Client: Municipal Corporation of Greater Mumbai (M.C.G.M.)
Project Location: Influent Pumping Station (IPS), Bandra, Mumbai
Pump Capacity: 311 MLD
Pump Make & Model: Sulzer – NPSV 1000-1300/59

Project Overview

Vijay Engineering and Machinery Private Limited (VEMPL) successfully executed a critical engineering and retrofit project for the Municipal Corporation of Greater Mumbai (M.C.G.M.) at the Influent Pumping Station (IPS), Bandra — one of Mumbai’s most vital sewage handling installations.

The scope involved the design, manufacture, supply, installation, and commissioning of a back pull-out pump assembly for a 311 MLD Sulzer make sewage pump. The solution was engineered to ensure faster maintenance, reduced system downtime, and improved operational reliability for a pumping station that operates continuously to manage Mumbai’s sewage inflow.

Project Challenges

The Bandra IPS plays a crucial role in the city’s sewage infrastructure and operates eight large-capacity Sulzer sewage pumps on a continuous basis. The key challenges faced were:

• Pumps commissioned in 2003, operating without a spare or backup assembly
  
• Absence of original OEM drawings and design documentation
  
• High dependency on uninterrupted pump availability
  
• Risk of prolonged downtime during breakdowns or scheduled maintenance
  
• Requirement to ensure compatibility with existing pump hydraulics and site conditions
  

Given the critical nature of the installation, even minimal downtime could lead to major operational disruptions.

VEMPL Scope of Work

VEMPL delivered an end-to-end engineered solution, including:

• Reverse engineering of the existing Sulzer pump assembly
• Hydraulic and mechanical design of a compatible back pull-out assembly
• Manufacturing of the complete pump assembly
• Supply, installation, and commissioning at site
• Performance validation to match and improve original pump parameters

The solution was executed in close technical coordination with Kirloskar Brothers Limited (KBL) engineers to ensure design integrity and reliability.

Engineering Expertise & Technical Innovation

Due to the unavailability of original Sulzer design data, VEMPL employed advanced reverse engineering techniques to accurately replicate and enhance the pump assembly.

The newly developed back pull-out assembly was engineered to:

• Match existing pump casing and piping interfaces
  
• Improve hydraulic performance without altering system design
  
• Enable quick removal and replacement during maintenance
  

This approach ensured seamless integration with the existing pumping system while delivering measurable performance improvements.

Improved Pump Performance

The newly designed and commissioned back pull-out assembly demonstrated enhanced hydraulic performance compared to the original pump:

• Flow Rate:
  13,005 m³/hr (earlier 12,900 m³/hr) – ~1.0% increase
  
• Head:
  33.09 m (earlier 31.08 m) – ~6.8% increase
  
• Efficiency:
  90.86%, exceeding the original efficiency of 90%
  

These improvements were achieved while maintaining operational stability and compliance with system requirements.

Project Outcomes & Benefits

By successfully delivering this project, VEMPL enabled M.C.G.M. to achieve:

• Reduced Maintenance Downtime
  Back pull-out assembly allows faster pump replacement during breakdowns or scheduled servicing
  
• Improved System Efficiency
  Enhanced flow and head without compromising energy efficiency
  
• Enhanced Operational Reliability
  Availability of a ready backup assembly significantly strengthens pumping station reliability
  
• Long-Term Infrastructure Support
  Reduced dependency on OEM spares for legacy equipment
  

Conclusion

This project highlights VEMPL’s strong engineering capability, problem-solving approach, and execution excellence in handling complex retrofit and reverse-engineering assignments for critical municipal infrastructure. We are proud to partner with Municipal Corporation of Greater Mumbai (M.C.G.M.) in ensuring the smooth, efficient, and reliable operation of Mumbai’s sewage pumping infrastructure, reinforcing VEMPL’s position as a trusted solution provider for large-capacity pumping systems and customized engineering solutions.