HOW TO REGISTER FOR GRUNDFOS DOUBLE WARRANTY
All eligible Grundfos pumps* purchased must be registered in-store at either the Rockhampton Branch or Mackay Branch of Dowdens Pumping & Water Treatment (Grundfos Authorised Dealers) from which the pump is purchased from in order to qualify for DOUBLE WARRANTY. Please be aware that there is no other way to register eligible pump* purchases for DOUBLE WARRANTY!
Once a Grundfos product has been successfully registered in-store by Dowdens Pumping & Water Treatment (Mackay or Rockhampton Branches), customers will receive an email confirmation of the registration sent to their nominated email address. A copy of this confirmation must be kept, in addition to the original Tax Invoice as proof of purchase.
* BELOW IS AN OVERVIEW OF THE ELIGIBLE GRUNDFOS PUMPS:
Dowdens Pumping & Water Treatment's Rockhampton branch were engaged by local beef cattle graziers Lance and Colleen Sypher (located in Alpha, QLD) to deliver a unique surface mounted Solar Array and Pump Float to supply onsite dam water to both their residence and the property's many cattle watering troughs.
Lance and Colleen Sypher approached Dowdens Rockhampton seeking a design for a solar pumping system with the ability to float on their dam, eliminating the need for any power cables or pump modules to be placed on the bank as is the case with traditional dam solar pumping systems. Having the unit completely isolated (floating) on the surface of the dam would remove the potential for the pumping unit sustaining damage from cattle walking along the edge of the dam. Cattle are known to cause damage to solar pump modules (in particular the associated power cables) that are situated on the edge of dams.
The innovative solar pumping unit design that Dowdens developed needed to meet a required flow rate (during the summer months on average the pumps required duty is 25,000 L/day @ 10m total head). Part of this new design incorporated the solar arrays being installed level with the dams surface, the main advantage of this design feature means the pumps power supply is not affected if the floating pontoon swings or floats across the dam. Having the solar arrays set at an angle, as is found on most traditional solar pumping units, would mean the pontoon would need be to be anchored to the floor of the dam (to avoid any rotation away from direct sun), thereby substantially increasing the overall cost of this project. Angled arrays would have also increased the potential for the arrays to catch any high winds, potentially flipping the unit over into the dam.
Dowdens Pumping & Water Treatment's Rockhampton branch specialises in the design, manufacture and installation of innovative customised Solar Pumping systems for the commercial, agriculture and mining sectors of Central Queensland and the greater Capricorn Coast regions.
The final design incorporated a Mono Pumps 600 Watt SUN-RAY SRX Solar Pump due to it's highly efficient, self-priming helical rotor pump. The pontoon has been designed in a way that it can accommodate a wide range of solar pumping units, making it customisable for whatever site requirements are presented. Dowdens believe this is the first time any pump shop has mounted both the solar arrays and pump unit on a float for this application. Having the solar pump operating independently saves the customer spending time and money travelling to and from the dam each day to switch on the pump.
The entire solar pump float system was designed, manufactured, installed and commissioned on time and within budget. Dowdens Pumping & Water Treatment's Rockhampton branches design philosophy for this project was: Cost Effectiveness - Innovation - Ease of Installation - Simple & Effective Pump Operation - System Reliability & Reduced Ongoing Maintenance.
Dowdens Pumping Rockhampton's Unique Solar Pump Float - Key Components:
Cannonvale was amongst the hardest hit regions during Cyclone Debbie, so it was no surprise to Dowdens Pumping & Water Treatment's Proserpine Branch to hear Queensland Health had been advised they couldn't be guaranteed potable water supply to their Whitsunday Community Health Centre located in Cannonvale immediately after Cyclone Debbie.
Luckily Dowdens Pumping & Water Treatment's Head Office in Mackay had a portable Ultrafiltration Treatment System available, capable of supplying up to 70,000 litres of potable water per day. Queensland Health and the Whitsunday Community Health Centre in Cannonvale instructed Dowdens Pumping to supply/install the unit immediately on a temporary 'Hire' agreement in-case all mains water supply was lost.
There were two water sources available at the time - the mains water supply or bore water from the Proserpine Hospital. Queensland Health instructed Dowdens to connect the UF Treatment System to the bore water supply, in an effort to remain as self-sufficient as possible post-Cyclone Debbie.
