Abstract:
A unitary concrete structure pumping station useful in pumping waste fluids and the like during the passing of such materials from one part of a gravity flow waste system to another. This concrete structure is simple to install and use and many of the problems associated with conventional pumping stations are alleviated. The structure is comprised of several parts that can be made pre-assembled at the factory or assembled in the field prior to installation. By being a unitary structure this pumping station is resistant to movements within the earth and therefore less likely to incur line breaks.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to the fields of waste and storm water pumping and waste product management and more particularly to the means of pumping such waste materials into a pressurized pipe and further on into a gravity sewer waste handling system for further treatment and processing. More particularly, this invention relates to gravity flow waste handling systems. Still more particularly, this invention relates to an improved pumping stations for such waste handling and to a unitary structure employed as a system with submersible pumping systems or pump stations. Even more particularly, this invention relates to pumping stations that can be installed within the flow and area of vehicular traffic. 
   2. Description of the Prior Art 
   Most commercial waste handling systems usually employ some sort of gravity flow to carry the waste along a piping system and subsequently to treatment or other handling systems. Many of these systems are aqueous flow systems that handle sewage and other aqueous waste products including storm water run off and the like. It is difficult, however, to provide a total gravity flow system and it is sometimes necessary to have one or more pumping stations within the waste handling flow areas in order to move the waste stream along to its ultimate destination. For example, the waste from a higher source can flow along the piping or drainage system for a period of time but usually has to be pumped up over to some higher elevation. These pumping stations are very common within the prior art and usually employ a collection point in which a submersible pump is placed. As the collection point fills up with the aqueous waste product the pump sends this material up into an internal piping system through a check valve and into a gate valve apparatus and the pipe from thence sends the waste product on its way to the next point. There may be, and in fact usually are, several of these pumping stations between the aqueous waste source and the ultimate destination, which may be a waste treatment facility or just some drain source for normal storm drains and the like. Additionally, it is sometimes requisite to install a pumping station under the street or highway area in order to pump storm water and the like. 
   There are some serious problems with current pumping stations within the prior art. Most of these systems are round, concrete elements and are furnished as at least two or more, separate elements. Such a dual element includes the collection or pumping container (commonly called a wet well) and the container or chamber and the container or chamber for the valves and other elements (commonly called a valve chamber). They are inserted under ground in such a manner that the collection point containing the submersible pump is deeper than the container for the valves. In between these two, cementitious containers or chambers, there is normally a line or pipe to move the waste from the collection point to the valve chamber. Since the ground must be disturbed during the installation of these two points there is a tendency for the disturbed ground to settle and this settling causes movement of the piping between the collection point and the valve chamber and occasionally a line break occurs. This line breakage is a serious event and it is always necessitates the need to excavate the area around and between the two points in order to get to the line for repair. This is a very costly step and when there are several such pumping stations and several such line breaks the costs elevate considerable. Additionally, any leaks that may occur around these pumping stations can result in ground water pollution. Most of the current pumping stations are not suitable for installation under streets and the like since they must survive the constant flow of vehicular traffic without cracking lines and the like. 
   There is also considerable installation costs incurred by using these prior art pumping stations. Considerable ground must be excavated and putting together the two chambers or containers is time consuming and sometimes dangerous. As mentioned previously, it is difficult to sufficiently compact the ground around the containers and thus the shifting and/or settlement problems occur as previously mentioned. The two or more container system is also complicated requiring a great deal of skill to construct. Also, since the valve chamber or container is smaller in size it tends to “float” and/or “sink” in the disturbed ground area causing additional strain such as shears and breaks on the piping system. 
   Finally, since the two container or chamber system is more complicated, the construction of pumping stations using these prior art systems is also very complicated and requires a lot of individual parts. Thus, the installer must have on hand a great variety of elements and this is very expensive. 
   SUMMARY OF THE INVENTION 
   There is a pressing need or object within the prior art for a unitary pumping station for pumping aqueous waste or storm materials from one level to another. There is also a pressing need or object within the prior art for a pumping station that can be installed without fear of breakage when the disturbed ground moves after installation. Finally, there is also a pressing need or object for a pumping station that can be manufactured usually in a single pieces with the requisite parts and elements already installed and so as to permit joining of these pieces, especially in larger systems, of chambers right on the site. There is also a need to provide smaller systems that can be entirely manufactured away from the installation site and thus improve installation thereof. This will reduce the time requisite for installation thereof. Also, there is a pressing need to have a secure and safe pumping station that can be installed underground in streets and the like and that will survive vehicular traffic that passes overhead. These and yet other objects are achieved in a unitary cementitious pumping station for moving aqueous waste materials from one level to another comprising in order, 
   a. a squared fluid receiving container having a bottom with integral filets, four sides and a top with an inlet on one side, an exit line on the side opposite to said inlet and wherein said exit line is attached to a submersible pump contained therein; 
   b. a smaller and squared valve container having a bottom, four sides, a top wherein said top is essentially at the same level as the top from said receiving container, and a exit line on one side, said smaller container attached to the exit line side of said receiving container, and wherein said exit line in said smaller container is on the side opposite to the side attached to said receiving container, a fluid transit line attached to said exit line from said receiving container and to said exit line in said smaller container, and wherein said smaller container also contains at least one valve within said attaching line, 
   so that when aqueous waste enters said receiving container and begins to fill up said receiving container, said pump will pump said aqueous waste up through said exit line contained therein and through said fluid transit line and said valve and out said smaller container exit. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a side view of the basic design of the unitary, cementitious, squared pumping station of this invention. 
