DAFF Asset Renewal Across Two Victorian Regional Plants
South Gippsland Water engaged FILTEC as principal contractor to deliver targeted DAFF (Dissolved Air Flotation) upgrades at the Devon North and Lance Creek water treatment plants. Both facilities required asset renewal works to improve reliability, restore process performance and extend operational life.
At Devon North, the existing saturator vessel had reached end of life due to corrosion. At Lance Creek, air dispersion and polymer batching systems required renewal to improve flotation efficiency and sludge handling performance.
FILTEC delivered coordinated design and construction upgrades across both sites within an integrated programme.
Treatment Continuity During Critical Asset Replacement
Both plants operate as key regional drinking water assets, requiring carefully sequenced works to minimise disruption. The upgrades required:
Replacement of corroded DAFF saturator (Devon North)
Air dispersion manifold upgrade (Lance Creek)
Polymer batching system renewal
New instrumentation and PLC controls into existing SCADA
Works within confined and live operational environments
The project demanded precise planning, safe shutdown coordination and controlled recommissioning to maintain treatment continuity.
Saturator Replacement and Controls Upgrade – Devon North
FILTEC supplied and installed a new stainless-steel DAFF saturator vessel at the 4 MLD Devon North plant. The works included removal of the existing vessel, instrument reinstatement, electrical reconnection, hydrotesting and coordinated plant restart.
A new differential pressure transmitter was installed and integrated into the plant control system, improving monitoring of saturator performance. Full functional testing and commissioning ensured stable restart of the flotation process and restored system reliability.
Manifold, Air and Polymer System Renewal – Lance Creek
At the 20 MLD Lance Creek facility, FILTEC fabricated and installed three new 316 stainless steel air dispersion manifolds, complete with dispersion valves and associated pipework modifications. Works were undertaken in confined spaces under strict isolation and safety controls, including compressed air system shutdown and reinstatement.
The existing polymer batching unit was replaced with a Prominent Tomal system, including a new service water connection and stand-alone PLC integrated into the plant SCADA network. Dry and wet functional testing validated performance prior to commissioning.
Integrated Delivery and Commissioning
FILTEC delivered mechanical installation, electrical works, instrumentation integration and control system modifications across both sites under a coordinated programme, including:
Vessel removal and replacement
Manifold fabrication and installation
Polymer system integration
SCADA and PLC updates
Hydrotesting and functional verification
Careful sequencing of shutdowns and staged commissioning enabled safe reinstatement of DAFF operations while reducing risk to ongoing water supply.
Improved DAFF Reliability and Operational Resilience
The completed upgrades have strengthened operational reliability across both treatment plants. South Gippsland Water now benefits from:
New stainless-steel saturator infrastructure at Devon North
Improved air dispersion efficiency at Lance Creek
Modern polymer batching and automation systems
Enhanced monitoring through SCADA integration
Extended asset life and reduced maintenance exposure
The two-site DAFF upgrade program improves maintainability, supports consistent flotation performance and enhances the long-term resilience of regional drinking water infrastructure in Victoria.