Dowdens Pumping have previously completed numerous bore water filtration systems treating bore water with our own brand of PURION Iron Removal Filters, so this emergency UF Treatment System was quick and easy to install. PURION Iron Removal Filters pre-treat the bore water before running it through the Ultrafiltration System which then doses the filtrate with liquid chlorine to further disinfect.
Once treated Dowdens Pumping manually transported numerous loads of the potable water from the Proserpine Hospital (where the UF System was installed) directly to the Whitsunday Community Health Centre in Cannonvale, where it was stored in a potable water grade storage tank. The treated water was then used to supply the medical centre. The entire supply/installation and commissioning was successfully completed on Saturday 1st of April - only 4 days after Cyclone Debbie had hit.
If you are ever in need of potable water during a storm or emergency contact Dowdens Pumping & Water Treatment. Dowdens only require access to a reasonable source of water (bore, dam, creek) and power (generator or mains power) and we can guarantee same day potable water supply, in any situation!
Peabody Energy Australia have engaged Dowdens Pumping & Water Treatment's [Mackay] Engineering Department & Fabrication Workshop to deliver a Specialised Pontoon Pumping System for use at their Moorvale Coal Mine, located 156 kilometres South West of Mackay, QLD. This project presented a number of challenges for the Dowdens Mackay engineering and fabrication staff, including but not limited to an extremely tight delivery timeline of only 8 weeks!
Peabody Energy's Moorvale Mine is an open-cut coal mine that produces low-volatile pulverized coal injection (PCI) coal, coking coal and thermal coal for export markets. The Moorvale Coal Mine is particularly challenging for its operators due to the coal seam being quite narrow with a number of fault lines. This requires excavators often having to work in confined areas. The three piles that make up the Moorvale coal seams are mined independently of each other.
Dowdens Specialised Pontoon Pumping System was needed to provide Peabody Energy more reliable access to good quality Raw Water from an on-site dam. This raw dam water was then to be pumped directly to the onsite Coal Handling & Preparation Plant (CHPP). The existing supply water was limited and of poor quality. Dowdens new pontoon pumping system allowed for an increased volume of water to be pumped from a dam containing higher quality raw water. Subsequently the Specialised Pontoon Pumping System that Dowdens supplied has helped facilitate an improvement in the CHPP's daily operations.
"This particular project had a tight lead & build delivery timeline (approximately 8 weeks). During this time Dowdens were in regular contact with us, the project coordination and regular contact I received from Dowdens Engineers enabled me to better plan for the delivery and installation of the gangway and pontoon, which required a 100 tonne crane to be booked and ready onsite for the unloading and installation.
Dowdens Engineering Department was prompt and professional in helping resolve revisions in the project scope. The design and the way the pontoon was packaged and delivered added to the "Zero Incidents" achievement during the installation of the Pontoon on site. I was satisfied with the product, price and customer service provided by Dowdens Pumping & Water Treatment - Mackay"
This project required both Dowdens Engineering Dept. & Fabrication Teams to deliver an innovative solution not previously attempted in-house. It was the first time Dowdens had manufactured 12m length gangways or a pontoon with a total weight of over 6 tonne. The total pontoon weight includes all steel work, flooring, pumps, piping etc. and is displaced using HDPE (high density polyethylene) Floats. The longest gangway Dowdens had supplied previously measured 8m in length, with the largest pontoon previously fabricated weighing in at 4.5 tonnes.
The new system meant Dowdens existing in-house designs had to be modified / improved with new floats being selected in order to safely carry the increased platform weight. Additional weight saving measures were implemented by Dowdens Engineers such as the use of light weight / high strength aluminium mesh flooring.
The timeline to design this pontoon pumping solution, manufacture the components and have them delivered to site was extremely tight. Engineering - Concept Design - Drawings & In-House Fabrication of the unique Pontoon Pumping System was completed & delivered to Moorvale Mine within their specified 8 week time frame!
No other pumping / manufacturing / engineering firm in Queensland are able to deliver such an all-encompassing product solution within the above mentioned time-frame.
