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:
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:
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!
Dowdens Pumping & Water Treatment's Proserpine branch provide a range of products and services to island resorts throughout the Whitsundays and Northern Queensland; supplying and servicing everything from pool pumps to major sewage treatment / pumping stations and irrigation systems. We pride ourselves on being able to provide a large range of products across all facets of resort infrastructure.
Dowdens Pumping & Water Treatment's Proserpine branch regularly service customers across local off shore resorts, as well as working extensively with mainland tourist attractions and resorts for both sales and servicing. With extensive knowledge and experience in this area we are confident that our team of experts can provide solutions to clients problems. Dowdens Pumping carries a large range of spare parts and our service team are proud to provide comprehensive and professional after-sales service.
Recently Dowdens Proserpine were engaged by Fullshare Holdings (owner / operators of the Sheraton Grand Mirage Resort Port Douglas) to upgrade 5 existing onsite pump stations that had reached the end of their service life. At the projects inception Dowdens Proserpine conducted a thorough audit of the onsite pumping systems - the subsequent detailed report submitted to Fullshare Holdings resulted in Dowdens being awarded the contract to replace the ageing sewage pump stations. Dowdens Proserpine then set about designing a more efficient and reliable sewerage pump system that was to include smaller and more energy efficient Grundfos pumps, resulting in a reduction in the required maintenance and considerably lower overall energy use onsite. Dowdens Pumping & Water Treatment are Authorised Grundfos Dealers throughout the Whitsundays / Mackay / Rockhampton regions.
"Fullshare (owners of Sheraton Grand Mirage Resort & Mirage Country Club) recently engaged Dowdens Pumping & Water Treatment's Proserpine branch to carry out an on-site audit & submit a report on the condition & performance of our 30 year old sewage pump stations. This audit & subsequent detailed report was thorough & included recommended actions, therefore allowing Fullshare to be fully informed on the condition & improvements required to improve the condition & performance of these important components of our asset. Following a Tender process, we engaged Dowdens Pumping & Water Treatment to carry out the recommended upgrade works to the sewage pump stations.
The challenges of the project were met well by Dowdens Pumping & Water Treatment under the management & extensive office / site based efforts of Kevin Krog (Dowdens Proserpine branch) & his industrial workshop team. Such challenges faced were a fully operational Resort & Country Club, difficult access to some stations, 30 year old supporting infrastructure & services including power supplies as well as contending with it being the wettest & most humid time of the tropical year. Kevin was also excellent at assisting us to liase with the Douglas Shire Council for these works. We will continue to utilise Dowdens Pumping & Water Treatment's expertise & personnel at this property when the need arises & would thoroughly recommend them for these types of works."
Once the design was accepted Dowdens began works that would see 10 new Grundfos sewerage pumps being installed in 5 existing pump stations. The projects scope included supplying and fitting all rails, brackets, lifting chains, concrete pump station lids and non-return valves. Together with the design and installation of Grundfos electronic control panels (Grundfos CU362 Waste Water Controllers) & remote monitoring systems (Grundfos Remote Management [GRM]) which allows for SMS & Email to be sent to relevant site operators alerting them to any faults. The GRM system also allows for system alarms to be reset and pump duties to be modified remotely via any smart-phone or PC. Full product and system descriptions can be viewed below.
The aim of this project was to provide a modern and efficient sewerage pumping system that was energy efficient, reliable, had improved remote monitoring capability and increased level of safety for Dowdens Servicing and onsite technicians. The Dowdens Infield Service Crew began by removing the existing 30-year-old pumps, rails, brackets, lifting chains, heavy concrete lids and control panels. These were replaced with more efficient and reliable Grundfos pumping and monitoring equipment. During installation and commissioning Dowdens had to schedule works to meet the resorts strict operation requirements, ensuring the project proceeded with little to no impact on the resort guests.
