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Challenges Faced in the Design of Large-Diameter Forcemain: Dundalk Pumping Station Forcemain Replacement, City of Baltimore, Maryland

The replacement of the 36-inch diameter sewage force main for the Dundalk wastewater pumping station for the City of Baltimore Department of Public Works poses several design challenges associated with large diameter pressure mains in congested urban areas. These design challenges include combination pressure and gravity hydraulics, isolation valves, horizontal and vertical alignment deflections, air release, thrust restraint, utility relocations, by-pass pumping, poor soil conditions, and possible localized soil contamination. The Dundalk pumping station located on Broening Highway at Keith Avenue in southeast Baltimore was constructed in 1946 and is of conventional wet well - dry pit configuration. The pump arrangement includes three parallel pumps with control valves connected to a manifold and a 36-inch cast iron force main. The existing 4,300foot force main pumps to a 54-inch gravity sewer. Maximum pumping capacity with all pumps running is 23,000 gpm (33 MGD) at 110 feet total dynamic head. The Department of Public Works has determined that a replacement main is required due to deterioration of the existing cast iron pipe. It is intended that the old main remain functional as a backup to the new replacement main. The initial design challenge is to find a suitable alignment for the new main since the original main is located in a narrow public utility easement through private industrial property. The choice of using the public road right of way for the new alignment results in a longer route and a highpoint about 800 feet from the discharge point and subsequent downhill run. This generates a potential hydraulic problem in the transition from pressure flow to gravity flow. The interconnection of the old and new mains require an isolation valve arrangement near the pumping station so that either main can be operated by a control switch inside the station. Due to limited space between major drainage structures and the existence of a concrete thrust restraint system for the old force main in the area where the dual control valves are to be placed a compact configuration is necessary. The 3,800 foot alignment in the industrial arterial road poses the usual complexity of congested. Selecting a horizontal and vertical alignment requires intense coordination between field topographic surveys, interpretation of often schematic record drawings, surface marking, and field reviews. Part of the main alignment falls within an area of land reclamation from the early part of the last century. The unconsolidated nature of the fill soil and high water table makes the thrust restraining joint systems a critical element of design.

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