORATION 1 LS $15,000 $15,000 STREET REMOVALS 100 SY $3 $300 CURB AND GUTTER 30 LF $30 $900 CRUSHED AGGREGATE BASE 40 CY $35 $1,400 ASPHALTIC PAVEMENT 80 SY $35 $2,800 SUBTOTAL $297,800 INFLATION (4% PER YEAR) $11,900 CONTINGENCY (20%) $61,900 ENGINEERING (20%) $61,900 TOTAL PROJECT $433,500 P:\50s\51\ \Calculations\Julie Avenue estimate.xlsx Completed By: EOE

24 DATE COMPLETED: 10/5/2017 CITY OF SPARTA HOESCHLER DRIVE LIFT STATION PRELIMINARY COST ESTIMATE Oct-17 ESTIMATE YEAR: CONSTRUCTION YEAR: DESCRIPTION QTY. UNIT UNIT PRICE TOTAL PRICE LIFT STATION IMPROVEMENTS NEW DUPLEX PUMP PUMP SYSTEM 1 LS $57,000 $57,000 PUMPMATE VALVE STRUCTURE 1 LS $35,000 $35,000 CONTROLS WITH SCADA 1 LS $45,000 $45,000 NEW BASIN MIXER 1 EA $10,000 $10,000 STANDBY ENGINE GENERATOR SET 1 EA $34,000 $34,000 FORCEMAIN FORCEMAIN, 10" 300 LF $70 $21,000 TRAFFIC CONTROL, EROSION CONTROL, AND TURF RESTORATION 1 LS $7,500 $7,500 STREET REMOVALS 700 SY $3 $2,100 CURB AND GUTTER 20 LF $30 $600 CRUSHED AGGREGATE BASE 160 CY $25 $4,000 ASPHALTIC PAVEMENT 700 SY $35 $24,500 SUBTOTAL $240,700 INFLATION (4% PER YEAR) $9,600 CONTINGENCY (20%) $50,100 ENGINEERING (20%) $50,100 TOTAL PROJECT $350,500 P:\50s\51\ \Calculations\Hoeschler Drive estimate.xlsx Completed By:EOE

25 Lift Station Evaluation Appendices City of Sparta, Wisconsin October 2017 Appendix C Calculations Project No October 2017 MSA Professional Services, Inc. \\msa-ps.com\fs\projects\50s\51\ \reports\lift station evaluation mjm.docx

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27 Julie Avenue Lift Station Flow Rates Area Served: 192 Acres Assumptions: 2.1 homes / acre 2.3 persons / home 100 gallons / cap / day Peak Factor 4.0 AVG Flow Qave 192 acres x 2.1 homes/acre x 2.3 persons / home x 100 gpcd = 92,736 gallons / day AVG Flow from run times provided by City 81,000 gallons /day 92,763 gpd / 24 hours / 60 minutes = 59.5 gallons / minute ~ 64 GPM Peak Flow Qpeak 64 GPM x 4.0 = 256 GPM Flow from Future Lots: 150 lots x 2.3 persons per lot x 100 gpd = 34,500 gallons / day Or 24 GPM Current Peak Flow Qpeak 64 GPM x 4.0 = 254 GPM Future Peak Flow Qpeak 90 GPM x 4.0 = 360 GPM Hoeschler Drive Station Flow Rates Qave based on pump run times: 240,000 gallons per day or 167 GPM Qave estimated by service area: Area Served: 492 Acres total (200 Acres Industrial / Commercial) (292 Acres residential) Assumptions: 2.1 homes / acre (residential) 10 employees / acres (industrial) 2.3 persons / home 100 gallons / cap / day 30 gallons / emp / day Peak Factor 4.0 Flow from Hormel Foods 75,370 gpd Calculations: 292 acres x 2.1 homes/acre x 2.3 persons/home x 100 gpcd = 141,036 gallons / day 200 acres x 10 emp / acres x 30 gped = 60,000 gallons / day Hormel Foods = TOTAL 73,370 gallons / day 274,400 gallons / day Or 190 GPM Flow from Future Lots: 300 lots x 2.3 persons per lot x 100 gpd = 69,000 gallons / day Or 48 GPM Current Peak Flow Qpeak 167 GPM x 4.0 = 670 GPM Future Peak Flow Qpeak 238 GPM x 4.0 = 950 GPM

28 Julie Avenue Proposed Cycle Times with existing pumps On/off separation 2.0 feet Tank = Gallons / foot Pumping Rate = 180 gpm During AVG Flows Fill time 2 feet x gal/ft = 423 gallons 423 gallons / 60 GPM = 7 minutes Pump time 423 gallons / (180 GPM 60 GPM) = 3.5 minutes TOTAL CYCLE TIME = 10.5 minutes Shortest Cycle Time Fill time 2 feet x gal/ft = 423 gallons 423 gallons / 90 GPM = 4.7 minutes Pump time 423 gallons / (180 GPM 90 GPM) = 4.7 minutes TOTAL CYCLE TIME = 9.4 minutes Hoeschler Drive Proposed Cycle Times with existing pumps On/off separation 2.0 feet Tank = Gallons / foot Flow Rate = 340 gpm During AVG Flows Fill time 2 feet x gal/ft = 423 gallons 423 gallons / 190 GPM = 2.2 minutes Pump time 423 gallons / (340 GPM 190 GPM) = 2.8 minutes TOTAL CYCLE TIME = 5.0 minutes Shortest Cycle time Fill time 2 feet x gal/ft = 423 gallons 423 gallons / 170 GPM = 2.5 minutes Pump time 423 gallons / (340 GPM 170 GPM) = 2.5 minutes TOTAL CYCLE TIME = 5.0 minutes

29 Julie Avenue Proposed Cycle Times Future Conditions On/off separation 2.5 feet Tank = Gallons / foot Pumping Rate = 360 gpm Shortest Cycle Time Fill time 2.5 feet x gal/ft = 528 gallons 528 gallons / 180 GPM = 2.9 minutes Pump time 528 gallons / (360 GPM 180 GPM) = 2.9 minutes TOTAL CYCLE TIME = 5.8 minutes Hoeschler Drive Proposed Cycle Times with existing pumps On/off separation 5.5 feet Tank = Gallons / foot Flow Rate = 860 gpm Shortest Cycle time Fill time 5.5 feet x gal/ft = 1163 gallons* 1163 gallons / 430 GPM = 2.7 minutes Pump time 1163 gallons / (860 GPM 430 GPM) = 2.7 minutes TOTAL CYCLE TIME = 5.4 minutes *Not room for this in wet well, use VFD s or build a bigger wet well to meet run time requirements.