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 1985-87 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) 2006-2008 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investigations little traction October 2009 – Peer Review Hyder Consulting 2009 – Advised by State that SCAP Funding Withdrawn loss of $1M back to Government November 2009 – Design Awarded to BTO December 2010 – Works commenced June 2011 – Works completed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

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

Existing Plant Overview

Existing Plant Overview

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

Clarifiers

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

Poor filter Performance

State of WTP in 2009 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

Poor Backwash System Air Blower Backwash Pump

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

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 Category Risk Item PROB CON Risk Score Risk Rating Water Quality Protozoa 4 70 280 Very High Bacteriological Disinfection By-Products 3 10 30 Moderate Aesthetics (Taste, Staining) 5 50 High Water Supply Short Term Loss of Supply 200 Extended Loss of Supply 210 Health & Safety Building & Stairways Chemical Handling 150

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

New Clarifier & Existing Filters New Clarifier & Existing Filters 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

New Clarifier & Existing Filters 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 5 4 3 2 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 5 4 3 2 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 5 4 3 2 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 5 4 3 2 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

New WTP Building

WTP Performance Old Performance New Performance Raw water quality Turbidity = 50 NTU Old clarifiers Turbidity = 3 NTU After refurbished filters Turbidity = 1 NTU Maximum flow (3 filters) = 36l/s! New Performance After Actiflo clarifier Turbidity = 1 NTU After refurbished filters Turbidity = 0.045 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???