Dowdens design philosophy for this project was: Fast Turnaround - Cost Effectiveness - Ease of Installation - Simple Plant Operation - Plant Reliability & Reduced Maintenance.
Key Project Features:
Grundfos has long been regarded for their high quality and reliable pumps. The Grundfos SCALA2 takes design innovation, comfort and simplicity to the next level and is set to be a game changer in domestic boosting. The NEW Grundfos SCALA2 is a robust, fully integrated, self-priming pump suitable for use from both above and below ground water sources. The compact system features a pump, motor, tank, sensor, drive and non-return valve in one compact unit that is quick and easy to install.
The SCALA2 is an energy efficient pump featuring an integrated speed controller that ensures constant water pressure regardless of variations in demand or inlet pressure. For those living in areas of poor power supply or those that are sometime affected by power outages, the SCALA2 can also be run on a generator, due to its ability to be able to handle varying voltages.
The variable speed controller also matches the power consumption with the required water output, which also helps to conserve energy and reduce your energy bills. To protect the pump and help ensure a long life, the SCALA2 includes a range of protective features. Dry run protection automatically stops operation when the water source runs out, to help prevent damage, and the anti-cycling feature detects any unnatural cycling and alerts the user via the protection indicator on the control panel.
Another unique benefit of the SCALA2 is its quiet operation, thanks to the permanent magnet motor and water cooling technology. The high efficiency motor is significantly quieter than traditional speed-controlled motors and the SCALA2 is cooled by the water it pumps, eliminating the need for a noisy fan. This makes the SCALA2 one of the quietest domestic boosting pumps currently available on the market.
For ease of selection, the SCALA2 suits most domestic pressure boosting applications and is capable of supplying water for small single level homes up to larger multi-storey homes.
Wesfarmers Resources, a significant Australian producer of metallurgical coal engaged Dowdens Pumping & Water Treatment's Industrial Workshop [Mackay branch] to deliver fast-turnaround servicing to a large selection of DAVEY Water Products Vertical Multistage In-Line Pumps [pictured below] that are used onsite at their Curragh Coal Mine, located 30km north of Blackwater in Central Queensland. This servicing project presented a number of challenges for the Dowdens Mackay Industrial Workshop, none more important than the tight timelines in which these repairs needed to be completed.
These DAVEY Vertical Multistage In-Line Pumps play a crucial role in the operation of the mine as they are used in various dewatering applications and also to boost supply of water to all of Curragh Coal Mine's various processing areas - including the vitally important Coal Handling & Preparation Plant (CHPP). Wesfarmers are supremely confident in having their pumps serviced by Dowdens Pumping, because after many years of working together they know Dowdens always aim to provide the sale / service of suitable pumps that maximise service life and minimise power usage and downtime. Improving levels of equipment utilisation whilst reducing planned / unplanned maintenance downtime increases the overall productivity of a coal mine.
Wesfarmers Curragh Coal Mine is an open-cut coal mine that provides metallurgical coal for export markets and supplies steaming coal to the Queensland Government's Stanwell Corporation under a long-term contract. Stanwell operate two major electricity generation assets, the Stanwell Power Station located in Central Queensland and the Tarong Power Station, located in the South Burnett, Southern Queensland. Wesfarmers Curragh Coal Mine has a well-established and geographically diverse customer portfolio with a number of long-standing relationships with world-leading steel-makers.
Like with any pump that arrives to Dowdens Pumping - Mackay's Industrial or Domestic Workshop, these Davey VM Vertical Multistage In-Line Pumps were serviced using Dowdens established workshop repair procedures. It was these established procedures and highly regarded workmanship that prompted Wesfarmers Resources to award Dowdens this important servicing contract. Dowdens Pumping - Mackay are so confident in our Workshop Servicing Capabilities we offer a "12 MONTH WORKMANSHIP GUARANTEE" for any service completed in-house - this is by-far the best guarantee available in or around Mackay, QLD. All pumps were successfully serviced and returned to site within Wesfarmers specified deadlines, meaning less downtime for Curragh Mine's related water infrastructure.
