Bundaberg Council Achieves Success with Cutting-Edge Pump Solution

The Bundaberg Regional Council invests heavily in infrastructure to deliver strong economic, social, and environmental outcomes across their community. To this end, a vacuum sewage system was constructed several years ago in their Woodgate area.

Operated by the Bundaberg Regional Council, the Woodgate Vacuum Sewer Station services approximately 3000 residents, with the population increasing to 8000 during peak holiday periods. This system consists of a network of vacuum lines to residences, leading to a large vacuum tank that draws all the wastewater by way of a large vacuum pump. Initially, a positive displacement lobe-style pump was used to move sewage from the vacuum tank to the wastewater treatment plant (WWTP).

Problem

It became evident that the main transfer pump (a positive displacement lobe pump) was starting to cause operational issues. Kevin Harris, Metal Trade Support Technician for the Council, said, “The design of our plant exerted immense strain on the pump, leading to excessive wear, excessive noise, and diminished efficiency over time.”

The consequences were escalating maintenance costs, dwindling efficiency, and mounting electricity bills. The velocity of sewage slowed within pipes, resulting in blockages and increased head pressures. This led to higher head pressures and increased power consumption. The system, which initially transferred 20 litres per second, was at times only moving 5 litres per second, using much more electricity to achieve the original output. Pumping time also became a limiting factor.

Kevin lamented, “We were grappling with reduced pumping capacity, surging power consumption, and imminent operational constraints.”

Determined to overcome these challenges, Kevin started looking for a better pumping solution. He visited the Queensland Water Industry Operations Workshop, where he encountered Garry Grant from Hydro Innovations. What ensued was a collaborative effort to devise a tailored, cost-effective remedy.

Solution

After discussing the issue and exchanging technical information, Garry Grant, General Manager at Hydro Innovations, proposed a Gorman-Rupp Ultra VS3A60-B (3″) two-stage, self-priming centrifugal sewage pump. A pioneering solution for this application, but offered in confidence because of the pump’s capacity to produce a vacuum large enough to overcome the vacuum in the tank, and also deliver the 70 metres of pressure required to transport the sewage to the WWTP. Equipped with a self-cleaning wear plate system and adjustable impeller clearance, the pump looked right for the job.

Despite its promising specifications, Bundaberg Regional Council opted for a trial run to validate its credentials. When the system was installed, the VS3A60-B pump exceeded expectations, delivering a new era of efficiency and reliability at the Woodgate Sewer Station.

“We are no longer wasting valuable time and money fixing an inefficient pump and can now focus on other core activities,” explained Kevin.

Results

Darren Caldwell, Hydro Innovations Regional Manager, recounted his visit recently to the Council Wastewater Treatment Plant, where the enduring performance of the Gorman-Rupp VS3A60-B pumps was evident. Shane Banks, the Council’s Electrical and Mechanical Team Manager, commended the pumps’ remarkable performance and minimal maintenance requirements.

Moreover, the two-stage design of the VS3A60-B facilitated a significant increase in pressure, enhancing overall operational performance by scouring built-up sludge in the line and delivering vastly higher flow rates.

In retrospect, the decision to embrace cutting-edge technology has not only alleviated maintenance burdens and reduced energy costs but also rewarded the Council’s commitment to sustainable sewage management and their willingness to adopt new technologies. With their investment in Gorman-Rupp Ultra VS3A60-B pumps, the Woodgate Vacuum Sewer Station stands as a testament to a Council’s courage to look past convention and a manufacturer’s commitment to quality and innovation.

The “Ultra V Series” of pumps from Gorman-Rupp are used extensively by water authorities and industry for tough wastewater pumping applications. They are able to be mounted at ground level, beside the wastewater wet well — not in it — providing a safer working environment for operators.

Not only are these pumps easier to access than conventional [submersible] wastewater pumps, but their design enables much of the service work (adjusting internal clearances and topping oil volumes) to be done without the need to open the pump. This reduces operator exposure to the wastewater being pumped and to electricity (no power cables to disconnect).

Asset owners or managers have a pump system (with their Gorman-Rupp Super T or Ultra V Series pumps) that requires much less intervention from operators and much less ancillary equipment. No cranes are required, and confined spaces equipment is rarely needed (if at all). All this equates to a more easily managed pumping system — one that will repay the investment many times over in maintenance cost savings and reduced stress levels.

For further information regarding the extensive range of Gorman-Rupp self-priming pumps and the services that Hydro Innovations are able to offer to remedy your wastewater, sewerage, aeration and any pump issues, please visit our very informative website at www.hydroinnovations.com.au or phone 02 9898 1800.