Wesfarmers Resources, a significant Australian producer of metallurgical coal engaged Dowdens Pumping & Water Treatment's Industrial Workshop [Mackay branch] to deliver fast-turnaround servicing to a large selection of DAVEY Water Products Vertical Multistage In-Line Pumps [pictured below] that are used onsite at their Curragh Coal Mine, located 30km north of Blackwater in Central Queensland. This servicing project presented a number of challenges for the Dowdens Mackay Industrial Workshop, none more important than the tight timelines in which these repairs needed to be completed.

These DAVEY Vertical Multistage In-Line Pumps play a crucial role in the operation of the mine as they are used in various dewatering applications and also to boost supply of water to all of Curragh Coal Mine's various processing areas - including the vitally important Coal Handling & Preparation Plant (CHPP). Wesfarmers are supremely confident in having their pumps serviced by Dowdens Pumping, because after many years of working together they know Dowdens always aim to provide the sale / service of suitable pumps that maximise service life and minimise power usage and downtime. Improving levels of equipment utilisation whilst reducing planned / unplanned maintenance downtime increases the overall productivity of a coal mine.

Wesfarmers Curragh Coal Mine is an open-cut coal mine that provides metallurgical coal for export markets and supplies steaming coal to the Queensland Government's Stanwell Corporation under a long-term contract. Stanwell operate two major electricity generation assets, the Stanwell Power Station located in Central Queensland and the Tarong Power Station, located in the South Burnett, Southern Queensland. Wesfarmers Curragh Coal Mine has a well-established and geographically diverse customer portfolio with a number of long-standing relationships with world-leading steel-makers.

Like with any pump that arrives to Dowdens Pumping - Mackay's Industrial or Domestic Workshop, these Davey VM Vertical Multistage In-Line Pumps were serviced using Dowdens established workshop repair procedures. It was these established procedures and highly regarded workmanship that prompted Wesfarmers Resources to award Dowdens this important servicing contract. Dowdens Pumping - Mackay are so confident in our Workshop Servicing Capabilities we offer a "12 MONTH WORKMANSHIP GUARANTEE" for any service completed in-house - this is by-far the best guarantee available in or around Mackay, QLD. All pumps were successfully serviced and returned to site within Wesfarmers specified deadlines, meaning less downtime for Curragh Mine's related water infrastructure.

A very brief synopsis of this projects Key SERVICING Procedures are listed below:

• Set up pump on work bench & preform suite of electrical tests on motor
• Remove motor from the pump wet end
• Once seperated, run the pump motor independently of pump wet end to establish & gauge motors efficiency
• Submit detailed quote to customer clearly illustrating what is required to repair motor/pump
• Once quote has been accepted immediately begin to repair motor/pump components

• Dismantle motor and replace worn bearings
• Dismantle wet end of pump - clean, strip & asses all components
• Repair and reassemble both motor and pump wet end
• Connect unit to the Dowdens 'Pump Test Bench' & check all pump curves/electrical operation is 100%
• Undertake final inspection before preparing pump for transportation back to Curragh Coal Mine

Since opening in Mackay back in 1973, Dowdens has grown to employ over 160 staff situated across 4 branches in Mackay, Proserpine, Rockhampton and Brisbane permitting us to confidently service customers throughout Queensland, nationally and internationally. Dowdens services now cover all aspects of water engineering and fluid handling resource management for the residential, commercial / industrial, agricultural and mining sectors. From project inception through to final commissioning - the team at Dowdens has the ability to deliver complete specialised long-term engineered solutions that are practical and innovative, ensuring our clients benefit from greater productivity and reduced downtime.

With dedicated departments of industry trained engineers, draftsmen, project managers, sales staff and tradespeople including fitters, mechanics, polywelders, machinists, plumbers, electricians and boiler makers - Dowdens Pumping & Water Treatment offer an unmatched range of world-class engineering solutions for any type of water management project. We truly are Queensland's premier one-stop-shop for pumping and water treatment systems! CLICK HERE TO LODGE AN ONLINE PUMP SERVICE REQUEST, OR REQUEST AN OBLIGATION FREE QUOTE.