The existing concrete lids were damaged and unsafe and needed to be replaced. Dowdens provided 'light lift' aluminium lids with integrated safety grates (pictured below) to minimise the risk of falling into the wet well whilst servicing the pumps. 3 out of the 5 existing control panels were deemed unsafe by Dowdens Electricians and required replacement with new stainless steel panels incorporating the Grundfos CU362 Pump Controllers and Grundfos Variable Frequency Drives on the 2 main pump stations. Dowdens also provided Sheraton Grand Mirage Resort Port Douglas with scheduled servicing of the Grundfos SEV & SE1 pumps; Grundfos CU362 Waste Water Controllers; Grundfos Remote Management [GRM] Systems; Dowdens custom built aluminium lids with safety grates; Stainless steel pump rails; 800kg rated lifting chains & the Backflow protection on wash down taps. The entire project was delivered on time and within budget.
Dowdens Pumping & Water Treatment design philosophy for this project was: Cost Effectiveness - Current Best Practice - Ease of Installation - Simple & Effective Plant Operation - Pump Station Reliability - Advanced Remote Management Capabilities - Reduced Ongoing Maintenance.
Sheraton Grand Mirage Resort (Port Douglas) - Sewage Pump Stations Key Components:
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.
Dowdens Pumping & Water Treatment [Mackay] have delivered yet another Soft Hose Travelling Irrigator to a local Sarina Sugarcane Farmer.
Harvey Matsen [pictured below] operates a 100ha sugarcane farm in Sarina. Due to the lack of rainfall during the 2014/15 growing season he decided to purchase a TRAILCO T-450-2 Soft Hose Travelling Irrigator to better manage the irrigation of his cane.
Wanting to purchase his new irrigator from a local business Harvey sought the services of the Dowdens Mackay Agricultural Sales Team - one of the most experienced Ag sales teams in Australia, with over 125 years of combined irrigation system design and operational experience between them. As a company that has built its foundation on the servicing and development of agricultural pumping systems, Dowdens Pumping & Water Treatment have the experience to engineer a solution to suit any agricultural application. For over 40 years Dowdens Pumping & Water Treatment have been selling & servicing irrigation products throughout Central & Northern Queensland - designing each and every system to improve farming efficiencies, reduce downtime and increase the longevity of pumps / irrigators.
Jeff Roberts from the Dowdens Mackay Agricultural Sales Team visited Harvey's farm on a number of occasions to investigate, design and then match an irrigator and irrigation plan to best suit the property. Taking into consideration the terrain, existing pump capabilities and source water availability Jeff suggested Harvey purchase a TRAILCO T-450-2 Soft Hose Travelling Irrigator with irrigation gun.
Harvey has access to pressurised irrigation water from the nearby Kinchant Dam. Located in Sarina near Kinchant Dam, meaning this farm has access to irrigation water coming via the Eton Water Supply Scheme. Kinchant Dam, situated near Mt Kinchant, 6kms southeast of Mirani, is the only major storage in the Eton Water Supply Scheme. It was constructed to capture runoff water from the small portion of the catchment of Sandy Creek and water pumped from the Pioneer River. Three water harvesting pump stations are located at Mirani Weir below the confluence of Cattle Creek and the Pioneer River, and divert water into an 8km diversion channel into Kinchant Dam. At farm door the dam feed water arrives at between 20 - 30psi. With the TRAILCO T-450-2 Soft Hose Travelling Irrigator needing a higher pressure to operate efficiently Dowdens utilised the farm's existing Power-Take-Off (PTO) Tractor driven booster pump, raising the feed water to over 70psi.
The T-450-2 is able to apply 50mm of water onto a 2ha area of cane whilst travelling along 300m of 4" soft hose - delivering 22.5L/sec @ 70psi. Together with flood irrigation (using the gravity fed Kinchant Dam feed water), an existing travelling irrigator and the new T-450-2 Harvey can now irrigate his property in half the time. In times of low rainfall when young cane is most vulnerable to dry soil conditions, Harvey can now irrigate his young cane faster ensuring they take root quicker and go on to deliver a better overall yield. The T-450-2 is an extremely efficient and reliable soft hose travelling irrigator - so much so it can easily pull Harvey's tractor towards it as it travels down the feed hose on an irrigating run [pictured below].
