BHP Billiton Mitsubishi Alliance (BMA) have engaged Dowdens Pumping & Water Treatment's Mackay Branch to deliver a specialised Modular Underground Dewatering System at their Broadmeadow Coal Mine, located approximately 200km South West of Mackay, QLD.

The Broadmeadow Underground Coal Mine is a 'Top Coal Cave Longwall Punch' mine located approximately 30km from Moranbah. Located on BMA's Goonyella open cut mine lease, the Broadmeadow Mine was established in late 2003 and feature's BMA's first application of punch longwall mining - a highly efficient underground technique utilising an existing open cut pit for longwall panel access. Broadmeadow Mine delivered a number of synergies between BMA's underground and open cut operations, including utilisation of the existing Goonyella coal preparation plant capacity, increased flexibility to respond to market demand, improved reliability of supply for customers and optimisation of product quality through selective blending.

The Modular Underground Dewatering System (MUDS) was designed / manufactured and installed by Dowdens Mackay to optimise further development of BMA's Broadmeadow mining operations by improving on-site dewatering efficiencies. The MUDS has been utilised in developing Broadmeadow panels 12 & 13, and will help to advance mine site progression for the entire life of operations. The main objective of this project was to provide a unique, custom built air / electric pump system to improve Broadmeadow's dewatering efficiency. This was achieved through the automation of pumping systems supplied and lowering any ongoing maintenance requirements - thereby saving site operator input, lowering air / power consumption and reducing the need for BMA to further invest in dewatering pump systems.

Dowdens were engaged during the concept phase of this project to provide input and engineering advice to help BMA overcome the many operational challenges this site presented. With intimate product knowledge and via extensive direct consultation 2 unique transportable Quick Docking System (QDS) Fish Tank Dewatering POD designs were developed. Capable of operating under 1,000V power, these modular POD systems required the ability to remain operational during regular power outages, utilising the limited underground supply of compressed air. Each pump station needed considerable storage / retention capabilities (5,000L per POD) and the capacity to operate seamlessly 'in-sequence' thereby delivering zero overflows onto roadways even during loss of underground power.

The composition of the water derived from the mine's development process posed its own transportation challenges with a high water content ratio of rock, coal, trash and coal fines. A solids management system consisting of various sieves, hoppers and tank agitation components was developed and tested to ensure the coal fines and inflow management system was capable of continuous operation, whilst also delivering simplified maintenance and cleaning procedures.

The coal fines and inflow management system was designed with the ability to:

• Retrofit to existing POD systems recovered from the Crinum underground coal mine
• Bolster the developing site dewatering fleet - with continuity of all pumps, instrumentation & control equipment used.

With the negotiations finalised, Dowdens proposed the fabrication of 2 Teams of 4x Dewatering PODs. Each Team is led by the newly designed 5m³ EXD QDS transportable roadway POD. 3x additional specially modified 4m³ Elliptical PODs (a combination of EXD & IP66 rated) are then positioned at strategic intervals along the panel as main gate development advances.

Dowdens Pumping & Water Treatment was successful in BMA's tendering process due to:

• Vast in-house engineering, drafting/design, fabrication, servicing capabilities & proven competencies
• Over 20 years' experience designing & producing specialised underground dewatering equipment
• The proximity of Dowdens head office [Mackay] & ongoing presence in the region
• Providing a competitively priced solution to the clients unique challenges
• High level of detail provided in the preliminary engineering proposal

After a successful tendering process Dowdens team of engineers and draftsmen immediately began analysing the recovered Crinum mine 4m³ POD design. After much consideration, a plan was established to incorporate all new specifications and functionality required whilst retaining as much of the existing structure as possible, saving both fabrication time and money. This design was carried over to the new generation 4m³ Elliptical PODs.

The Narrow Gauge 5m³ Lead POD had to utilise every inch of its restricted underground foot print to facilitate the 5,000L capacity and extra-large solids screening hopper. All work access steps and ladders were designed to be stowed away to avoid contact by passing machinery. All equipment was to be readily accessible to operators, even while positioned hard against the roadway rib. The complete set of design drawings were completed within 5 days and construction began immediately ensuring delivery was made within BMA's tight project deadlines.