Dowdens Pumping & Water Treatment have successfully designed, installed and commissioned a specialised Ultraviolet filtration system for the Queensland Health Mackay Renal Unit.

Project Requirements: The original system operated by pumping town water to individual filtering stations where the water would pass through a 5 micron, 1 micron and carbon filter on its way to the dialysis machine (which has an internal reverse osmosis filter).

The issue Dowdens faced was the original system filters were only lasting between 5 - 15 hours, and by this stage they were black and needed to be replaced!

After reviewing detailed water test results, Dowdens designed a compact, reliable system where the existing pump was upgraded, a water softening unit was added to remove iron, calcium and manganese. Large cartridge filters were also installed to pre-filter the water before it entered a dedicated UV steriliser.

Using the above system the Mackay Renal Unit now only needs to replace the systems filters every 7 to 10 days - saving thousands of dollars in ongoing system maintenance costs!

Key Plant Features:

• Due to limited space the system design had to be compact and robust
• Complex pipework was needed to reticulate above and around existing equipment
• All water treatment system components needed the ability to be isolated to enable easy service and system part replacements
• PURION water softening unit to remove iron, calcium and manganese
• All plumbing and pipe fixtures installed by Dowdens Pumping & Water Treatment
• Grundfos pump supplied on request from Queensland Health

Wilmar Sugar Australia Limited employed Dowdens Pumping & Water Treatment [Mackay] to deliver a broad acre irrigation system at their Gibson Creek sugarcane farm. Wilmar Sugar Australia Limited is Australia's largest raw sugar producer and one of the top 10 producers in the world.

The Gibson Creek sugarcane farm has a total area of 2,000ha, with works completed by Dowdens to date delivering irrigation to over 750ha of sugarcane - this project is still ongoing with the aim to irrigate the full 2,000ha upon completion. The broad acre irrigation system was designed, sourced, installed and commissioned by the Dowdens Pumping & Water Treatment Agricultural Sales Team, which has over 125 years combined agriculture irrigation experience.

The system is required to pump water stored in Wilmar's onsite dam (which when completed will hold a total of 2,000ML) to various irrigation devices watering 2,000ha of sugarcane.

To date the project has seen the team at Dowdens construct, install and commission six Valley Center Pivot Irrigators, with spans ranging from 520m down to 410m, and three hard hose poly line traveling irrigators.

Water for the irrigation system (sourced from Wilmar's 2,000ML onsite dam) required Dowdens to lay an extensive network of poly and PVC mains pipework ranging from 500mm to 150mm in diameter. In total over 12kms of mains pipe has been laid so far.

The entire system is gravity fed from the large onsite dam with a 6-cylinder John Deere diesel engine centrifugal pump feeding the six pivots, and three IVECO-Caprari multistage diesel booster pumps [pictured below] kicking in to raise mains pressure when water is required at the three hard hose poly line travelling irrigators.

The entire project was overseen and managed by Glenn Agnew from the Dowdens Pumping & Water Treatment [Mackay] Agricultural Sales Team.

Key Project Features:

• Six Valley Center Pivot Irrigators installed with spans ranging from 520m to 410m
• The Valley Center Pivots were fitted with auto-start generator sets - eliminating the need for farmers to travel to each individual Center Pivot to activate once feed pumps are on
• To date over 12kms of mains poly and PVC pipe has been trenched, welded and commissioned
• Dowdens sourced, delivered and commissioned three hard hose poly line traveling irrigators [2x Idrofoglia & 1x Trailco]
• 1x 6-cylinder John Deere diesel engine centrifugal pump feeds the six Valley Center Pivot Irrigators
• 3x IVECO-Caprari multistage diesel booster pumps transfer water to the three hard hose poly line traveling irrigators when required

Long-term customers Michelmore Grazing Company have recently purchased seven solar powered pumping systems from the Dowdens Pumping & Water Treatment Mackay branch. All the solar systems supplied are used to pump water from onsite bores to poly water storage tanks, to then feed the properties multiple cattle water troughs. Some existing bores were used to replace dated diesel setups / windmills, along with some new bores being added to increase the total number of watering points for the cattle. Michelmore Grazing Co. purchased three Solar Pumping Systems for Fort Cooper Station and another four systems installed at Kainga Station.

