Monbulk Water Pump & Penstock Renewal Project

Project summary

The Monbulk Water Pump and Penstock Renewal Project, completed in 2018, was a $5 million initiative managed by Senior Project Manager Adi Harsono. The project aimed to modernise the Monbulk No.2 water pump station (WP075) to enhance infrastructure efficiency and reliability. This case study highlights the project’s scope, challenges, execution, and innovative solutions that led to its successful completion.

…what we did on this project

The Monbulk Water Pump and Penstock Renewal Project was critical in updating the aging infrastructure of the Monbulk No.2 water pump station, which had been operational since 1981. This station plays a vital role in drawing water from the Silvan Reservoir, processing it through adjacent disinfection and fluoridation plants, and delivering it to the Monbulk Reservoir. The primary goal was to replace outdated components, including three 110kW vertical turbine pumps, and implement a temporary bypass system to ensure uninterrupted operations during the upgrade period.

The project involved replacing three 110kW vertical turbine pumps and various ancillary assets to improve the station’s operational efficiency. These upgrades were necessary to ensure the station could continue to meet the demands of water processing and delivery with enhanced reliability and performance. A key challenge was designing and executing a temporary bypass system to maintain operations during the 90-day upgrade period. This system had to comply with Melbourne Water’s Operational Requirement and Safety Standards. Adi Harsono oversaw the detailed planning and execution of this bypass system, ensuring it provided adequate mechanical protection and met all operational standards. The project adhered to a zero-harm policy, prioritising the safety of all personnel involved. Environmental management was also a crucial aspect, ensuring that all activities complied with relevant regulations and minimised impact on the surrounding environment.

Executing the Monbulk Water Pump and Penstock Renewal Project involved overcoming several technical and logistical challenges, including space constraints that made the use of submersible pumps unviable and ensuring the temporary bypass system’s components provided adequate mechanical protection. Adi Harsono’s management approach included cash flow forecasting and reporting, implementing a rigorous change management process, overseeing the design and execution of the bypass system, coordinating site investigation diving activities, and providing detailed input on construction methodologies and technical aspects of the bypass system. One of the key innovations was the introduction of an alternative solution for vibration monitoring equipment, which met the technical requirements and offered significant cost savings and compatibility with existing systems. The design and implementation of a temporary bypass system were crucial for maintaining operations during the 90-day upgrade period, ensuring continuous water supply and compliance with Melbourne Water’s Operational Requirement and Safety Standards.

The successful completion of the Monbulk Water Pump and Penstock Renewal Project on time and within budget stands as a significant achievement in enhancing the water infrastructure of the Monbulk region, underscoring the importance of meticulous planning, coordination, and skilled project management.