Wastewater Diversion Pipeline, Pump
Stations and Associated Works
Department of Sustainability,
Environment, Water, Population and
Communities
30 June 2012
Wastewater Upgrade
Program
Diversion Pipeline, Pump
Station and Associated
Works
Final Report
AECOM
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Final Report
Prepared for
Department of Sustainability, Environment, Water, Population and Communities
Prepared by
Townsville City Council
30 June 2012
Quality Information
Document
Final Report
Ref
60101328
Date
30 June 2012
AECOM
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Table of Contents
Executive Summary
1.0
Project Overview
1.1
Project History
1.2
Project Scope
1.3
Key Project Dates
2.0
Process and Methods
3.0
Project Results
3.1
Benefits
3.2
Conclusions
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3
4
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Executive Summary
At a total cost of $189 million, the Wastewater Upgrade Program (WUP), a component of the Integrated Regional
Water Strategy, is the largest single project undertaken by the Townsville City Council (TCC).
Through effective collaboration the WUP project team of Townsville City Council (Principal), AECOM Australia Pty
Ltd (AECOM), Hunter Water Australia Pty Ltd (HWA) and Baulderstone Queensland Pty Ltd (Baulderstone) has
delivered robust and reliable wastewater infrastructure which will support the rapidly growing northern and
western areas of Townsville well into the future and delivers significant benefits to the local community and the
environment.
These benefits include the reduction of sewerage treatment infrastructure located within residential areas, the
increase to sewerage capacity for future growth of the region, and a reduction in nutrient loading in Cleveland Bay
and the Great Barrier Reef.
The WUP includes the provision of the following major infrastructure works:
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106,500 Equivalent Persons (EP) wastewater purification plant (WPP) at Mt St John
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27 kilometres of pressure rising mains ranging from DN150 to DN750
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Four new pump stations (PS): Bushland Beach (PS B7), Kirwan (PS K16C), Deeragun (PS D0) and Bohle
Plains (PS BP03)
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Modifications to four existing pump stations: Kirwan (PS K13D, K13B and K15A) and Bohle (Bohle WPP PS)
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Decommissioning and demolition of four existing WPPs: Mt St John, Deeragun, Mt Low and Bohle WPPs
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Electrical and process upgrades to Condon WPP
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Upgrades to the Mather Street Pump Station
Of the above, the Australian Government, under the Water for the Future Initiative contributed $33,253,401
through the Water Smart Australia Program: Wastewater Diversion Pipeline, Pump Stations and Associated
Works, which comprised of the following:
-
27 kilometres of pressure rising mains ranging from DN150 to DN750
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Four new pump stations: Bushland Beach (PS B7), Kirwan (PS K16C), Deeragun (PS D0) and Bohle Plains
(PS BP03)
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Modifications to four existing pump stations: Kirwan (PS K13D, K13B and K15A) and Bohle (Bohle WPP PS)
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Decommissioning and demolition of three existing WPPs: Deeragun, Mt Low and Bohle WPPs
WUP was an extremely complex project, taking into consideration the geographical spread of an area in excess of
20 kilometres, a large number of trades involved, compressed time schedules for delivery and natural hazards
(including two significant wet seasons and three cyclones including one of the largest Cyclones to hit the east
coast of Australia). Over the duration of the project, more than 2,250 staff inductions were undertaken on-site and
off-site.
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Figure 1 WUP Project Area Overview
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1.0
Project Overview
1.1
Project History
Prior to amalgamation in March 2008, both the previous Townsville and Thuringowa Councils were responsible for
their own catchments and wastewater infrastructure. Formation of the amalgamated TCC presented the
opportunity to review the wastewater strategies in a more regional context, moving away from the development of
smaller treatment plants located adjacent to residential areas.
Concurrently, the new TCC was reviewing the potable water regional strategy with a view to looking at potable
water replacement opportunities. TCC recognized the importance of considering the wastewater treatment
upgrades as part of a future integrated water management strategy for the region and this consideration was
included in the assessment of infrastructure for WUP.