       FIG. 2  is another side view of the element of  FIG. 1  showing the various necessary connections to make the system unitary. 
       FIG. 3  is a view along the line B—C in  FIG. 1  showing some detail of the connection of the parts needed to make the system unitary. 
       FIG. 4  is another embodiment of the unitary pumping station of this invention showing a catch-type container prior to the entry point of the waste fluids. 
       FIG. 5  is a top view of the elements from  FIG. 4 . 
       FIG. 6  is yet another embodiment of the design in  FIG. 4  employing a macerating chamber in place of the catch container. 
       FIG. 7  shows a larger version of the element from  FIG. 4  with some extra reinforcing elements in place. 
       FIG. 8  is the same as the element of  FIG. 7  except for the addition of a flume container in place of a catch-type container. 
       FIG. 8   a  shows the flume container in more detail as. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Looking now specifically at the drawings particularly useful in describing this invention, but by which I am not limited,  FIG. 1  is a basic and simple form of the unitary pumping station useful in moving waste fluids from one level to another. In this showing  1  is the unitary pumping station as a whole shown beneath the ground  2 . A squared, fluid receiving container is shown as  3  and a smaller, squared valve container shown as  4 . Each of these two containers may have a man-hole access point as shown as  5  and  6 . In the fluid receiving container the fluid enters in at a certain level through inlet pipe  7 . As the fluid rises up in this container a submersible pump  8  pumps this fluid up into the smaller valve container  4  through a pipe  9 . This fluid passes through an integral check valve  10  and then through a gate valve  10   a  and exits through pipe  11  further into the system. The entire system is a unitary pumping station with fluid entering at a lower level and being pumped into a higher level to continue down the system. An optional ladder  50  is shown in the valve container so as to give access to the valves when a shut-down is required, for example. Both  3  and  4  are mated together as will be described in a later figure. This mating then forms the unitary pumping station  1 . Two of several mating bolts are shown as  12  and  12   a . A vent pipe  53  is shown to ensure that any noxious gases are removed from the unitized structure of this invention. A pair of pumps and a pair of check and gate valves may be employed in this system. 
     FIG. 2  is another view of the simpler, unitary pumping station from  FIG. 1  shown in an exploded side view so as to demonstrate the various elements and as to how they can be constructed and mated or joined in situ. In this particular figure the ground is not shown. Once again,  3  is the fluid receiving container and  4  is the smaller valve container. These two containers are joined together following the dotted line A and two of several bolts are shown as  12  and  12   a . A gasket  13  is furnished between the two containers in order to provide a tight seal. A supporting block is shown as  14  and this is connected to fluid receiving container  3  with several bolts, one of which is shown as  15 . The connection of pipe  9  is made via an opening  16  in the side wall  17  of fluid receiving container  3  that adjoins the valve container  4 . All of the connections can be made at the site as the various parts of the novel pumping station of this invention is assembled and installed. All insure a tight fit when so assembled to form the unitary element so useful as an aqueous waste pumping station. A front view of this supporting block  14  is shown in more detail with 3 bolt elements  15 ,  22  and  23 . The supporting block will support the valve chamber securely preventing any torque or other forces that plague the prior art elements and cause severe problems during operation of the system. 
     FIG. 3  is a showing of the connecting side walls taken along the dotted line B—C from  FIG. 2 . In this particular figure, the valve, submersible pump and various inlet and outlet pipes are not shown. The opening  16  in the side wall of the fluid receiving container  3  is shown as well as gasket  13 . Bolt receiving holes within the valve container  4  are shown as  18 ,  19 ,  20  and  21  and these match up with bolt receiving holes  18   a ,  19   a ,  20   a  and  21   a  in the fluid receiving container  3 . Bolts passing through from one container to the other can be used to pull the containers tight against each other. The supporting block  14  with one bolt  15  along with at least 2 other bolts  22  and  23  can be installed under the valve container  4  to provide support therefore. One of several filets in the bottom of the fluid receive container  3  is shown as  53 . These concrete filets are useful in the management of solids found within the fluid entering this container. 
     FIG. 4  shows yet another embodiment of the unitary pumping station of this invention. In this figure an inlet trapping container  24  is shown. This container is designed to trap larger materials that might flow in to the system, materials such as small branches and the like. The fluid enters through pipe  25  and any debris is caught on a sloping filter or screen shown from the side as  26 . The filtered or screened fluid then continues on through pipe  7  and into fluid receiving container  3 . An optional man hole cover may  27  may also be included to access this inlet container to clean out filtered or screened debris, for example. Connections and supports may also be included as described in  FIG. 3  to attach inlet container  24  properly to fluid receiving container  3  in a like fashion. Removing such debris helps maintain the system and reduce and possible plugging of the subsequent pumping operation within the fluid receiving container  3 . 
