Richmond superintendent warns of control-system failures and operator shortfall at wastewater plant

Superintendent Steve told the Town of Richmond Water and Sewer Commission on March 16 that the plant has experienced repeated control failures since a new influent pump was installed, forcing staff into constant manual monitoring and nearly causing a wet-well overflow.

"I'm going to end up sitting here all night ... none of the influent pumps are working right ... it's wearing me out," Steve said, describing multiple nights of manual interventions, a broken incline screw that was repaired, and recent episodes in which both pumps ramped down prematurely and failed to restart automatically. He said the problem appears to lie in the control/SCADA side of the system rather than the pumps themselves.

Why it matters: the influent pumps regulate flow into the treatment process; repeated failures can risk plant performance and public health if sewage handling is interrupted. The commission said the fault could be in PLC/SCADA cards, sensor feedback, or firmware compatibility between a decades-old control system and new pump hardware.

Commissioners and staff discussed troubleshooting steps and next actions. Steve said he had contacted a trusted controls technician, Tom Allen, and listed other potential contractors (Dom/Don Martin and Champlain-area firms). He also reported that the plant's contract operator (named in the transcript as likely to give notice) is stretched thin and may give 30 days' notice, increasing the near-term staffing risk.

Commissioners offered immediate support and several short-term options: try to secure a control specialist to diagnose and repair the PLC/SCADA interface, consider hiring temporary help to cover overnight shifts, and, if feasible, have staff members sit rotating shifts while contractors work on a permanent fix. One commissioner suggested commissioning/design oversight when major components are replaced to avoid similar compatibility problems.

Steve outlined why a quick vendor visit is needed rather than a full SCADA reboot: "Every time we do that ... there's the chance that it will not come back," he said, noting the system includes legacy components and that a poorly timed restart could worsen operations. Commissioners agreed the risk of continued operation in the current state justifies expedited contractor outreach.

On safety and compliance, Steve said the plant has completed many items flagged in a recent audit (new dewatering control panel cover, air-compressor work, permanent guards) but still needs to purchase compliant ladders, extension cords, and a self-closing gate for the influent-pump access (estimated $500–$600) and to arrange an inspection of a 1973 overhead lift (inspection estimated at roughly $2,500).

The commission also discussed meter-reading and online-portal problems with Zenner equipment and named vendor contacts (Noah, Daniel) who are working on trouble codes and battery/reader issues; those meter issues were presented as a separate but concurrent technical problem.

The commission asked staff to keep pressing control contractors and to arrange temporary coverage if the contract operator departs. No formal vote or expenditure was taken at the meeting specifically for emergency control repairs; commissioners signaled support for expedited vendor engagement and for using available funds to make needed safety and compliance purchases.

The commission adjourned after scheduling follow-up work. The next immediate procedural step noted at the meeting was an effort to reach Tom Allen or alternate controls specialists for an emergency diagnosis and to confirm whether temporary operator help is available.