Dhabeji Pumping Station

Karachi, the fifth densely populated city of the world with an enumerated figure of 14.90 million, is the provincial capital and the financial hub of Pakistan. Water requirement for such a metropolitan city has always been a challenge to be met. Considering the significance and sensitivity of this issue, a pumping complex was built five decades back comprising of 06 pumping stations having a total planned capacity of 520 MGD in Dhabeji (a suburb of Karachi city). With the increasing demand of water, a new pump house of 100 MGD (455,808 m3/day) was proposed in 2016 to be added in the same premises, to fully utilize the canal water capacity of 620 MGD.

An international EPC tender was floated on 20th April, 2016 to build a new pump house. KSB Pakistan with its consortium partners for civil and associated mechanical works, qualified both technically as well as financially for this project. The contract was signed on 2nd November, 2016 with a construction period of three years followed by one year of O&M. Contract included the engineering design, construction of civil works (excavation, piling and concreting), mechanical works (piping, overhead crane & screening system), electrical & instrumentation works (HT/LT cabling & SCADA) and installation & commissioning of the complete system.

Physical Hydraulic Model Testing was performed by M/s Hydrotec Consultant Ltd., Leeds, UK in May 2017 followed by detailed engineering under KSB Pakistan’s supervision. KSB’s scope of supply worth 6.70 Million Euro, primarily consisted to design the pump house with major equipment supplies. With an excellent support from KSB SE & Co. KGaA,  KSB Italia S.p.A., KSB S.A.S and KSB Middle East FZE, 06 vertical pumps (RDLO V 600-885 A1 GC PF) with 1125 KW Siemens Motors, each measuring a capacity of 113,952 m3/day (25MGD) along with a wide range of Gate Valves (Cobra SGP DN 150 ~ 900), Butterfly Valves (APORIS DN 600 ~ 2000), Air Release Valves (BOAVENT AVF DN 200), Pressure Release Valves (Ecoline XLC420 DN 500) and Check Valves (Cobra TDC DN 900) were a part of the project supplies.

For the civil works, excavation was of 7800 m3, followed by concrete works of 4500 m3 along with steel bars of approx. 650 Tons. Piping for the pump house ranged from DN100 to DN2000 of approximately 120 meter.

KSB Pakistan successfully completed this landmark project within the stipulated timelines, both for the construction and testing periods. The pump house was inaugurated earlier this year whereas the contractual testing period has successfully been completed on 30th June, 2020. Trouble-free commissioning of this project was highly admired by the Client (Karachi Water & Sewage Board) as well as the Consultant (M/s Osmani & Company Private Limited) and fully endorsed KSB’s professionalism to plan & execute such a complex and challenging project.

With an experience of such a composite project under its belt, KSB Pakistan eyes on different large-scale EPC projects across Pakistan especially in Water and Waste Water Segment.