This 6 month project saw Dowdens Mackay source, supply, install and commission a number of GRUNDFOS & MONO solar pumps, a MONO 2400 WATT Solar System (all used in conjunction with solar panels / frames) and undertake repairs on an existing Mono Diesel Pump system at Michelmore Grazing Co.'s Fort Cooper and neighbouring Kainga Stations (Nebo, QLD). The repairs carried out on the existing Diesel Driven Mono Helical Rotor Bore Pump involved replacing the rusted head housing with this pump now being used as a back-up for one of the new Solar Pumping Systems.

The high-quality GRUNDFOS & MONO Solar Pumping Systems have already delivered Michelmore Grazing Co. notable cost savings via a reduction in diesel fuel usage and a significant decrease in the need for ongoing diesel motor maintenance. Michelmore Grazing Co. now saves both time and money by not having to undertake laborious daily checks on the diesel pump sets fuel levels.

As a company that has built its foundation from the servicing and development of agricultural pumps and water treatment technology / applications, Dowdens Pumping & Water Treatment have the experience to engineer a solution to suit any agricultural application. For over 40 years Dowdens have been providing customers with solutions-based technology - designed to improve efficiency, reduce downtime and increase longevity of products and systems. Dowdens provide affordable and efficient solar pumping solutions to help combat ever increasing electricity prices. From stock watering systems through to large scale broad acre irrigation our dedicated sales, installation and service crews have you covered. All systems are expertly designed to suit any site specifications, utilising a variety of efficient engine and electric pump units.

Key Project System Features:

• 4x GRUNDFOS SQF2.5-2 SOLAR PUMPS (these pumps can be run by a generator if needed)
• 1x GRUNDFOS SQF3A-10N SOLAR PUMP (this pump can be run by a generator if needed)
• 1x GRUNDFOS SQF5A-7N SOLAR PUMP (this pump can be run by a generator if needed)
• 1x MONO 2400 WATT SOLAR SYSTEM running 1x MONO SS062 PUMP
• Multiple 250 WATT SOLAR PANELS

FORT COOPER SOLAR SYSTEMS

Comet Bore:

• The largest of the systems is a MONO 2400 Watt Tracking Solar System, which delivers up to 40m³ per day from a bore feeding four tanks up to 8kms away. This system consists of three tracking arrays and a MONO SS062 Pump.
• Repairs were also carried out on the existing Diesel driven MONO Helical Rotor Bore Pump by replacing the rusted head housing. The pump is now used as a back-up for the new solar pumping system.

Yards Bore:

• This six panel GRUNDFOS Solar System was installed at Fort Cooper's main yards to transfer water from a bore to a high level tank which in-turn feeds the main homestead area and cattle yards. The system uses a GRUNDFOS SQF5A-7N Solar Pump and 6x 250 watt panels on a post mount delivering up to 30m³ per day.

One Mile Bore:

• A three panel GRUNDFOS Solar System was installed at the One Mile Bore supplying water 600m from the bore to a storage tank. The pump used was a GRUNDFOS SQF2.5-2 Solar Pump that delivers up to 17m³ per day.

KAINGA SOLAR SYSTEMS

Bruce's Bore:

• This is a six panel GRUNDFOS Solar System installed on Bruce's Bore delivering water to 3 poly tanks up to 2km away. The GRUNDFOS SQF2.5-2 Solar Pump can deliver up to 25m³ per day.

Donaldson's Bore:

• This is a four panel GRUNDFOS Solar System installed on Donaldson's Bore delivers water to a poly tank situated 300m away. The GRUNDFOS SQF2.5-2 Solar Pump can deliver up to 25m³ per day.

Cattle Creek Bore:

• This is a three panel GRUNDFOS Solar System installed on the Cattle Creek Bore delivers water poly tanks situated 500m away. The GRUNDFOS SQF3A-10 Solar Pump can deliver up to 25m³ per day.

Walter's Bore:

• This is a four panel GRUNDFOS Solar System installed on Walter's bore delivering water from the bore to a poly tank 500m away. The GRUNDFOS SQF2.5-2 Solar Pump can deliver up to 25m³ per day.