A very brief synopsis of this projects Key SERVICING Procedures are listed below:
Since opening in Mackay back in 1973, Dowdens has grown to employ over 160 staff situated across 4 branches in Mackay, Proserpine, Rockhampton and Brisbane permitting us to confidently service customers throughout Queensland, nationally and internationally. Dowdens services now cover all aspects of water engineering and fluid handling resource management for the residential, commercial / industrial, agricultural and mining sectors. From project inception through to final commissioning - the team at Dowdens has the ability to deliver complete specialised long-term engineered solutions that are practical and innovative, ensuring our clients benefit from greater productivity and reduced downtime.
With dedicated departments of industry trained engineers, draftsmen, project managers, sales staff and tradespeople including fitters, mechanics, polywelders, machinists, plumbers, electricians and boiler makers - Dowdens Pumping & Water Treatment offer an unmatched range of world-class engineering solutions for any type of water management project. We truly are Queensland's premier one-stop-shop for pumping and water treatment systems! CLICK HERE TO LODGE AN ONLINE PUMP SERVICE REQUEST, OR REQUEST AN OBLIGATION FREE QUOTE.
Here are two videos taken from the latest series of 'Irrigation Efficiency' Case Studies produced by the Dowdens Pumping & Water Treatment Agriculture Department.
The first video illustrates the remarkable energy and water use savings that have resulted from a Valley Polyline Pivot installation at Tony Bugeja's local Mackay Sugar Cane Farm located in Homebush, QLD.
The second video illustrates the considerable energy and water use savings that have resulted from a Variable Speed Drive Irrisys irrigation system working in conjunction with a Valley Centre Pivot and Davey pump on John Fox's 300ha Sugar Cane Farm located in Wagoora, QLD.
Following on from the successful construction and commissioning of the Coppabella Water Treatment Plant Aurizon Holdings Limited engaged Dowdens Pumping & Water Treatment [Mackay & Brisbane Branches] to deliver a much needed Sewage Treatment Plant (STP) Upgrade at their Coppabella Township, located on the Goonyella Rail Corridor (the world's largest metallurgical coal rail system) - 159 kilometres South West of Mackay, QLD. The Coppabella STP Upgrade project entailed the addition of an Ultra-Filtration (UF) 'Polishing' Plant onto the existing STP. Dowdens new UF 'Polishing' Plant can produce up to 180 kL/day of treated Class A effluent.
The township of Coppabella was primarily designed and built to service the junction of two railway lines (one from Goonyella Coal Mine and one from Saraji Coal Mine) and to provide accommodation to the regions coal mine workers in work depots. The town is wholly owned and operated by Aurizon Holdings Limited and contains: stations, residences, single-quarters, work depots, hotel, a shop, swimming pool, football oval, caravan park, school, ambulance, fire brigade, the recently completed Dowdens whole-of-town Water Treatment Plant and of course the upgraded Sewage Treatment Plant which is now capable of producing 180kL of treated Class A effluent per day for above ground irrigation applications. The local Coppabella Golf Course is one area where this treated effluent is used for irrigation.
After successfully completing various projects for Aurizon Holdings Limited, Dowdens won the tender to provide the process design together with equipment supply, civil construction, installation, commissioning and training for the STP plant operators. The construction phase of the project began with extensive civil works being undertaken to raise the ground level for the new STP components. The pre-existing STP has historically been subject to flooding during heavy rainfall events due to the sites proximity to the local creek. Upon surveying the sites substrate a water table was discovered 1m below ground level.
Working with local Civil Engineers Cardno a substantial foundation was designed / laid to ensure the new buildings, plant components and 4,000 tonne water tank would be stable and remain above the flood plain even during heavy rainfall. Once foundations were laid Dowdens began construction of the 400,000L lined stainless steel water tank, new building to properly house the STP process equipment, an operators office, laboratory facilities and a back-up generator used to power the entire STP in the event of power loss.
After extensive effluent testing and thorough examination of the existing STP process a UF 'Polishing' Plant was designed by Dowdens inhouse Water Treatment Engineering Dept. capable of processing up to 180kL of partially treated sewage effluent per day. The partially treated sewage effluent was rated as Class C and needed to be treated to an acceptable level (Class A) to then be used for above ground irrigation. This treatment process consists of three stages of filtration and sterilisation, including UF. This three-stage process runs as follows:
When the treated effluent arrives in the 400kL stainless steel tank a recirculation system pumps it through a chlorine analyser and back to the treated effluent tank. The chlorine analyser then controls the residual free chlorine level in the treated water and will start / stop a chemical dosing pump as required to maintain the pre-set residual free chlorine level.
