What are the types of a commercial lift station pumps?

A wastewater lift station is a pump station that uses a collecting system to transport wastewater or sewage from a lower to a higher elevation. Pump stations are frequently used to transport wastewater from residential and commercial buildings to wastewater treatment plants. Sewage lift stations are generally used to cut the cost of gravity flow sewage systems' original capital development. The benefit of this method is that it eliminates the need for costly excavation for sewer pipe installation, often known as trench shoring.

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Installing a sewer line sometimes necessitates digging deeper than 10 feet below the surface. While lift stations within a wastewater treatment infrastructure offer intrinsic benefits over the high expense of underground gravity sewage systems, manually monitoring these lift station assets for equipment health can be time-consuming and labour-intensive.

Pumps for commercial sewage lift stations are available in a range of designs (effluents, grinders, etc.) Two questions must be answered in order to decide which type is appropriate for your application:

How big will the solids have to be pumped? What is the discharge pipe's diameter?

Simply put, 2-inch particles cannot be pumped through a 1-inch pipe. If these are the application's characteristics, a grinder pump will be required to cut the solids into smaller, more manageable chunks. This is only one example of how the type of pump you choose will be influenced by the pump duty.

The many types of pumps, as well as the applications for which they are best suited, are described below:

1: Sump Pump: Dirty water applications where solids are not typically present and are unlikely to ever exceed 3/8”.

2: Effluent Pumps: Partially or completely treated wastewater applications with solids of 1” or less.

3: Sewage Pumps: Commercial sewage applications where solids are 2 ½” or larger.

4: Vortex Pumps: Applications involve lengthy, stringy, and/or fibrous solids in trash. Raw sewage lift stations, storm water applications, and waste from paper mills are all examples.

5: Grinder Pumps: When the solid size is expected to exceed the discharge pipe's capacity. These pumps contain a hardened stainless steel cutting system that shears solids so they can pass through smaller tubes. Also beneficial in high-pressure discharge systems seen in groups of homes, motels, schools, retail malls, and other similar structures.

To meet the International Plumbing Code (IPC) criteria, any pump chosen must be capable of maintaining a velocity of 2 to 8 feet per second (See Table below). However, it's always a good idea to double-check local plumbing codes, as they may go beyond the IRC's requirements.

Your pump model selection will be based on the following:

- Flow rate

- Solid size

- Pump style

- TDH

- Discharge pipe size

- RPM

It's All About Control

On the designs, all of these features, as well as the unique pump selection and control needs, should be noted. The type of Level Controller required for the pump system, as well as all of the following components that are included within the control panel itself, will be part of the control requirements:

- Breaks the connection

- Begins with Overload Protection.

- T-O-A (Test-Off-Automatic)

- Security Systems

- Pump Rotation is automated.

Lift stations are a critical component of the functional operation process of wastewater and sewage management. Within both residential and industrial settings, lift stations play an important role in assisting when gravity alone cannot move wastewater or sewage from point A to point B. Many of us don’t even realize just how important lift stations are for the basic functions of society. 

In this full scale guide, we’ll be going over everything from lift station basics consisting of what they are and how they work, to all of the applications, components, and maintenance requirements of lift stations. Ideally, through this guide, you’ll have a comprehensive understanding of what lift stations can do for you and your household with wastewater management.

What is a Lift Station?

A lift station, also known as a pump station, is essentially a mechanically operated system which is designed to move wastewater, sewage waste, or excess stormwater from a lower elevation to a higher elevation. If your home or business is at the base of a sloped hill, you’re vulnerable to flooding of various forms of water. A lift station “lifts” the wastewater from said lower elevations to higher elevations to prevent problems from developing and can allow wastewater management to be more cost effective and overall efficient.

How Does a Lift Station Work?

Lift station operations will typically involve a complex combination of hydraulic, mechanical, and electrical systems which work together to successfully transport wastewater. Below is a breakdown of how the process works, step by step:

1. Wastewater Collection

The first step is the wastewater collection itself. The wastewater will flow into a wet well, which is a storage tank or basin with a collection point. From there, the wastewater is temporarily held within the tank or basin.

