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Equipped for the future: Refurbishing a waste water pumping station

Refurbishing an existing system often requires more know-how than setting up a new installation. The equipment being repaired may no longer be cutting edge, but it still serves its purpose for the operator. Comprehensive documentation may be missing and spare parts hard to come by. KSB SupremeServ specialises in these complex challenges and successfully applies a tailored catalogue of measures.

Condition of the pumping station before work started (left) and the completed system (right)

The project: Refurbishing the Hannover-Herrenhausen waste water treatment plant

The inlet pumping station of the Hannover-Herrenhausen waste water treatment plant has been working reliably for almost 60 years. It collects raw waste water from various city districts which is then transported to the different treatment stages. Refurbishment was necessary in order to secure the system’s operation for further decades.

Non-clogging impeller pump before and after cleaning

Non-clogging impeller pump before and after cleaning

The customer: Stadtentwässerung Hannover

The utility company for the state capital of Lower Saxony has reliably disposed of the city’s waste water for over 115 years. 
Collected from an area of approx. 450 square kilometres, Hannover’s waste water is pumped and transported via 2500 kilometres of public sewers.

Around 750,000 people benefit from the professional cleaning of waste water in one of the company’s two treatment plants.

The challenge: Repair and modernisation during ongoing plant operation

Although the refurbishment period was only scheduled to last 10 months, the plant had to remain fully operational throughout. This required close coordination between all parties involved. All work that had to be carried out on the system was announced and approved in good time.

Corrosion and wear had affected the pumping equipment and parts of the foundation. Alongside the modernisation and optimisation of the pump trains, the operator also requested a slight power adjustment to ensure that the pumping station is equipped for increasing waste water flow and possible heavy rainfall.

The solution: Customised measures – analysis, planning, organisation, maintenance, optimisation

KSB implemented the refurbishment project incl. risk analysis and repair work for Stadtentwässerung Hannover. The repair work covered not only the pumps, but also their drives, the requisite valves and the entire piping system.

Due to the pumping equipment’s age (approx. 60 years old), some of its technical documentation was incomplete and some spare parts were no longer available. KSB’s reverse engineering department was therefore commissioned to measure and reproduce five severely damaged three-channel impellers. The impellers’ diameters were increased to a maximum of 605 mm during this reproduction process. As the 16 gate valves installed could not be repaired, KSB supplied replacement valves; the swing check valve on the discharge side was refurbished. 

After successful commissioning, KSB’s specialists provided instruction to the operating staff to ensure they became familiar with the new pumping equipment and the entire refurbished pumping station.

Pump and foundation before and after refurbishment

Pump and foundation before and after refurbishment

Figures I Data I Facts

  • Location: Hannover-Herrenhausen
  • Company: Stadtentwässerung Hannover
    Over 2500 kilometres of public sewers serving 750,000 people over an area of approx. 450 square kilometres
    Established: Approx. 1899
  • Sales revenue: Waste Water Technology
  • System: Hannover-Herrenhausen waste water pumping station
  • End user: Stadtentwässerung Hannover

Refurbishment work in detail

  • Project planning, organisation and coordination – incl. risk analysis
  • Provision of building site facilities incl. transport/lifting equipment and containers for offices, staff facilities, storage and washrooms
  • Commissioning of the station including instructing the operating staff
  • Complete documentation of the refurbishment work
  • Disposal of all parts to be scrapped 
  • Pump service:
    • Production of five three-channel impellers using reverse engineering
    • Repair of four waste water pumps with three-channel impellers (KSB KWvd 350) – incl. conversion to double mechanical seals
    • Refurbishing the pump foundations
    • Test run on KSB’s test facility – incl. power and emissions measurement
  • Motor service:
    • Renewing and adapting the pumps’ drives
  • Valve service:
    • Replacing the four valves installed in each pump train (suction-side gate valve, gate valve for suction-side drainage, discharge-side knife gate valve and discharge-side flood gate)
    • Supply of a new swing check valve for installation on the discharge side (protective grill)
  • Piping service:
    • Repair and coating of pipes
    • Manufacture and installation of additional pipe supports
    • Repair of sand traps
    • Affixing signs incl. flow direction arrows
    • Commissioning of the station including instructing the operating staff 
    • Complete documentation of the refurbishment work
    • Disposal of all parts to be scrapped

KSB es uno de los principales fabricantes de bombas y válvulas industriales del mundo

KSB fue fundada en 1871 en Frankenthal (Alemania) y lleva más de 100 años siendo uno de los fabricantes líderes de bombas y válvulas industriales. Con más de 15 500 empleados en todo el mundo y oficinas de ventas, plantas de producción y red de servicio posventa propios, desarrolla y fabrica bombas a medida para una gran variedad de aplicaciones.

La gama de productos de este experimentado fabricante de bombas es utilizada en los sectores de la edificación e industria, el transporte de agua, el tratamiento de aguas residuales y en procesos de centrales eléctricas. Gracias a una innovadora investigación y desarrollo, KSB está en posición de satisfacer los requisitos más diversos de sus clientes. Cuenta con muchos años de experiencia y conocimientos técnicos como fabricante de bombas reconocido.

El fabricante de bombas KSB: la mejor solución para su instalación
Las bombas y válvulas industriales de KSB son aptas para una gran variedad de aplicaciones y sumamente eficientes en consumo energético. Sus productos convencen por su tecnología innovadora y son utilizados en instalaciones desde hace muchos años con excelentes resultados, entre ellos la bomba de agua normalizada Etanorm. Con más de 1,5 millones de unidades vendidas, Etanorm es una de las bombas de agua normalizadas con más éxito del mundo. Repuestos y los servicios de KSB aseguran la fiabilidad operativa de sus bombas y válvulas industriales. Los sistemas hidráulicos, la tecnología de materiales y la automatización son los puntos fuertes tecnológicos del fabricante de bombas, y en ellos precisamente se basa la fórmula del éxito de sus bombas de altas prestaciones.

Un servicio profesional desde el primer momento
Sus numerosas plantas de producción permiten al fabricante de bombas KSB ofrecer cercanía al cliente y un servicio de primera. Especialistas certificados con una amplia experiencia garantizan la excelente calidad de los productos. KSB Service se ocupa de la puesta en marcha, inspección, mantenimiento y puesta a punto de sus bombas, válvulas e instalaciones completas directamente in situ. Además, KSB se encarga de que los repuestos se reciban en un plazo breve. Como consecuencia, usted recibe el mejor servicio directamente del fabricante de sus bombas.