The new Townsville City Council (TCC) reviewed the wastewater strategy for the city’s rapidly growing western
and northern suburbs. Critical to the outcome of this review, was the identification and delivery of a reliable,
robust, long term wastewater infrastructure program.
It was also important to TCC to provide a solution that was cost effective and provided excellent value for rate
payers. This challenge provided the project team with a previously unrealised opportunity to develop a regional
approach to wastewater treatment and to provide the community with an innovative solution.
With the existing wastewater treatment infrastructure serving Townsville’s northern and western suburbs at
capacity, there was a risk to TCC that to meet its service commitments and existing environmental licence
conditions it may need to slow growth in the area. This meant that the upgrades or provision of new infrastructure
to these rapidly growing areas needed to be operational by October 2011. A fast tracked program was developed
to deliver the WUP project from a preliminary concept to fully operational infrastructure within three years.
The consultancy firms AECOM and HWA were engaged by TCC in 2008 to undertake the planning, followed by
additional engagements for the detailed design and construction administration support of the infrastructure
developed through the program.
The WUP project required the assessment of a number of regional wastewater strategies in terms of cost (capital,
operating and lifecycle (NPV)) and non-financial criteria (environmental, social, future reuse, sound/ and long term
infrastructure, and project timing). The project team of TCC and AECOM/HWA developed a compelling business
case for a centralised water management strategy, which presented TCC with a saving of approximately
$75 million from the system used prior to amalgamation. In addition to the capital cost savings, non-financial
factors also provided a compelling case for the centralised strategy which was endorsed by TCC in July 2008.
Additionally, TCC was able to attract funding from both the Australian and State Governments on the basis of
financial and social benefits WUP provided to the Townsville community.
Baulderstone Queensland commenced construction in September 2009 and the Mt St John WPP and Diversions
works were completed in July 2011. HWA commissioned the plant to achieve effluent targets well before the
October 2011 target completion date in line with the DERM licence requirements.
1.2
Project Scope
The Wastewater Upgrade Program was broken into five parts as detailed below:
Part A – Mt St John WPP
New WPP at Mt St John
Part B – Diversions
27 km of pressure rising mains, four new pump stations and
modifications to four existing pump stations
Part C – Decommissioning & Demolition
Decommissioning and demolition of four existing WPPs
Part D – Condon WPP
Electrical and process upgrades to the Condon WPP
Part E – Mather Street PS
Upgrades to the Mather Street Pump Station
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Of the above project parts, the Australian Government, under the Water for the Future Initiative contributed
$33,253,401 through the Water Smart Australia Program: Wastewater Diversion Pipeline, Pump Stations and
Associated Works, which comprised of Part B – Diversions and three of the existing WPPs under Part C –
Decommissioning & Demolition. Specifically, the following infrastructure was subsidised by the Australian
Government:
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Bohle Plains rising mains BP02 and BP03
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Bohle Plains pump station BP03
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Bushland Beach pump station B7
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Northern Beaches pump station D0
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Northern Beaches rising main B7
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Kirwan rising main K16C
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Kirwan pump station K16C
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Modifications to pump stations K13D, K13B and K15A
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Decommissioning and demolition of the Bohle, Deeragun and Mt Low WPPs
Figure 2 Centralised Strategy
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1.3
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Key Project Dates
Centralised Strategy Approved by Council
July 2008
Detailed Design Phase
November 2008 – June 2009
Early Contractor Involvement Period
March 2009 – June 2009
Construction Contract Commenced
September 2009
Practical Completion of Part A – Mt St John WPP
July 2011
Practical Completion of Part B – Diversions
July 2011
Completion of Commissioning of Parts A and B
October 2011
Practical Completion of Part C – Decommissioning & Demolition
January 2012
Practical Completion of Part D – Condon WPP
October 2011
Practical Completion of Part E – Mather Street PS
Ongoing, target completion date
is July 2012
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2.0
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Process and Methods
Project Delivery Method – e.g. ECI process
Concurrently, the new TCC was reviewing the potable water regional strategy with a view to looking at potable
water replacement opportunities. TCC recognised the importance of considering the wastewater treatment
upgrades as part of a future integrated water management strategy for the region and this consideration was
included in the assessment of infrastructure for WUP.
