Critical Upgrade Using Flomatic Valves Restores Stability
A FLOMATIC CASE STUDY
Flomatic Valves Partners with W2O Pump and Service at Cayuga Heights WWTP
Aging Infrastructure Poses
Operational Risks
Built in 1952, the Cayuga Heights Wastewater Treatment Plant in the Village of Cayuga Heights, New York, serves not only the local population but also the Village of Lansing, small portions of the Town of Lansing, the northeastern area of the Town of Ithaca, and a small section of the Town of Dryden. The facility has a permitted operating capacity of 2.0 million gallons per day (MGD), with average flows ranging between 1.5 MGD and 2.0 MGD.
The plant utilizes a trickling filter system for biological treatment and includes tertiary phosphorus removal processes to enhance effluent quality before discharge. Previously, three aging Allis-Chalmers end-suction pumps were responsible for delivering wastewater to the trickling filters. To comply with permit requirements, two pumps must operate continuously, with the third kept on standby and used as a backup during routine maintenance or emergency repairs. To balance wear and extend equipment life, the backup pump was periodically rotated into service.
After decades of operation, the Allis-Chalmers pumps had become outdated, inefficient, and increasingly prone to breakdowns. Despite ongoing modifications and rebuilds, only two remained operational — both rapidly approaching the end of their service life.
The pumps were outfitted with aging check and butterfly valves, both of which had become nearly inoperable. Check valves are critical for ensuring unidirectional flow of wastewater, thereby preventing backflow that could potentially damage equipment or disrupt operations. The Butterfly valves, on the other hand, are essential for shutoff purposes, enabling operators to halt the flow to the pumps during maintenance or repairs.
“The check valves had to be manually opened and closed,” said Mike Albro, lead operator with YAWS Environmental, the plant’s operator.
“We were actually using a six-foot bar attached to the end of the valve to lift and close them. The valves were no longer responding to hydraulic loading from the pumps.”
Likewise, the butterfly valves had lost their ability to hold water. None could completely seal, and two barely functioned at all. With the risk of failure growing more critical, an immediate solution was needed to ensure system reliability.
Flomatic’s swing check and plug valves are featured above. SEE MORE HERE.
Urgent Response
Ensures Compliance
Recognizing the urgency of the situation, YAWS Environmental issued an emergency contract and engaged W2O Pump & System Services, a trusted partner with extensive experience in pump and valve selection.
“YAWS was very concerned about the condition of the equipment,” said W2O owner Dereck Withey. “If either of the two remaining pumps failed, the system wouldn’t be able to send enough wastewater to the trickling filters to meet permit requirements.”
Having worked with W2O and Withey for a decade, Mike Albro felt confident allowing their team to make critical decisions regarding equipment replacement.
“W2O is my go-to when I need a dependable solution,” Albro said.
“They’ve handled our routine service and emergency work for years. I trust their guidance and know the decisions they make will be reliable.”
W2O selected and installed three Wilo-Rexa Norm pumps, replacing the outdated Allis-Chalmers units. The pumps were chosen for their reliability, ease of installation, and ability to meet plant performance requirements.
Additionally, W2O replaced the failing check and butterfly valves with high-quality, long-lasting valves from Flomatic. During the selection process AWWA C517 E-Centric Plug valves were recommended and approved, a much better valve product for wastewater systems with large solids.
The Valve Upgrades Included:
10-inch Flomatic lever and weight swing check valves with air cushions installed in a vertical orientation.
The valves were designed to meet and exceed AWWA C508.
12-inch Flomatic AWWA C517 Flo-E-Centric® plug valves (replacing butterfly valves), on both the suction and discharge sides, complete with handwheels and chainwheels, respectively.
Withey specified air cushions with Flomatic’s swing check valves to protect against water hammer, a pressure surge caused by a rapid change in flow velocity. “The pumps are VFD-driven, but in the event of a power outage, the VFD wouldn’t slow the pump down, which creates the risk of water hammer and slamming,” Withey explained.
“The air cushion protects against that, absorbing the slam and allowing it to shut instead of continued hammering.”
Reliability In Action
The valve upgrades resolved both the sealing failures in the previous butterfly valves and the unreliable operation of the original check valves.
“Working together, YAWS and W2O were able to install the new pumps and valves to prevent a major system failure,” Albro said.
“Our wastewater treatment plant discharges directly into Cayuga Lake, so maintaining proper equipment functionality is critical. The trickling filters provide biological treatment, and without them, we would only be chlorinating and discharging. These pumps and valves play an essential role in our treatment process.”
W2O’s trust in Flomatic Valves extends beyond the emergency project. “We voluntarily standardize on Flomatic valves,” Withey said. “We’ve never had a warranty claim or an issue with any Flomatic valve we’ve installed. I’ve been in the industry for 18 years, and Flomatic offers better customer service and responsiveness than any other valve manufacturer I’ve worked with.”
He recalled an early experience that solidified his trust in Flomatic’s support. “When I first started this division at W2O, I ordered a Flomatic pressure relief valve through another distributor but accidentally received a pressure-sustaining valve instead. It was an emergency job and later that evening I was able to connect on a call with Flomatic’s president. He walked me through how to modify the valve to make it work for our application, allowing us to get a well pump online.”
With the new pumps and valves in place, the Cayuga Heights WWTP is now better equipped for long-term reliability.
