Modular Extraction & Infiltration Systems — Utility Steam Station

A utility-owned steam station in North Carolina required a Phase 2 full-scale groundwater Modular Extraction and Infiltration System (MEIS) to support ongoing remediation across six well fields (Areas A through F). Because the site had existing infrastructure in Areas A through D and greenfield requirements in Areas E and F, the equipment package had to combine new containerized control buildings with retrofit manifold legs and motor starters that would integrate with enclosures already in the field.

The procurement was a competitive bid managed by an environmental consulting firm on behalf of the utility, with strict submittal, factory acceptance testing, and shipping requirements. Each Area had a different count of extraction and injection legs — from four (4) per manifold up to seventeen (17) — and each leg required a consistent instrumentation package with magnetic flow transmitters, pressure transmitters, check valves, diaphragm valves, and sample ports. All equipment had to arrive on site fully tested and ready for the onsite contractor to install.

Fliteway fabricated two (2) new 8-ft by 20-ft shipping-container Control and Monitoring Enclosures for Areas E and F. Each enclosure was outfitted with 1" spray-foam sound and thermal insulation on the walls and ceiling, bed-liner non-slip floor paint, four (4) LED strip lights with switch, one (1) 6400-BTU heater and air-conditioner unit, a containment trench drain with leak detection switch, and swing doors on both ends.

Inside each Area E and F enclosure, Fliteway installed the full Sch. 80 PVC extraction and injection manifold package per the consulting firm's design drawings — Area E with eight (8) extraction legs and seven (7) injection legs, and Area F with seventeen (17) extraction legs. Each leg included a 1" stainless steel ball valve, a 1" Emerson PICO Mag magnetic flow indicating transmitter, an IFM pressure transmitter, a pressure gauge with Sch. 80 PVC sample port and isolation valve, a 1" true union Sch. 80 PVC diaphragm valve, and a 1" Sch. 80 PVC check valve. Injection legs added a stainless-steel solenoid valve and a Sch. 80 PVC air release valve. Main headers included 2" ball, diaphragm, and solenoid valves.

For the existing Areas A, B, C, and D, Fliteway supplied loose Sch. 80 PVC extraction and injection manifold legs for onsite installation by the site mechanical contractor, plus motor starters for the existing Motor Control Enclosures. A NEMA 4 Motor Control Enclosure (MCE) with Allen-Bradley starters was installed in each new Area E and F enclosure and pre-wired to the HVAC equipment; extraction well pump wiring and termination was left to the onsite contractor per the bid scope.

Fliteway performed full factory acceptance testing prior to shipment — pipe pressure testing to 1.25× operating pressure, instrumentation loop checks and calibration, alarm testing, electric and manual valve operation checks, HVAC and heating checks, motor and wire megger testing, and motor starter operation checks. A ten (10) day onsite start-up was included to shake down process equipment and instrumentation once the enclosures were placed by others; the Emerson control system hardware and programming were provided by others per the bid package.

An option package added forty-one (41) Grundfos Model 10S5-9 extraction well pumps (1/2-HP, 460-VAC three-phase) with additional PVC cable above top of casing, forty-one (41) KPSI Model 700 extraction well transducers, and forty-one (41) KPSI Model 700 infiltration well transducers — each with ten (10) feet of additional cable above top of casing.

The two (2) new Area E and F Control and Monitoring Enclosures and the loose manifold and motor starter packages for Areas A through D shipped on schedule from Fliteway's Wisconsin facility with full factory acceptance testing documentation. Containerized fabrication eliminated most field mechanical and HVAC work at the site.

Standardizing on the same instrumentation across all six Areas — Emerson PICO Mag flow transmitters, IFM pressure transmitters, Sch. 80 PVC diaphragm valves, and stainless steel ball valves — simplified site operation, calibration, and spare parts management. The optional extraction and infiltration well equipment package gave the consulting firm and the utility a single procurement covering forty-one (41) wells of pumps and transducers.