Dowdens Pumping & Water Treatment are proud to announce securing Australia-wide exclusivity of the MIRACELL Rotating Biological Contactors (RBCs) Sewage Treatment Systems. MIRACELL RBCs are the systems are most preferred globally by customers who clearly understand the economic value in purchasing an expertly designed and professionally built Sewage Treatment System!
MIRACELL RBC Sewage Treatment Systems are fully automatic, modular designed Rotating Biological Contactor (RBC) treatment systems specifically designed for sewage treatment applications in capacities ranging from 50 to 20,000 equivalent people (treatment of between 10m3 up to 4000m3 / day). Representing the ultimate in Sewage Treatment Systems, a MIRACELL RBC consumes as little as one fifth of the electricity and requires as little as one third of the space of its competitors based on the activated sludge technology.
Having exclusive rights to MIRACELL RBCs has increased Dowdens capacity to design, supply, install and service large scale Sewage Treatment Systems suitable for use by municipalities, caravan parks, mining camps and a wide range of other commercial / industrial sites where onsite sewage treatment is needed.
Dowdens Pumping & Water Treatment employs an experienced team of WTP and STP Project Specialists comprising of Mechanical and Process Engineers, Project Managers, Draftsmen with 3D Autocad skills and qualified installation and service crews, together with our in-house workshop facilities for the fabrication of steel and stainless steel skids and bases, Dowdens has little to nil reliance on outside contractors when delivering complex Water and Sewage Treatment systems - in essence we are a 'one-stop pumping, water and sewage treatment shop'.
Examples of Dowdens Water and Sewage Treatment projects:
BHP Billiton Mitsubishi Alliance (BMA) have engaged Dowdens Pumping & Water Treatment's Mackay Branch to deliver a specialised Modular Underground Dewatering System at their Broadmeadow Coal Mine, located approximately 200km South West of Mackay, QLD.
The Broadmeadow Underground Coal Mine is a 'Top Coal Cave Longwall Punch' mine located approximately 30km from Moranbah. Located on BMA's Goonyella open cut mine lease, the Broadmeadow Mine was established in late 2003 and feature's BMA's first application of punch longwall mining - a highly efficient underground technique utilising an existing open cut pit for longwall panel access. Broadmeadow Mine delivered a number of synergies between BMA's underground and open cut operations, including utilisation of the existing Goonyella coal preparation plant capacity, increased flexibility to respond to market demand, improved reliability of supply for customers and optimisation of product quality through selective blending.
The Modular Underground Dewatering System (MUDS) was designed / manufactured and installed by Dowdens Mackay to optimise further development of BMA's Broadmeadow mining operations by improving on-site dewatering efficiencies. The MUDS has been utilised in developing Broadmeadow panels 12 & 13, and will help to advance mine site progression for the entire life of operations. The main objective of this project was to provide a unique, custom built air / electric pump system to improve Broadmeadow's dewatering efficiency. This was achieved through the automation of pumping systems supplied and lowering any ongoing maintenance requirements - thereby saving site operator input, lowering air / power consumption and reducing the need for BMA to further invest in dewatering pump systems.
Dowdens were engaged during the concept phase of this project to provide input and engineering advice to help BMA overcome the many operational challenges this site presented. With intimate product knowledge and via extensive direct consultation 2 unique transportable Quick Docking System (QDS) Fish Tank Dewatering POD designs were developed. Capable of operating under 1,000V power, these modular POD systems required the ability to remain operational during regular power outages, utilising the limited underground supply of compressed air. Each pump station needed considerable storage / retention capabilities (5,000L per POD) and the capacity to operate seamlessly 'in-sequence' thereby delivering zero overflows onto roadways even during loss of underground power.
