Project Scope
The project scope involved replacement of two existing blowers the Townsville Sewage Treatment Plant with Sulzer HST 2500-1-A Centrifugal Turbocompressor Blowers, including necessary pipework modifications, to enhance efficiency, reduce noise levels, and improve safety.
The Townsville Sewage Treatment Plant, treats approximately 16 ML of wastewater per day to serve a population of 106,000. The existing oxidation ditch blowers, equipped with a high-density fine bubble diffused aeration system, were identified to exceed the required sound level limits, posing potential safety concerns. To address this issue and improve overall performance, the decision was made to replace the existing blowers with Sulzer HST 2500-1-A centrifugal Turbocompressor Blowers in four stages over a five-year period. The initial stage focuses on decommissioning and disconnecting the existing blowers while supplying, installing, and commissioning the new Sulzer blowers, along with necessary pipework modifications.
- Construct with design responsibilities
- Procurement, installation, test and commissioning of Two (2) Sulzer HST Blowers including decommissioning of existing equipment.
- Undertake extension of profibus communications and integration of Sulzer HST Blowers.
Challenges
- Restricted time frames during critical electrical, mechanical changeovers and control system integration.
- Gap in design versus construction deliverables.
- Complex commissioning requiring additional mechanical design effort.
- Commissioning new equipment with existing electrical infrastructure.
- Integration of new technology into existing process with known constraints and limitations.
- Long lead delivery of critical process plant and equipment.
Outcomes
- Successful design and implementation of missing design gap including site integration.
- Reduction in complex commissioning allowing for a streamlined approach and increased redundancy during critical changeovers.
- Concurrent design effort during construction and commissioning to assist issues found utilising existing electrical hardware.
- Design and construction activities undertaken concurrent to assist in meeting critical time frame.
- Successful project delivery and reduction in excess noise production from new process equipment.