2. Level Monitoring

Sensors or float switches will monitor the level of water in the wet well. At a certain point, the water will reach a level where the lift station is activated to prevent overfilling of the wet well or basin.

3. Pumping

Pumping is the act of the lift station pushing the wastewater into and through a pressurized pipeline known as a “force main”. This specific pipeline has the ability to direct water into a higher level of elevation. 

4. Discharge

The wastewater exits the force main and enters a treatment plant, sewer main, or another destination. The discharge is the wastewater exiting the force main and entering a sewer main or other destination for processing.

5. Deactivation

When the water level in the wet well drops to a safe level, the pumps turn off automatically until they’re needed again.

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Components of a Lift Station

Lift stations have several key areas and components to ensure efficient and effective operation:

1. Wet Well

A wet well is a large, sealed tank which collects wastewater and subsequently stores said wastewater for pumping. It’s essentially the central area of the lift station itself and it’s where the wastewater is pumped from.

2. Pumps

While there are many different kinds of pumps (including centrifugal pumps for industrial applications), Residential Lift stations will typically utilize the following types of Submersible Pumps:

• Effluent Pumps: These are pumps that can handle freshwater/small solids (under 1in), depending on the build-type they can be high or low pressure, although typically low-pressure variants are used in lift stations.
• Solids Pumps: These are low-pressure, high GPM pumps that can typically pump 2-inch solids a moderate distance, like from a basement up to a tank on the surface.
• Grinder Pumps: These are high pressure, low GPM pumps designed to grind larger solids before pushing the resulting wastewater either upwards a long distance, or inject the waste into a high pressure main (or sometimes both)

3. Float Switches or Sensors

Float switches are also quite literally what they sound like: floating switches. These switches float in the wet well and they signal the pumps to start or stop when the water level reaches a certain point. There are two types of float switches:

• Control-Duty Float Switches

These switches are only designed to handle smaller currents, sending signals to the control panel from down inside the wet well.

• Pump-Duty Float Switches

These switches are beefier, designed to directly control the water pump in the wet well with the pumps current passing through the switch, typically not sending any signals back to the panel.

4. Control Panel

The control panel helps to maintain all operations of the lift station, It helps manage the pump activation, the system performance, and it will also signal signs of malfunction.

5. Force Main

The force main has a pressurized pipeline which helps to transport the wastewater from the lift station itself to the final destination.

6. Ventilation

Proper ventilation is required to prevent buildup of harmful gases. These harmful gasses could consist of everything from methane to hydrogen sulfide within the wet well itself. Having proper ventilation will help to ensure safety and reduce the presence of accumulating odors.

Types of Lift Stations

Lift stations are able to be categorized through two types:

1. Dry-Well Lift Stations

Dry-Well Lift Stations are typically found in larger commercial and industrial applications.

• Design: The design of a dry lift station consists of pumps and motors which are typically housed in a separate, dry chamber which is adjacent to the wet well
• Advantages: Much easier to repair and maintain, since the components are not submerged
• Disadvantages: Higher costs and larger footprint

2. Submersible Lift Stations

As a homeowner, this is typically the type of lift station you can expect to encounter.

• Design: The pumps and motors are located within the wet well and are fully submerged in the wastewater.
• Advantages: Smaller-sized design, lower initial costs, and typically a quieter level of operation noise.
• Disadvantages: Maintenance can be much more challenging as the components need to be fully removed from the wet well in order to be repaired or replaced.

Applications of Lift Stations

Lift stations are used across residential, commercial and industrial settings. Here are some of the most common applications:

1. Municipal Wastewater Systems

Lift stations are essential to municipal wastewater stations. The lift station will successfully transport wastewater from neighborhoods and commercial vicinities to the treatment plants. 

