Kerroc

Kurri Kurri Waste Water Treatment Works

Clients

Hunter Water Corporation

This contract involves the upgrade of the existing biosolids handling facilities at Kurri Kurri Waste Water Treatment Works (WWTW). The works was Design, Development, Construct and install

The main works include but are not limited to the following

Extension to Digester Cells
New conveyors Systems
New switch room building
New Electrical Switchboard, controls and upgrade and modification to existing switch room
New diffuser aeration system
Pneumatic airline. Vales and Blowers
Installation of Client supply Gravity Deck and Centrifuge
Associated, design, design development, excavations, piling, foundations, trenching, concreting, saw cutting, reinforcement, associated, steel works, valves, fittings and Pipework
Roadworks—construct Access road to new switch room building, Reconstruction & sealing of existing site access roads
Removal and disposal of redundant equipment
Testing and commissioning

Extension of the digester tanks

The existing 3 cell aerobic digester at Kurri Kurri was augmented by the construction of 2 new cells and a new buffer tank
Dismantle and dispose of the existing diffused aeration system the existing aeration system was completely replaced to provide aeration to the new 5 cell digester
Modifications to the access platform over Cell 1 and associated work
Install stairs and handrails to provide access to the area between the old digester holding cells and the new ones

Digested Waste Activated Sludge (DWAS) pumping facilities

Installation of the new DWAS pumps, pipe work, valves, access stairs, access steps, the monorail, electrical cable trays, cables (where possible), lighting, GPO etc. in and around the DWAS pump station
construction of the DWAS rising main to the centrifuges

Aeration system

The existing aeration system was completely replaced and a new aeration to the new 5 cell digester was provided
Design and construct the diffused aeration system including air pipework, diffusers. diffuser pipework, valves etc for the new digester cells
Dismantle and dispose of the existing diffused aeration system

Blower Room

Modifying the blower room to suit the new blowers
The installation of the new air pipe from the plant room to the biosolids building
Connection of the new blowers’ pipelines and the new DWAS
Connection of air supply to all pneumatic valves
Sludge Thickening device
Disassemble the existing gravity Deck
Installation of the New Gravity Drainage Deck (GDD) and Centrifuge
Installing the support frame for the inlet box for the GDD
Modifying and provide new drainage bunds, new/existing floor grating to suit the new GDD arrangement
Install the WAS inlet pipe work to suit the new GDD

Centrifuge Dewatering System

Disassemble and remove the existing centrifuge and make modifications to suit and install the new centrifuge
Provided miscellaneous valves and connections as required
Modifying and provide new drainage bunds, new/existing floor grating to suit the new arrangement

Conveyor system

Design & install new conveyor system (conveys sludge from the centrifuge) provide and install a screw conveyor solids inlet chute to suit the new centrifuge for discharge to the fixed screw conveyor

Switch room and electrical

Construct new Switch room with floor plan of 16 m x 6 m (internal)
Provision of all electrical equipment in a new fire-rated switch room containing the new MCC switchboard, harmonic power correction equipment, PLC, UPS, and VSDs to cater for the plant upgrade
Power, control, instrumentation, and communication cabling including electrical pits, aboveground/underground conduits and cable ladders
Connections of power, control and instrumentation wiring to new equipment and instruments
Switchboard, field control panels and field instrument panels
Relocate the DWAS and instrument electrical panels
Connections of power, control and instrumentation wiring to new equipment and instruments
Terminations of wiring in switchboards, field instrument panels, field control panels, etc
Integration of vendor packaged plant including GDD polymer dosing system (and centrifuge polymer dosing system)
Modifications to the existing main switchboard and associated control and instrumentation for Plant upgrades
Connection of power supply to the blowers
Connection of bulk cabling to instrumentation

Challenges

Planning & rescheduling of the work program around the issues to achieve progress and prevent interruption to the treatment plant.

Overcoming Numerous latent conditions e.g. mechanical, geotechnical, electrical, structure, redundant services (buried sedimentation tanks, structures pipework. cables) and delays in client supplies.

Underground cabling throughout the site including 11kv feed to transformer.

High noise levels in Blower room and Dewatering building.

Contact with sewage and gases.

Handling and Disposal of Biologically Contaminated Materials.

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