Vision Equipment Blog
Is Your Headworks System Really Fine? 5 Common Mistakes in Screening Maintenance
Most water and wastewater treatment issues don’t start in the lab — they start at the headworks.
Your screening system is the first and most critical line of defense, protecting downstream equipment from damage, blockages, and costly inefficiencies. And while many systems seem to be working “just fine,” unnoticed issues in screening maintenance can quietly create operational problems that spiral into major expenses.
In this article, we’ll cover five of the most common screening maintenance mistakes — and how you can avoid them.
Why Headworks Screening Matters More Than You Think
Headworks screens remove large debris and inorganic solids from the influent flow before they reach pumps, clarifiers, digesters, or biological treatment systems. When screens underperform, those solids make their way deeper into your process, where they can cause:
- Pump clogs and excessive wear
- Premature blower failures
- Inefficient sludge settling or digestion
- Odor complaints and permit risks
In short: weak headworks = weak plant performance.
5 Common Mistakes in Screening Maintenance
1. Assuming “Automatic” Means “Maintenance-Free”
Even the best self-cleaning bar screens and drum screens require regular inspection. Wipers, chains, and bearings wear over time. If routine maintenance is skipped or delayed, you risk reduced performance and sudden equipment failure.
Pro Tip: Schedule quarterly inspections—even on newer systems—and keep spare wear parts on hand.
2. Not Accounting for Peak Flow Events
Most screens are rated based on average daily flow conditions. But when Texas storms hit, flow volumes spike, and outdated or undersized screens often can’t keep up. That can lead to bypassing, backups, or flooding.
Solution: Evaluate your system’s performance during high-load periods. Consider storm-resistant screens or screening redundancy where needed.
3. Skipping Basic Cleaning and Lubrication
Operators are stretched thin. It’s easy to push maintenance to “next week” when things seem normal. But missed cleaning or lubrication intervals can cause buildup, corrosion, or premature motor strain.
Reminder: Establish a realistic PM schedule based on your equipment type — and stick to it.
4. Overlooking Screen Capture Performance
Coarse screens may remove visible debris but still allow smaller solids to pass through. Over time, this can foul downstream equipment or disrupt biological processes. Many operators miss this until problems show up later.
What to Watch For: If you’re seeing more rags in pumps or strange BOD/solids readings, the screen may be underperforming.
5. Waiting Until It Breaks
“Run to failure” might work for some equipment — but not for headworks screens. Emergency repairs cost more, require rushed approvals, and can risk non-compliance with TCEQ discharge permits.
Prevention Pays: Most screen failures show early signs (excessive vibration, slower raking cycles, increased rag buildup). Don’t ignore them.
What It’s Really Costing You
Failing to maintain your headworks screening system doesn’t just shorten equipment life — it affects every downstream process. You may be paying for:
- More frequent pump maintenance
- Emergency rental equipment
- Odor control interventions
- Compliance testing and reporting
- Lost staff time dealing with avoidable issues
Over time, even small inefficiencies add up to significant costs.
What to Do Next: Get Ahead of the Problem
Here’s how proactive plants stay ahead of headworks issues:
- Inspect your screen performance regularly – including during storms
- Update your maintenance log and parts inventory
- Benchmark your system’s capacity vs. current flow demands
- Evaluate modern screen technologies with higher capture efficiency and lower maintenance demands
Conclusion: “Fine” Isn’t Always Good Enough
If your screening system hasn’t been evaluated in the past few years, it might be time for a second look. New technologies and updated sizing standards can help you improve efficiency, reduce costs, and extend the life of downstream equipment.