Each of the GMF, UF and ACF processes are periodically backwashed and cleaned, with residual waste being fed to a nearby buffer dam where chlorine is allowed to dissipate. Based on the level in the buffer dam and the level in the treated effluent tank, the water may then be returned to the pump station at the front of the STP for reprocessing.
With a history of successful installations over the past 20 years throughout the Queensland Mining Sector Dowdens Pumping & Water Treatment have the ability to expertly design / manufacture / install and commission specialised pumping and water treatment solutions that are built primarily in-house & onsite to client's specific unique requirements. The Coppabella STP Upgrade project is yet another example of Dowdens unparallelled capability to deliver specialised long-term engineered fluid handling solutions from project inception through to final commissioning / handover.
Dowdens Pumping & Water Treatment's Mackay Branch has completed commissioning of the Moranbah 'whole-of-town' Automated Irrigation System. This Dowdens designed irrigation system was delivered to improve the control and ongoing maintenance of township irrigation within Moranbah, QLD.
Isaac Regional Council (IRC) specified a number of key criteria during the tendering process that the system was to deliver. These system criteria included, but were not limited to: provide the ability for night time automatic irrigation to numerous local Athletics Fields that have previously been irrigated manually (using static sprinklers and travelling irrigators) during the day; to replace an aging irrigation system located on Mills Ave. and achieve an overall reduction in labour relating to ongoing maintenance.
Dowdens Mackay successful tender was centred on an innovative Central Control System that enabled remote monitoring and maintenance of the 52 irrigation sites throughout Moranbah. The Dowdens designed controller is based in the Goonyella Road Council Depot. Dowdens Central Control System comprises of a desktop computer, irrigation software, an online weather station and localised communication/data collection infrastructure (routers, modem and radio transmitters/receivers).
This irrigation system is the first time Central Control System architecture has been utilised anywhere in the Isaac Regional Council shire. The system transmits all data collected / collated via several forms of communication i.e. radio frequencies, internet connection (Wi-Fi / 3G) and direct wired connections.
The Dowdens designed Central Control System has the ability to communicate to all Toro Sentinel Controllers via either radio frequency or internet connection. The operator has the ability to program and monitor all controllers via the Central Controller. The operator can set independent watering days, start times and run times for each and every station (valve) connected to Sentinel Controllers. Each day a detailed activity report is sent to all operators notifying them of all system activities, such as no. of actual stations operated, how long for, if any stations recorded abnormal flow (high or low), system communication success or failures, abnormal solenoid coil current (high or low) and the status of all soil moisture sensors. Reports can easily be generated to show the history of all/specific system activities such as those listed above.
A wireless Weather Station and remote Soil Moisture Sensors were installed and connected to the Central Controller to efficiently monitor the regions weather conditions in real-time, and then adjust the systems parameters accordingly. The Weather Station and remote Soil Moisture Sensors are used primarily to prevent irrigation occurring during and after localised rain events and to calculate Evapotranspiration (ET) based irrigation running times. For example the Central Control System is programmed to turn all irrigation off for 3 days (adjustable timeframe) when more than 10mm of rain is received on any 1 day (adjustable timeframe). Weather Station calculates the daily ET and automatically adjusts irrigation duration accordingly (lower ET = lower run time).
This systems has provided IRC control and monitoring capabilities of 52 irrigation sites throughout Moranbah from one central site. Delivering vastly improved energy and water use efficiencies this Dowdens designed irrigation systems features automatic shutdown of all irrigation during rain events; automatic adjustment of irrigation run times based on ET; daily automatic reporting of all irrigation sites activity; automatic irrigation for 75% of median strips located on Mills Avenue; addition of quick coupler valves to flush lateral lines thereby minimising blockages; automatic irrigation of Little Athletics / AFL Sporting fields resulting in reduced labour required for manual setup of irrigators; reduction of effluent contact with public via system only watering at night; filters on effluent mainline have minimised blockages to irrigation valve and sprinklers, thereby reducing labour required to clear blockages.
