Beyond Repair: Why Retrofitting Your Wastewater Pump Station is a Strategic Investment

Three Key Drivers for a Pump Station Retrofit

If you are experiencing any of the following, it is time to consider an upgrade.

1. Overly Expensive and Increasing Energy Costs
Older pumps and motors, especially those running at a fixed speed, are notoriously inefficient. They often run at full power regardless of the actual flow, consuming vast amounts of electricity.

• The Retrofit Solution: Installing modern, high-efficiency pumps paired with Variable Frequency Drives (VFDs) allows the system to perfectly match its output to demand. This single change can often reduce energy consumption by 30-50%, delivering a rapid return on investment.

2. Pump Station Unreliability and Downtime
If emergency callouts are becoming more frequent or a regular occurrence? Ageing mechanical components, corroded pipework and outdated controls could all be a factor in downtime. The cost of emergency repairs, clean-up operations and potential environmental fines far outweighs the cost of a planned upgrade.

• The Retrofit Solution: New pumps, valves, and guide rails, combined with modern control systems, drastically improve reliability. Proactive upgrades prevent catastrophic failures and move your team from a reactive “firefighting” mode to a planned, preventative maintenance schedule.

3. Evolving Compliance and Environmental Standards
Regulations around environmental discharge and overflow monitoring are becoming stricter. An old system with no remote monitoring or data logging capabilities can leave you vulnerable to compliance breaches and hefty penalties.

• The Retrofit Solution: A modern control panel with telemetry allows for 24/7 remote monitoring, data logging and automated alerts. This ensures you have a complete, auditable record of the station’s performance and can prove compliance with ease.

Core Components of a Modern Retrofit

A successful retrofit is a holistic process that addresses the entire system, not just one component.

• Pumps and Motors: This is the core of the upgrade. We replace outdated, inefficient pumps with modern solids-handling pumps designed for reliability and energy efficiency.
• Control Systems: The old panel is replaced with a modern inverter driven, HMI/PLC controller, remote monitoring and BMS connections based. This provides intelligent pump control, fault detection and the ability to integrate remote monitoring for 24/7 visibility. We also upgrade to more robust and accurate level control systems, which provide precise data to the control panel for optimised pump operation.
• Pipework and Valves: Corroded pipework is replaced and crucial components like non-return valves and isolation valves are upgraded. This not only improves flow and efficiency but is critical for safe and easy maintenance in the future.

A Phased Approach to a Seamless Upgrade

Minimising downtime is critical. A well-executed retrofit follows a meticulous, phased approach.

1. Comprehensive Site Survey & Audit: The first step is always a thorough assessment. Our engineers analyse the existing infrastructure, review historical performance data and understand your specific operational challenges and future needs.
2. Tailored Solution: Based on the audit, we design a solution tailored to your application. This involves selecting the right pumps, intelligent controls and creating a plan that ensures all components are optimised.
3. Project Management & Planning: We coordinate everything, from cleaning out the station prior to works, through to installation and commissioning. Our certified engineers carry out the mechanical and electrical installation to the highest standards. Commissioning involves rigorous testing of every component and control sequence to ensure the system operates exactly as designed.
4. Handover & Training: We do not just walk away. We provide comprehensive operator training and full documentation, including O&M manuals and electrical drawings. Our Dura Pump Connect App, will also file all this critical asset information for you to access anytime, anywhere, simplifying future maintenance and compliance.

Velocity Sentiman – A Future-Proof Investment

Velocity Sentinam exclusively by Dura Pump is an intelligent pumping solution for critical wastewater infrastructure. Specifically designed to deal with fats, oils and grease buildup (FOG) and high solid content, this solution will stop the need for regular tankers to clear out stations that are not operating effectively.

Equipped with advanced cutting, shredding and tearing capabilities together with our intelligent control and level system, the Velocity Sentinam solution will deliver operational excellence, minimum maintenance and long-term energy savings.

Our exclusive solution can also be retrofitted to deliver:

• Reduced costs: You could save hundreds of thousands of pounds by eliminating reliance on tankers.
• Minimised Downtime: Zero blockages means reduced engineering time and uninterrupted operations.
• Improved Monitoring: Enhanced control and visibility will allow you to address issues proactively.
• Peace of Mind: Confidence in knowing the system will not let you down.

Retrofit for a Long-Term Security

Retrofitting your wastewater pump station is more than just a repair—it is a strategic investment in the long-term health of your facility. It is an opportunity to reduce operational costs, eliminate the stress of unreliability, ensure compliance and build a more resilient, sustainable infrastructure.

If you are ready to turn your pump station headaches into a high performing asset, contact us today.