The composition of the water derived from the mine's development process posed its own transportation challenges with a high water content ratio of rock, coal, trash and coal fines. A solids management system consisting of various sieves, hoppers and tank agitation components was developed and tested to ensure the coal fines and inflow management system was capable of continuous operation, whilst also delivering simplified maintenance and cleaning procedures.
The coal fines and inflow management system was designed with the ability to:
With the negotiations finalised, Dowdens proposed the fabrication of 2 Teams of 4x Dewatering PODs. Each Team is led by the newly designed 5m³ EXD QDS transportable roadway POD. 3x additional specially modified 4m³ Elliptical PODs (a combination of EXD & IP66 rated) are then positioned at strategic intervals along the panel as main gate development advances.
Dowdens Pumping & Water Treatment was successful in BMA's tendering process due to:
After a successful tendering process Dowdens team of engineers and draftsmen immediately began analysing the recovered Crinum mine 4m³ POD design. After much consideration, a plan was established to incorporate all new specifications and functionality required whilst retaining as much of the existing structure as possible, saving both fabrication time and money. This design was carried over to the new generation 4m³ Elliptical PODs.
The Narrow Gauge 5m³ Lead POD had to utilise every inch of its restricted underground foot print to facilitate the 5,000L capacity and extra-large solids screening hopper. All work access steps and ladders were designed to be stowed away to avoid contact by passing machinery. All equipment was to be readily accessible to operators, even while positioned hard against the roadway rib. The complete set of design drawings were completed within 5 days and construction began immediately ensuring delivery was made within BMA's tight project deadlines.
Specially equipped 1,000V electric motors were incorporated in the build to operate custom made hard-metal centrifugal pumps - primarily selected for water transfer between PODs operating 'in-sequence'. The Cast Iron WILDEN T15 Air Operated Double Diaphragm Pump was selected to serve as the auxiliary system for its robustness and relatively small weight-to-flow ratio. The lower weight and lower capital cost of the T15 allowed two pumps to be incorporated into each pump station to serve in duty / standby, or duty / assist mode if required.
A pneumatic control system provides seamless switching between air and electric pumping modes. Non-powered level controls allow maximum tank differential between the air pumps 'on & off' functions saving air consumption. Potential overflows are prevented by a pneumatically operated, inflow regulating valve. Each of the POD inflow manifolds are equipped with 4 auxiliary 50mm pump inputs to integrate localised pumping to the 'outbye' system. Custom built electrical control panels incorporate all EX'd field devices providing temperature, pressure, flow & fault communications via a PLC to the site Citect system. Area lighting and visual pump status indicator lights can be positioned remotely ensuring clear viewing from the mines underground roadways.
Dowdens Pumping & Water Treatment design philosophy for this project was: Cost Effectiveness - Current Best Practice - Ease of Installation - Simple & Effective Plant Operation - Plant Reliability & Reduced Ongoing Maintenance.
Modular Underground Dewatering System's Key Components are listed below:
BHP Billiton Mitsubishi Alliance (BMA) engaged Dowdens Pumping & Water Treatment [Brisbane] to design, manufacture, install & commission a 200kL / day Sewage Treatment Plant (STP) which included three pump stations and a specialised central control room at their Saraji Coal Mine, located 60km southeast of Moranbah and 200km southwest of Mackay in the Bowen Basin, Central Queensland.
Saraji Coal Mine has coal reserves amounting to 648 million tonnes of coking coal, one of the largest coal reserves in Asia and the world. The mine has an annual production capacity of 5 million tonnes, utilising open-cast extraction methods with a total of 11 coal seams.
Saraji Coal Mine required a new STP due to the existing onsite plant failing to meet release limits and becoming unsafe to operate. Dowdens Brisbane designed a new STP that incorporated the innovative MIRACELL™ Rotating Biological Contactors (RBC). RBC technology is a type of sewage treatment process in which disks that are connected to a shaft are rotated at a very low speed (3.7 rpm) by means of a motor which is equipped with a reduction gear. The MIRACELL™ RBCs are designed such that 40% of the disks remain in the wastewater.
