From Emergency Response to Long-Term Infrastructure Solution
When a critical pumping station failure threatened operations at HMP Berwyn in North Wales, immediate action was required to protect one of the UK’s largest correctional facilities.
What began as an emergency response to a failing sewage pumping station quickly evolved into a complex, four-month infrastructure project. Metro Rod Deeside & North Wales provided continuous support to maintain operations while implementing a permanent solution.
The Challenge: Critical Pumping Station and Sewer Pump Failure
The main sewage pumping station serving HMP Berwyn experienced a complete failure when both primary sewer pumps became non-operational, placing the site’s foul drainage system at immediate risk.
The facility had an ongoing issue with debris entering the system, including rags, wipes and other materials that frequently blocked the pumping station. Although a de-ragging system had previously been installed, it failed shortly after commissioning.
Without urgent intervention, wastewater could have backed up across the prison, creating significant operational disruption, as well as serious health, safety and environmental risks.
The Solution: Emergency Pumping Station Support and Sewer Pump Installation
Metro Rod Deeside & North Wales rapidly deployed a temporary over-pumping system to maintain wastewater flow and stabilise the failing pumping station.
A 6-inch Selwood sewer pump was installed and operated continuously, 24/7, throughout the project. To ensure consistent performance, the system was monitored and maintained every 12 hours.
The solution evolved into a fully managed sewage pumping station support programme, including:
- 24/7 monitoring of the temporary pumping station
- Two 12-hour engineering shifts, including weekends and bank holidays
- Regular maintenance and fuel checks to sustain continuous operation
- Frequent manual de-ragging to prevent blockages
Engineers faced a significant challenge with debris accumulation, as the strainer within the pumping station required clearing approximately every hour to keep the system running efficiently.
Specialist Pumping Station Engineering Works
To deliver a long-term solution, Metro Rod carried out essential pumping station engineering and sewer pump installation, including:
- Confined space entry to clean and clear the sewage pumping station
- Removal of solids and debris to protect new pumps
- Installation of two new Flygt sewer pumps
- Installation and commissioning of a new control panel
- Testing and assessment of the compactor system
- Recommendations to restore full operational efficiency
These works ensured the upgraded pumping station would operate reliably and reduce the risk of future failures.
The Outcome: Resilient Sewage Pumping Station and Reduced Risk
Following installation and commissioning of the new sewage pumping station infrastructure, the site was successfully returned to full independent operation.
Throughout the project, the system managed approximately 30,000 litres of wastewater per day, ensuring uninterrupted service.
Key Results
Operational Continuity
The prison remained fully operational throughout, with no disruption to essential services thanks to effective pumping station management.
Improved Sewer Pump Reliability
The installation of new sewer pumps significantly reduced the risk of blockages and system failures.
Environmental Protection
Continuous wastewater control prevented overflow incidents and safeguarded the surrounding environment.
Cost Avoidance
The intervention prevented a potential full system failure, which could have required prisoner relocation and resulted in substantial operational and financial costs.
“I would like to state that Metro Rod and you have been exemplary and very professional in carrying out all the work in regard to all work completed at HMP Berwyn. Communication has been excellent throughout along with response times and completion of work. On all occasions I can honestly say that we would have really struggled without Metro Rod and will continue to use you in the future for similar work. I would also highly recommend you and Metro Rod to any new customers you have in the future.”
Specialists in Pumping Station Installation, Maintenance and Repair
This project demonstrates Metro Rod’s expertise in delivering:
- Emergency pumping station response
- Temporary over-pumping solutions
- Sewage pumping station repair and upgrades
- Confined space operations
- Sewer pump installation and maintenance
- End-to-end infrastructure project management
By combining rapid response with long-term engineering solutions, the team successfully transformed a critical pumping station failure into a resilient, future-proof system.
If you’re experiencing issues with a pumping station or sewer pump, our expert team is here to help.
Get in touch today to discuss your requirements and find out how we can support your infrastructure with reliable, compliant and cost-effective solutions.
Talk to your local Metro Rod specialist
We are always happy to arrange a free site assessment and no obligation quotations for any work you might need. Alternatively, you can call our emergency hotline number on 0800 66 88 00
Get in touch Drainage Services
