Normanton/Karumba WTP Upgrade Matt Fanning Director TBG Pty Ltd

Normanton/Karumba Shire pop: 2100 (Wet season) Karumba residents: 600 Karumba tourists: 2,000 Industry: Mining, tourism fishing

Existing Scheme  Normanton/Karumba Water Treatment Plant –1963 – Normanton Water Supply Established –1982 – New 300mm rising main and Clear water storage, 23km rising main – Karumba connected 42km rising main –1999 – capacity upgrade (copied existing clarifiers), new storages both Normanton and Karumba –Capacity of 3.5 ML/day, –Storage Capacity 2.36ML Normanton, 5ML Karumba

Project Summary  Normanton/Karumba Water Treatment Plant –2000 – Planning report – $1.68M –2003 – SCAP funding awarded - $3M grant –2004 – Glenore Weir raising investigation –2006 – Telemetry system implemented (basic automation, but mainly alarms and reporting) – further investigations little traction –October 2009 – Peer Review Hyder Consulting –2009 – Advised by State that SCAP Funding Withdrawn loss of $1M back to Government –November 2009 – Design Awarded to BTO –December 2010 – Works commenced –June 2011 – Works completed

Scheme Issues High Operator costs – Manual processes Difficult to operate – SCADA not full automation High risk of water quality failure Changing water quality guidelines Building required renewal Equipment out dated and high maintenance Upgrade could only occur during the wet season

Scheme Vision To implement a cost effective and reliable Water Treatment System for the towns of Normanton and Karumba.

Basic Principles of WTP Pump water from source location

Basic Principles of WTP Remove large particles in clarifier Coagulant

Basic Principles of WTP Remove fine particles in gravity filter

Basic Principles of WTP Apply disinfection – generally chlorine TO SUPPLY

Filter 6 Clarifier 6 Filter 5 Clarifier 5 Filter 4 Clarifier 4 Filter 3 Clarifier 3 Filter 2 Clarifier 2 Filter 1 Clarifier 1 Washwater Air Scour Raw Water Existing Building Res. #1 Res. #3Res. #2 Dosing Points Existing Plant Overview

State of WTP in 2009 WTP review (2009) 1. Catchment management issues leading to raw water contamination; 2. Extremes of turbidity in the raw water difficult to treat; 3. High filtered water turbidity leading to risk of pathogen shielding and breakthrough; 4. Elevated iron levels leading to oxidant consumption and discoloured treated water; 5. Compromised disinfection efficiency; 6. Presence of Hydrogen Sulphide in Supply Sources; 7. Tastes and odours in the treated water.

State of WTP in 2009 Existing chemical systems Did not meet Workplace H&S standards Chemical make-up labour intensive Chemical quality open to human error Chemical dosing set by operator Dosing not proportional with flow

Dosing System

State of WTP in 2009 Existing Clarifiers Poor performance at high flows Poor performance when high turbidity Problems de-sludging Odour problems Solids carry-over to filter

Clarifiers

State of WTP in 2009 Existing Filters Poor filtration (poor water quality) Manual washing; Labour intensive Damage to filter media

Poor filter Performance

Old Backwash system (used to clean filters) Flow too low (poor washing of media) No standby pump Difficult to prime Labour intensive No NRV fitted to pump State of WTP in 2009

Backwash Pump Air Blower Poor Backwash System

State of WTP in 2009 Old Air Scour (used to help wash filters) Air flow too low (poor agitation of media) No standby blower Labour intensive

Poor Air Scour System

State of WTP in 2009 Chlorine dosing Not proportional to flow No gas detection & alarm Labour intensive

Poor Chlorine Dosing System

State of WTP in 2009 General state of building Not cyclone rated Termite damage Leaking Possible asbestos

Risk? Risk Assessment Risk CategoryRisk ItemPROBCON Risk ScoreRisk Rating Water Quality Protozoa Very High Bacteriological470280Very High Disinfection By-Products31030Moderate Aesthetics (Taste, Staining)51050High Water Supply Short Term Loss of Supply450200Very High Extended Loss of Supply370210Very High Health & Safety Building & Stairways470280Very High Chemical Handling350150High