Dowdens Pumping & Water Treatment's design philosophy for this project was: Cost Effectiveness - Current Best Practice - Ease of Installation - Simple & Effective System Operation - System Reliability & Delivering Greatly Reduced Ongoing Maintenance Requirements.
Moranbah Township Irrigation ~ Key System FEATURES & Components:
CENTRAL CONTROL ROOM Components
TORO Sentinel Water Management System software - EATON Computer with Printer, Router, UPS - DAVIS Vantage Pro2Plus Weather Station Console (Inside Temperature, Humidity, Barometric Pressure Sensors) - DAVIS Vantage Pro2Plus Integrated Sensor Suite (Anemometer, Tipping Rain Collector, UV Sensor, Solar Radiation Sensor, Outside Temperature Sensor, Outside Humidity Sensor) - WEATHERLINK Software - TORO NSN Support Systems (24/7 Phone Support for IRC operators)
FIELD CONTROLLERS Overview
Field (or Satellite) Controllers were installed at 52 sites throughout Moranbah. These units control the irrigation at their respective sites by direct wire connection to solenoid valves. The field controllers act as stand alone units, operating independently from the central controller. However all of the Controller's programming information comes via the Central Controller. This allows Field Controllers to operate even if the Central Controller is not operational for any reason (loss of power, phone network outages etc.). The Central Controller and Field Controllers automatically communicate at the end of each day to tabulate current programming changes, and again each morning to receive detailed system activity reports. The Field Controllers can be powered by AC if available on site, or DC via by 12V batteries trickle charged by solar panels.
Controllers were either mounted on existing structures or on Dowdens fabricated galvanised steel posts, hinged to allow access from ground level. Each of the 4 irrigated Sports Field sites have a wireless soil moisture sensor attached. The Field Controllers can be set to prevent watering when the soil moisture is above 50% of capacity (all are adjustable). A Mobile Soil Moisture Sensor was also supplied to allow IRC operators to manually test and record soil moisture levels at any location. All Field Controllers have a built in radio for communication to a 'Base' or 'Node' Controller. Base Controllers also have a 3G modem to communicate with the Central Controller.
MILLS AVENUE - MEDIANS IRRIGATION Overview
This portion of the project involved the design, supply and installation of 17 irrigation systems for all median strips on Mills Avenue, Moranbah (running from Goonyella Road to Clements Street). The existing systems were old, had unreliable battery powered controllers and required high levels of IRC operator maintenance. Most of the medians were generally turf with established large trees, approximately 10 metres wide, ranging anywhere from 10 - 230 metres long.
Each median irrigation system that Dowdens supplied consisted of: DC Sentinel Controller with radio, battery, panel, antenna, hinged pole, connection to existing Effluent mainline, flow sensors, isolation ball valves, solenoid valves / valve boxes, Toro T5 pop-up sprinklers with flexible risers and quick coupler valves placed at the end of the lines for flushing purposes.
LITTLE ATHLETICS / AFL FIELD IRRIGATION Overview
This portion of the project involved the design, supply and installation of an irrigation system for the Moranbah Little Athletics Field. The existing system consisted of a large travelling irrigator, which involved the IRC operator setting up the machine, manually turning it on and off and moving it to each position on the field. This produces uneven watering and often resulted in irrigation needing to undertaken during the day which goes against the applicable effluent re-use guidelines.
The irrigation system that Dowdens supplied incorporated: AC Sentinel Controller with radio & antenna (also incorporating AFL coverage), connection to existing Effluent mainline, 80 mm semi-automatic filter, flow sensors, isolation ball valves, solenoid valves / valve boxes, Toro 640 pop-up sprinklers with articulated risers and a wireless soil moisture sensor was installed on the AFL field to monitor soil moisture content.
MAINLINE FILTERS Overview
This portion of the project involved the design, supply and installation of semi-automatic filters at various locations along the effluent mainline. A 200 mm filter was installed in the mainline behind Moranbah High School, a 100 mm filter at Tallon Street and an 80 mm filter at the Athletics / AFL Field. Each of these filters included galvanised steel pipework to allow filters to be mounted above ground, isolation valves, filter, concrete pad and a Dowdens fabricated lockable enclosure. The filters are easily cleaned by opening a valve / turning a handle to allow the suction scanners to clean the entire filter without needing the removal of the element - a huge time saver for the IRC operators.
