The Tetra Tech Digital Systems Group optimized lift station performance through advanced control strategies and data analysis, reducing energy use and extending asset life for Encina Wastewater Authority (EWA).
EWA operates the Agua Hedionda Lift Station that supports wastewater conveyance for more than 400,000 residents in Carlsbad, California. The station includes four lift pumps and four force-main pumps designed to move wastewater efficiently to the treatment plant.
The original system design intended single pump operation to maximize gravity transfer, with operators often running multiple pumps in parallel to maintain flow. Over time, impeller fouling reduced hydraulic efficiency, increased energy consumption, and accelerated equipment wear. EWA needed a solution to improve performance, reduce operating costs, and extend asset life without replacing existing control infrastructure.
Our digital systems experts delivered a control strategy and optimization solution that improved pump performance using existing infrastructure. The team analyzed flow data from installed meters to evaluate real-time pump efficiency and identify performance thresholds. Tetra Tech implemented control logic that automatically removes pumps from service when efficiency drops and rotates pumps to distribute wear evenly. We also restored hydraulic performance through targeted impeller replacements and refined operating conditions to reduce inefficient parallel operation.
Tetra Tech eliminated the need for hardware upgrades while improving system performance by executing programming and control strategy updates within the existing programmable logic controllers (PLC) and SCADA environment. The optimized control approach enables operators to maintain required flow with fewer pumps running, reducing energy demand and mechanical stress on equipment.
Benefits
- Reduced energy consumption through optimized pump operation
- Improved system efficiency using data-driven control strategies
- Extended pump life through rotation and targeted maintenance
- Reduced maintenance costs and equipment wear
- Avoided capital costs by leveraging existing infrastructure
The Tetra Tech Digital Systems Group delivered software-driven optimization that improved performance without hardware upgrades.