Peru, Ind. Upgrading Strained Lift Stations

Peru, Ind. | Commercial | Lift Station Repairs

Overview:

The three lift stations on this property had not been serviced in several years and were showing signs of deterioration. The property owner contacted AQUALIS to perform a full inspection and recommend repairs to restore reliable operation and prevent future system failures.

Neglecting lift station maintenance can lead to severe consequences including equipment burnout, sanitary sewer overflows, or complete system shutdown. Early intervention not only reduces costly emergency repairs but also ensures compliance with environmental and health regulations.

Problem:

Upon inspection, AQUALIS technicians found that all three lift stations were operational but severely strained, signaling impending failure. Most critical issues included:

• Heavy debris accumulation restricting flow and reducing capacity in all stations
• Outdated guiderail systems preventing safe removal of pumps for servicing
• Lift station #1 had a break in the discharge line causing the pump to overwork

These signs of distress are common indicators of under-maintained infrastructure. Identifying early warning symptoms of failure is essential for preventing business interruptions and environmental hazards.

Station 1 Before

Station 2 Before

Station 3 Before

Solution:

AQUALIS implemented a multi-phased restoration plan designed to improve reliability, enhance accessibility and extend the service life of each lift station.

Cleaning and Assessment

Industrial vacuumation was used to remove years of built-up debris. This process combines high-pressure water and vacuum suction to break up sediment and clear blockages. Once the wet wells were cleaned, technicians conducted a detailed assessment of mechanical and electrical components to confirm the full scope of needed repairs.

Confined Space Entry and Equipment Upgrades

Since lift stations are enclosed environments with limited oxygen and potential gas hazards, confined space entry procedures were implemented to ensure technician safety.
Inside each wet well, AQUALIS:

• Installed new pumps to restore efficiency.
• Upgraded to modern guiderail systems, allowing safe and easy removal of pumps for future maintenance.
• Replaced float switches, which serve as automatic triggers for pump activation and deactivation as water levels fluctuate.

Electrical and Control Enhancements

Each control panel was inspected and modernized:

• Duplex control panels were installed to provide increased capacity. In addition to providing additional power, this ensures that if one pump or contactor fails, the second can continue operation, minimizing downtime.
• New conduit configurations were integrated to protect electrical components from landscaping or environmental damage.
• Manual electrical disconnects were installed at each station, simplifying future maintenance and ensuring compliance with safety standards.

Discharge Line Replacement and Valve Installation

At Lift Station #1, a broken discharge line had caused significant mechanical strain on the pump. Stations #2 and #3 had lines showing advanced wear. AQUALIS replaced all discharge lines and added check valves and isolation valves to prevent backflow and allow controlled system shutoffs during repairs: critical improvements for operational safety and efficiency.

This project restored full reliability to all three lift stations and eliminated the potential for near-term failure. The upgrades not only improved operational efficiency but also simplified future inspections and maintenance.

Key Takeaways for Property Owners:

• Proactive maintenance prevents costly emergencies. Regular inspections can identify warning signs before they become failures.
• Modern technology, such as duplex control panels and upgraded guiderail systems, improves system reliability and reduces downtime.
• Regulatory compliance is more easily maintained when infrastructure operates as designed, protecting both the property and surrounding environment.

Lift station technology has evolved significantly to meet modern performance and compliance standards. By partnering with AQUALIS, property owners gain a long-term maintenance partner who understands the importance of both operational reliability and environmental stewardship.