The team at Flow Control have significant experience of dealing with water utility companies including Welsh Water and its contract partners. During the last 20 years the team have secured and supplied valve framework to all water utilities in the United Kingdom. The team have been responsible for supplying over £100 million of valves, actuators and flow control equipment including major infrastructure works where our expertise has been instrumental in the successful implementation of new works.

The team has worked closely with Welsh Water supplying valves and penstocks to sites throughout the territory including Prioress Mill, Portis LLechryd, Cog Moors, Pontsticill, Bryn Cowlyd.

The team members are experts in either a valve category or process and have been responsible for changing the way the valve industry interacts with its customers. The emphasis of the business is on partnering with customers to deliver the customer’s vision and assist in achieving regulatory and business targets. Consistently offering independent, impartial advice and selecting the right product or process for a job we offer bespoke solutions to customers requirements. Our research and development activities have seen both improvements to existing products and the introduction of new products.

Our product selection consultancy is available free of charge to customers.

Key to selecting the correct valves is a detailed understanding of the operating specifics of each valve category and how they interact with other products and processes. This has been developed by years of working in the valve industry. We use a combination of sizing programmes and testing to enable valve selection. All employees at Flow Control have over 25 years experience within the field. We employ individuals with actuation experience including ex-rotork employee who spent 18 years at Rotork as a field service engineer and sales engineer.

Our approach is characterised by the supply of valves penstocks and actuators to the Birmingham Resilience Project. The business has currently supplied over £4 million of products to the site.

The water treatment works supplies water to 1 million people in Birmingham. It was imperative that in delivering the project the contractors built a works that would be able to operate for years to come to serve the growing population of Birmingham whilst complying with health & safety, environmental and both Severn Trent and industry leading performance standards. Key to achieving this was the quality and efficacy of products chosen by the contractor.

Severn Trent and its contracting partners, Doosan Enpure, NMC and Barhale needed a valve partner that understood the specific performance requirements, had experience in product selection and performance levels to deliver on the scheme’s targets. The Flow Control Group was identified as having the skills and knowledge across the spectrum of valves, penstocks, actuators and auxiliary equipment to achieve this.

As a specialist valve package supplier Flow Control were able to engage with contractors at design stage to optimise product selection. This led to changes to concept design and enhancements to the performance of the plant. This in turn led to cost savings on initial purchase and to whole life performance costs. In selecting valves and auxiliary equipment we used proprietary sizing software, Inventa design software and experience to select products and to design extension spindles and other auxiliary equipment.

The valves available to contractors are vast but selecting the correct valve for an application involves a detailed understanding of operation characteristics including required operating performance, pressure requirements, flow control characteristics, chemical concentration, treatment performance, pressure and transience. Selecting the correct valve for a requirement required a valve supplier who could assess the correct valve for a particular operation and who had at its disposal the necessary valve sizing, flow control and performance data and programmes necessary to choose the correct valve.

Flow Control have the capabilities to carry out the analysis to select the correct valve. We worked closely with the contractors to design and supply a complete package of valves and actuators  including manual and actuated valves which met the performance criteria specified by Severn Trent. This included ancillary equipment including spindles, support brackets, pedestals and headstocks all designed and manufactured in house.

Valves supplied as part of the package included manually operated and actuated valves and included both valves for isolation and flow control. Valves supplied included, gate valves, non return valves, eccentric plug valves, butterfly valves, pinch valves, ball valves, penstocks, stop logs, knife gate valves, air valves.

Air valves supplied included triple function modified air valve for handling low pressures and piped outlets where proprietary software was used to design and select the correct air valve. This included carrying out scenario testing on a purpose built test rig and the production of specific flow graphs based on information provided by the contractor.

In the South Tower an existing part of the plant we were able in conjunction with the contractor to plan a refit of non standard rising spindle valves and design a plan of works using infrared 3 D modelling camera. The use of modular assembly allowed for ease of installation and reduced health and safety hazards and led to cost savings.

Drawing on our experience we were able to offer a full actuation service including actuator sizing and selection with actuators being fitted, set and tested in house for ease of installation on site, saving time and reducing health and safety issues. This included electric Pneumatic and hydraulic actuators.

Auxiliary equipment required to operate the valves included spindles, couplings, universal joints, guide brackets, machined drive bushes, pedestals and headworks. All of these were designed and manufactured in house.

We employ four design engineers with experience of Autocad Inventa and other design software together with FEA software and actuator sizing programmes.

Our site services team were able to carry out full installation commissioning and testing of products and offer confirmation of performance including telemetry to prove functionality against design conclusions.