As the discs rotate contact with the wastewater causes turbulence and consequently aeration. As a result of this repetitive process, organisms accumulate on the discs. The organisms receive the necessary oxygen from the air during the rotation of the discs and consume the pollutants existing in the wastewater, converting them to carbon dioxide and water in a totally natural way. The treated water discharged from any MIRACELL™ STP is guaranteed to meet the most stringent discharge standards and may be used for dust suppression, irrigation or directly discharged to a waterway subject to Environmental Authority approval.
MIRACELL™ Sewage Treatment Plants are fully automatic, utilising modular designed RBCs specifically designed for sewage treatment applications in capacities ranging from 50 to 20,000 Equivalent People (treatment of between 10m³ up to 4000m³ per day). Representing the ultimate in sewage treatment systems, a MIRACELL™ STP consumes as little as one fifth of the electricity and requires as little as one third of the space of its competitors based on the activated sludge technology.
Dowdens Pumping & Water Treatment are proud to hold Australia-wide exclusive distribution rights for MIRACELL™ STPs - these systems are most preferred by customers who clearly understand the economic value in purchasing an expertly designed and professionally built system. Offering a comprehensive range of innovative MIRACELL™ STPs, Dowdens provide an all-in-one service approach to each project. From project inception through to final commissioning, our team of industry trained engineers, draftsmen, project managers, sales staff and tradespeople including electricians, fitters, polywelders and plumbers will have you covered!
Dowdens Pumping & Water Treatment [Brisbane] were successful in the initial tendering process as we could deliver a complete turnkey Sewage Treatment Plant solution within the limited project budget, whilst also meeting all of BMA's specifications.
The standalone Sewage Treatment Plant Dowdens Brisbane supplied BMA provided an expertly-designed system that allowed them to meet their regulatory requirements, whilst providing a reliable, easily operated and maintained system. The new Saraji MIRACELL™ STP needed to accommodate the total mine site workforce of 645 Equivalent Persons (EP). Dowdens have designed the Saraji MIRACELL™ STP to treat up to five times the Average Dry Weather Flow rate of 40 kL/day - meaning the STP has the capacity to easily process and treat up to 200kL/day.
The Saraji MIRACELL™ STP and three fibreglass pump stations have been designed to capture and treat all waste influent (both Sewage & Grey Water) from the entire mine site and deliver it to the STP for processing. The system's design had to not only deliver the desired treated effluent quality but also incorporate strict safety requirements while adhering to the Queensland Government's Department of Environment and Heritage Protection stringent environmental conditions.
The Saraji MIRACELL™ STP includes a pH correction system to allow for pH correction. The pH correction dosing system comprises a pH correction chemical storage tank and a dosing pump. An Electromagnetic flow meter installed on the inlet of the chlorine contact tank automatically adjusts the chemical dosing rate based on the incoming treated effluent volume. This ensures the pH on the outlet of chlorine contact tank is always within the range of pH 6-9.
The Saraji MIRACELL™ STP is also equipped with a remote monitoring feature that enables the Saraji Mine operators to check the status of the STP from anywhere in Australia via portable devices such as smartphones or tablets.
Dowdens Pumping & Water Treatment [Brisbane] design philosophy for this project was: Cost Effectiveness - Current Best Practice - Ease of Installation - Simple Plant Operation - Plant Reliability & Reduced Maintenance.
Beginning in June, running through to October 2015 the Saraji Mine MIRACELL™ STP was delivered on time and within budget. Extensive onsite works were undertaken by Dowdens Pumping & Water Treatment to enable the new system to be properly housed and connected to existing site, power and pipework infrastructure. The STPs construction works involved (but was not limited to) civil, electrical, mechanical, hydraulic and structural works utilising Dowdens Infield Service / Installation Crew, Supervisors, Engineers and Project Management.
Key Project Milestones & System Components are listed below:
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: