How one pumping station set up can save you money

Nicola Brittain

A new technology reduces operating costs with service-free pumping stations.

In recent years, the composition of wastewater has changed considerably, and pumping of untreated raw wastewater has become more and more challenging. Pump hydraulics which were used in the past without any problems and with satisfactory results, are becoming clogged increasingly often.

In response, international pump manufacturer Egger launched its Turo TA Vortex pump series for clog-free and safe pumping of raw sewage - the range was released five years ago and designed to improve the operational security of maintenance intense pumping stations.

As a result, numerous pumping stations have since installed the Turo TA Vortex pump to deal with raw sewage, municipal and industrial wastewater, sludge and suspensions with a high content of fibres, and other viscous media.

The pump features include fibre-repellant vortex hydraulics, special axial spiral casing (tuned to the hydraulics); and interchangeability with other impeller types.

The pump has been designed to allow operation for up to four years without the need for regular service and maintenance work on the units. The pump also reduces operating costs for operations where the lifting stations are located far from the main treatment plant, since the pumps operate autonomously – this reduces operating costs.

One plant run by PW Engineering, Romerberg (pictured) is a space saving and operator friendly vertical installation, it uses the Turo TA sewage hydraulics and the unique hydrodynamic shaft seal Eurodyn which converts the pumps to maintenance free units.

Other customers include wastewater associations such as the German water boards, the Emschergenossenschaft and Lippeverband, which also benefit from the maintenance-free pumping stations and are currently successfully running several of these.

In 2021, the Lippeverband put the first maintenance-free pumping station into operation in its Hamm municipal drainage system with the renovation of the Soester Straße pumping station.

The water board claims only 10% of the previous maintenance time is needed to control the technology resulting in enormous efficiency savings, because freed-up capacities can be invested in further innovation in plant technology.

Shortly afterwards, the Lippeverband installed the same technology at its Hoppeistraße pumping station. One of the technicians said: “After a good two years of operation, an initial balance can be drawn and our conclusion is positive: the maintenance-free pumping stations keep their promises. The Soester Straße pumping station, for example, only has to be closed once every six months.”

The automated review mechanisms can not only identify problems, but also independently rectify small, regular faults. If, for example, a pump is clogged by wet wipes disposed of incorrectly down the toilet. Such a situation can otherwise result in the failure of the pumping station.

The Emschergenossenschaft and Lippeverband (EGLV) operate more than 500 pumping stations in the Emscher and Lippe areas. Some of them, such as the Oberhausen pumping station are already partially equipped with the automated testing mechanisms described. The nationwide expansion of maintenance-free technology is the aim of these associations, but this still holds some challenges because not all pumping stations are the same.

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