Sector
The Summary
This lift station rehabilitation project in League City required the plant to be taken offline, relying entirely on a temporary bypass system to keep sanitary sewer flows moving to the treatment plant. With two incoming lines feeding the station, the project demanded a dual‑system bypass using four 6” vacuum‑assist diesel sound‑attenuated pumps.
Each setup pulled suction from separate manholes—one outside the plant and one inside—and all four pumps discharged through a manifolded system into a single force main. Automated float controls and a full alarm agent system ensured continuous monitoring and responsiveness throughout the project.
Challenge 1
Managing extremely high suction lift and significant head pressure on the pipe plug.
The outside setup required a suction lift of approximately 23 feet—already near the upper practical limit for vacuum‑assist pumps. The greater concern was the amount of head pressure being placed on the pipe plug, which had to be carefully managed to avoid system stress or failure.
Solution 1
BPR’s experienced team engineered the bypass to optimize suction performance and control system pressures. By carefully tuning pump operation, monitoring vacuum conditions, and managing discharge flows, the team maintained stable suction lift while preventing excessive head pressure on the plug—ensuring reliable and safe operation throughout the bypass.
Challenge 2
Safely discharging four 6” pumps into a single 8” discharge line without overwhelming the plant connection point.
With all pumps tied into a common 8” discharge, there was limited capacity at the plant. Pump interactions (“fighting flows”) and system overload were real risks if too many pumps ran simultaneously or at mismatched rates.
Solution 2
Using deep knowledge of pump behavior, flow control, and fluid dynamics, BPR was able to “dial in” the system to ensure smooth, compatible flows. Manifold arrangements—with check and gate valves—allowed controlled discharge, and pump sequencing ensured the force main could accept all incoming flow.
The result was a balanced, efficient bypass operation with no hydraulic conflicts and no risk to the plant’s infrastructure.
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