Wastewater Pump Station Repair
The Challenge
A major UK food and drink manufacturer was facing a critical failure at their Pump Station B. The station’s infrastructure was compromised by a significant split and blistering in the main chamber wall.
The damage resulted in several critical challenges:
- The structural damage posed an immediate environmental hazard and risked complete failure, and a halt in production.
- The existing valves and pipework were aged and inefficient, hampering the station’s performance and reliability.
- The primary concern was that if the tank was beyond repair, a full excavation and replacement would involve higher cost, extensive works and prolonged, operational downtime for the 24/7 facility.
Dura Pump conducted a thorough assessment to find the best solution for continued performance while minimising disruption.
The Solution
Dura Pump’s solution was a two-step strategic repair plan. Step 1 was to repair the station’s mechanical components and step 2 was to address the complex structural repair to the tank. The work was scheduled over a three-day period to align with the client’s operational constraints.
Step 1: Mechanical & Pumping Overhaul
Restore the reliability of the system’s core components:
- Pit Preparation: A tanker was deployed, removing 1,000 gallons of effluent from the valve chamber and main pit to create a safe working environment.
- Valve & Pipework Replacement: Our engineers decommissioned and removed the failing legacy valves from the valve chamber. They were replaced with two high-performance Non-Return Valves to prevent backflow and two Gate Valves to allow for future isolation and maintenance.
- Pipework Modernisation: New, durable MDPE (Medium-Density Polyethylene) pipework was installed. Together with new rocker pipe between the valve and chamber pit.
- Re-commissioning: All new mechanical and electrical connections were made and the system was fully tested to ensure it was operationally sound ahead of the structural work.
Step 2: Structural Tank Repair
With the mechanicals upgraded, the focus turned to the critical tank repair.
- Pump Station Preparation: A tanker emptied the pump station, removing 3,000 gallons of fluid to prepare it for repair.
- GRP Repair: Multiple layers of GRP were applied directly over the split, effectively sealing the split and creating a new, robust inner wall. To address any blistering, expanding structural foam was injected behind, reinforcing the area.
The Outcome
The project was completed on time and delivered a comprehensive repair, avoiding a full excavation and replacement.
This successful outcome delivered the following benefits to our customer:
- Costly Replacement Avoided: The successful structural repair meant the client avoided a higher cost and extensive downtime associated with a full station excavation and replacement.
- Full Integrity Restored: The GRP repair restored the pump station to a safe, structurally sound condition, extending its operational lifespan.
- Enhanced System Reliability: The new valves and fusion-welded MDPE pipework have eliminated previous inefficiencies and created a robust, reliable system.
- Minimal Operational Disruption: By completing the entire project within the planned three-day window, Dura Pump ensured delivery of the client’s critical production schedule.
Before
After
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