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Our Projects

Malabar WWTP: Digester Heating System Audit

As part of the Malabar Process and Reliability Renewals (PARR) project, Sydney Water has included an upgrade of the digester heating system. The 4Malabar alliance, consisting of John Holland, GHD and UGL, approached Stark Engineering Consulting for a thorough review of the system. Due to our intimate knowledge of the associated cogeneration plant, we were able to provide the alliance with a comprehensive audit of the existing system and recommendations for the planned upgrade.


Our scope of work included:

  • Detailed desktop review of existing information

  • Options and recommendations for the upgrade under the PARR project

  • Heating system modelling for additional heating capacity

  • Heating system modelling and comparison with site measurements for validation

  • A targeted measuring campaign for the verification of critical component's actual performance

Prospect Mini Hydro: Remediation Works

Sydney Water Corporation (Sydney Water) is the largest water utility in NSW, providing water treatment and wastewater services to Sydney and outer suburbs and the Illawarra. In 2007, Sydney Water undertook a renewable energy program that included installing a 3.7 MW hydro power station at the outlet works of the Warragamba pipeline, before the Water Filtration Plant at Prospect. The hydro generator, as installed was treated as a flow delivery device by Sydney Water and generates whenever flow is available through the pipeline.


The generator, when P.E.T. and Stark Engineering Consulting were engaged, had only 5,400 hours of runtime in the four years since original commissioning. Several failures had occurred and confidence had been lost in its ability to reliably deliver flow and generate power.

Stark's Role
As part of the REG O&M contract (see here), Sydney Water engaged P.E.T. and Stark Engineering Consulting to investigate the plant's condition and propose a remediation strategy. Stark EC provided technical engineering, drafting and project management services for the both the initial investigation and the execution of the project. P.E.T. provided the necessary fabrication and installation works, as well as expert advise on bearing technology.


Responsibilities for the Prospect remediation program included:

  • Project scoping, budgeting and management. Stark EC adopted a multi-criteria assessment approach to identify and evaluate several potential options for project delivery

  • Documentation: Stark EC prepared specifications and RFQ documentation for consulting, technical and fabrication of new parts and services.

  • Risk workshop and option analysis

  • Failure workshop, which brought specialist hydro consultants into the room after a desktop study to determine the root causes of previous failures

  • Re-design of the mechanical seal flushing arrangement

  • Re-design of the runner end bearing arrangement

  • PLC modifications and control modification

  • Testing and commissioning

The re-engineered non-drive bearing assembly is considered a fit-for-purpose solution. Current runtime has already exceeded the lifetime of the previous bearing.


As a result of the remediation works, the hydro-turbine has been proven reliable and is contributing significantly towards Sydney Water's renewable energy target. P.E.T., together with Stark EC have been able to restore confidence in the plant by the asset owners.

Kangaroo Valley Sewerage Scheme

Here at Stark Engineering Consulting we're excited to be providing commissioning support to AJ Lucas for the Kangaroo Valley Membrane Bio-Reactor waste water plant. The MBR plant is part of a new sewerage scheme, which is a major investment by Shoalhaven City Council. It will provide a pressure sewer system to collect and treat wastewater from homes and businesses in the developed areas of Kangaroo Valley and part of Barrengarry. More information can be found here.


Stark Engineering is sub-consulting to AJ Lucas' water group, reporting to the Lead Process Engineer responsible for the commissioning (Sri Nayak).  As senior process engineer, Peter is responsible for all aspects of commissioning on behalf of AJ Lucas. Leaning on his extensive commissioning experience with tertiary & water treatment plants, Peter provides trouble shooting for mechanical and electrical failure, fault finding on PLC issues and process optimisation. Peter is also responsible for the liaison and coordination with other contractors and suppliers for the completion of the commissioning.   

REG O&M contract

Sydney Water REG Portfolio: Operation & Maintenance

Sydney Water awards a contract to P.E.T. for the operation and maintenance services of their renewable energy portfolio: 11 gas engines and 3 hydro-turbines. The contract is for a period of 5 years and includes day-to-day operation, routine and breakdown maintenance and major overhauls and project work.


At Stark Engineering Consulting we're proud about our contribution to securing this contract. The extensive knowledge in our team with regards to the design and operation of these plants, combined with industry best-practice in asset maintenance resulted in a contract-winning offer. Already delivering many design and construction projects for Sydney Water, P.E.T. is now also strategically positioned with Sydney Water in the delivery of maintenance services. Additionally, this contract helps P.E.T. to diversify and enter the growing market of renewable energy.


For the execution of the contract, P.E.T. will set up a new team of expert technicians and admin support. Embedded within the existing company structure, P.E.T. aims to retain existing expertise whilst ensuring an effective organisational structure. As part of this execution strategy, Stark Engineering Consulting will continue to provide P.E.T engineering and management support.


​More information can be found here and here.

Design & Commissioning: 2 Cogeneration Plants

Sydney Water awards a contract to P.E.T. for the construction of two new cogneration engines. The project upgraded the existing cogeneration unit at Cronulla WWTP from 475kW to 835kW and installed an additional 1MW cogeneration unit at North Head WWTP. The project was aligned with Sydney Water’s Energy and Greenhouse Gas Mitigation Strategy to provide cost effective reduction of greenhouse gas emissions by on-site generation of renewable energy.


At Stark Engineering Consulting we're proud about our contribution to the completion of the project, including:

  • Detailed process, mechanical and controls design for the biogas conditioning plant upgrade

  • Detailed process, mechanical and controls design for the heat recovery

  • Detailed design of the overall control and integration with the anaerobic digesters

  • Commissioning of the above

  • Contract management for the two GE Jenbacher engine packages, provided by Clarke Energy Australia 

​More information can be found on the website of OzWater 2015, where a public presentation of the project will be provided by Sydney Water.

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