     FIG. 5  is a top view of  FIG. 4  in yet another embodiment showing a double submersible pump and a bar-screen system for filtering or screening out debris. In this figure, the fluid enters into an inlet container  26  through pipe  25 . A bar-screen  26  is shown and a pair of baffle plates or bars as  28  and  28   a . The screened or filtered fluid can then be passed via two pipes  29  and  29   a  into the fluid receiving container  3  and from thence by two submersible pumps ( 8  and  8   a ) in a pair of valves  10  and  10   a  located at an elevated level in valve container  4 . From thence the fluid passes through pipe  11  on into the system. 
     FIG. 6  shows a top view of  FIG. 5  wherein a macerator replaces the filter or screen element and any solids that are present within the fluid are ground up so that they can pass through without damage to the following pump or pumps. In this showing  24  is the inlet container and the fluid enters through pipe  27  and exits into the fluid receiving container (not shown) through pipe  7 . Inside this particular embodiment there is equipment requisite to macerating any solids that might be present within the entering fluid. This equipment comprises in order a “Y” pipe  30  one end of which leads to a valve  31 . The other end of this “Y” leads through an elbow  32  to a flushing “T”  33 . The macerator is shown as  34 . Additional valves are shown in the system as  35  and  36 . When valves  31  and  35  are open and valve  36  is closed, fluid goes through the macerator  34 . When it flushing of the system is necessary, valves  31  and  35  are closed and valve  36  is opened and flushing of the system can occur through flushing “T”  33 . 
     FIG. 7  shows a larger version of the pumping station shown in  FIG. 4  and all of the elements within that figure are here too. Since the system may be somewhat larger, optional supporting elements may be needed to ensure that the unitized structure, as installed, will sit safely under ground without significant movement or shifting of the various parts. Two additional supporting blocks  36  and  37  are shown placed under inlet trapping container  24  and valve container  4 . The base  38  of the fluid receiving container  3  has been enlarged and two embedded tension cables  39  and  40  have been added. 
     FIG. 8  is the same as  FIG. 7  except that the inlet container has been replace by a flume chamber shown as  60 . In  FIG. 8   a  the flume chamber  60  is shown in a little more detail. This chamber (known as a Parshall Flume Chamber) contains flumes  61  and  62  and narrows down the flow of aqueous material coming in pipe  25  to aid in the measurement of that flow. 
   As noted previously, no one provides a suitable unitary structure (containing pumps, piping, vavling and optional screening and/or flow measurement devices) for pumping waste materials from one level to another. The prior art usually segregates the pumping container from the valve container and the pipe or line connecting these two containers can be severed or broken during the movement of the earth around the system. The inlet trap or flume chambers or containers are also installed separately and are separated from the pumping station itself. Additionally, the prior art usually offers round containers and these are more difficult to pre-cast and to store prior to installation, especially when mass produced. My novel and unique system offers squared, pre-cast, cementitious containers that are either connected at the factory or they can be assembled in situ to form the unitary structure described and shown in the drawings and figures attached hereto. My unique and novel design will withstand the strain and pressure of installation under streets and highways. The correct and universal term for this type of installation is commonly referred to as a Full Traffic Loading as defined by the American Association of State Highway and Transportation Officials and the rating they give for such installation is referred to as AASHTO (H-20) 16,000 lb. Wheel Loading. My novel structure will meet this definition. 
   The intent of this unique and novel structure is to act as a collection point in a gravity waste water or sewer system. All of the requisite elements to perform the task of pumping these materials from one level to another including the pumps, guide rail systems, valves and the like can be pre-installed within the pre-cast cementitious containers, taken to the site and then installed as one piece, for the smaller units, or, for the larger units, united together on the site together to form the unitary pumping station. As described, an optional auxiliary container or chamber can be offered and attached in a like manner to help with the flow of materials where excess or unusual solids may be present. These can be screened or filtered out or passed through a macerator system to grind them up suitable for passage through the pumping system. In addition, a flow monitoring device such as a Palmer-Bolus or Parshall Flume element may be included herein as shown in  FIGS. 8 and 8   a.    
   Conventionally, my novel unit is sectional as delivered to the site and cast from square sections of reinforced and pre-cast concrete having a minimum inside dimension of about 36″ square to pieces as large as 144″ square or whatever is practical to ship. Alternatively, smaller units can be furnished as a single piece. I prefer that the concrete used have a minimum, compressive strength of 6000 psi at 28 days and be reinforced with steel elements that meet ASTM A-615 Grade 60. Wall thickness should be about 6″ at a minimum depending on the overall depth of installation of the unitary structure in the earth. Each portion of the pre-cast concrete as assembled should be of tongue and groove or shiplap shape and employ a two course field applied butyl rubber gasket system that seals via compression. Sealing between each of the containers should also be accomplished by the use of butyl rubber gaskets, specialized rubber links or non-shrink grouts, for example. 
   Although the specification and drawings contained herein show particularly preferred embodiments and showings of this invention other modifications to the connections and support systems, for example, may be envisioned within the metes and bounds therein. I do not feel limited to those particular elements and processes described.