1300 083 042
Wetalla Aeration Upgrades D&C
About the project
The Wetalla WRF faced issues with a corroded aeration header and aging blowers that caused inefficiencies in the bioreactor. Pensar was engaged to install new positive displacement blowers and an above-ground header to resolve these problems. Additionally, the aerobic digesters required improved aeration, and Pensar was tasked with installing new duty/standby blowers and above-ground headers.
Location
Toowoomba, Queensland
Client & Duration
Toowoomba Regional Council
May 2023 - Jul 2024
Project Scope
- Detailed design, supply, installation, and commissioning of the new Aerobic Digester 2 blower building
- Refit of two existing buildings with new blowers and associated connecting pipework
- Staged changeover of the existing blowers following the commissioning of the new blower building
- Design and installation of two new motor control centres (MCCs) and 12 variable speed drives (VSDs).
Challenges
- The primary challenge was ensuring the existing treatment plant remained fully operational during blower changeovers. This was managed through a carefully developed staging plan that maintained sufficient redundancy, allowing the new equipment to be commissioned without interrupting the process
- Ensuring the treatment process was not disrupted during installation and commissioning was critical. Pensar collaborated closely with TRC, Rienmac, and pH Water to develop and execute a commissioning plan that integrated seamlessly with the ongoing operations. Expectations were managed through regular communication, aligning timelines, and ensuring all parties were informed and in agreement throughout the project.
Achievements
- The construction was staged effectively to eliminate any shutdowns exceeding 4 hours, which ensured minimal impact on the treatment plant process
- The project was successfully completed 2 months ahead of schedule, demonstrating effective planning and execution
- All pipework was fabricated offsite without the need for on-site welding, facilitated by a detailed 3D laser scan and comprehensive 3D modeling, enhancing efficiency and safety
- Zero safety or environment incidents.
