What Municipalities Should Know About Upgrading Old Pump Controls
Many municipal water and wastewater systems are still running on control panels installed decades ago. In many cases, those systems still work. The problem is not that they stopped working. The problem is what happens when they finally do.
Upgrading old pump controls does not have to mean a full system replacement or a budget breaking project. With the right approach, municipalities can modernize controls, improve reliability, and extend system life without unnecessary cost.
This guide outlines what small town water departments should understand before upgrading aging pump control systems.
Old Controls Fail Quietly Until They Do Not
Older pump controls often give little warning before failure.
Relays wear mechanically. Contactors pit and stick. Legacy PLCs lose battery backed memory.
Obsolete HMIs fail with no replacement available.
When failure happens, it often results in emergency service calls, downtime, or temporary bypass wiring that introduces new risks.
Proactive upgrades allow municipalities to plan costs instead of reacting to failures.
You Do Not Need to Replace Everything at Once
One of the biggest misconceptions is that modernization requires replacing the entire control system in one project.
In reality, upgrades can often be phased:
- Replace obsolete PLCs while keeping existing starters or VFDs
- Add modern monitoring and alarming without changing pump hardware
- Upgrade communications and remote access first
- Improve power protection and surge suppression incrementally
A staged approach spreads costs over time and minimizes operational disruption.
Modern Controls Improve Visibility and Diagnostics
Older control panels were designed to run pumps, not explain problems.
Modern control systems provide:
- Clear alarm messages instead of generic fault lights
- Runtime and cycle tracking
- Trending of pressure, flow, and level
- Easier troubleshooting for operators and technicians
Better visibility means faster response, fewer unnecessary callouts, and more confidence in system operation.
 
Standardization Matters More Than Features
Small municipalities often inherit a mix of equipment installed by different contractors over many years.
This creates challenges with training, spare parts, and support.
When upgrading pump controls, standardization should be a priority:
- Use a common PLC platform across sites
- Use consistent programming structure and naming
- Standardize HMIs and alarms where possible
Standardization reduces long term maintenance cost more than adding extra features.
Remote Monitoring Does Not Have to Be Complicated
Many older pump systems require on site checks to confirm status.
Modern upgrades can add remote visibility without full SCADA replacement:
- Cellular or radio based alarming
- Simple web based dashboards
- Secure remote access for troubleshooting
Even basic remote alarming can significantly reduce response time and operator workload.
Budget Planning Is Easier With Clear Scope
Upgrades often fail at the budgeting stage due to unclear scope.
A well defined scope of work helps municipalities:
- Understand exactly what is being upgraded
- Separate necessary upgrades from optional improvements
- Compare proposals fairly
- Avoid surprise costs during installation
Clear scope leads to predictable outcomes.
BEA’s Approach to Municipal Control Upgrades
At Britton Electronics and Automation, we focus on practical upgrades that improve reliability without overengineering.
Our goal is to modernize systems in a way that:
- Fits municipal budgets
- Maintains operator familiarity
- Improves long term serviceability
- Avoids vendor lock in
Every municipality is different. The right upgrade path depends on system condition, staffing, and long term plans.
Modernizing old pump controls is not about chasing the newest technology. It is about reducing risk, improving reliability, and giving operators better tools to do their job.
With the right planning, municipalities can upgrade aging control systems responsibly and cost effectively.
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