Location
Belgium
Industry
Chemical
Flow increased from 10 m³/h to 100 m³/h
A tenfold boost in wastewater transfer capacity.
Custom system without changing existing piping
Tailored solution enabling non‑self‑priming pumps to operate within the original layout.
Reliable and future‑proof wastewater transfer
Enhanced with double mechanical seals, frequency control, NPSH calculations, and optimized control logic.
Challenge
At the site of our customer, a global player in advanced materials, wastewater management is critical for operational continuity and environmental compliance. Two large underground tanks (~ 13,000 m³ each) collect wastewater for the entire facility.
Originally, three self-priming pumps were in operation, but their capacity was limited to only 10 m³/h, far below the ideal 100 m³/h. To increase capacity and maintain the existing piping layout (a key customer requirement), they decided to replace these pumps and add additional units.
Solution
We opted to replace the existing pumps with Schegler Vigor horizontal slurry pumps with high-efficiency impellers, ideal for wastewater transfer. However, these pumps are not inherently self-priming. To meet the requirements, and to avoid major adjustments to the existing piping layout, we engineered a custom priming system:
- Vacuum pump with float tank on the suction side to enable priming
- Float box to isolate the vacuum line from the pump during normal operation.
- Krux pneumatic knife gate valves to prevent backflow and isolate the discharge line during start-up and shutdown.
- Air vent valve at the highest point for safe venting.
To ensure reliability and performance, we implemented several additional engineering measures. The pumps were equipped with an upgraded double mechanical seal rated for 10 bar(g) and a custom electrical cabinet with frequency control was installed for optimized operation. Detailed NPSH calculations were carried out to prevent cavitation, allowing full flow (100 m³/h) down to 4 m below the pump centerline and reduced flow (40 m³/h) down to 5.8 m depth.
The project also included P&ID development with multiple iterations for sensor placement and valve configuration, as well as control logic and PID regulation for precise flow and level monitoring. Finally, operating and start/stop procedures were designed and tested from scratch to guarantee safe and efficient operation.
Key pump specifics:
- Suction: 4” | Discharge: 3”
- Impeller: High Chrome (27%) closed 4-vane, high-efficiency design
- Motor: 22 kW
- Duty point: 100 m³/h @ 35 m head
Result
- Flow capacity increased from 10 m³/h to 100 m³/h.
- Reliable, efficient wastewater transfer without major adjustments to existing piping layout
- A solution tailored to the client’s constraints and future-proofed for demanding conditions.
