When Royal Waterworks acquired an aging utility system, it also inherited a master lift station in need of immediate attention. The station relied on two wet wells, four pumps, and a single outdated control panel. Frequent pump and equipment failures created a significant risk of wastewater overflows, requiring a temporary bypass pump to remain on-site around the clock.
As Royal Waterworks’ operations and maintenance partner, U.S. Water developed and implemented a comprehensive rehabilitation plan to improve the station’s reliability, eliminate single points of failure, and simplify future maintenance. U.S. Water also continues to provide ongoing operations and maintenance services for the utility system.
Phase 1: Structural and Mechanical Rehabilitation
The first phase focused on restoring the wet wells and replacing the station’s aging mechanical equipment. The work included:
- Removing the existing pumps and corroded internal piping
- Repairing and sealing both wet wells
- Applying protective coatings to help prevent future corrosion
- Installing new pump bases and heavy-duty discharge piping
- Replacing check valves and isolation valves to improve flow control and maintenance access
- Adding an emergency pump-out connection to support the station during unexpected equipment failures or maintenance activities
Phase 2: Electrical and Control System Upgrades
The original station used a single control panel to operate all four pumps across both wet wells. A failure of that panel could have taken the entire station offline.
To reduce this risk, U.S. Water redesigned and replaced the station’s electrical and control systems. The improvements included:
- Removing the outdated control panel
- Installing a new weather-resistant electrical equipment rack
- Adding two dedicated control panels, allowing the pumps to operate independently and providing greater system redundancy
- Integrating a new SCADA system for remote monitoring, operational data collection, and alarm notifications
The Result: A Safer, More Reliable System
The completed rehabilitation eliminated the need for the temporary bypass pump and significantly reduced the risk of station-wide failure. Royal Waterworks now has a modernized master lift station with improved mechanical redundancy, protected infrastructure, and real-time monitoring.
The upgraded station is easier to operate and maintain while providing greater protection for public health, the environment, and the surrounding community.