Upgrades to Hunter Water Corporation's Kurri Kurri wastewater transportation system. Stage 1 was comprised of upgrades to Kurri Kurri 1 wastewater pump station (WWPS) and the inlet works to the waste treatment plant

The works includes but not limited to the following:

• Design, set up & maintain, pump station temporary bypassing system. To avoid disruption of service during all works
• Demolition of the above ground portion, roof slab by wall sawing and valve chamber of the existing Kurri Kurri 1 WWPS
• Conversion of wet well/dry well clover leaf station to a wet well submersible station including installation of new gate valves
• Core 2 X 600dia holes through diverting wall
• Remove existing pumps and pipework, Modify the existing chambers to suit upgrades and connections
• Construct install new chambers, valves pits, drainage lines and fittings
• Supply and install knife gate valve with extension spindles, supports & surface box, DN400 SS pipework arrangement including flange plate connection & drop tubes, new pumps, guide rails, brackets, above ground local switchboard, associated pipework, fittings, electrical equipment, telemetry and connections
• Construct 1 Km of sewer lines from the WWPS to the WWTW consisting of DN 450 DICL PN 35 Rising Main, DN 900 GRP Gravity Main and Dn1200 manholes
• Complete the inlet and outlet works at the WWPS and connection to Kurri Kurri Treatment Plant
• Construction thrust block and trench stops
• Construct Km of water supply pipeline9 DN 25 & DN 100 PVC from the Treatment Plant to the WWPS & Valve Chambers
• Construction of Vent stack, educt and in-duct
• Construction of a (26m X 7m) 300 m3 Concrete emergency storage Tank including 9m-deep excavations
• Construct DN 140 HDPE Washdown header and spray nozzles including pipe supports within the Emergency storage tank
• Construction of associated pipework and connections
• Removal & restoration of concrete pavement & services adjacent to chemical bunds at WWTW
• Construction Hard stand areas and security bollards
• Construction of Road Works - 900m access road with bypass lane including drainage, stormwater, and water supply

Challenges and achievement

Delay in the Client HV supply

Overcoming issues associated with the additional LV electrical design and supply to the Site Pole e.g. Environmentally sensitive, challenging terrain, creeks and avoidance of theft)

Handling and disposal of Biologically Contaminated Materials and Prevent Spillage to nearby watercourses, avoiding disruption to the treatment Plant or networks .and avoiding breaching the Client EPA License

Securing the site from track riders, vandalism, thief of copper

Scheduling of outages and connections to avoid theft of copper wiring

The bypass system (originally designed for a few weeks) ran the pump station for two years (due to Client delays with HV electrical supply) without need for call outs or interruption to the networks or treatment plant. due to Client delays with HV electrical supply