Project Overview

Vijay Engineering and Machinery Private Limited (VEMPL) successfully completed a comprehensive pump refurbishment project at the Bhandarwada Hill Reservoir for the Brihanmumbai Municipal Corporation (BMC).The project involved the refurbishment of four horizontal split casing pump sets, which had been in continuous operation for over 20 years. The objective was to restore hydraulic efficiency, reduce power consumption, and extend the operational life of these critical pumps supporting Mumbai’s water supply network.

Project Challenges

Over prolonged operation, the pumps experienced performance degradation due to natural wear and tear. The key challenges identified were:

• Significant reduction in pump efficiency
  
• Increased power consumption
  
• Aging internal components affecting hydraulic performance
  
• Need for refurbishment without compromising potable water safety standards
  

A systematic and technically sound refurbishment approach was essential to restore performance and ensure long-term reliability.

VEMPL Scope of Work

VEMPL executed the project through a structured and detailed refurbishment methodology:

Detailed Inspection & Planning

• Comprehensive assessment of pump condition and performance
  
• Evaluation of wear patterns and efficiency losses
  
• Development of a customized refurbishment plan for each pump unit
  

Refurbishment Process

Each pump underwent a complete refurbishment cycle, including:

• Dismantling and thorough cleaning of all components
  
• Abrasive blasting of internal and external surfaces
  
• Application of a specialized glass flake coating suitable for potable water applications
  
• Replacement of worn-out components such as bearings, wear rings, and gland packing
  
• Dynamic balancing of the impeller to ensure smooth and efficient operation
  

Rigorous Testing & Validation

• Pre-coating inspection and baseline performance testing
  
• Initial performance testing prior to refurbishment
  
• Final performance and efficiency testing post refurbishment to validate results
  

Project Outcomes & Performance Improvements

The refurbishment project delivered measurable and verifiable performance gains:

• Efficiency Improvement:
  Increased from 64.82% to 73.71%
  
• Reduced Power Consumption:
  Decreased from 232 kW to 220 kW, resulting in energy savings
  
• Extended Equipment Life:
  Refurbishment significantly enhanced pump longevity, reducing the need for premature replacement
  
• Improved Water Delivery Reliability:
  Restored hydraulic performance ensured consistent and dependable water supply
  

Benefits to the Client

• Lower operational and energy costs
  
• Enhanced reliability of water pumping infrastructure
  
• Deferred capital expenditure on new pump replacements
  
• Compliance with potable water safety and quality requirements
  

Collaboration for Success

The success of this project reflects the effective collaboration between BMC’s Hydraulic Engineer’s Department and VEMPL’s experienced engineering team.

VEMPL’s expertise in pump refurbishment, combined with strict adherence to quality standards and project timelines, ensured smooth execution and successful completion.

Conclusion

The Bhandarwada Hill Reservoir Pump Refurbishment Project serves as a strong example of how strategic infrastructure maintenance and technically sound refurbishment practices can deliver significant improvements in efficiency, cost savings, and service reliability. Through this project, VEMPL has reinforced its position as a trusted partner for pump refurbishment, performance optimization, and lifecycle extension solutions for critical municipal water infrastructure.