PROJECT DETAILS

Nebo Rd WTP – Chlorine Contact Tank Flow Meter Replacement

Project Details

In September 2025, GE Maintenance Solutions (GEMS) successfully completed the Nebo Rd Water Treatment Plant flow meter replacement, a critical upgrade for Mackay Regional Council (MRC)'s main water treatment plant.

The works involved removing the existing 1.2-metre flow meter and installing a new Krohne unit within the chlorine contact tank. Due to the essential nature of this infrastructure, meticulous planning was required to ensure Mackay’s water supply was not interrupted beyond the approved timeframe.


Planning the Approach

Before works commenced, GEMS worked closely with the MRC Treatment Operations team to ensure all reservoirs were full, allowing the plant to be safely taken offline for the duration of the works. The Nebo Rd Water Treatment Plant flow meter replacement required precise planning. As a result, the team trialled pump-downs and confirmed a lifting plan before shutdown.

Key planning steps included:

  • Trialling and confirming a pumping arrangement to drain down the inlet and outlet pipework quickly.
  • Conducting a trial lift of the 15-tonne concrete pit lid using a 55-tonne crane to confirm removal and reinstatement would be achievable.
  • Fabricating and painting new steel spool pieces, internally coated with acid-resistant epoxy to withstand chlorine exposure.
  • Procuring and staging all gaskets, gibaults, flange bolts, and fittings onsite ahead of the shutdown.

This preparation ensured every step could be carried out seamlessly within the strict 6-hour shutdown window.


The Maintenance Works

The flow meter replacement required a coordinated effort across multiple teams and disciplines. The key steps included:

  • Lifting and removing the 15-tonne pit cover with a 55-tonne crane.
  • Isolating and draining the line using dual pumps to save critical time.
  • Removing the existing flow meter and preparing the pipework.
  • Installing and aligning the new Krohne flow meter with fabricated spools.
  • Reinstating all fittings, gaskets, and protective coatings.
  • Lowering and resealing the pit lid on completion.

Throughout the works, GEMS technicians maintained strict confined space entry protocols, ensuring safety was prioritised at all times.


Delivering Results

The project was completed within the allocated 6-hour window, including pumping down, removal, installation, and recommissioning.

Key outcomes included:

  • Reliable installation of a new 1.2-metre Krohne flow meter.
  • Zero unplanned disruption to Mackay’s drinking water supply beyond the planned shutdown.
  • Corrosion-resistant spool sections ensuring long-term asset protection.
  • Safe and efficient project delivery in a challenging confined space environment.

Why This Matters

The Nebo Rd WTP is Mackay’s primary water supply asset. By replacing the aging flow meter with a new Krohne unit, GEMS has helped ensure accurate flow measurement, reliable water dosing, and continued compliance with operational requirements.

In addition, this project demonstrates the importance of careful planning, close collaboration, and precision engineering in maintaining critical infrastructure.

From detailed pre-works planning to hands-on execution, this project reinforces how GEMS provides more than maintenance, we provided a complete solution that keeps Queensland communities supplied with safe, reliable drinking water.

👉 If your facility needs flow meter replacements or treatment plant maintenance, get in touch with the GEMS team today.

Contact us

Get in touch today to discuss your Treatment Plant requirements.

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