Additionally, TCC identified an alternative delivery mechanism to ensure that Council’s operational requirements
were met. Constructability was incorporated into the detailed design and TCC and Townsville ratepayers received
value for money through a competitive tendering process. Council undertook a comprehensive assessment of
numerous project delivery strategies and ultimately selected a Competitive Early Contractor Involvement (ECI)
process. It was the first time that this style of delivery was undertaken in NQ to the scale of the WUP project.
The direct result of using this alternative delivery process is that the capital cost of the project is approximately
20% less in terms of $/EP than wastewater infrastructure schemes of a similar magnitude and complexity.
Project team
Through effective collaboration the WUP project team of TCC (Principal), AECOM Australia Pty Ltd (AECOM),
Hunter Water Australia Pty Ltd (HWA) and Baulderstone Queensland Pty Ltd has delivered robust and reliable
wastewater infrastructure which will support the rapidly growing northern and western areas of Townsville well into
the future whilst providing a number of benefits to the community and the environment.
During construction the WUP was driven by the Joint Management Team which held representatives from each
part of the project team, a Project Leadership Team which consisted of managers from each company and a
Dispute Resolution Board which was made up of an independent panel who oversaw the progress during the
construction phase.
Community Engagement
Client and community focus was an integral part of delivering the project for all team members on a daily basis.
From the start of the project in the planning stages, consideration was given to the location of one large WPP to
ensure it was not placed next to residential developments, as opposed to small plants around residential areas.
Through the construction phases, initiatives included special recirculation procedures during decommissioning of
the old treatment plants to minimise odour, and careful attention to design of cutover activities to ensure that
community services were not disrupted. These processes were driven by a high level of community and
stakeholder engagement and feedback during the construction period to ensure we were achieving objectives.
Recognising the importance of client and community satisfaction, Baulderstone was directly measured on their
success in maintaining client and community satisfaction through a contract that included performance criteria
(Key Result Areas and Key Performance Indicators), with financial incentives. The project team developed and
implemented a Community Liaison Plan and employed a community liaison officer to implement the strategies in
the plan. This enabled great results to be achieved by minimising the disruption to the community from
construction activities.
The project employed a variety of methods to keep the community informed of construction progress and potential
issues. These updates included letter box drops, community door to door consultation, a fulltime 1800 project
hotline number, and regular inclusions in Council’s ‘City Update’ community newsletter. Community surveys,
undertaken regularly received positive responses evidencing the high level of community satisfaction. Further,
community liaison success was measured by a call register recording all calls placed to the 1800-number. At the
completion of the project only 18 percent of all calls received were complaints, and these calls, on average were
resolved within one (1) day of receiving the call.
Townsville City Council’s project driver for an integrated team providing a robust, flexible and easily operable plant
with a high level of redundancy was the key focus of the WUP delivery team throughout the project. To achieve
this, it was imperative that TCC’s operations team was integrated into the project team. For example:
-- Operators were encouraged to observe construction works to build their familiarity with the new treatment plant.
-- Operators participated in commissioning activities and maintenance activities while these were still the
responsibility of Baulderstone to ensure they were well prepared and ready to take on the new treatment plant.
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-- Operators spent time operating similar Hunter Water treatment plants in New South Wales during the
construction phase so that they could become experienced in the system and processes for when the new
treatment plant came online.
-- Operators were given a high level of training and the project team developed and trained operators in a userfriendly customized web-based Operations and Maintenance (O&M) database.
-- Operators were fully involved in all stages of design development including final sign-off of design
documentation.