All valves and auxiliary equipment supplied are manufactured under a quality system to ISO9001 2015, have a design life of 25 years minimum and a standard warranty of 5 years which can be extended on negotiation. The quality system is administered by a quality manager who reports directly to the General Manager. Quality records for every job are maintained and are available for inspection. Full traceability of all products is available and products capable of being identified by tag numbers and cast identification marks.

We aim to be able to provide a holistic approach to customers that aligns with their individual mission objectives and business outcomes by designing and installing the greatest range of valves and penstocks.

Flow control achieve this by providing unparalleled levels of service in design, consultancy and product selection as well as quality products backed by industry leading after sales service. Where others provide product, we aim to provide engineered solutions to customer’s bespoke applications.

In delivering our vision we will be guided by five key principles:

• SERVICE - Always delivering a positive customer experience by providing a high-quality service.
• COMMITMENT - Always proud to deliver. Our people and partners share and support our vision and are proud to deliver our product and service commitment.
• SUSTAINABLE - We aim to do the right thing for our customers through responsible management we will be a sustainable business.
• LEADERSHIP - We aim to act with integrity, and focus on understanding and delivering solutions that are right for customers.
• PARTNERSHIP - We will use the skills of our people and the potential of our assets to grow value for our business and our customers.

Our approach was demonstrated by supplies to Davyhulme WwTW where we have supplied and continue to supply products for the last 8 years including bespoke product designed by our team of engineers.

Davyhulme WwTW has been in operation since 1894 and serves a population equivalent of 1.2 million for sewage treatment in and around the city of Manchester.

To cope with increase in population a multimillion-pound investment programme was announced. The modernisation programme involved the construction of six circular primary settlement tanks (PST) and a new activated sludge plant (ASP) with ten circular final settlement tanks (FST). As an ancillary works a thermal hydrolysis plant (THP) was commissioned.

The works will, in addition to coping with increased demand for sewage treatment, lead to significant environmental benefits for the site, improving the outflow, and subsequently the quality, of water entering the Manchester Ship Canal and reducing the carbon footprint.

As a by-product of the treatment works Davyhulme is set to become a valuable source of renewable energy. The benefits of the upgrade include the generation of up to 10 megawatts of electricity, 24 hours per day, from biogas
Flow Control and its team of engineers have been central to the supply of equipment packages to Davyhulme including gate valves, non-return valves, air valves, knife gate valves, penstocks, concentric plug valves. Included in the supply was the complete valve package on the THP works in association with Cambi.

The nature of the treatment works at Davyhulme means the valves supplied are multi-functional including isolation, flow control and valves to regulate discharge during the process. Flow Control has significant experience in the design of treatment plants, the selection of the correct valve for a specific function and has the necessary understanding of the impact of a valve chosen in one part of the works will have on the operation of other parts.

Engineers at Flow Control can demonstrate through time served experience a detailed understanding of flow control requirements including pressure management, valve sizing and media requirements. Selecting the correct valve and plant design can lead to improvements in efficiency and reductions in operation costs. Being independent Flow Control can advise on the correct solution and has the knowledge and experience to deliver this time and again. It is for this reason that the team of engineers at Flow Control is a valued partner to many water utilities and contractors in the UK utility market and overseas.

Flow Control is a package valve supplier identifying the correct valve for an application. The business specialises in project supply where multi valve applications are needed. Valves engineers employed by the business can identify the correct valve for an application and using proprietary software can advise on selection and valve sizing. Its in house actuation team can size, select, fit test and install actuated valves and carry out retrofit and maintenance services.

The THP works at Davyhulme involved the supply of specialist manual and actuated valves including, knife gate valves, bellow sealed globe valves, bursting discs pressure relief valves ball valves v port control valves spring loaded wafer check valves. Due to the nature of the plant Cambi required a special knife gate valve to be developed and approached Flow Control its long-term valve partner to assist in the valve development.

As part of its product development and innovation initiative the team at Flow Control held detailed discussions with Cambi engineers to ascertain the performance requirements of the new style valve. Utilising its experience and Inventa design software Flow Control produced sample designs including prototype valves. This involved producing 3D models, new patterns and test equipment. All manufacture, including castings was carried out in the UK with machining coating and assembly being carried out by the Flow Control Group.

Flow Control employ four Cad engineers who between them have over 100 years’ experience of valve design. They are all experienced in Autocad 3D design with the business standardising design using Inventa software. This is capable of interfacing with our client’s design software and as part of our contract commitments we will allow designs to be incorporated into client’s plant design where necessary. We will also pass on knowledge to clients. Design and development are carried out in accordance with the attached Design and Development Procedure which forms part of our Integrated Management System.

The new valve was required to operate under high pressure high temperature conditions with a requirement to develop new seal technology and seating system. The valve also needed to be capable of being maintained on site with a range of spare parts available due to the vigorous operating conditions.

