Articles & Case Studies

Pumps maximise operational reliability and enhance the working environment at Old River Tees Pumping Station

Posted: Monday 20th October 2008

Built in 1977, Old River Tees Pumping Station, on the banks of the River Tees in Stockton, is one of Northumbrian Water’s largest pumping stations, containing over 1810kw of pumping power.

ITT Water & Wastewater, the leading solutions provider within the water and wastewater treatment market, was brought in by Northumbrian Water to install Flygt pumps in a major redesign and refurbishment of the station, to ensure its ongoing operational reliability and enhance the working environment for the station staff.

Consultants Montgomery Watson Harza, brought in in 2005 to look into the design and refurbishment of the station, worked with contractors Byzak on the project - replacing the existing pumps with Flygt pumps to improve the efficiency of the station. The Flygt pumps used in the redesign and refurbishment included four 160kw units, two 37kw units and two 60kw units.

ITT Water & Wastewater’s range of Flygt Close Coupled Submersible Dry Mount Pumps were installed for most of the main duties as this style of pump reduces maintenance time and costs – however, there were quite a few challenges for the team of engineers to overcome before installation could begin.

Firstly, one of the main design issues, which made installation of new Flygt pumps with inline suctions and discharge pipeworks very difficult, was that the original units featured an offset suction and discharge design and, the suction pipework ran in channels in the raised concrete floor of the bottom of the dry well. Engineers also found a lack of any flexibility in the original design making the installation even more challenging.

The new Flygt pumps have made maintenance activities easier and quicker, plus, the fact that the impeller is bolted directly onto the motor shaft iradicates alignment or balancing issues. In particular, where it was possible, ITT Water & Wastewater fitted N design impellers to optimise efficiency by minimising blockages, therefore dramatically reducing maintenance time and costs – adding to overall cost savings for the station.

Finally, ITT Water & Wastewater also fitted the larger units with the MAS monitoring relay which provides protection for the pump and valuable maintenance information. It reduces the whole life costs of the pumps as the MAS will indicate when a service is required rather than the maintenance team following an arbitrary chronological period for servicing the pumps.

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