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Wastewater 16.09.2014

Pumps From Allweiler® In Istanbul´s Largest Modern Sewage Plant

Background

What´s the story about?

The metropolitan region of Istanbul currently has 15 sewage treatment plants serving nearly 20 million residents. The largest plant is located in Ambarli and is also one of the most modern and largest sewage treatment plants in Europe. German water and wastewater engineering firm PWT was the project manager for this plant, designing and operating it since its completion in mid-2012, under contract from Istanbul’s Water and Wastewater Company (ISKI). Argus Makine, the Istanbul-based representative of German pump manufacturer Allweiler®, handles maintenance and optimization of all pumps in the plant.

Challenge

What should be achieved?

90 Allweiler® pumps

Thirty-six progressing cavity pumps of the type "ALL-OPTIFLOW®" from Allweiler® form the core of the plant. The pumps are indispensable in virtually every step of the process, from delivery of raw sewage to pumping of sludge.

The plant produces biogas as a byproduct of the treatment and sludge-drying processes, which it uses to power turbines for electrical energy and to generate heat. Six Allweiler® high-temperature pumps of the "ALLHEAT®" series are used in this process. Each pump moves "mobiltherm 605" synthetic heat transfer oil at a rate of approximately 210 m³/h (925 gpm), at a temperature of up to 300 °C (572 °F), and a pressure of 4 bar (58 psi).

Application:	Sludge transfer
Pump series:	ALL-OPTIFLOW® AEB1F
Pump size:	5503
Flow:	100 m³/h / 440 gpm
Pressure:	3.5 bar / 50.8 psi

Application:	Sludge transfer
Pump series:	ALL-OPTIFLOW® AEB1F
Pump size:	5503
Flow:	100 m³/h / 440 gpm
Pressure:	3.5 bar / 50.8 psi

Application:	Heat transfer
Pump series:	ALLHEAT®
Temperature:	220 °C / 428 °F
Pressure:	6 bar / 87 psi

Solution

What´s the solution?

Lower operating costs

High efficiency and low maintenance-induced downtime are important for the plant's operation. ALL-OPTIFLOW® pumps are optimized for this role. Special stator and rotor surfaces and other design details result in extremely low starting torques and frictional losses. Both characteristics reduce power consumption. Allweiler®'s exclusive ALLDUR® stators ultimately extend maintenance intervals by up to 500 percent. These stators are extremely durable for a longer service life. This is less critical for feed and metering pumps, but is very important when pumping wastewater and sludge with abrasive components like sand. These pumps move material at a pressure of 1.5 to 3 bar (21.8 to 43.5 psi) and a flow rate ranging from 0.4 m³/h to 220 m³/h (1.76 gpm to 969 gpm). Proportioning pumps that feed materials like polymers are at the lower end of the range, while pumps moving raw and activated sludge account for the higher values. Six progressing cavity transfer pumps achieve flow rates of up to 1,300 m³/h (5724.35 gpm).

Result

What's the result?

Flawless operation

In the view of plant director Gökhan Demirel the choice of Allweiler® pumps was a good one. They show only minor wear and when spare parts are needed, they can be obtained economically. Another factor is the targeted selection of stator material according to the characteristicsof the sludge and liquid. Finally, procuring all pumps for a plant from a single manufacturer greatly simplifies maintenance. Due to the large number of common parts used in a variety of pumps, only a small number of spare parts must be kept in stock, minimizing the associated capital commitment. In this case, because nearly all pumps come from a single manufacturer, only one experienced partner (Argus Makine) is needed for service. This has proven advantageous during dimensioning and optimization of the pumps as well. At the same time, the on-site plant representative has been able to ensure rapid delivery of spare parts. Similarly positive experiences from other plants gave Ambarli yet another good reason to buy nearly all of its pumps from German manufacturer Allweiler®.

The plant is designed to handle two million resident equivalent units. The daily volume of processed wastewater is currently at 300,000 m³ (392,385 cubic yards), maximum capacity is 400,000 m³ (523,180 cubic yards) and an expansion is in the works. The maximum hourly intakevolume (during rainstorms, for example) is 46,800 m³/h (206,076 gpm).

Pumping thickened sludge to digesters

Progressing Cavity Pumps

Allweiler

Optimizes all hydraulic characteristics such as flow pattern, power absorption and distribution, and lubrication to ensure long service life and maximum efficiency.

Max. Capacity [l/min] :

3.800

Max. Discharge Pressure [bar] :

Max. Fluid Temperature [°C] :

135

Max. Viscosity [mm²/s] :

300.000

More details

Centrifugal Pumps

Allweiler

Designed for safe and reliable pumping of heat transfer fluids - whether your heat transfer fluid is organic mineral oil-based, synthetic heat transfer oil up to 400 °C, or hot water up to 207 °C.

Max. Capacity [m³/h] :

1.450

Max. Delivery Head [m] :

100

Max. Outlet Pressure [bar] :

Max. Fluid Temperature [°C] :

400

More details