Construction of pumping stations

Professional design, supply, installation and commissioning of comprehensive fluid pumping systems for drinking and process water supply, wastewater disposal, fire extinguishing and production processes.

Reliable and uninterrupted operation of pumping equipment is critically important for utilities, industrial enterprises, agricultural complexes and infrastructure facilities. LLC «Dalgakiran Compressor Ukraine» implements comprehensive projects for the construction, reconstruction and automation of pumping stations of any purpose and capacity «turnkey».

We take full responsibility for each stage — from calculating hydraulic parameters and selecting pump types to construction and installation works, connecting control cabinet systems with variable-frequency regulation, commissioning and subsequent service maintenance.

Why is it worth ordering the construction of a «turnkey» pumping station?

• Single contractor and responsibility: One contractor is responsible for the entire scope of work — from engineering and hydraulic calculations to commissioning the facility.
• Maximum energy efficiency: The use of frequency converters (FC) and high-efficiency electric motors makes it possible to reduce electricity consumption by up to 30–50%.
• Protection against water hammer and accidents: The implementation of soft-start systems, variable-frequency control and safety valves extends the service life of pipelines and equipment.
• Automated control and dispatching: The ability of the station to operate in a fully autonomous mode with data transmission to the operator’s control panel or mobile devices.

Stages of construction of «turnkey» pumping stations

1. Hydraulic audit and calculation of pumping parameters

The first stage is determining the actual or calculated needs of the facility for fluid supply and the required pressure.

• For operating enterprises and networks (modernization): An audit of the existing pumping station is carried out, actual flow rate ($Q$, m³/h), head ($H$, m), electricity consumption, condition of pipelines and shut-off valves are measured, leaks and peak load modes are identified.
• For new facilities (construction from scratch): The required hydraulic parameters are calculated based on the requirements of the technological process, general plan, number of floors, fire safety standards or wastewater volumes.

Stage result: Determination of the types and number of pumping units (operating and backup), their operating scheme (parallel/series), required head, flow rate and requirements for the quality and composition of the fluid (clean water, drainage, sewage or aggressive media).

2. Feasibility study (FS) and efficiency calculation

At this stage, various equipment options and control schemes are compared to achieve the lowest operating costs.

We calculate:

• Projected reduction in electricity consumption through the implementation of a variable-frequency drive (VFD);
• Reduction of service maintenance and repair costs by eliminating water hammer;
• Reduction of water losses and elimination of emergency shutdowns;
• Investment payback period (ROI) and the overall economic effect of modernization or construction.

Stage result: A substantiated feasibility study with a comparison of capital and operating costs and the investment payback period.

3. Development of project documentation

The third stage covers the development of sets of project and estimate documentation in accordance with the current construction, technological and environmental standards of Ukraine.

The project includes the following sections:

• Technological part (TX): Selection of pumps, suction and discharge manifolds, shut-off and control valves, check valves, filters and measuring instruments;
• Construction part (BCh/KB): Foundations for pumping units, underground tanks, receiving tanks (for SPS), station premises;
• Electrical part and automation (EO, ATX): Power supply, pump control cabinets (with FC or soft-start devices), pressure, level and flow sensors, grounding and lightning protection;
• Dispatching and telemetry: Data transmission via Modbus, Profibus, GSM/GPRS protocols to the upper control level.

Stage result: An approved project that has passed the necessary approvals, a completed equipment specification and work estimate.

4. Construction works and site preparation

The fourth stage provides for the performance of general construction and preparatory works directly at the facility.

• Capital construction or reconstruction of premises: Construction or repair of the station building, arrangement of vibration-isolated foundations for pumps, preparation of drainage pits, laying of cable ducts and technological openings.
• Sewage pumping stations (SPS) and underground tanks: Earthworks, installation of reinforced concrete or fiberglass tanks/certified SPS housings, waterproofing works and preparation of receiving chambers.

Stage result: A completed construction part that meets the technical requirements for the installation of heavy pumping and hydraulic equipment.

5. Supply, installation and engineering piping

The fifth stage includes prompt delivery of pumping units, control cabinets, pipelines and fittings, their positioning and installation.

Our specialists perform:

• Installation of end-suction, borehole, submersible, multistage or self-priming pumps;
• Installation of discharge and suction manifolds made of stainless steel, galvanized steel or modern polymer materials;
• Installation of butterfly valves, check valves, gate valves, vibration-damping inserts (compensators) and mesh filters;
• Installation of control cabinets, measuring instruments (pressure gauges, flow meters, dry-run sensors) and connection of power and control cables.

Stage result: A fully installed pumping station, tested for hydraulic strength, tightness of connections and compliance with project documentation.

6. Commissioning works, adjustment and personnel training

The final stage — comprehensive testing and commissioning of the pumping station.

Engineers of «Dalgakiran Compressor Ukraine» carry out:

• Flushing and pressure testing of hydraulic lines;
• Adjustment of frequency converters, calibration of pressure and level sensors;
• Testing of automatic switching algorithms «operating/backup pump», soft start and stop;
• Checking the operation of protection systems (against dry running, overload, phase imbalance, leaks);
• Testing the pumping station in all operating and peak load modes.

Personnel training: We provide detailed instruction to the customer’s technical personnel on the rules of safe operation of pumping equipment, working with control cabinets, scheduled maintenance and actions in case of emergency situations.

Stage result: Signing of the commissioning certificate, transfer of a set of as-built documentation and acceptance of the facility for warranty service.

Main areas of pumping station construction

• Water supply pumping stations (pressure boosting): For supplying drinking and process water at industrial facilities, residential complexes and utility networks.
• Sewage pumping stations (SPS): Comprehensive solutions for pumping domestic, industrial and storm wastewater using submersible pumps with grinders.
• Fire-fighting pumping stations: Certified installations (sprinkler and deluge) with 100% redundancy and guaranteed automatic start-up.
• Industrial pumping systems: Specialized solutions for pumping chemically active, viscous, hot or abrasive fluids in the technological cycles of enterprises.

Additional solutions from «Dalgakiran Compressor Ukraine»

• Compact packaged pumping stations (in containerized or modularversion): Fully ready-to-connect factory units that do not require the construction of separate capital structures.
• In-house assembled control cabinets: Individual development of automation systems based on components from leading global brands (Schneider Electric, ABB, Siemens, Danfoss).
• Service support and repair 24/7: Scheduled maintenance, on-site diagnostic service, shaft alignment, replacement of mechanical seals and supply of original spare parts throughout Ukraine.

Need to calculate the parameters of a pumping station or order an audit of the hydraulic system?

Contact our engineers from the pumping equipment department to receive professional consultation and arrange a specialist’s visit to your facility.