Need a Lift? A Lake Superior Community's Lift Station Upgrade

Chocolay Township, located along the southern shore of Lake Superior in Marquette County, Michigan, faced challenges with aging lift stations, impacting both employee safety and operational efficiency. This case study explores how Crane Engineering collaborated with Chocolay Township to upgrade lift stations, enhancing safety, efficiency, and resilience in harsh winter conditions.

With nearly 6,000 residents and an average daily wastewater flow of 50,000 gallons, Chocolay Township relies on multiple lift stations to transport wastewater to the Marquette Regional Wastewater Treatment Plant. The existing lift stations, operating for nearly half a century, posed maintenance challenges and safety concerns for the public works department.

PROBLEM

The traditional lift station design involved a steel can reaching 20 to 30 feet below grade, requiring two workers to perform maintenance in confined spaces. To navigate these spaces, staff used man lifts to descend and ascend into and out of the stations, with an emergency ladder available. With aging equipment and obsolete parts, bi-weekly maintenance checks became a considerable challenge for the township.

OBJECTIVE

Chocolay Township needed to address safety concerns, enhance operational efficiency, and replace aging lift stations with a more resilient solution that would hold up to the harsh winters. Our goal was to get them an enclosed building where the piping header, controls, and everything is inside versus the traditional style that must be serviced with the double doors open, flapping up against maintenance technicians while they’re working on their knees.

SOLUTION

Crane Engineering, in collaboration with Gorman-Rupp, proposed the installation of Gorman-Rupp Reliasource® Above-Ground Submersible Valve Packages (ASVP) stations. This newer design included an enclosed building, providing a more secure and weather-resistant environment for station operations.

IMPLEMENTATION

Crane Engineering converted five lift stations to the new design, featuring Gorman-Rupp SF Series submersible pumps. The mechanical and electrical engineering teams custom-tailored lift stations based on designs from Crane Engineering, streamlining the manufacturing, testing, shipping, and installation process.

RESULTS

• Maintenance workflow remained consistent with bi-weekly checks but with added benefits.
• SCADA and standby generators were integrated, simplifying repairs and reducing downtime.
• Alarms equipped with cellular network capabilities enhanced real-time monitoring and response.
• The new design eliminated the need for confined space work, no longer requiring two people to do the work.
• Boosted efficiency and increased flow by 10-15% while maintaining the same horsepower as the original units.

The upgrade to Gorman-Rupp lift stations significantly improved employee safety, operational efficiency, and system resilience for Chocolay Township. The success of the initial installations has led to continued conversion of the remaining lift stations to the new, more efficient design.

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