Dowdens Pumping & Water Treatment's Mackay branch were engaged by longstanding customer Anglo American (Moranbah North Coal Mine Site) to deliver an innovative valve system that could help maintain the safe and reliable delivery of general purpose & fire water services to their ever-expanding underground mining operations. With growing demand for reliable water flow & pressures at ever-increasing operating depths, Dowdens decided it was time to design & produce a new generation 35 bar Dual Pressure Control Station, expanding our range of standardised pressure reducing valve stations.

Dowdens Pumping & Water Treatment fabricate and fit out a range of standardised pressure reducing valve stations, but this station required a higher pressure rating not available with our standard 'off the shelf' systems that are available in 16 / 25 bar (35 / 40 bar rated systems are built to order). Dowdens have manufactured these products for many years to help our resource industry customers arrest any water pressure spikes and/or surges in pipe systems and to aid these mines operating within and remaining fully complaint with Queensland Government Mine Site Compliance legislation, standards & guidelines.

This new Dual Pressure Control Station has been built to optimise plant reaction speeds, allow for greater operating ranges from between 2 - 35 bar and is manufactured with high-quality, reliable and readily available components. The design needs for the new Dual Pressure Control Station were borne primarily from Dowdens detailed underground observations of hydraulic occurrences within the mines existing water network. Working closely with the mines water infrastructure operators Dowdens were able to engineer, manufacture and deliver a product that increased the reliability of their mine water supply systems and assist with premeditated preventative maintenance routines.

All design, fabrication, installation & commissioning of the 35 bar Pressure Reducing Valve Station was undertaken by Dowdens Mackay's in-house Engineering, Fabrication & Workshop Departments. With a history of successful installations over the past 20 years throughout the Queensland Mining Sector Dowdens Pumping & Water Treatment have the ability to expertly design / manufacture / install and commission specialised pumping and water treatment solutions that are built primarily in-house & onsite to our client's specific unique requirements. Dowdens dedicated departments of industry trained engineers, draftsmen, project managers, sales staff and tradespeople including fitters, mechanics, polywelders, machinists, plumbers, electricians and boiler makers enable us to offer an unmatched range of world-class engineering solutions for any type of fluid handling project. We truly are Queensland's premier 'one-stop-shop' for pumping and water treatment systems!

At this projects inception Dowdens visited site to examine and document the specific operating requirements. After initial observations it was concluded that a wider operating range would be required for effective control of both the High and Low Flow demands and a higher adjustment range - meaning the standard Dowdens 25 bar Pressure Reducing Valve Station needed to be modified to suit this application. This higher pressure is not normally encountered with Queensland underground mine water supply systems so unique and customised hydraulic control layouts, pilots & hardware were seamlessly incorporated into the build by the Dowdens Mackay Workshop and Project Engineers.

This projects entire design, manufacture, installation & commissioning process was completed on budget and within a tight timeline of 4 weeks set by the customer.

Anglo American (Moranbah North Coal Mine) 35 bar Pressure Reducing Valve Station - Key Components:

• BERMAD WW720 PN35 Heavy Body Control & Relief Valves
• Hardy Spicer Hydraulic Hoses & Fittings

• Custom in-house design & drafting by Dowdens Mackay Projects Engineering team
• Custom in-house fabrication of all steel pipework

Dowdens Pumping & Water Treatment's Rockhampton branch were engaged by the Queensland State Government's Department of Environment and Heritage Protection to deliver an efficient solar pumping system at the disused Mount Chalmers Gold Mine (located 15km North-East of Rockhampton, QLD).

As part of this sites ongoing rehabilitation process the Department of Environment and Heritage Protection needed an efficient solar pumping system to recirculate contaminated mine water collected from a sump, back into the main pit, thereby eliminating any contaminated mine water runoff from site. The Department of Environment and Heritage Protection has been managing the key environmental issues at the Mount Chalmers Gold mine since the former operators Affinis Pty Ltd was placed into liquidation in December 2014. EHP is also supported by other government agencies including the Department of Science, Information Technology and Innovation (DSITI) who are providing scientific advice on technical aspects of site management. The primary ongoing focus is to prevent any discharge of contaminated water from the site.