Why Automate? Main reasons to automate the WTP –Reduce labour costs ($200k/yr) –Improve quality of water –Optimise chemical use (save $$$) –Improve reliability of plant –Accurate reporting and alarming

First Step? Options study –1 – Refurbish existing plant –2 – New clarifier & refurbish existing filters –3 – New clarifier & membrane filtration –4 – Membrane filtration only Include –New intake at Glenore Weir

Which Option? CAPEX Refurbishment Only New Clarifier & Existing Filters Clarifier & Membrane Membrane Only $ 2,401,000$ 3,046,000$ 4,346,000$ 4,355,000 OPEX Refurbishment Only New Clarifier & Existing Filters Clarifier & Membrane Membrane Only $ 277,000$ 253,000$ 369,000$ 359,000

Which Option? Estimated NPV Year Refurbishment Only New Clarifier & Existing Filters Clarifier & Membrane Membrane Only 15$ 4,595,000$ 4,986,000$ 7,183,000$ 7,106,000 20$ 4,943,000$ 5,305,000$ 7,647,000$ 7,558,000 25$ 5,181,000$ 5,522,000$ 7,964,000$ 7,865,000 30$ 5,315,000$ 5,644,000$ 8,142,000$ 8,039,000

Preferred Option New clarifier & refurbish existing filters –New air scour system –New washwater system –New chemical dosing –New buildings –Complete automation

Actiflo Clarifier

Implementation Construction issues –Operational plant (Normanton & Karumba) –Remote location (Materials & skilled labour) –Procurement (Australian & New Zealand) –WEATHER! –4 phase construction

Construction Sequence 1 Filter 6 Clarifier 6 Filter 5 Clarifier 5 Filter 4 Clarifier 4 Filter 3 Clarifier 3 Filter 2 Filter 1 Washwater Air Scour Raw Water NEW Building Res. #1 Res. #3 Res. #2 ACTIFLO

Temp chemical dosing systems

Demolition

Construction Sequence 2 Filter 6 Clarifier 6 Filter 5 Clarifier 5 Filter 4 Clarifier 4 Filter 3 Clarifier 3 Filter 2 Filter 1 Washwater Air Scour Raw Water NEW Building Res. #1 Res. #3 Res. #2 New Backwash Water New Air Scour ACTIFLO

Fabrication

Staff Induction Training!

Construction Sequence 3 Filter 6 Clarifier 6 Filter 5 Clarifier 5 Filter 4 Clarifier 4 Filter 3 Clarifier 3 Filter 2 Filter 1 Washwater Air Scour Raw Water NEW Building Res. #1 Res. #3 Res. #2 New Backwash Water New Air Scour ACTIFLO

New pipe work and control valves

New Clarifier

Construction Sequence 4 Filter 6 Clarifier 6 Filter 5 Clarifier 5 Filter 4 Clarifier 4 Filter 3 Clarifier 3 Filter 2 Filter 1 Air Scour Raw Water NEW Building Res. #1 Res. #3 Res. #2 New Backwash Water New Air Scour ACTIFLO

New MCC Building

Filter Refurbishment

Filter Control

New chemical Dosing System

New WTP Building

WTP Performance Old Performance –Raw water quality Turbidity = 50 NTU –Old clarifiers Turbidity = 3 NTU –After refurbished filtersTurbidity = 1 NTU –Maximum flow (3 filters)= 36l/s! New Performance –Raw water quality Turbidity = 50 NTU –After Actiflo clarifier Turbidity = 1 NTU –After refurbished filtersTurbidity = NTU –Maximum flow (3 filters)= 50l/s!

WTP Performance

What Else? Additions to main contract –Norman River PS –Karumba chlorination system upgrade –Telemetry system upgrade –Procurement –Construction management –Commissioning

Lessons Learnt? Keep it simple Appreciation of location –Supply of materials –Available labour/contractors –Weather Build as much off site as possible Good working relationship with client

Why Use BTO? Excellence in Water & Wastewater Engineering They delivered on their promises: –on time –with clear reports & designs –with staff / resources promised –on budget BTO don’t just write reports – they get things done and deliver!

QUESTIONS???