Specially equipped 1,000V electric motors were incorporated in the build to operate custom made hard-metal centrifugal pumps - primarily selected for water transfer between PODs operating 'in-sequence'. The Cast Iron WILDEN T15 Air Operated Double Diaphragm Pump was selected to serve as the auxiliary system for its robustness and relatively small weight-to-flow ratio. The lower weight and lower capital cost of the T15 allowed two pumps to be incorporated into each pump station to serve in duty / standby, or duty / assist mode if required.

A pneumatic control system provides seamless switching between air and electric pumping modes. Non-powered level controls allow maximum tank differential between the air pumps 'on & off' functions saving air consumption. Potential overflows are prevented by a pneumatically operated, inflow regulating valve. Each of the POD inflow manifolds are equipped with 4 auxiliary 50mm pump inputs to integrate localised pumping to the 'outbye' system. Custom built electrical control panels incorporate all EX'd field devices providing temperature, pressure, flow & fault communications via a PLC to the site Citect system. Area lighting and visual pump status indicator lights can be positioned remotely ensuring clear viewing from the mines underground roadways.

Dowdens Pumping & Water Treatment design philosophy for this project was: Cost Effectiveness - Current Best Practice - Ease of Installation - Simple & Effective Plant Operation - Plant Reliability & Reduced Ongoing Maintenance.

Modular Underground Dewatering System's Key Components are listed below:

• Creation of a completely new Custom Narrow Gauge POD Design to suit clients space restrictions near Development Miner
• Supply of 2x teams of 4x PODs, 1 team for each main-gate under development (each team consisting of a special Narrow Gauge 5m³ Lead POD & 3x Modified 4m³ Elliptical PODs)
• Automatic Duty / Standby Cast Iron WILDEN T15 Air Operated Double Diaphragm Pump Backup with full starting / stopping control to minimise air consumption
• Automatic Shutdown of incoming water on High Tank Level (preventing overflows)

• Two levels of screening for incoming water to eliminate pump blockages
• Colour Coded POD visual lighting to indicate whether POD is healthy ('green') or in fault ('orange')
• System designed with site operators needs in mind - No entry to tank required to maintain field devices
• Supply of specially fabricated stainless steel canopies for Pump Starter (top & back) to protect against physical damage
• Provision of DN50 Camlock inlets - providing a readily accessible connection point for incoming water

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.

CLICK IMAGES TO VIEW FULL PROJECT GALLERY

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

CLICK IMAGES TO VIEW FULL PROJECT GALLERY

Anglo American have engaged Dowdens Pumping & Water Treatment's [Mackay] Engineering Department & Fabrication Workshop to rectify an issue with a new valve station installation that was experiencing water hammer, resulting in the longwall mining operation being suspended at their Grasstree Coal Mine, located at Middlemount in the centre of the Bowen Basin, QLD.

Underground mines require water management systems in place to manage working water that is utilised for production, dust suppression, hydraulic jacks etc. Mines employ various methods of underground water transportation systems including Longwall Boost Pump Stations & filtered water from the mine surface networks. The filtered water system is an important piece of infrastructure for underground coal mine providing clean water for dust suppression & feeding the powerful hydraulic piston pumps that are used to jack up the roof in the longwall mining process.

When water is fed into an underground mine it is received at a very high pressures due to the vertical drop to the mine workings. This pressure needs to be reduced & controlled to levels that can be safely managed in the underground operations. Dowdens Pumping & Water Treatment has provided Grasstree Coal Mine with several Pressure Reducing Valve Stations over the life of the mine, enabling reliable & trouble free operation.

Responding to the urgent help request from Grasstree Mine, Dowdens immediately travelled to site to undertake system 'fault finding' & begin planning the delivery of a timely & cost effective solution to the problem.