2. Residential Applications

A lift station plays a crucial role in residential wastewater disposal systems, particularly in homes situated below the main sewer line, those requiring connection to a pressurized main, or properties with on-site septic or treatment systems positioned higher than (or at a significant distance from) the home’s outlet.

3. Industrial Facilities

Industrial facilities, such as wastewater treatment plants and manufacturers need lift stations to help optimize their workflow and input/output processes. 

4. Stormwater Management

If you encounter heavy rain in your area, you’ll want lift stations throughout the specified locale, as this will help prevent stormwater from accumulating and causing flooding.

5. Agricultural Irrigation

Agricultural uses of lift stations are plentiful. Farms and other agricultural operations will often require lift stations to transport water for irrigation purposes, or to remove excess water from fields to prevent crop damage.

Challenges and Maintenance of Lift Stations

Below are some common challenges and maintenance suggestions for lift stations:

1. Power Failures

• Challenge: Lifts stations rely on electrical sources of power, making them vulnerable to power outages. Depending on the installation scenario, lack of power could lead to a backup or overfill into your home.
• Solution: Having a backup generator in place can be a great way to help ensure your lift station is always operating.

2. Clogs and Blockages

When relying on a lift station for wastewater management, understanding the capabilities of the lift station and its submersible pump is essential.

• Challenge: Non-biodegradable material such as wet wipes and rags, or objects that are larger than the pump’s intake rating can get stuck in the pump’s intake, causing costly damage. Furthermore, excessive grease can cause clogs in the pipes flowing into the lift station.
• Solution: To prevent backups and overflows, carefully manage what goes down your kitchen sink and toilets. Depending on the type of submersible pump installed, something as simple as a rubber glove getting lodged in the pump’s intake can lead to a costly repair.

4. Odor Control

• Challenge: Foul odors may present with the accumulation of waste.
• Solution: Install proper ventilation and odor control systems.

5. Switch Malfunctions

• Challenge: A faulty float-switch may prevent the correct signals from reaching the control panel or submersible pump.
• Solution: Routinely test and replace your floats to ensure proper functionality.

How to Maintain a Lift Station

Proper maintenance is crucial for the long-term performance of a lift station. Here are some of the best practices to adhere to:

• Regular Inspections

Inspect the wet well, pumps, and control panel quarterly to identify potential issues early with a proactive approach.

• Clean the Wet Well

Remove debris and grease as needed during your routine inspections of the unit.

• Schedule Professional Servicing

Hiring professional help can ensure you’re receiving the expertise you need to keep everything running at peak performance and spot smaller issues before they turn into major ones.

Cost of a Lift Station

The estimated cost of purchasing and installing a lift station by type is broken down below:

• Residential Lift Stations: $5,000–$10,000
• Commercial Lift Stations: $10,000–$50,000
• Industrial Lift Stations: $50,000–$500,000

Maintenance costs can typically run around $200 - $2,000 per year.

Future Trends in Lift Station Technology

There are many advancements being made in lift station technology as each year goes by. Below are some of the latest advancements:

1. Smart Monitoring Systems

Remote monitoring and IoT (Internet of Things) technology are allowing users to have full control of many operational elements of the lift station system.

2. Energy-Efficient Pumps

Energy efficiency within pumps has reached all-time highs without sacrificing quality of processes.

Conclusion

Lift stations are essential components of modern wastewater and stormwater management, helping to keep communities clean, safe, and functional. Whether for residential, commercial, or industrial use, these systems provide an efficient solution for moving water and wastewater in areas where gravity alone isn’t enough. 

By understanding how lift stations work, their components, and the importance of regular maintenance, you can ensure your system operates smoothly for years to come. Whether you’re installing a lift station or upgrading an existing one, investing in quality equipment and proper care will pay off in the end. Feel free to contact us if you have any questions. We look forward to hearing from you soon!

Contact us to discuss your requirements of Commercial Sewage Lift Station Pumps. Our experienced sales team can help you identify the options that best suit your needs.