Projects

Cardiff 1 WWPS Upgrade

Clients

Hunter water corporation

The Cardiff No. 1 WWPS collected sewage from many large districts within Newcastle and a part of the inlet works to the Edgeworth wastewater treatment (EWWT) by pumping the sewerage across the Creek. The site was located within a sensitive environment on the western and eastern shores of Cockle Creek in the vicinity of the junction of Cockle Creek, Cocked Hat Creek and Brush Creeks and access to the site was through the golf course.

Upgrade of the pump station required an increase to flows and capacity.by converting the wet/dry well to a wet well and modifying the structure of the well, benching and the construction of the additional pipeline by DN 900 Trench crossing of the creek to the EWWT.

Kerroc offered trenchless Twin PE DN710 Creek Crossing pipelines to minimize the environmental disturbance to the surrounding area, Creeks and fish passage and innovative work methodology in the conversion of wet/dry wet to a Dry well which further increased the capacity of the pump station and flows.

Works involved
  • Trenchless crossing pipeline x 2, valve and flange fittings
  • Construct DN600 rising Main
  • Diversion of Flows From wet 1 to Wet well 2 and applicable electrical, Scada and programming changes.to the existing board
  • Isolate Wet Well 1-electrical and Mechanical and Upgrade
  • Demolish all existing structures, Dismantle, remove, salvage & dispose of Pump Valves Fitting as required to construct the works
  • Undertake all civil work upgrades to Well 1 including new valve pit, pipework and pumps, Hatches
  • Install Educt Vent Stacks and Induct Vents
  • Piling of the Foundation to the 2 transformer kiosks, new switch room and thrust Blocks
  • Piling and construction of Valve Chamber Pit, pipework, and eastern connection into new rising main
  • Thrust Blocks and Vale Platform, stairs and rails
  • Connections on eastern and western banks
  • Acid sulphate soil treatment
  • Construction of hardstand Area
  • Upgrade the water supply
  • Upgrade Energy Australia’s High Voltage network including the installation of two Energy Australia kiosk substations and removal of redundant high voltage equipment as required
  • Construct New Switch Room and Subfloors
  • Installation new Switchboards, Controls VSD and Electrical equipment
  • Install consumer Mains Supply and install all fittings, cables, conduits, and trenching required to complete the installation
  • Maintaining existing Switchboard to run Wet well 2 and supply to Golf Course Pump station during construction of works
  • Testing and Commissioning
Challenges and achievement

Removing the existing Kiosk and installation of 2 new Kiosks, within the electrical outages time frame and avoiding disruption to the golf Club and surrounding suburbs.

Good relationship with the Golf through consultation and open communication.

Forward Planning and scheduling with the Client and Networks for isolations, diversion and shutdowns, mitigating the risks of disruptions and overflow.

Limited and restricted site movement compelled the programming of major construction works progressively rather than parallel steps in the interest of safety.

Monitoring of specific site hazards controls for; confined space, movement around site, working from heights, travelling through the Golf course for site access and exit (Tee off Just the right of the site gateway) And ensuring flotation of the well did not occur.

Daily monitoring to protect the environmentally sensitive area, maintaining sediment and control. Managing the lantana noxious weed spread. Minimised impacts to surrounding vegetation by clearing only the minimum area necessary.

Completion of trenchless crossing without Frac out or disturbance to the contaminated Creek Bed.

Security the site against Thief of electrical cabling

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