Replacement and Retrofit Lift Station
At Romtec Utilities we provide a variety of services mainly focusing on the design and supply of pump stations. However, we do replacements and retrofits to pump stations frequently as systems age out and upgrades are routinely needed.
To determine how to retrofit or replace a system, the technician must perform an assessment to determine what parts of the system are failing and what components could stay. If it’s determined the whole system is beyond retrofitting, then a replacement system is the route to take.
Once an evaluation is complete, the engineering begins to integrate the existing system with new retrofitted parts.
We provide preliminary designs and estimates at no upfront cost!
Lift Station Retrofit
Sometimes, pump stations fail because one of those aspects of the system becomes too old, breaks, or becomes unsuitable for changing conditions.
Pump station repair and retrofit involve evaluating all aspects of the pump station to determine if any of the structural, mechanical, electrical, or communication systems are suitable for continued long-term operation. Then, Romtec develops a plan to integrate all the new pump station components and systems with those that can be retained from the existing system.
Pump Station Retrofit Services Should Always Involve 3 Phases:
Evaluating the existing system to identify the scope of the required retrofit.
Engineering and planning the retrofit work to integrate fully with the existing equipment.
Completing the retrofit work as defined in the pump station retrofit engineering documents.
This is a simplified summary of the process, but a good pump station retrofit needs to define the full problem and how the problem will be resolved. Without a clear plan, pump station retrofits can cause ripple effects that result in a continual series of “fixes” without a prescribed stopping point. This can delay the service of your pump station and cost you money.
Every piece of equipment in the Romtec Utilities supply package carries a warranty and an operations and maintenance manual to assure the long-term effectiveness of the repair or retrofit.
A complete repair or retrofit design allows Romtec Utilities to manufacture a specific package adapted to each customer’s equipment needs and pumping requirements. This ensures that the supply package for each repair and retrofit project is accurate, effective, and economical.
Typically, the wet well is the primary piece to determining if a lift station retrofit can take place. A healthy wet well can save large amounts of time and money in engineering, manufacturing, and installation costs.
Retrofitting a lift station goes beyond simply swapping the pieces. A good lift station retrofit will upgrade system components to the current industry standards with complete lift station design and engineering. A lift station retrofit will only be successful if it ensures a functional system, utilizes existing components, and saves time and money over a lift station replacement.
Lift Station Replacement
A lift station replacement is a straightforward procedure in some ways, but there are considerations that should be made before undertaking this type of project. Pump stations are typically not designed for any downtime. Considering this premise, how do you remove and install a lift station without shutting off the system?
Canyon de Chelly, Arizona
Romtec Utilities recommends that a new lift station replacement be installed adjacent to the existing system if the property size permits such construction methods. At Canyon de Chelly in Arizona, the Navajo Nation and National Park Service were able to replace an existing system in this manner. The new system was constructed and “tapped” into the existing inlet line and discharge force main. When the replacement system was started up, it simply overtook influent from the existing lift station, allowing the existing system to be retained for emergency purposes.
Goleta Beach, California
At Goleta Beach in California, the County of Santa Barbara operates a pump station with a much smaller footprint (property). At this site, construction of an adjacent system would have been impossible. Bypass pumping was utilized during the removal of the existing lift station and the construction of the lift station replacement. It is important to have precise lift station engineering and construction/start-up schedules when using bypass pumping during a replacement.
Shafter, California
The City of Shafter, CA needed to repair or replace an existing lift station that was on the verge of failing. There was not enough funding for a complete lift station replacement, so the City contacted Romtec Utilities to see what could be done to retrofit the system. Romtec Utilities provides complete repair and retrofit service for pump and lift stations to save owners money.
Within a couple of weeks, Romtec Utilities sent a field technician to the N. Schnaidt pump station to meet with utility personnel from the City. Working together, the City crew and the Romtec Utilities technician completed a review of all the existing lift station components. Romtec Utilities completes similar evaluations of every repair and retrofit project to define a clear criteria of work and establish the necessary steps for a successful retrofit.
For the City of Shafter, the review established that the wet well and valve vault concrete structures were still in good condition at the N. Schnaidt lift station. Having reliable structural components eliminates a substantial amount of construction requirements. By cleaning and refurbishing the existing concrete vault and well, a retrofit process would help the City get a fully functional lift station at a fraction of the cost of a replacement.
The mechanical and electrical lift station components were out of date. The City personnel and Romtec Utilities technician determined the best solution would involve removing and replacing the existing mechanical and electrical systems.
While onsite, the Romtec Utilities technician gathered all of the necessary measurements and specifications required to create a complete plan set drawing of the retrofit.
Based on the dimensions and information collected from the site visit, Romtec Utilities engineered a complete plan set for the retrofit project with our in-house mechanical and electrical engineering experts. The plan set showed the new lift station mechanical, new pumps, new electrical systems, and new communications equipment. The new components and systems were engineered to both meet the City pumping and communication requirements and be installed within the existing wet well and valve vault structures.
After the installation was completed, Romtec Utilities performed start-up, testing, and training for the retrofitted system. “As built” and operation and maintenance documentation for the retrofitted lift station were also provided during the start-up and training.
By choosing to work with Romtec Utilities, the City of Shafter got a fully functional lift station at a substantially reduced price tag than a lift station replacement.
Retrofit Option
The first step of the retrofit process is to evaluate the existing pump or lift station and to specify the pumping requirements of the completed system.
Evaluation
Evaluating the existing system allows our engineers to determine what components can be retained for an extended period of time. It also allows our engineers to design the system retrofit with new components that will function correctly with the hardware that is retained. Designing a compatible retrofit is very important to the success of a project.
Pumping systems can outwardly appear simple, but these are sophisticated, engineered systems that require specific engineering to function correctly. It is typically not effective to simply replace existing components with new components. The reason Romtec Utilities uses a detailed process for pump and lift station retrofits is that it results in the best system for the customer.
Define a plan
The next step is to define a retrofit plan. The retrofit plan clearly details what the existing system looks like, what components will be removed, what components will be installed, and the pumping capabilities of the completed system.
The retrofit plan provides the complete scope of work, the complete bill of materials, and roles and responsibilities of Romtec Utilities and the retrofit package installer. Once a plan is created by Romtec Utilities, we provide it to the customer to review. When the plan is agreed upon, the retrofit package can then be assembled.
This process gives customers the opportunity to save money by improving the existing system and it does so through an engineering process that has a guaranteed result. Without taking the time to evaluate, engineer, and supply a defined package, retrofit projects can become money pits where components are not compatible and there is a lack of understanding as to what constitutes a finished system.
Unfortunately, this is an all too common pitfall with retrofit projects, but Romtec Utilities always makes sure our customers get a fully function system with the cost savings of a retrofit process.
FAQ
Who can replace or retrofit a lift station?
Romtec Utilities can replace or retrofit a lift station for your project. They have designed, reviewed, and supplied a retrofit system that will help a system last while upgrading certain parts. They likewise can replace a lift station system, to meet new needs or if the system has reached the end of its life cycle.
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