Flow Control were able to develop the valve which was tested under live conditions at another Cambi site and then incorporated into the THP at Davyhulme. Cambi relied heavily on the design expertise at Flow Control in developing the valve. This reliance extends to the supply of the complete valve package where Cambi recognise the expertise and flow understanding available within the Flow Control business. This recently resulted in Flow Control being appointed as the sole valve supplier for Cambi THP plants worldwide and will see in excess of £2 million valves and actuators be supplied yearly including a full range of spare parts for maintenance.

In relation to general valves on Davyhulme we have supplied manual and actuated valves including:

• Gate valves both resilient seated and metal seated in sizes up to 1200mm and pressures up to 25 bar were supplied for both manual and actuated operation with and without gear box and bypass. The supply included valves supplied with slippers and guides for horizontal installation, valves with upgraded coatings and fixings for buried duty application.
• Butterfly valves up to 2200mm diameter operating at pressures to 16 bar including wafer type, fully lugged and tapped, double flanged, concentric and double concentric types capable of being operated both below and above ground. Manually operated and electrically operated. Various disc materials supplied dependent of media.
  Non return valves supplied included Recoil check valves including non-slam type Swing, Nozzle, Dueo, Ball up to 900mm.
• Air valves supplied included triple function modified air valve for handling low pressures and piped outlets where proprietary software was used to design and select the correct air valve. This included carrying out scenario testing on a purpose-built test rig and the production of specific flow graphs based on information provided by the contractor.
• Ball valves supplied included for isolation and diversion offering easy and fast operation sizes ½” to 300mm in various materials including brass, stainless steel, bronze, steel and plastic with various connections to BSP, NPT, DIN and ANSI standards. Specialist ball valves also available.
• Concentric plug valves as an alternative to a butterfly valve to achieve greater control of flow achieving a near linear solution. In recommending the valve we were able to demonstrate using valve sizing software the enhanced flow characteristics. Pinch Valves pneumatically operated to achieve pressure relief thereby protecting the plant from high pressures.
• Pinch Valves pneumatically operated to achieve pressure relief thereby protecting the plant from high pressures.

Valves supplied to the site have a design life of 25 years and carry a 5-year warranty. All valves manufactured and supplied including valves manufactured by third party partners are subject to Flow Control’s quality management system. This forms part of the businesses Integrated Management System bringing together quality, environmental and health & safety under a common management system to ensure compliance and drive industry leading standards.

The business is certified to ISO 9001 2015. The system sets out measures to drive quality through all aspects of the business from design, manufacture supply and installation. The system is administered by a quality manager who reports directly to the General Manager. Quality is central to every part of our operation. Procedures are set out in a quality manual and set out procedures for activities including design, metallurgy testing, castings, machine tolerances, coating specifications, testing, assembly and installation. To support quality procedures works method statements are used. A skills matrix is used to identify skills required of all personnel and a training programme including refresher training is in place.

Flow Control Company believes that continuous improvement of products by itself and its suppliers is achieved by innovation which in turn leads to initial cost savings and whole life cost savings. We are constantly striving to improve our products and learn from our experiences. Advances in technology have allowed us to push the boundaries of valve design.

The company philosophy is Innovation through proven design, backed up by 40 years of quality craftsmanship. Its ethos is to utilise the right materials and know-how, offering products and services, which add value to clients, by providing the best means of handling and controlling challenging product media. Conditions encountered and resisted are typically high temperature and pressures, abrasion, corrosion and erosion.

We believe innovation operates on two levels, product innovation and an innovation of approach.

While product innovation sees improvements to individual products of application, we consider innovation of approach will lead to greater savings and efficiencies within the water and wastewater market over the AMP7 period and beyond.

The breadth of experience and technical capability within the group allows us to take a holistic view of the market. With this comes a detailed knowledge not only of the individual components of a network but of the relationship between each element.

This approach has led to major improvements in some of the products we are offering as part of this tender. This is particularly the case in respect of penstocks air valves gate valves and control valves where innovative features designed by our engineers have led to the development of products which will offer enhanced features.

Our engineering team has also by utilising CAD design and FEA analysis supported by photo elastic stress analysis being able to optimise the design of penstocks, knife gate valves and air valves to provide a maximum strength cost ratio giving improved performance, value and whole life cost savings.

In delivering the Davyhulme project like any other project we offer customers one point of contact throughout a project ie. same person coordinates estimating, valve selection, quotation, engineering, contact management and final documentation.

We employ an ex-Rotork sales and field engineer who heads up our actuation department and site services division.

We offer In-house design/manufacture of actuator mounting kits, extension spindles and pedestals. This ensures valve actuation packages work when they arrive at site with no need to fit and set as this will already have been done