I had a clarifier so fed up with the sludge it started overflowing like it was auditioning for a water feature! Funny part is, I had just gone through a bunch of optimization measures. Always makes me think: is it really the system that needs fixing, or just a cry for help? Ever had a piece of equipment that seemed to have a mind of its own?
Sounds like your clarifier was really at its limit — ever think of adding a pre-treatment step to ease the load? We’ve seen some success with that approach. 
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, it drives me nuts when equipment throws a tantrum after we think we’ve got it all under control! I remember a time my clarifier overflowed right after a big optimization too; it felt like a cruel joke. Sometimes I wonder if adding a pre-treatment step wouldn’t just buy us some peace of mind. @melissa_j32, have you ever tried that approach?
I hear you! Sometimes it feels like our clarifiers just need a spa day instead of more maintenance. Maybe a good backwash and some downtime could do wonders — did yours ever throw a fit during peak hours?