Mackay Regional Council: Armstrong Beach Water Pump Station Renewal
The Challenge
Mackay Regional Council needed to upgrade the ageing electrical and control systems at Armstrong Beach Water Pump Station while maintaining water supply with zero downtime. The project required design, installation, and commissioning of a new dual-pump skid, telemetry system, and SCADA infrastructure — all within a strict 6-hour single-day service window to avoid multiday outages.
Our Approach
Deftec delivered a complete design-and-construct solution centred on upgrading the station’s RTU from an outdated SCADAPack 357E to a modern SCADAPack 474 platform, paired with a new Red Lion HMI and expanded I/O for integrated flow metering and pump status monitoring. We designed and installed a new dual-pump skid with 400V power distribution, integrated 24VDC instrument cabling with discrete signal separation via PVC conduit shielding, and comprehensive cable tray routing to cleanly separate power, control, and data circuits. The work included detailed electrical schematics, cable schedules, gland terminations, and RPEQ-certified as-built documentation. All equipment was pre-staged and tested to ensure the critical installation and commissioning was completed within Mackay Regional Council’s tight operational window.
The Outcome
The station was successfully commissioned with all new telemetry signals — including suction and discharge flow metering, pump status, chlorine dosing control, and tank level monitoring — seamlessly integrated into Council’s existing GeoSCADA environment. The upgrade provided Armstrong Beach WPS with modern, reliable remote monitoring and control capability while maintaining uninterrupted water supply to the community. Council’s pre-qualified SCADA support provider handled final RTU and HMI programming, supported by Deftec’s comprehensive technical documentation and on-site assistance.
Technologies and Capabilities
- SCADAPack RTU migration and configuration (357E to 474 platform)
- HMI design and programming (Red Lion CR1000 touchscreen)
- PLC I/O mapping and signal conditioning (digital inputs, discrete outputs, analogue monitoring)
- Modbus/TCP industrial data communications
- 400VAC three-phase power distribution and switchboard design
- 24VDC instrumentation and control wiring (shielded, segregated)
- Cable tray system design and installation (LT3 ladder tray, IP68 glands)
- Flow meter signal integration (dual pulse inputs with totaliser capability)
- Electrical asset documentation (schematics, cable schedules, as-built drawings)
- RPEQ certification and compliance with Australian electrical standards
- Commissioning and live-site testing protocols