As a direct result of Dowdens Pumping & Water Treatment's long standing & responsive working relationship with Anglo American's Grasstree underground coal mine, the Dowdens Engineering Department was called on to assist with a new valve station installation that was experiencing water hammer resulting in the longwall mining operation being suspended. Dowdens Engineers attended the mine site & listened/observed the problems that were being experienced such as pressure surges & water hammer in the feed pipes leading to the longwall operation.

Dowdens Engineering Dept. designed & developed a Pressure Setting Spool sized specifically to meet the specific duty required. The spool was custom designed using engineered fluid mechanics to reduce the pressure before it entered the valve station, taking part of the load off the station. Pipe supports were also engineered to provide a secure installation of the station.

The timeline to find the solution & manufacture the components was very tight. Engineering - Concept Design - Drawings & In-House Fabrication of the unique Pressure Setting Spool Piece [with roof bolt anchoring points] were completed & delivered to Grasstree Mine within 5 days from the first site meeting! No other pumping / manufacturing / engineering firm in Queensland was able to deliver such an all-encompassing product solution in the above mentioned time-frame.

Dowdens design philosophy for this project was: Fast Turnaround - Cost Effectiveness - Ease of Installation - Simple Plant Operation - Plant Reliability & Reduced Maintenance.

The unique system required at Grasstree Coal Mine needed to address the following issues:

• Reduction of water pressure 'spikes'
• Surge control of high pressure water
• Provide system roof bolting anchoring points
• Secure range piping & bore column

Key Project Features:

• As filtered water flows vertically from the surface the pressure at the mine level can be several thousand kPa. Normal orifice or flow restrictors induce high velocities in a very short space with resulting cavitation & sonic sound which can erode the components & reduce their effect. Dowdens customised Pressure Setting Spool Piece dissipates the energies over a larger area resulting in lower component wear & longevity of the systems performance
• Water hammer was reduced & pressure fluctuations were controlled, allowing the valve station to operate at the flows & pressures for the specific location & duty
• Dowdens Pressure Setting Spool Piece has resulted in no more loss of coal production

Longreach Regional Council recently engaged Dowdens Pumping & Water Treatment's Mackay & Rockhampton branches to manufacture and install a specialised pool water treatment system for the Yaraka Community Pool in Yaraka (a small town in Central West Queensland located 220 kilometres south of Longreach).

This project began with Longreach Regional Council asking for tender submissions to fully upgrade the Yaraka's Pool onsite filtration & treatment systems. Dowdens Pumping & Water Treatment was successful in winning the tender thanks to our price competitiveness, delivery times and unique in-house fabrication capabilities. On hearing about the tender a representative from the Dowdens Rockhampton branch immediately attended the pool to properly assess and quote the job. It quickly became apparent that a specialised filtration system was needed due in part to the pools remote location (limiting the possibility of regular system servicing), and the extreme weather patterns (high temperatures, dust storms & limited / sporadic rainfall) experienced in Central QLD.

Dowdens then set about designing the new filtration system utilising inhouse Engineering, Workshop Fabrication & Mobile Pool Servicing Departments. The end result was a unique twin-filtration systems that was mounted onto a fabricated galvanised skid to aid in maneuverability, ease of installation & transportation. The skid base was fabricated specifically to fit the existing shed onsite.

Having all the system components plumbed up on a single sturdy base made installation easy as only the Pump Inlet, Pool Water Return and Wastewater Pipes needed to be connected and the system was ready to go. The skid comprised 2x Pool Glass Media Filters, 2x Pool Pumps and 2x Salt Water Chlorinators. The Salt Water Chlorinators are fully automated allowing for round the clock (controlled via sensors) pH and chlorine / acid dosing together with chlorine generation. This has drastically reduced the need for regular onsite water testing and manual chemical dosing at the community pool. On Dowdens recommendation Longreach Regional Council also purchased a Dolphin Robotic Pool Cleaner which has noticeably improved the pools cleanliness.

All design, manufacture, delivery and installation / commissioning was successfully completed by Dowdens well within Longreach Regional Council's delivery deadline of six weeks.