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3.0
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Project Results
As a result of the WUP, nutrient levels discharged to the receiving environment of the tributary region of the Bohle
River have been greatly reduced from loads discharged by the previous Mt St John trickling filter WPP. It is
estimated that load reductions in the order of 70% nitrogen, 62% phosphorus and >98% ammonia will be
achieved when the new WPP is at it’s anticipated maximum capacity in 2025. These reductions will be further
increased as re-use opportunities are identified and implemented in the future. Both BOD (Biological Oxygen
Demand) and TSS (Total Suspended Solids) are also reduced due to the targeting of low nitrogen targets during
the treatment process which reduces the levels of BOD and TSS by utilising BOD in the nitrogen removal process
and low TSS being required to meet the nutrient limits and therefore ensuring the adoption of a best practice
approach to the adopted clarifier design.
A summary of some general key project results are provided below:
3.1
Benefits
The WUP was commissioned to address the growing strain on wastewater treatment infrastructure due to
population growth in the Townsville region. The new facility is designed to provide the community with
infrastructure that will handle population growth until 2026, and also includes facilities to accommodate 2040
population forecasts.
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Removing the treatment plants and the respective discharges from Mt Low, Bohle and Deeragun communities,
means these neighbourhoods now benefit from the elimination of odour, noise and nearby urban encroachment
issues. Removal of these plants also enables the opportunity for restoration of the long term visual amenity; and
enabling land redevelopment for the future.
Achieving higher environmental standard than the treatment plants that it replaced, the new plant at Mt St John
has significantly reduced the load and environmental impact to the receiving environment of the Bohle River and
ultimately the Great Barrier Reef Marine Park - valuable environments to the community of Townsville for both
recreation and commercial purposes.
The objectives of the WUP were:
1.
To deliver 106,500EP Wastewater Purification
Plant
This objective was met by construction of the new BNR
treatment facility at Mt St John.
2.
Effective engagement with the stakeholders
before, during and after construction
The project employed a variety of methods to keep the
community informed of project progress and potential
issues. These updates included letter box drops,
community door to door consultation, a fulltime 1800
project hotline number, and regular inclusions in
Council’s “City Update” community newsletter.
3.
Construction of Wastewater Upgrade Program
Stage 2 (WUP) by 6 April 2011
This objective was not met due to the project
encountering two tropical cyclones during two separate
wet seasons, however the revised timeframes were
achieved and the WUP was cut over on 1 August 2011.
4.
To deliver WUP within $189M budget (total project
costs)
The WUP was achieved $10 million under budget.
5.
To deliver a wastewater treatment plant to produce
treated effluent to agreed EPA licence conditions
plus process headspace
Achieving higher environmental standard than the
treatment plants that it replaced, the new plant at Mt St
John has significantly reduced the load and
environmental impact to the receiving environment of
the Bohle River and ultimately the Great Barrier Reef
Marine Park.
6.
WPP plant to be easy to operate and fully
accepted by the TCC Operations Group in terms of
redundancy, operability and flexibility.
Feedback from the TCC Operations Group is positive
in relation to the WUP and the strategy which has been
delivered. The WUP also incorporated a 12-month
Commissioning Assistance Management Plan which
delivered additional support during the transitional
period, providing assistance to the operators and
facilitating prompt resolution of any defects.
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3.2
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Conclusions
The Townsville Wastewater Upgrade Program is the largest ever project undertaken by Townsville City Council
(TCC) and it addresses the wastewater needs of the fast growing northern region of Townsville.
The Program consisted of the planning, detailed design, construction and commissioning of a new Wastewater
Purification Plant, 27 kilometers of pressure rising mains, four new pump stations, modifications to five existing
pump stations, and decommissioning and demolition of four wastewater treatment plants.
With a significant funding contribution by the Australian Government, the WUP has delivered considerable
community benefits through the removal of sewerage treatment infrastructure within residential areas,
accommodating future growth, reducing nutrient loading to the Great Barrier Reef, and providing opportunities for
inclusion into Council’s future water strategies.
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