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FEATURED CASE STUDIES & LATEST NEWS

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Cannonvale Medical Centre Water Treatment System post Cyclone Debbie

Wednesday, 19 April 2017

Severe Tropical Cyclone Debbie made landfall near Airlie Beach on the Nth QLD coast 28th March 2017. It was a slow-moving category 4 system that generated wind gusts exceeding 160 km/hr, heavy rainfall and storm surges along the Nth QLD coastline. 27 hours later, after having tracked inland over Airlie Beach, Proserpine, Cannonvale and Collinsville it was downgraded to a Tropical Low. Dowdens Pumping & Water Treatment's Proserpine Branch is again open for business.

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.

PURION - Water Treatment Products by the Dowdens Group

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 installing a temporary Water Treatment Plant at Proserpine Hospital [Cyclone Debbie 2017]

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Emergency Irrigation Pivot Repairs

Case Study

Customer: Racecourse Projects

Location: Marwood, QLD

Specifications & Features:

Racecourse Projects - Dowdens Emergency Infield RepairsRacecourse Projects recently engaged Dowdens Pumping & Water Treatment's Mackay 'Infield Service Crew' to undertake emergency repairs to a damaged Valley Irrigation Centre Pivot Irrigator at their Sugar Cane Farm located in Marwood, QLD.

This project began, like most emergency repair jobs do with an unexpected call from our customer. Racecourse Projects rang the Dowdens Pumping Agricultural Sales Team to inform them a Cane Haul-Out Truck had struck the first span of their Valley Centre Pivot. The pivot was now hanging precariously and needed to be repaired immediately. Daryn Gray (Dowdens - Industrial Workshop [Engineering Support]) and Brett Hayes (Dowdens - Agricultural Sales) promptly attended the Marwood site and assessed the pivot. Dowdens advised the pivot needed to be supported or it may have collapsed further. Straightaway the Dowdens 'Infield Service Crew' were onsite to elevate and secure the damaged span.

After speaking directly with the manufacturer of the damaged Valley Centre Pivot (Valmont Industries - Australia) Dowdens confirmed with Racecourse Projects there were no suitable spans for that machine currently available anywhere in Australia. This meant repairs needed to be undertaken promptly before the machine potentially collapsed completely - making any further repair work impossible. Dowdens then promptly engaged a local subcontractor to work alongside the Dowdens 'Infield Service Crew' repairing the machine in situ (whilst still suspended in the air). As the repairs had to be effected whilst the machine was still standing, this required coordination between 2 cranes and a telehandler forklift, along with a man box (attached to the all terrain telehandler) for 2 men to carry out the repairs. All the repairs and commissioning of the irrigator were successfully completed within 2 days of the accident!

Dowdens Pumping & Water Treatment [Mackay] are the sole authorised Valley Irrigation Master Dealers for the Mackay / Whitsunday region enabling access to the best possible pricing and product support, an unmatched range of spare parts & fast-turnaround repairs for all of our customers irrigators.

Dowdens Pumping & Water Treatment Emergency Infield Repairs [Marwood, QLD]

Details:

Dowdens Pumping & Water Treatment's methodology for the Racecourse Projects Centre Pivot Irrigator Repair was: Fast Response Time - Cost Effectiveness - Fast Turnaround Servicing - Ease of Installation - Limiting Product Downtime - Enable Farming to Continue as per normal whilst the Dowdens 'Infield Service Crew' was onsite.

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. As a company that has built its foundation on the servicing and development of agricultural pumping systems, Dowdens Pumping and Water Treatment have the experience to engineer a solution to suit any agricultural application.

The entire project was overseen and managed by the Dowdens Pumping & Water Treatment [Mackay] Agricultural Sales Team. The Dowdens Mackay-Whitsunday Agricultural Irrigation Team of Glenn Agnew, Brett Hayes, Jeff Roberts, Kevin Krog, Mike Sanderson, Eileen Mason and Nathan Cross are one of the most experienced Ag sales teams in Australia, with over 125 years of combined irrigation system design and operational experience between them.


"I just wanted to say thank you to Dowdens Pumping & Water Treatment Mackay for the prompt and painless way in which you managed our irrigator repairs. Your co-ordination between your maintenance team, the contractors and insurance people has been seamless. The way in which this matter was able to be dealt with and resolved so quickly is greatly appreciated."

George Williams
Operating Partner - Racecourse Projects Pty Ltd
Racecourse Projects - Marwood QLD

Dowdens Pumping & Water Treatment Emergency Infield Repairs [Marwood, QLD]

 
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Game changing GRUNDFOS SCALA2 PUMPS now at Dowdens

Tuesday, 14 March 2017

Dowdens Pumping & Water Treatment are your local pump experts and are Authorised Grundfos Dealers. Dowdens are Mackay's ONLY Authorised Grundfos Dealer & Dowdens Rockhampton branch is also an Authorised Grundfos Dealer. Grundfos pumps are market leaders, committed to providing new and innovative products that take comfort and simplicity to the next level, for these reasons we sell and recommend the new SCALA2 domestic pump.

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.

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Longwall Boost Pump Station

Case Study

Customer: Anglo American - Australia

Location: Moranbah North Coal Mine - Moranbah, QLD

Specifications & Features:

Dowdens Pumping and Water Treatment was engaged by Anglo American Moranbah North Coal Mine to design, engineer and build a boost pump station to supply raw water to the longwall area.

Dowdens Pumping and Water Treatment designed and built the longwall boost pump station utilising dual variable speed pumps to enable the station to cater for varying duties as the underground workings progress further away from the station.

Anglo American's Moranbah North coal mine began operation in 1998 and currently supplies 4.5m tonne annually of high fluidity premium hard coking coal mainly for export to iron and steel manufacturers in Japan, Korea and Taiwan.


