Projects

Design Construction Installation UV Steriliser Modules     Supply of 14 packaged Ultraviolet Steriliser modules for various sites around Western Australia The project involved the design, installation and commissioning of 14 Portable Ultra-Violet Steriliser modules, for sites in the South West, Great Southern and Agricultural regions. The modules were designed to be transportable, so that they can be easily re-located to new sites if required. Three of the sites were required to be operational within about 12 weeks of contract award. This was very tight, given that equipment delivery from the UK was eight weeks. The remaining modules where completed over the next nine months. There were many design issues due to actual water quality and site conditions differing significantly to those provided in the specifications. All these issues were overcome by Watercon’s design and construction teams working closely with the Water Corporations project team. All work, excluding the construction of the sandwich panel buildings was conducted in-house. This included the fabrication of the stainless steel pipe specials, galvanised support frames, workshop assembly and testing, site civil works, site welding, mechanical installation and commissioning. The modules were transported and unloaded at site using Watercon’s 8t truck fitted with a 4mt extendable boom crane. The ability to do most of the work in-house provided flexibility and ensured that resources were available when required. This was particularly important, given the nature of the project and the requirement to respond to the ‘dynamic’ design conditions.

10 Mile Brook Dam Ultra Violet Steriliser   Design and Construction of the 10 Mile Brook Dam Ultra Violet Steriliser  Package Margarat River for the Water Corporation. Workshop design and construction of an Ultra-Violet Steriliser package for the Water Corporation\'s 10 Mile Brook Dam Water Treatment Plant in Margaret River. A skid mounted package was designed for ease of transport and to minimise the site installation time and costs. The design, fabrication, mechanical and electrical installation comprised: Design of equipment layout, pipe specials, electrical and control system. Fabrication of the DN300 stainless steel pipework, skid frame and pipe supports. Supply and installation of the electrical cubicle and equipment. Workshop assembly of the equipment. Factory Acceptance Testing. Transport to site. The available footprint on-site for the UV system was very limited. The package was modelled in 3D to optimise the layout, while ensuring that all equipment would fit, and that appropriate clearances were maintained for access and maintenance. This design methodology, whereby highly accurate 3D arrangement drawings are produced, results in significantly reduced fabrication and construction time and costs, thus providing a better service to our customers. The UV package was tested at our Malaga workshop and then transported to site using Watercon\'s truck, thus ensuring delivery to site undamaged.

Bunbury City WaterLink   Construction of a DN600 MSCL Pipeline and Bunbury City WaterLink Transfer Pump Station as part of the $8M CityWaterLink Project. A landmark project for both Aqwest and Watercon, this project will secure Bunbury’s long term water supplies. Aqwest awarded two contracts, one for the suction main and pump station, the second for the 8.4km of MDPE pipeline. Watercon was awarded the contract for the construction of the suction main and pump station at Tech Reservoir and the reservoir connections. The work involved: 300m of DN600 MSCL for the suction main out of Tech Reservoir. Tilt up concrete panel pump station building. Fabrication of the MSCL pipe specials and pipe supports. Supply of all valves. DN500 MSCL pipework and specials for the connections at Hastie and Roberts Reservoir. Supply of electrical switchboards. Mechanical and electrical installation. PLC, Citect and SCADA upgrades. Testing and Commissioning of the complete system. The system is designed to operate in a number of different modes, providing for different source and delivery options. Electrically actuated butterfly valves provide automatic mode selection via the Citect HMI located in Aqwest’s administration complex. Work commenced in June 2007 and water was being pumped mid December. The system was officially opened by the Minister for Water Resources John Kobelke on May 16 2008.

Harding Dam Sulphuric Acid Dosing System Upgrad   The Harding Dam Sulphuric Acid Dosing System Upgrade at the Harding Dam Water Treatment Plant 35km East of Karratha Western Australia. The project scope consisted of the following items. The existing dosing system at Harding Dam required upgrading due to a significant number of failures of the cPVC pipework and valves from overheating. This system was upgraded to prevent future failures, and to overcome other design shortcomings of the original system. The design incorporated additional instrumentation to provide better process control and monitoring of system temperatures, pressures and flows. Pipework was all 316 stainless steel. PFA/PTFE lined pipe and fittings were used for the dilute acid circuits. These had long lead-times, and there was no possibility for field fit joints. Accuracy of the completed layout had to be guaranteed. To achieve this, a site survey was carried out, and the entire layout was modelled in 3D in AutoCAD. Shop drawings were created from this model. The result was mm perfect accuracy during on-site erection. Some field fit joints were allowed for on the unlined pipe spools. This is a construction methodology which Watercon had applied on previous projects with excellent results. The panels were assembled and pre-tested in Perth, loaded into Watercon’s sea container site workshop and transported to site on Watercon’s 8t truck. This provided the additional peace of mind that the load was treated with care for the entire journey. The existing system had to be de-commissioned before the new equipment could be installed. This required careful planning and execution due to the hazards associated with concentrated sulphuric acid. This work proceeded smoothly with no incidents. It was discovered during decommissioning the internal lining of the storage tank had failed. The tank to be completely drained, and washed to allow an internal inspection to be undertaken. Special procedures had to be developed for this, as none existed in the plant operating manuals for this work. The decommissioning procedures were based on those developed for the decontamination of the FSA storage tank at Two Peoples bay WTP. Again this work was completed safely and without incident. Installation of the new system was completed as designed, with all the pipes spools, valves and equipment bolting upaccurately.

Vasse Newtown Vacuum Sewerage Pumping Station   Construction of  the Vasse Newtown Vacuum Sewerage Pumping Station, for a new housing estate south of Busselton Western Australia Construction and commissioning of a vacuum pumping station with an ultimate capacity of 55.7 litres/second wastewater inflow. The mechanical installation consisted of installation of: 4 x Busch Mink vacuum pumps with a design capacity of 500 m3/hr each. 2 x PX Pumps PX3-150 sewage pumps. Stainless Steel vacuum collection vessel. ABS suction pipework. Stainless Steel exhaust pipework. S/S sewerage pipework and associated valves. Fabrication and installation of all landings, walkways, stairways and hand rails. The installation also included the installation of electrically actuated plug valves on the four vacuum inlet mains. The commissioning of the scheme included pot testing and tuning over 70 existing AIRVAC vacuum interface valves.

Dalyellup WTP Caustic Soda Dosing System Upgrade   Design and construction of a new steel storage tank, concrete bund and dosing system for a WTP in Bunbury Western Australia Upgrade of the Caustic Soda (Sodium Hydroxide) dosing system at the Dalyellup Water Treatment Plant. The project involved the design, construction and installation of: Concrete Storage Bund and Loading Apron. Fabrication of a 20,000L Carbon Steel Storage Tank to API650. Dosing pump system and pipework. Tank Access Platform and ladders. Electrical Equipment, Control and Instrumentation. Following the construction activities, Watercon carried out the commissioning of the system, as well as operator training.