Anglo American's Australian Coal division engaged Dowdens Pumping & Water Treatment [Mackay] to deliver 8 specialised underground pumping PODs used for various dewatering applications at their Grosvenor Coal Mine, located 190km southwest of Mackay in Moranbah, Central Queensland.
The Grosvenor mine is a developing underground longwall operation that makes up part of Anglo American's plan to triple hard coking coal production at their Moranbah mine sites. Located next to their existing Moranbah North coal mine, Grosvenor is set to produce up to 5 million tonnes of hard coking coal per annum for export. The Grosvenor mine utilises a 10km overland conveyor to transport high-quality metallurgical coal to the Moranbah North Coal Handling & Preparation Plant.
Construction on Anglo American's $1.95 billion Grosvenor longwall project began back in January 2013, with the development celebrating a number of industry firsts including being the first underground coal mine in Queensland to use a tunnel boring machine to develop the drifts, or access tunnels, in coal mine development. Anglo American aimed to have the Grosvenor mine raise the bar for onsite system and production efficiency - making the supply of unique underground POD pumping systems a perfect match for Dowdens Pumping & Water Treatment's experienced Engineering Department.
Dowdens Engineering Department's comprehensive abilities have been on the radar of many Central Queensland/Bowen Basin mines for some time through direct contact and working with industry leading consulting engineering firms. Dowdens ability to expertly design/manufacture/install and commission unique equipment built to specific client needs, together with a history of successful installations over the past 15 years in the Bowen Basin has positioned the business as Queensland's premier pumping & water treatment organisation.
Underground Pumping PODs are used in mines as part of the site water management process. Mine water is collected from sumps and wet areas by Wilden air operated diaphragm pumps and delivered to PODs where water level sensors then activate the pump and transfer the collected mine water to a mains pump station, underground storage dam or directly out of the mine portal. Mine water is typically dirty with coal fine, rocks and dirt; therefore slurry pumps are needed to handle such water. PODs can be located in hazardous areas and can be fitted with Flame proof motors and motor controllers with PLC (Programmable Logic Controllers) and SCADA (Supervisory Control and Data Acquisition).
The Grosvenor mine site requirements meant each POD needed to have a 200kW power rating. With the site's physical constraints (i.e. the underground mined roof height and width, as well as the site lifting equipment for transporting) meant careful consideration was required for the overhung load whilst transporting this equipment. Capacity of a standard Dowdens POD is 4m3 with a 110kW motor, however with the larger flow rate required to and from the POD meant a 6m3 capacity working volume was needed. Bigger capacity and higher duty equated to a larger size motor and pump, more robust steel framework and additional accessibility for scheduled servicing.
Dowdens standard POD design incorporates a dirty water receiving area. This area, integral to the main hopper (container for collection of bulk material such as rock or soil), ensures particles that are too large for the pump to digest and transport are separated and manually removed periodically ensuring trouble free pumping.
Pumps selected by Dowdens for this harsh duty were Stalker 400SHD model with mechanical seals, seal lubrication and cooling. Motors selected were WEG brand Flameproof mine spec motors. The control for the pumps is a flameproof 200kW model with PLC and HMI (Human Machine Interface) screens. The controller starts and stops the pump, whilst also monitoring for faults and relaying important information to the mine surface via SCADA. Dowdens PODs built for the Grosvenor mine have the ability of easily interchanging the motors/pumps for differing duties. These will be identified as 200kW and 132kW cassettes. To accommodate this change the Main Control Unit (MCU) has the capacity to operate at either 200kW or 132kW with only slight changes to load controls.
The larger size and the flexibility to change the duty, together with Dowdens strategic POD site placement advice has enabled Anglo American less manoeuvring of the POD through development, saving costly underground labour and downtime. Without reliable pumping the mine's production slows/halts causing delays and safety issues which cost the mine many thousands of dollars each day. It was imperative the system worked and was extremely reliable. This project was delivered on time and within budget. Key project system components are listed below:
Unique features specific to the 8x Underground Dewatering Grosvenor PODs included:
Key Project Features: