Project Overview
Malcolm Thompson Pumps (MTP) was engaged to design and supply a customised self-priming pumping system for a major power station, Western Australia, a long-established power generation region in the state’s south-west that supplies electricity to the Western Australian power network.
The system was required for a coal run-off (fly ash) pond application, where effective dewatering is essential to maintaining site operations, environmental compliance, and protecting critical site infrastructure. The project formed part of an upgrade to ageing pumping equipment, aimed at improving performance, reliability, and suitability for the site’s operating conditions.
Application Requirements
The pumping system was required to operate within defined site constraints and performance parameters typical of a power station run-off application. Key requirements provided by the customer included:
- Available site power: 40 kW
- Material pumped: Water with a pH of approximately 3, containing minor sediment in suspension
- Required flow rate: 70 m³/hr
- Maximum discharge head: 50 m
- Priming requirement: Self-priming via a vacuum priming system
- Drive arrangement: Direct drive preferred
- Motor specification: High-efficiency, mine-spec electric motor
- Base and coupling: To be designed and supplied as part of the complete pump package
These requirements guided our highly skilled MTP technical engineers in the pump selection, material specification, sealing arrangement, and priming method.
Our Engineered Solution
MTP engineered and supplied a purpose-configured self-priming pump package designed to meet the performance and operating requirements of the application.
To support reliable operation under variable pond levels, a vacuum priming system was incorporated to maintain consistent prime during intermittent, start-stop operation. A dry-run capable cartridge mechanical seal was specified to reduce the risk of seal damage during periods of low or no flow.
Material selection focused on long-term performance in acidic conditions, with all wetted components manufactured in 316 stainless steel. The drive arrangement was selected to deliver dependable performance while operating within the site’s available power constraints.
System Configuration
At the core of the system was a Stalker ISO 125×80-400 centrifugal pump, featuring 316 stainless steel casing and impeller construction, along with a 431 stainless steel shaft for durability in corrosive service. The pump was driven by a TECO MAXe3 Premium Efficiency mine-spec motor (30 kW, IP66), matched to the hydraulic duty and preferred direct-drive configuration.
Reliable priming was achieved using an Aquaplus diaphragm vacuum priming pump, driven from the main pump shaft. This arrangement ensured consistent priming performance despite fluctuating water levels, reducing reliance on manual intervention.
All equipment was mounted on a hot-dip galvanised fabricated steel base frame, designed for long-term service in an outdoor industrial environment. High-visibility safety yellow guards were fitted to rotating components to align with site safety requirements.
The package was completed with stainless steel suction and discharge pipework, incorporating compound and pressure gauges for operational monitoring, a discharge check valve, and provision for future flow monitoring if required.
Project Outcomes
The completed system delivered a reliable, corrosion-resistant self-priming pumping solution that met all operational requirements for the Power Station coal run-off pond.
Key outcomes included:
- Improved reliability compared to the previous pump installation
- Reduced risk of damage during dry-run and start-stop operation
- Consistent self-priming performance under fluctuating pond levels
- Long-term durability in acidic water conditions
- Enhanced operational efficiency with reduced maintenance requirements
Need a customised self-priming pump solution for your site?
With decades of experience in self-priming pump systems and dewatering applications across power generation and heavy industry, Malcolm Thompson Pumps combines deep application knowledge with in-house pump design expertise to deliver customised, engineered solutions suited to demanding operating environments.
Contact Malcolm Thompson Pumps to discuss a system tailored to your application. Call 1800 950 276 or email sales@mtp.com.au to speak with our team.
