Avoiding Emergencies: A Lift Station Upgrade in Wisconsin

This Wisconsin city is home to approximately 11,000 residents. Located near Lake Michigan, this vibrant community has a rich history and a commitment to maintaining its infrastructure. Recently, the city partnered with us to upgrade one of its aging can stations, transforming it into a modern lift station.

This case study explores how we successfully completed this project, ensuring the city’s wastewater system continues to operate efficiently.

CHALLENGE

Crane Engineering was approached by the city to help improve the operations at one of its lift stations.  The existing station was constructed of a “steel can”, which extends 20 feet below the ground elevation.  This station had served the city for over 30 years but was approaching the end of its expected life span.  Although it was still functional, the city recognized the importance of preventative maintenance. Rather than waiting for a potential failure that could lead to an emergency, the decision was made to proactively upgrade the station.

OBJECTIVE

To address the city's needs, we replaced the old can station with a Gorman-Rupp Reliasource® Above-Ground Submersible Valve Packages (ASVP) station. The new system, including the re-use of the existing wet well with submersible pumps, is designed to increase the station’s capacity and improve its overall efficiency. By upgrading to the ASVP station, we ensured that the city’s collection system would be more reliable, easier and safer to maintain.

KEY STEPS TO A LIFT STATION UPGRADE

Converting a Can Station to a Lift Station

Crane Engineering completed this project in 3 days and maintained continuous operation of the collection during the upgrade.

1. Initiating the project with a thorough evaluation of the existing system
2. Establishing a traffic control plan
3. Installing a bypass pumping system to maintain continuous operations
4. Excavating the existing force main to install a bypass valve
5. Removing the old wet well cover
6. Installing a wet well extension and adaptor ring
7. Installing the guide rail system, submersible pumps, discharge piping and connection to the existing force main
8. Backfill, grading and restoration around the new ASVP station
9. Decommissioning the old station
10. Startup and training of city staff by factory-trained personnel

Initiating the project with a thorough evaluation of the existing system

Bypassing the existing system

Excavating the site to install the bypass valve

Removing the old wet well cover

Integrating the new force main with the existing wet well

Installing a wet well extension and adaptor ring for the ASVP

Setting up the submersible pumps and piping within the existing wet well

Installing and grading the new ASVP, followed by the commencement of backfilling

Decommissioning the old can station and filling it with slurry

RESULTS

• Eliminate Confined Space: No longer need 2-3 employees to perform daily checks.  Eliminated the safety hazard of employees climbing a ladder.  Allow maintenance of valves from above grade.
• Better handling of “Flushable Wipes”: Improved impeller designed especially for stringy materials.
• Increased Pumping Capacity: New pumps were capable of 600 gpm.

The upgraded system increased the flow rate from 400 gallons per minute to 600 gallons per minute! This enhancement not only improved the capacity of the station but also made it easier and more efficient for operators to service and maintain the system. By completing the upgrade as a preventative measure, the city avoided the risks associated with a potential failure, ensuring a seamless transition to a more reliable and modern wastewater solution.

Questions about lift stations? We’re here to help. Call us at 800-776-4425

Crane Engineering also builds and designs customized skid systems nationwide so contact us, today! 

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