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West Whiteland reviews $5.5 million Clover Mill pump station rehabilitation as new pumps underperform
Summary
West Whiteland officials heard that the Clover Mill Pump Station rehabilitation has reached $5.5 million (originally budgeted at $2 million) and that newly installed pumps are operating below design capacity; staff is testing the pumps with the manufacturer and Carroll Engineering.
West Whiteland Township supervisors on March 11 heard that a major rehabilitation of the Clover Mill Pump Station has cost far more than planned and that the new pumps are not meeting expected performance. Ed Culp, Public Works Operations Manager, told the board the station—built in 1970 and last upgraded in 2006—handles roughly 2.4 million gallons of sewage per day and carries about 36% of Uwchlan Township's flow to the Downingtown treatment facility (DARA).
Culp said the project was done in two phases: Phase I addressed electrical systems (emergency generators, pump controls and a new HVAC system) and Phase II addressed mechanical components (wet well steps, roof and stop gates, a bar screen and hoist system). He said the project had an original 2021 budget of $2 million and included a $964,000 grant but that cost to date is $5.5 million, with increases blamed in part on the pandemic and supply-chain disruptions. He added the station’s annual operating cost is about $170,000, primarily for electricity and excluding personnel costs.
Culp reported that performance tests show the newly installed pumps are operating below their design flow capacity. "We are experiencing performance issues with the new pumps," he said; staff has conducted numerous tests and is working with the pump manufacturer and Carroll Engineering to identify and resolve the problem. Vice Chair Rajesh Kumbhardare asked staff to investigate whether the same model pumps are meeting expectations at comparable installations elsewhere.
The board did not take formal action on the pump performance issue during the meeting; Culp said the matter remains under evaluation and staff will report back with test results and recommended next steps. The presentation also noted the Downingtown treatment facility is expanding capacity and planning a rate increase, which could affect downstream operations and rates, though the board did not adopt any policy changes at the session.
Next steps: staff will continue diagnostic testing in coordination with the pump manufacturer and Carroll Engineering and will update the board when more conclusive findings or recommended corrective work are available.
