Overview

A municipal wastewater facility needed to improve its influent pump station and headworks while expanding solids digestion to incorporate energy recovery. The existing infrastructure could not meet regulatory pumping capacity requirements, and headworks screening and grit removal were insufficient. A design‑build team engaged a controls integrator to provide instrumentation and controls design upgrades and to integrate new process equipment into the plant’s SCADA system.

Challenge

• Meet regulatory criteria for firm influent pumping capacity
• Improve screening and grit removal at the headworks
• Replace aging pumps and upgrade electrical infrastructure
• Retrofit existing structures for new filtration and multi‑rake screens
• Expand solids digestion and implement a micro‑turbine cogeneration system
• Integrate new systems into the existing SCADA platform while maintaining operations

Solution

The integrator collaborated closely with the design‑builder to upgrade the influent pump station and headworks. Three existing pumps and associated piping were replaced, and electrical improvements were made to support the new equipment. The existing headworks building was retrofitted to accept a new primary filter, and a new structure was built to house multi‑rake screens and a grit removal system. The former grit room was converted to an electrical room with new MCCs, a transformer and a master control panel. A new 40‑foot‑diameter digester and control building were constructed, featuring mixing pumps, heat exchangers, gas conditioning systems and micro‑turbines to convert digester gas into electricity. Instrumentation and control of all new and updated systems were integrated into the existing SCADA, providing operators with unified visibility and control.

Technical Scope

• Replacement of influent pumps and piping
• Electrical upgrades including new MCCs, transformer and master control panel
• Retrofit of headworks for new filtration equipment
• Construction of additional structure for multi‑rake screens and grit removal system
• New digester and control building with mixing pumps, heat exchangers, gas conditioning and micro‑turbine cogeneration
• Integration of new instrumentation and controls into the existing SCADA system

Results

The upgraded pump station and headworks restored compliance with firm pumping capacity requirements and significantly improved screening and grit removal. The new digester and cogeneration equipment enabled the facility to recover energy from biogas, reducing operating costs and environmental impact. By integrating new systems into the existing SCADA, operators gained centralized control and monitoring of all process areas, enhancing reliability and ease of operation. The project also increased the plant’s future capacity and resilience.

Key Advantages Delivered

• Compliance with regulatory pumping capacity and headworks standards
• Enhanced energy efficiency through biogas cogeneration
• Centralized monitoring and control via SCADA integration
• Improved reliability with new electrical and mechanical equipment
• Future‑ready infrastructure supporting plant growth

Closing Summary

Through comprehensive pump station, headworks and digestion upgrades, the wastewater facility enhanced its capacity, reliability and sustainability. The project not only met regulatory requirements but also introduced energy recovery, demonstrating how modern controls and process integration can strengthen wastewater operations.

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