Boundary Circuit Sewer Pump Station

Scope

QMAX was engaged by Newlands Group to undertake the comprehensive design and construction of a new sewer pump station for the Boundary Circuit development in Toowoomba. This essential infrastructure has been meticulously designed to provide a robust and reliable wastewater management system for the developing community as part of the region’s expanding infrastructure network.

The project encompasses a complete turnkey solution, delivering a state-of-the-art pump station fully controlled by an integrated system compliant with Toowoomba Regional Council (TRC) standards. Our scope includes the design and installation of a precast concrete pump station, measuring 3.6 meters in diameter and 7 meters deep, engineered with a 100-year design life and 170mm wall thickness. The system is equipped with two Flygt NP3202 submersible wastewater pumps, each powered by 47kW motors, configured in a duty/assist/standby arrangement to efficiently manage the wastewater flow. The project also includes a segregated valve chamber, dual flow meter pits for comprehensive monitoring, and a grit collector chamber with stainless steel components to protect the system from sediment damage.

The overall holistic approach ensures the delivery of a highly efficient, reliable, and future-proof wastewater management solution for the Boundary Circuit community. QMAX has supplied and installed a TRC-specification switchboard featuring Schneider Altivar variable speed drives, Modicon M340 PLC control system, and a 10-inch HMI colour touch screen for intuitive operation. The system incorporates advanced features including radar level transducers, backup float switches, active harmonic filtering, and emergency power provisions with genset connectivity. Additional equipment includes McBerns well washer and vent units to maintain optimal operational conditions. The project showcases QMAX’s ability to deliver advanced, tailored solutions with complete works-as-executed documentation and comprehensive operation and maintenance manuals, ensuring seamless handover and long-term operational excellence.

Challenges

The Boundary Circuit project has presented several unique challenges that require meticulous planning and coordination to ensure a safe and successful installation.

A primary challenge is the site’s location within an established area with existing infrastructure constraints. The pump station is situated in close proximity to overhead powerlines and residential properties, requiring careful planning and strict adherence to safety protocols throughout the installation process. This sensitive location demands a highly coordinated approach to protect existing utilities and minimise disruption to nearby residents. Our team has implemented comprehensive safety measures and conducted detailed risk assessments to ensure all work is carried out safely around the powerlines while maintaining appropriate clearances. The installation of the precast concrete components, including the substantial 3.6-meter diameter pump well, requires precise crane operations with careful consideration of overhead constraints. Additionally, as QMAX is responsible for the complete detailed design and installation of not only the pump station but also the flow meter pits and screening pit, this requires meticulous coordination of multiple interconnected elements to ensure seamless integration within the existing regional infrastructure network.

Another significant challenge is the compressed project timeline from mobilisation to completion. The accelerated schedule demands exceptional project management and coordination across all phases, from detailed design and engineering through to manufacturing, installation, and ultimately commissioning. Our team is addressing this by implementing an efficient workflow that overlaps design approvals with manufacturing preparation, ensuring components are ready for delivery as construction drawings are finalised. This tight timeline also necessitates careful coordination of crane hire, labour resources, and the sequential installation of precast items, internal fit-out works, and the sophisticated TRC-specification control system. The project demands meticulous attention to detail in every aspect while maintaining an accelerated pace, from the pouring of the first concrete mould through to the final commissioning and handover phase.

QMAX’s expertise in managing complex infrastructure projects is being demonstrated throughout this challenging installation. Our comprehensive approach, from initial design through to the upcoming commissioning and documentation phases, will ensure the client receives a fully compliant, high-performance wastewater management system on schedule. This project stands as a testament to our commitment to engineering excellence, safety, and our ability to navigate complex site constraints and demanding schedules while delivering exceptional results.