A high-tech manufacturing campus required a scalable, highly engineered lift station solution to handle a wide range of industrial wastewater streams across indoor and outdoor areas of their facility. The system needed to integrate seamlessly with existing building automation, ensure precise level monitoring and pump control, and withstand chemically aggressive environments. Burt Process was selected to deliver a fleet of fully integrated, prefabricated duplex lift stations tailored to site-specific conditions and chemical compatibility needs.
Industry
High-Tech Manufacturing
Challenge
Complex Wastewater Management
Solution
Challenges
- Transporting and managing diverse process waste streams—some highly corrosive and requiring chemical-resistant materials
- Meeting space constraints for indoor installations while also accommodating large-volume outdoor tanks
- Enabling centralized control and system-wide alarm visibility via the plant’s BACnet/IP building automation system
- Maintaining precise flow, level, and pressure monitoring for each lift station to support safety and uptime
- Delivering units ready for plug-and-play installation, minimizing downtime and site labor
- Tank materials included double-walled polypropylene, PVDF, and 304 stainless steel, depending on chemical compatibility
- Tank sizes ranged from 10 gallons to 6,735 gallons, supporting both compact and high-volume requirements
- All tanks included bolt-down covers, leak detection, and interstitial monitoring, ensuring robust secondary containmentQO485 – Hanwha Q Cell …
Pumping Systems
- Each lift station was built as a duplex system with two pumps for redundancy
- Pump types included Finish Thompson self-priming pumps, Vertiflo stainless steel pumps, and Price vertical centrifugal pumps
- Flow rates ranged from 2 GPM to 1,100 GPM, with discharge heads up to 114 feet TDH, all designed for duty/standby operation
- Wetted materials (PP, PTFE, PVDF, SS) were selected to handle acidic, caustic, and particulate-laden fluids
Instrumentation & Process Monitoring
- Flowline radar level sensors and paddle wheel flow sensors provided accurate fluid level and flow data
- Discharge pressure gauges, check valves, and point level switches enabled both operational and fail-safe controls
- Integration of pneumatically actuated butterfly and ball valves with position feedback ensured precise feed control
Smart Control Panels
- Pre-wired NEMA 4/4X/12 304 SS UL control panels with isolated high- and low-voltage compartments
- Included Siemens S7-1200 PLCs, BACnet IP/MSTP connectivity, and Ethernet switches for automation system integration
- Features: emergency stops, stack lights, audible alarms, power indicators, discrete relay outputs, and soft starters for each motor
- Cabinet-mounted AC/heating units maintained panel temperature in harsh indoor and outdoor conditionsQO485 – Hanwha Q Cell …
Structural Accessories
- Custom painted carbon steel panel stands were provided where wall-mounting was not feasible
- Adjustable riser platforms were added for elevated pump installations, accommodating piping redesignsQO485- Tank Adjustments…
Solutions & Impact
Burt Process delivered a modular, scalable network of lift stations to manage wastewater handling across multiple zones of the facility. Each system was customized to its specific operational conditions—indoors, outdoors, chemical composition, and flow demands. The integration-ready control architecture enabled seamless communication with the facility’s existing building systems, while full preassembly and skid-mounting simplified on-site installation.
The result is a fleet of high-performance lift stations that offer:
- Reliable operation under harsh environmental and chemical conditions
- Fully networked control and alarming for proactive maintenance and monitoring
- Reduced installation time and cost with prefabricated plug-and-play systems
- Optimized flow and pressure handling, from low-volume polishing systems to high-flow facility drains
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