Nyrstar Port Pirie Transformation - Sea Water Pump Station

As part of Nyrstar’s Port Pirie Transformation Project, AEP Elical undertook the detailed design for a 3.3 MW Sea Water Cooling Pump Station, including the Sea Water Return Line and underwater discharge diffuser. The pump station is based around three 1.1 MW vertical turbine pumps located in a concrete wet well. The intake into the well is through three passive screens, each of which can be cleaned by air burst backflushing. Following its path through the plant process systems, the cooling water is then discharged back into the Port Pirie River through an underwater diffuser recessed into the riverbed.

With the initial pump duty and the overall site specifications being provided by others, AEP Elical’s scope was:

  • Preparation of a functional layout for the pump station including sizing of the pump well. Significant changes were made to the original concept design to decrease construction costs.

  • Assistance with the selection of the sea water cooling pumps.

  • Undertaking detailed design for the plant piping including AutoPIPE modelling of the main pipeline. Pipe materials were selected to decrease cost and provide adequate corrosion resistance where required.

  • Selection of valves.

  • Design of the earthworks as well as concrete and steel structures including temporary construction earthworks and coffer dams.

  • Specification and assistance with the procurement of the intake screens and intake isolation penstocks.

  • Detailed design of the discharge diffuser for return of the cooling water back into the Port Pirie River.

  • Specification and assistance with the selection of instrumentation.

  • Electrical interface design.

  • Input into HAZOP, Design Reviews, Constructability Reviews, and Access and Maintenance Reviews.

  • 3D drafting, allowing the pump station model to be imported into the overall site model and the model to be available to the construction contractor.

The result was a cost-efficient, fully integrated system supporting the smelter’s cooling needs while ensuring environmental compliance and ease of construction.