With limited mains power available to the site the use of solar power was a perfect fit for this pumping application. Solar powered pump solutions are always improving, none more so than Grundfos Solar Water Solutions. During initial site inspections the pumps required operating duty was calculated to be 13L/sec @ 18.5m Total Head. To meet these high flow requirements a Grundfos Solar Inverter (RSI) was selected to power the Grundfos R Series Submersible Pump [SP46-3 5.5kw 415V] that the Department of Environment and Heritage Protection already had onsite. The Grundfos R Series SP46-3 is a Stainless Steel pump capable of handling the low pH, slightly acidic mine water (measuring between 2 & 3 pH) needing to be pumped.

Utilising a combination of Grundfos Solar Water Solution products (inverter / pump / solar panels) appealed to the Department of Environment and Heritage Protection as it meant Dowdens could supply a system that not only costs less to install and maintain, but importantly can pump a larger volume of water under solar power. Put quite simply the ability to run large 415V pumps capable of greater pump duties is making the decision to 'go green' and install solar powered systems more attractive in the current climate, for miners and farmers alike.

Dowdens Pumping - Rockhampton initially visited site to establish location of the solar arrays and calculate pump duty. Once known the following components were sourced and prepared for installation: 36 x 270 Watt Grundfos Solar Modules, 2 x 18 SolarTerrace Module Fixed Array Frames, 7.5 kW Grundfos RSI Inverter & Sine Wave Filter and 200m of 110mm PN10 Poly Pipe. The Grundfos SP46-3 5.5kw Pump was attached to a specialised float that sits on the surface of the sump (pictured below). Pump starts & stops via a level float switch mounted on 4m pole that can be swivelled over to the sump's bank should any maintenance be required.

Local contractors were then engaged to complete the site earthworks and trenching needed for all electrical conduits. Once the solar array support posts were cemented in place, Dowdens Pumping - Rockhampton assembled the SolarTerrace Array Frames and mounted the 36 modules (2 x 18 Modules) ready for the electrical components to be installed.

Electrical contractors RILEC Electrical (accredited electrical/solar contractors) completed the electrical fit-out. As part of these works Dowdens Pumping - Rockhampton delivered the Grundfos Solar Inverter Sinewave Filter & String Connection Box (pictured below) to the RILEC workshop so it could be mounted in a powdered coated, lockable enclosure with sufficient ventilation to ensure the inverter remains cool during the day. RILEC then brought the control box to site, mounted it and completed all wiring to meet electrical standards and the site specifications. All commissioning of this system was undertaken by Dowdens Pumping - Rockhampton.

Dowdens Pumping & Water Treatment's Rockhampton branches design philosophy for this project was: Cost Effectiveness - Innovation - Ease of Installation - Simple & Reliable Pump Operation - System Reliability & Reduced Ongoing Maintenance. The entire Grundfos RSI Solar Pumping System was designed, manufactured, installed and commissioned on time and within budget.

Mount Chalmers Gold Mine ~ Solar Pumping System - Key Components:

• 36 x 270 Grundfos Watt Solar Modules
• Grundfos R Series Submersible Pump [SP46-3 5.5kw 415V]
• 7.5 kW Grundfos RSI Inverter & Sine Wave Filter

• 2 x 18 SolarTerrace Module Fixed Array Frames
• Specialised Float to suspend the Grundfos Submersible Pump on the sump's surface
• 200m of 110mm PN10 Poly Pipe

As an Australian owned company that began life in 1973 selling and servicing agricultural pumps, Dowdens has grown to employ over 160 staff situated across 4 branches in Mackay, Proserpine, Rockhampton and Brisbane permitting us to confidently service customers throughout Queensland, nationally and internationally. From project inception through to final commissioning - the team at Dowdens has the ability to deliver complete specialised long-term engineered solutions that are practical and innovative, ensuring our clients benefit from greater productivity and reduced downtime.

With dedicated departments of industry trained engineers, draftsmen, project managers, sales staff and tradespeople including fitters, mechanics, polywelders, machinists, plumbers, electricians and boiler makers - Dowdens Pumping & Water Treatment offer an unmatched range of world-class engineering solutions for any type of water management project. We truly are Queensland's premier one-stop-shop for solar pumping and water treatment systems!