Table of Contents

Page
TRUCKFILL STATIONS AND PUMP HOUSES
9.1 INTRODUCTION........................................................................................................................... 9-1

9.2 FLOW RATE REQUIREMENTS................................................................................................... 9-1

9.2.1 Minimum Flow Rate.......................................................................................................... 9-1
9.2.2 Flow Rates - Watermain Feed.......................................................................................... 9-2
9.3 INTAKE SYSTEM ......................................................................................................................... 9-2
9.3.1 Concrete Structures ......................................................................................................... 9-3
9.3.2 Intake Screens .................................................................................................................9-3
9.3.3 Carrier Pipe ...................................................................................................................... 9-4
9.3.4 Submersible Pump ........................................................................................................... 9-4
9.3.5 Discharge Pipe ................................................................................................................. 9-4
9.3.6 Electric Heat Trace........................................................................................................... 9-4
9.3.7 Pump Skid ........................................................................................................................ 9-4
9.3.8 Pull Cable ......................................................................................................................... 9-5
9.3.9 Number of Intakes ............................................................................................................ 9-5
9.4 SELF-DRAINING CAPABILITY ................................................................................................... 9-5
9.4.1 Check Valves ................................................................................................................... 9-5
9.4.2 Pipe Grading .................................................................................................................... 9-5
9.4.3 Drain Valves ..................................................................................................................... 9-6
9.4.4 Air/Vacuum Valves ........................................................................................................... 9-6
9.4.5 Twin Intake ....................................................................................................................... 9-6
9.5 TRUCKFILL MEANS .................................................................................................................... 9-6
9.5.1 Couplings ......................................................................................................................... 9-6
9.5.2 Articulating Arms .............................................................................................................. 9-6
9.5.3 Overhead Fill Arm ............................................................................................................ 9-7
9.5.4 Activation Pushbuttons..................................................................................................... 9-7
9.5.5 Lighting............................................................................................................................. 9-7
9.6 BUILDING ENVELOPE ................................................................................................................ 9-8
9.6.1 Insulation .......................................................................................................................... 9-8
9.6.2 Interior Finish.................................................................................................................... 9-8
9.6.3 Exterior Finish .................................................................................................................. 9-8
9.6.4 Floor ................................................................................................................................. 9-8
9.6.5 Door Hardware ................................................................................................................. 9-8
9.6.6 Windows........................................................................................................................... 9-8
9.6.7 Foundation ....................................................................................................................... 9-8
9.7 BUILDING LAYOUT/FLOORPLAN.............................................................................................. 9-9
9.7.1 Working Space ................................................................................................................. 9-9
9.7.2 Room For Future Expansion ............................................................................................ 9-9

GOOD ENGINEERING PRACTICE Apr-04

Truckfill Stations and Pump Houses
9.8 MECHANICAL/ELECTRICAL SYSTEMS .................................................................................... 9-9
9.8.1 Interior Water Piping......................................................................................................... 9-9
9.8.2 Truckfill Arm Piping .......................................................................................................... 9-9
9.8.3 Heating/Ventilation/Lighting ........................................................................................... 9-10
9.9 SITE GRADING .......................................................................................................................... 9-10
9.9.1 Drainage......................................................................................................................... 9-10
9.9.2 Truck Access.................................................................................................................. 9-10
9.9.3 Parking ........................................................................................................................... 9-11
9.9.4 Pump Removal............................................................................................................... 9-11
9.10 STANDBY POWER .................................................................................................................... 9-11
9.10.1 Standby Power ............................................................................................................... 9-11
9.11 SITE-GENERATED POWER...................................................................................................... 9-11
9.11.1 Economic Analysis ......................................................................................................... 9-11
9.11.2 Load Management ......................................................................................................... 9-11
9.12 SECURITY .................................................................................................................................. 9-12
9.12.1 Truckfill Station/Pump House ......................................................................................... 9-12
9.12.2 Reservoir ........................................................................................................................ 9-12

GOOD ENGINEERING PRACTICE Apr-04

Truckfill Stations and Pump Houses
9.0 TRUCKFILL STATIONS AND PUMP HOUSES

9.1 INTRODUCTION

Many northern communities rely on water delivery by truck rather than by pipe. A means of
loading the trucks is required, which must be simple and reliable in extreme weather conditions.

