UV Disinfection Upgrade for Non-Potable Reuse
Coliban Water required replacement of the aging UV disinfection system at the Castlemaine Water Reclamation Plant to maintain non-potable reuse performance and regulatory compliance. The plant services approximately 15,500 people across Castlemaine and surrounding communities.
FILTEC delivered a new TrojanUV3000Plus system within the constraints of an operating facility, maintaining continuous treatment throughout construction. The project included structural modifications, custom civil works and integrated maintenance access infrastructure to support long-term operational continuity and safe plant maintenance.
Replacing Critical UV Infrastructure Within an Operating Facility
The existing UV system required replacement while maintaining uninterrupted plant operations and ongoing non-potable reuse capability. The constrained layout of the aging facility created several integration challenges, including:
Continuous disinfection during construction
Limited space for new UV infrastructure
Integration with existing pipework
Restricted access around live assets
Safe maintenance access requirements
The upgrade needed to improve operational performance while minimising disruption to existing treatment operations.
Integrated UV Retrofit and Structural Modifications
FILTEC supplied and installed a TrojanUV3000Plus unit alongside the existing UV system to maintain continuous disinfection throughout the upgrade works. Space constraints within the existing building required partial demolition of the shed structure, wall reinstatement and construction of a new external mounting platform.
The upgraded UV system improves disinfection performance for non-potable reuse while integrating with existing plant infrastructure and operational requirements.
Custom Structural and Civil Integration
FILTEC designed and constructed a custom concrete support structure to align the new UV unit with existing connection points. Restricted access and an existing discharge pipe beneath the outlet tank increased installation complexity.
Onsite detailing ensured accurate integration with existing infrastructure while minimising disruption during construction.
Safe Maintenance Access and Long-Term Support
FILTEC installed a custom access platform with a monorail gantry system for UV lamp rack removal. The configuration reduced platform footprint requirements while improving lifting safety and maintenance access.
Ongoing preventative maintenance support includes UV lamp, wiper and seal replacement services to support continued disinfection performance and operational continuity.
Improved Operational Continuity for Reuse Applications
The upgraded UV disinfection system supports non-potable reuse and compliance at the Castlemaine Water Reclamation Plant. The project successfully delivered:
Continuous operation during installation
Retrofit delivery within a constrained facility
Improved UV maintenance access
Sustained non-potable reuse performance
Ongoing preventative maintenance support
The upgrade strengthens the resilience and maintainability of the reuse infrastructure supporting Castlemaine and surrounding communities.