The pump station boosts water pressure to the longwall currently some 6,000m away.

Comprehensive 'pre-challenge' testing was completed prior to the station being transported to site, with all parameters being set during this time.

Dowdens team of specialised engineers, CAD draftsmen and tradespeople were able to design and build the station on time and to a tight budget, with Anglo American extremely happy with the work undertaken and product supplied.

Testimonial: Anglo American - Australia (Moranbah North Coal Mine) reported "The longwall booster pump station was taken underground into immediate service after only a couple of days. There is normally a one or two month delay with above ground commissioning for all new units. Since the pump powered up after the first run it has not stopped running and is sitting at only 10% duty. The longwall has cut 128,000 tonnes so far which is exceptional. Any future boost pump orders from Dowdens Pumping and Water Treatment will not require any changes to the design or manufacture."

Key Pump Station Features:

  • All wiring / electrical installation & commissioning on these pump stations was undertaken by Major Electrical Pty Ltd
  • KROHNE flow meter
  • Pump station utilises four pressure transducers to feed real time pumping data to the computer control
  • Two vertical stage pumps directly coupled to two 45kW motors
  • As the booster pump station was dealing with high pressures all piping and flanges have a 3,000kPa rating
  • Pump station fitted with QDS (Quick Detachment System) lift points - allowing the station to be transferable via the underground Line Eimco
  • Touch screen interface enables underground miners access to real time amperage, bearing temperature and flow rate data
  • The unit operates via a PLC (Programmable Logic Controller) and SCADA (Supervisory Control and Data Acquisition) system meaning it can be remotely operated from the mine control room on the surface, or underground via the unit's electronic controls

Total Water Volume Transfer: 30L/sec @ 80m head (currently)


 
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Pressure Setting Spool Piece

Case Study

Customer: Anglo American - Grasstree Coal Mine

Location: Middlemount, QLD

Specifications & Features:

Anglo American - Australia

Anglo American have engaged Dowdens Pumping & Water Treatment's [Mackay] Engineering Department & Fabrication Workshop to rectify an issue with a new valve station installation that was experiencing water hammer, resulting in the longwall mining operation being suspended at their Grasstree Coal Mine, located at Middlemount in the centre of the Bowen Basin, QLD.

Underground mines require water management systems in place to manage working water that is utilised for production, dust suppression, hydraulic jacks etc. Mines employ various methods of underground water transportation systems including Longwall Boost Pump Stations & filtered water from the mine surface networks. The filtered water system is an important piece of infrastructure for underground coal mine providing clean water for dust suppression & feeding the powerful hydraulic piston pumps that are used to jack up the roof in the longwall mining process.

When water is fed into an underground mine it is received at a very high pressures due to the vertical drop to the mine workings. This pressure needs to be reduced & controlled to levels that can be safely managed in the underground operations. Dowdens Pumping & Water Treatment has provided Grasstree Coal Mine with several Pressure Reducing Valve Stations over the life of the mine, enabling reliable & trouble free operation.

Responding to the urgent help request from Grasstree Mine, Dowdens immediately travelled to site to undertake system 'fault finding' & begin planning the delivery of a timely & cost effective solution to the problem.

Dowdens Pumping & Water Treatment - Anglo American [Grasstree Coal Mine] Pressure Setting Spool Piece

Details:

As a direct result of Dowdens Pumping & Water Treatment's long standing & responsive working relationship with Anglo American's Grasstree underground coal mine, the Dowdens Engineering Department was called on to assist with a new valve station installation that was experiencing water hammer resulting in the longwall mining operation being suspended. Dowdens Engineers attended the mine site & listened/observed the problems that were being experienced such as pressure surges & water hammer in the feed pipes leading to the longwall operation.

Dowdens Engineering Dept. designed & developed a Pressure Setting Spool sized specifically to meet the specific duty required. The spool was custom designed using engineered fluid mechanics to reduce the pressure before it entered the valve station, taking part of the load off the station. Pipe supports were also engineered to provide a secure installation of the station.

The timeline to find the solution & manufacture the components was very tight. Engineering - Concept Design - Drawings & In-House Fabrication of the unique Pressure Setting Spool Piece [with roof bolt anchoring points] were completed & delivered to Grasstree Mine within 5 days from the first site meeting! No other pumping / manufacturing / engineering firm in Queensland was able to deliver such an all-encompassing product solution in 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.

The unique system required at Grasstree Coal Mine needed to address the following issues:


Key Project Features:


Dowdens Pumping & Water Treatment - Anglo American [Grasstree Coal Mine] Pressure Setting Spool Piece

 
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Modular Underground Dewatering System

Case Study

Customer: BHP Billiton Mitsubishi Alliance (BMA)

Location: Moranbah, QLD

Specifications & Features:

BHP Billiton Mitsubishi Alliance (BMA)

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:

  • Retrofit to existing POD systems recovered from the Crinum underground coal mine
  • Bolster the developing site dewatering fleet - with continuity of all pumps, instrumentation & control equipment used.

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 - Modular Underground Dewatering System [Moranbah, QLD]

Details:

Dowdens Pumping & Water Treatment was successful in BMA's tendering process due to:

  • Vast in-house engineering, drafting/design, fabrication, servicing capabilities & proven competencies
  • Over 20 years' experience designing & producing specialised underground dewatering equipment
  • The proximity of Dowdens head office [Mackay] & ongoing presence in the region
  • Providing a competitively priced solution to the clients unique challenges
  • High level of detail provided in the preliminary engineering proposal

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:

Dowdens Pumping & Water Treatment - Modular Underground Dewatering System [Moranbah, QLD]

 

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