Truckfill facilities are of two main types:

dedicated truckfill operations directly from a source or storage tank; or
truckfill operations from an existing watermain.

Photo 9.1 – Typical Truckfill Station

9.2 FLOW RATE REQUIREMENTS

The rate of flow to the trucks governs many of the station parameters and must be one of the first
items addressed in the design.

Recommendation Rationale
9.2.1 Minimum Flow Rate
A minimum flow rate of 1,000 L/min. For trucks up to 15,000 L capacity, 1,000 L/min generally
is recommended. provides an acceptable fill time.

Per MACA, Water and Sewage Facilities, Capital

Programs: Standards and Criteria (July 1993).

A higher flow rate may be desirable If bulk water hauling by larger vehicles is desired, fill rate
with large capacity vehicles. should be set to allow filling in 5 to 10 minutes to
maximize haul efficiency.

GOOD ENGINEERING PRACTICE 9-1 Apr-04

Truckfill Stations and Pump Houses
9.2.2 Flow Rates - Watermain Feed
Recommend a system analysis if The truckfill operation is a large demand on a system
the truckfill is fed from a piped which, if not properly designed, will result in large system
watermain system. pressure loss and/or pump requirements.

9.3 INTAKE SYSTEM

An intake system can take many forms. In northern Canada, a simple inclined shaft system was
developed, refined and has enjoyed a good success. While the inclined shaft is the predominant
intake system for truckfill stations, other forms of intakes, such as wetwells with gravity intake
lines, are also in use.

Figure 9.1 – Typical Inclined Shaft Intake

GOOD ENGINEERING PRACTICE 9-2 Apr-04

Truckfill Stations and Pump Houses
Figure 9.2 – Typical Wetwell Intake

Recommendation Rationale
9.3.1 Concrete Structures
Recommend avoiding use of Generally good quality aggregate or aggregate of proper
structural concrete in isolated dimensions is not available.
communities.

9.3.2 Intake Screens

Recommend screens be a minimum Clearance from the bottom is required to avoid the intake
of 1.0 m above the bottom of the of bottom sediments.
river or lake.

Recommend screens be a minimum To prevent ice damage, and minimize facial ice buildup.
of 1.0 m below the maximum winter
ice cover.

Recommend the lowest water level Lake or river levels can vary substantially.
of the source be determined.

Recommend screens be sized to Legislative requirement.

suit Department of Fisheries
requirements.

GOOD ENGINEERING PRACTICE 9-3 Apr-04

Truckfill Stations and Pump Houses
9.3.3 Carrier Pipe
Recommend insulation of carrier Minimizes heat loss from the carrier pipe.
pipe for all areas above the level of
lowest ice formation.

Recommend use of high density Eliminates corrosion potential.

polyethylene (HDPE) as a carrier
pipe. Can be field bent as required to follow intake grades.

9.3.4 Submersible Pump

Recommend submersible pumps of Submersible pumps operate well in inclined shafts.
appropriate size be installed to
below the level of maximum ice The pump must be below the level of ice formation to
formation. prevent damage if the intake freezes.

Recommend no check valve be Allows the discharge pipe to drain after a truck-loading
installed at the pump. operation.

9.3.5 Discharge Pipe

Recommend the discharge pipe Eliminates corrosion potential.
from the pump to the station be
HDPE. Generally does not rupture if frozen.

9.3.6 Electric Heat Trace

Recommend two heat trace per Should one heat trace fail, the backup unit can be used
carrier pipe be installed - one duty, to thaw the intake.
one standby.

Recommend a controller be utilized Minimizes energy costs.

to maintain the carrier pipe
temperature.

Recommend controller include high Heat trace may cause overheating to the point of intake
temperature shut-down feature. damage.

Recommend heat trace be installed The majority of heat trace cannot be immersed in water.
in watertight metal tubes.
Metal tubing ensures ready transfer of heat to the
water/ice in the carrier pipe.

9.3.7 Pump Skid

Recommend the pump be mounted Prevents the pump from catching on the carrier pipe
on a skid with smooth runners. joints.

GOOD ENGINEERING PRACTICE 9-4 Apr-04

Truckfill Stations and Pump Houses
9.3.8 Pull Cable
Recommend an aircraft grade Pulling directly on the HDPE discharge pipe can result in
stainless steel cable be attached to breakage.
the pump skid for removal purposes.

9.3.9 Number of Intakes

Recommend two inclined shaft Provides a backup fill means if one pump fails or the
intakes if the truckfill station intake is frozen. One intake only may be appropriate if
provides water directly from the the conditions in “9.10 Standby Power” are met.
source for fire-fighting purposes.

Recommend truck drivers have the Valuable time can be lost in a fire situation if a station
ability to switch to the second intake. operator must be found before a switch to the second
intake can be made.

Figure 9.3 – Typical Submersible Pump in a Carrier Pipe

9.4 SELF-DRAINING CAPABILITY

In the life of a facility, it is quite probable that heat will be lost. To the extent possible, all water
piping should drain, when not in use, to minimize freeze damage potential.

Recommendation Rationale
9.4.1 Check Valves
Recommend check valves not be Allows piping to drain when not in use.
used unless required for system
functioning.

9.4.2 Pipe Grading

Recommend piping be graded to Allows piping to drain when not in use.
drain.

GOOD ENGINEERING PRACTICE 9-5 Apr-04

Truckfill Stations and Pump Houses
9.4.3 Drain Valves
Recommend solenoid drain valves De-energizing solenoids allow(s) draining of pipes when
be used on trapped low points on not in use.
piping. Ensure solenoid valves flow
water at zero pressure.

9.4.4 Air/Vacuum Valves

Recommend use of air Allows air release on startup and air entry when piping
release/vacuum release valves drains.
when required where some piping
cannot be drained.

9.4.5 Twin Intake

Where two intakes are installed, a Allows two intakes to feed one overhead fill arm while
Tech Taylor® or similar valve is still being self draining.
recommended.

Photo 9.2 – Tech Taylor Valve

9.5 TRUCKFILL MEANS

A means is required to connect the truck to the fill point and, hence, transfer water.

Recommendation Rationale
9.5.1 Couplings
Recommend not using a system that Hose couplings are difficult to handle in cold weather
relies on hose couplings or similar and are prone to ice buildup.
connections.

9.5.2 Articulating Arms

The use of articulating arms is not The seals in the arms freeze when not in use and must
recommended. be broken free. The useful life of the seals is short.

GOOD ENGINEERING PRACTICE 9-6 Apr-04

Truckfill Stations and Pump Houses
9.5.3 Overhead Fill Arm
The use of an overhead fill arm Does not require coupling the fill pipe to the tank.
connected to an open hatch on the
tank is recommended. Overhead arms are easily graded to promote self-
draining.

Recommend adjustable two-piece One-piece fill hoses are very stiff when frozen and
fill hose. difficult to maneuver into the tank hatch.

Photo 9.3 – Overhead Fill Arm

9.5.4 Activation Pushbuttons
Recommend truckfill activation Allows truck operator to start/stop filling operation from
buttons be mounted on the the top of the truck.
overhead fill arm.

Recommend truckfill activation To minimize the safety hazards associated with falls.
buttons be mounted on the outside
of the truckfill station and a loading
platform be provided, or an
alternative system be provided so
the driver does not have to climb on
the truck.

Recommend pushbuttons be rated Oil-tight or covered pushbuttons will not operate at

for -50°C. extreme temperatures.

Recommend pushbuttons be Operators must be able to utilize the pushbuttons in

useable even if the operator is extreme weather conditions.
wearing heavy mitts or gloves.

9.5.5 Lighting
Recommend at least one light on Operator safety.
the overhead fill arm.

GOOD ENGINEERING PRACTICE 9-7 Apr-04

Truckfill Stations and Pump Houses
9.6 BUILDING ENVELOPE

Recommendation Rationale
9.6.1 Insulation
Recommend a minimum of R20 for Minimize heating costs.
roof, walls and floor.

Recommend that building insulation A higher insulation level than the minimum may be
levels be determined on a case-by- warranted.
case basis.

Recommend polyurethane sandwich Pre-finished and minimal site labour required.

panels, if possible.

9.6.2 Interior Finish

Recommend pre-finished metal liner Low maintenance.
panels.

9.6.3 Exterior Finish

Recommend pre-finished metal Low maintenance.
panels, if possible.

9.6.4 Floor
Recommend concrete floor topping, Fuel and/or water spillage is a high probability and must
if possible. be contained.

9.6.5 Door Hardware

Recommend heavy duty door Lower maintenance.
hardware.

9.6.6 Windows
Recommend minimal or no Minimizes vandalism.
windows, particularly on remote
stations.

9.6.7 Foundation
Recommend obtaining the Many sites are on permafrost and site-specific or
recommendation of a Geotechnical specialized foundations may be required.
Engineer.

GOOD ENGINEERING PRACTICE 9-8 Apr-04

Truckfill Stations and Pump Houses
9.7 BUILDING LAYOUT/FLOORPLAN

Recommendation
9.7.1 Working Space
Recommend space for a water
quality and monitoring test station
be incorporated into the layout of the
building.
Recommend that provisions for a
sink or wash basin be included in
the design of the water quality and
monitoring test station.
Rationale
Daily tests are performed on chlorine residual and, in
some locations, iron and manganese. A test station
provides the operator with a designated area to store the
testing equipment and space to perform the required
tests.
The cleanliness of the testing equipment affects the
accuracy of the results. A sink allows the operator to
keep the test station and test equipment clean.

9.7.2 Room For Future Expansion

Recommend that the site selected
allow for future expansion.
Recommend that the treatment
process, as well as the structure
itself, be designed with the
anticipation of future additions to the
treatment process.
Due to continuous research in the area of water quality
and the development of new water treatment methods,
the standards and guidelines for drinking water quality
are continually revised. As a result, treatment processes
and truckfill stations/pump houses often require
upgrades and expansions to meet the new regulations.

9.8 MECHANICAL/ELECTRICAL SYSTEMS

Building mechanical and electrical systems should follow the "Good Building Practice" guidelines.

Truckfill station may have high humidity and/or chlorine vapours, requiring ventilation and protection of
components.

Recommendation Rationale
9.8.1 Interior Water Piping
Recommend use of non-corrosive Uncoated steel piping is subject to corrosion.
piping, such as PVC, inside the
building.

9.8.2 Truckfill Arm Piping

Recommend use of coated steel Exterior piping must withstand extreme temperatures
piping on the exterior truckfill arm. and forces generated when trucks strike a frozen
discharge hose.

Recommend exterior truckfill arm be Ensures blockage potential due to ice buildup inside pipe
insulated and electrically heat is minimized.
traced.

GOOD ENGINEERING PRACTICE 9-9 Apr-04

Truckfill Stations and Pump Houses
9.8.3 Heating/Ventilation/Lighting
Refer to Section 1.0 General Utility
Objectives.

9.9 SITE GRADING

Site development needs to address issues of drainage, vehicle access and pump removal.

Recommendation Rationale
9.9.1 Drainage
Recommend area of truckfilling Water spillage during truckfill operation is common.
operation be sloped away from the
building.

Recommend a hard-surfaced splash Water spillage during truckfill operation is common and
pad be provided, if practical, in the can cause erosion.
truckfilling area.

Recommend surface drainage be Minimizes ponding and erosion potential.

directed away from the building and
intake location.

Recommend culvert use be Culverts are prone to freezing.

minimized.

Recommend culverts, if installed,

have a thaw means.

9.9.2 Truck Access

Recommend water truck path Difficult to position truck properly in the middle of a
incorporate a straight access to the curve.
fill point.

Recommend turning radiuses be for Larger trucks may be obtained over the life of the facility.
largest truck contemplated.

Recommend using larger turning Difficult for drivers to deal with ‘minimums’ on a routine
radiuses than the ‘minimums’ basis.
published.

Recommend centre of turning bulb Open centres are drainage problems and present a
be filled to road grade. vehicle hazard.

GOOD ENGINEERING PRACTICE 9-10 Apr-04

Truckfill Stations and Pump Houses
9.9.3 Parking
Recommend providing at least two Station operators can block the water truck's access if no
parking stalls. parking is provided.

9.9.4 Pump Removal

Recommend unobstructed route be A route must be available to remove the complete length
available for pump removal if an of discharge piping when removing the pump.
inclined shaft intake is used.

9.10 STANDBY POWER

The truckfill facility may require the provision of a standby power source.

Recommendation Rationale
9.10.1 Standby Power
Standby power is recommended The truckfill station must be capable of providing water at
unless: all times unless other alternate means are in place and
operable as a backup system.
- Water storage for emergency and
fire protection use is stored
elsewhere; and
- A readily accessible standby pump Alternate means of fire protection require approval of the
and water access point is Fire Marshal.
maintained year-round.

9.11 SITE-GENERATED POWER

On occasion, the water source is remote from the community and commercial power is not
available.

Recommendation
9.11.1 Economic Analysis
Recommend a 20-year life cycle
cost analysis be undertaken prior to
deciding on the power source.
Rationale
An economic analysis is required to determine the best
long-term power solution; site generated or power line
from the community.

9.11.2 Load Management

Recommend electrical loads be Careful load management is required to minimize
carefully reviewed during design of generator size and fuel burn.
site-generated power.

Recommend that non-essential If certain loads can be turned off when pumping, the
building loads be shut off during generator size can be minimized. This also reduces fuel
brief truckfill periods. usage and ensures the generator has an acceptable load
when not pumping.

GOOD ENGINEERING PRACTICE 9-11 Apr-04

Truckfill Stations and Pump Houses
9.12 SECURITY
Recommendation
9.12.1 Truckfill Station/Pump House
Recommend that the access door
be equipped with a lock and that the
door remain locked when there is no
operator present.
Recommend the outside operator’s
panel be locked and the fire
department be provided with a key.
Recommend the fire department
and the SAO or Band Manager be
provided with a spare key to the
truckfill or pump house and that they
be taught how to turn the water
supply on and off.
Recommend that all hazardous
materials be stored in a secure
container or area, be well labeled,
and that the MSDS be kept in the
truckfill station or pump house.
It is recommended that “Hazardous
Materials Storage Area” be posted
on the outside door of all truckfill
stations and pump houses.
9.12.2 Reservoir
Recommend that the access gates
to the reservoir be closed and
locked at all times when the
operator is not present.
GOOD ENGINEERING PRACTICE
Truckfill Stations and Pump Houses
Rationale
Sensitive equipment and hazardous chemicals are used
and stored in the building. Keeping the door locked
reduces the chances of exposure to hazardous materials
by community members, and helps minimize vandalism
and tampering with equipment. The health of the entire
community depends on proper equipment setting and
functioning.
The fire department staff will have access to the water
supply in the event of a fire.
If the outside operator panel has been shut off by
accident, the fire department will have access to the
building and the ability to turn on the water supply in the
event of an emergency.
Public and operator safety.
Helps to deter vandals and acts as a reminder to the
operators and the public that caution should be taken
while in the building.
To minimize the risk of humans or animals falling into the
reservoir and hurting themselves and/or contaminating
the reservoir.
9-12 Apr-04