The Yaraka Community Pool is now clean and ready for summer. The new equipment Dowdens supplied has reduced the need for costly regular maintenance whilst improving the automation of the pools chlorine levels - keeping the pool sanitised and chemically balanced at all times is extremely important for any community pool. Dowdens Pumping & Water Treatment's design philosophy for this project was simple: Cost Effectiveness - Ease of Installation - Simple & Effective System Operation - System Reliability & Delivering Greatly Reduced Ongoing Maintenance Requirements.

Yaraka Community Pool Filtration System ~ Key System Features & Components:

Dowdens Pumping & Water Treatment's Rockhampton branch were engaged by local beef cattle graziers Kurrajong Pastoral (located near Springsure, QLD) to deliver a GRUNDFOS RSI Invertor Solar Pumping System at the Crystal Plains property to supplying onsite bore water to the property's many beef cattle watering troughs. Crystal Plains is a 3,018ha (7,458 acre) Springsure buffel grass property located 52km south of Emerald and 22km north of Springsure. The property comprises 10 dams, three bores, 14 grazing paddocks, plus several holding paddocks and water squares.

Dowdens Pumping - Rockhampton began the design of this solar pumping system with a site visit to record the height / depths of bores and to meet with the customers and garner their exact requirements for this system. Although not required for this particular bore inspection, Dowdens can offer our customers affordable Borehole and Drain inspection services using a range of Wireline Cameras. Our Wireline Cameras can operate up to a depth of 100m and deliver our customers high-resolution video and images straight to laptop / USB.

Once the proposal had been accepted, the Dowdens Industrial Workshop began sourcing the 18 x 270 Watt Solar Modules that were to be attached to 3 x 6 Module Fixed Post Array Frames. As an Authorised Grundfos Distributor Dowdens Pumping - Rockhampton were able to confidently recommend a Grundfos RSI Inverter together with the efficient SP7-17 415V Submersible Pump to be mounted and installed on this solar pumping system. The system pumps directly from a bore to an elevated position on Crystal Plains where the customer is then able to gravity feed from their established tank farm to the greater majority of his property. On average the pump transfers 50,000L/day.

Dowdens Pumping & Water Treatment's Rockhampton branch specialises in the design, manufacture and installation of innovative customised Solar Pumping systems for the commercial, agriculture and mining sectors of Central Queensland and the greater Capricorn Coast regions. Dowdens Rockhampton work closely with beef cattle producers to deliver innovative solar powered stock watering systems that not only minimise human interaction with cattle, but add value to the farms via efficient energy and water consumption.

The existing pump that Dowdens replaced was an old line shaft MONO pump that was operated by Diesel engine. The installation of the new Grundfos solar system lowered ongoing maintenance and operation costs considerably as the clients no longer had to replace the column due to the accumulation of rust. To ensure this wouldn't happen again Dowdens utilised stainless steel and poly pipe in the construction.

Operating costs were lowered via the system utilising a Grundfos Invertor with Sine Wave Filter Isolation Switch together with a tank level pressure switch - meaning the pump would start and stop automatically, only when needed. This automatic operation eliminated the need for the client to regularly drive to the bore to start and stop the pump. This increased pumping efficiency also saved on the overall cost of diesel to refuel the pump. The Grundfos Invertor with Sine Wave Filter Isolation Switch, together with the Grundfos SP7-17 415V Submersible Borehole Pump were pre-wired on a custom-fabricated steel mounting frame to enable easy 'plug & play' installation. Dowdens supplied 5km of poly pipe for both the tank fill line and the gravity feed lines.

Dowdens Pumping & Water Treatment's Rockhampton branches design philosophy for this project was: Cost Effectiveness - Innovation - Ease of Installation - Simple & Effective 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.

Kurrajong Pastoral's Crystal Plains Solar Pumping System - Key Components:

• Grundfos 2.2 kW RSI Invertor
• Grundfos Sine Wave Filter & Lockable Isolator
• Grundfos SP7-17 415V Submersible Borehole Pump

• 3 x 6 Module Fixed Post Array Frames
• 5km of 63mm PN8 Iplex Poly Pipe with Plasson Ag Fittings & Joiners
• 18 x 270 Watt solar modules

...

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!

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.