Construction of Rossi Water Pump Station

Project Description

The Goulburn Mulwaree Council (GMC) intended to upgrade and commission the Rossi Water Pumping Station (WPS) at Goulburn.

The existing station was operated via a dry well with three pumps. These pumps were connected to branch lines from a common suction header connected to a screen intake behind the weir. The three delivery branches connected into the delivery pipeline. The pumps did not have the capacity to pump solo to Sooley Dam. Pumping to Sooley had to be done with two pumps in operation otherwise a discharge valve would have to be manually closed to throttle the flow.

These existing fixed speed pumps were replaced by variable speed driven pumps. Electrical connections and switchboards required upgrading to suit the proposed pump replacement. A significant part of this upgrade was the conversion from HV pumps and gear to LV pumps and gear.

Project Details

Goulburn Construction of Rossi Water Pump Station (WPS)
Goulburn Mulwaree Council
Rossi Water Pump Station Upgrade

Case Study

This Specification details requirements for the upgrade of the water pumping station including associated works and connections to suction and discharge mains at Rossi WPS, Goulburn.

Goulburn Mulwaree Council supplied all materials, plant, labour and all that was necessary to construct the water pumping station, pipework and associated works to the lines, levels, grades and in the specific location identified.

Construction was completed using the materials and methods in the Specification.

The Pump station was to remain online during construction, however to assist with construction and commissioning shut down periods of up to 24 hours per 48 hour period were allowed. Pump 1 was to be replaced and commissioned prior to pumps 2 & 3 being taken offline. After Pump 1 was commissioned the remaining pumps could be replaced and the remaining works could be completed.

The main items of work to be constructed in this Contract included, but were not limited to, the following:

  1. Supply and installation of three (3) pumps within the existing pump well, two variable speed pumps for raw water transfer to the water treatment plant in a duty + standby arrangement and one variable speed pump for raw water transfer to Sooley Dam. The design is based on pumps available from KSB as noted in the drawings.
  2. Supply and install electrical switchboard including variable speed drives, and PLC. Supply and install the three pump suction isolation valves. Supply and install a new electrical actuated butterfly valve on the discharge of the Sooley Dam pump.
  3. Installation and commissioning of the power supply upgrade works in accordance with the provided ASP3 certified design.
  4. Supply, installation, testing and commissioning of three (3) floor standing ABB ACS 800-37-0510-3 low harmonic variable speed drive.
  5. Decommissioning and removal of all existing equipment including but not limited to existing Main Switchboard,  existing 415V distribution board and all redundant cabling and replacing with all equipment specified in the contract.
  6. Design, manufacture, supply and installation of the following switchboards;
    • Outdoor IP56 rated, powder coated aluminium or grade 316 stainless steel main switchboard.
    • Indoor IP54 rated, powder coated mild steel or grade 316 Stainless Steel PLC panel.
    • Indoor proprietary IP54 48 pole distribution board.
    • Outdoor IP56 rated, powder coated aluminium or grade 316 stainless steel generator connection cubicle.
  7. Design and installation of an earthing system in accordance with an MEN earthing system as defined within AS3000 including;
    • Design of a protective (equipotential) earthing system which bonds all exposed metal of equipment, structures and pipework to earth.
    • Installation of an earthing box to protect the main earth stake. Earthing box minimum dimensions to be 150mm x 250mm.
    • Supply and installation of a new underground cable pit and conduit system in accordance with the provided Contract drawings.
  8. Design, supply and installation of a new cable ladder system to accommodate all supplied and tested cabling within the pump house.
  9. PLC programming of the new CompactLogix PLC, PanelView HMI and Kingfisher RTU’s in accordance with the functional specification including supply and installation of three (3) emergency stop stations within the pump well and all mounting accessories.
  10. Supply and installation of all ancillary electrical equipment not shown on the Contract drawings but required to complete the works e.g. junction boxes, cable lugs, terminals, conduits etc.
  11. Installation of miscellaneous items including room thermostat, smoke detectors, door limit switches etc.

PCI also supplied Operation & Maintenance Manuals in accordance with the electrical specification and training in accordance with the electrical specification.

PCI completed a changeover methodology plan and submitted for review a minimum of two weeks following Contract award. This included a detailed breakdown of all tasks and their associated time frames and key risks and mitigation measures in place to manage these risks.

PCI also completed all civil, mechanical and electrical work associated with items above and work not specifically stated but reasonably required to comply with the requirements of the Specification.