Booster Pump Overhaul for Regional Water Authority

Tomlinson Hall was commissioned to carry out a full mechanical overhaul of two large in-line single-stage booster pumps on behalf of a regional water authority.

The pumps had been left unused on-site for several years and arrived at our facility in extremely poor condition. In addition to significant corrosion and wear, both 185kW drive motors were beyond economical repair and had to be fully replaced.

The project required a complete strip-down, refurbishment, reassembly and return to site — all within a strict turnaround window.

Following detailed inspection, our engineering team identified the key components for replacement and refurbishment.

We sourced and fitted two new 185kW high-efficiency motors, procured from Australia to match the original units. The pump casings and internal components were blast cleaned, reconditioned, and refurbished as needed.

To ensure compliance with potable water use, we applied a WRAS-approved long-life coating to the internal pump surfaces, providing corrosion resistance and extending future service life.

The hydraulic sections of the pumps were completely rebuilt with new components, including:

• New shafts and sleeves

• Cutlass bearings (water-lubricated and cooled)

• Thrust pads and mechanical seals

After final assembly and testing, both pumps were transported back to site and reinstalled well within the required timescale, ready to return to active service.

• Fully bespoke booster sets built exactly to the client’s design and technical specification

• Fire-retardant enclosures manufactured to a 30-minute safety standard and colour-matched

• Dual control functionality offering pressure or level-based operation via MARB control

• Robust stainless steel construction using 316-grade materials for durability

• Delivered ahead of schedule despite evolving requirements and extended project duration