Supply Chain - Security Solutions -

In response to stricter Environment Agency permits for phosphorus removal, the water industry has quadrupled the number of phosphorus reduction schemes since AMP5. This surge in efforts is widely regarded as one of the most significant challenges the industry has ever faced. The Water Industry National Environment Programme (WINEP) comprises a series of mandatory actions that water companies in England must implement. These actions aim to enhance the environment and ensure compliance with relevant environmental legislation. The consent date for these measures is 22 December 2024. Glanua Group was appointed to deliver four P removal schemes to help Yorkshire Water meet the requirements at Thorne, Aldwarke, Lundwood and Castleford STWs. Supply chain selection

Due to the scheduling and repetition of work being undertaken within the four-project portfolio, there was a strategic approach to the appointment of specific sub-contractors to maximise programme benefits and acceleration across the projects.

The primary area that was focused upon was the supply of chemical dosing kiosks with a DfMA approach and the mechanical and electrical installation services.

Thorne STW, Doncaster: Contract value: circa £1.7m

The Thorne STW scheme has a quality driver to reduce phosphorus concentrations in the final effluent to 2.0 mg/l without exceeding iron concentrations of 4 mg/l.

[caption id="attachment_14967" align="alignnone" width="1200"] 3D render of Thorne STW - Courtesy of Glanua Group[/caption] The new works has been carried out in the north-east corner of the site, adjacent to the sludge balancing tank. An existing concrete spur off the access road will be broken out and replaced by a new RC concrete tanker delivery bay with ferric dosing kiosk slab adjacent. A standard 7.5m3 ferric sulphate storage tank and dosing kiosk will be delivered and installed in a single DfMA off-site fabricated SR4 rated kiosk (due to site security classification).

The new ferric sulphate dosing unit will run automatically, and the operator will only be required to ensure that there is a constant supply of chemicals.

A new liquid polymer plant will be installed to replace the existing powder polymer system which feeds the existing gravity belt thickener. To facilitate the replacement a temporary containerised rig was installed and commissioned prior to the removal of the existing plant which removed the existing H&S risk associated with powdered polymer.

The scope also included a full clean up of the existing polymer plant to help facilitate the safe installation and construction works.

Thorne STW: Supply chain - key participants Principal designer & contractor: Glanua Group Outline design: Stantec UK Civils design: AtkinsRéalis Polymer dosing: Richard Alan Engineering Ferric dosing kiosk: NPS Engineering Group Systems integrators: Saftronics Ltd Mechanical installation: Staptina Limited Electrical installation: PLR Building Services Ltd Civil works: M Cooper Civils Safety showers: Aqua Safety Showers International Ltd Aldwarke STW, Rotherham: Contract value: circa £2.5m

The Aldwarke STW P scheme project has a quality driver to reduce phosphorus concentrations in the final effluent to 0.7 mg/l without exceeding iron concentrations of 4 mg/l (2.5 mg/l Al).

[caption id="attachment_14970" align="alignnone" width="1200"] Aldwarke STW ferric kiosk delivery and installation - Courtesy of Glanua Group[/caption]

The proposed solution is to chemically remove the phosphorus with a primary and secondary ferric sulphate dose upstream of the primary settlement tanks and upstream of FSTs 1-4 respectively.

A new standard ferric dosing kiosk was provided with two dosing pumps and two 10m3 storage tanks complete with a remote fill point panel and remote wash system installed as a single DfMA off-site fabricated kiosk. This feeds two duty/standby POAs at the inlet works facilitated by a newly installed air mixing system as well as two duty/standby POAs at the RAS distribution chamber.

The project also included the decommissioning, removal and installation of like for like PST desludge ram pumps and pipework. During the removal of the existing ram pumps we had to run both the existing and the new pumpsets in order to maintain the resilience within the process. This was enabled by sequencing the pumps and pipework and inserting temporary pipework in order to run both systems.

The FST A & B scum removal boxes were also replaced as well as isolation penstock installation. The existing scum pump was replaced and new MLSS probes were installed on the ASP outlet channels.

Aldwarke STW: Supply chain - key participants Principal designer & contractor: Glanua Group Outline design: Stantec UK Civils design: Eastwood Consulting Engineers Ferric dosing kiosk: NPS Engineering Group Systems integrators: Lintott Control Systems Ltd Mechanical installation: Alpha Plus Ltd Electrical installation: PLR Building Services Ltd Civil works: Rack Construction Safety showers: Aqua Safety Showers International Ltd Lundwood STW, Barnsley: Contract Value: circa £2m

At Lundwood STW the quality driver is to reduce phosphorus concentrations in the final effluent to 2.0 mg/l without exceeding iron concentrations of 4.0 mg/l.

The solution was to convert the existing secondary treatment activated sludge plant (ASP) to a RAS anoxic configuration. This process will change the existing ASP into an enhanced biological phosphorus removal (EBPR) plant. To limit recycling of phosphorus from the dewatering process back into the EBPR plant, the project will provide ferric sulphate for P removal and caustic soda dosing to the settled sewage to mitigate against the impact of ferric sulphate dosing on the final effluent alkalinity.

[caption id="attachment_14969" align="alignnone" width="1200"] Lundwood STW sodium hydroxide kiosk delivery - Courtesy of Glanua Group[/caption]

Standard 7.5m3 ferric sulphate and sodium hydroxide (caustic) storage tanks and dosing kiosks were to be delivered and installed in a single DfMA off-site fabricated SR4 rated kiosk (due to site security classification). Both chemicals are pumped to their designated POAs and dosed into the PST distribution channel via a bespoke designed V-notch brackets positioned above the top water level of the channel, with the mixing in the channel facilitated by air-mixing provided by newly installed blowers.

The project benefited from carbon savings and construction efficiencies by reviewing the original proposed site location and relocating it to an area which eliminated the demolition of existing assets.

Lundwood STW: Supply chain - key participants Principal designer & contractor: Glanua Group Outline design: Stantec UK Civils design: Eastwood Consulting Engineers Ferric dosing kiosk: NPS Engineering Group Sodium hydroxide dosing kiosk: NPS Engineering Group Systems integrators: Lintott Control Systems Ltd Mechanical installation: Alpha Plus Ltd Electrical installation: PLR Building Services Ltd Civil works: Indepth Civil Engineering Safety showers: Aqua Safety Showers International Ltd Castleford STW: Contract value: circa £900k

The driver at Castleford is to reduce phosphorous concentrations in the final effluent to 2.0 mg/l without exceeding iron concentrations of 4.0 mg/l.

The proposed solution is to chemically remove the phosphorus by dosing ferric sulphate dose upstream of the final settlement tanks.

The primary ferric sulphate dosing system includes constructing foundations and support structures, installing a 7.5m3 storage tank with duty/standby dosing pumps, and integrating with the existing SCADA and telemetry systems. Civil works required modifications to access pathways and safety installations. Electrical installation works ensured the new plant was fully integrated into the existing works control systems.

The POAs dosed into a splitter box upstream of the final settlement tanks which ensured even distribution of ferric sulphate within the FST distribution chamber.

Castleford STW: Supply chain - key participants Principal designer & contractor: Glanua Group Outline design: Stantec UK Civils design: Eastwood Consulting Engineers Ferric dosing kiosk: NPS Engineering Group Systems integrators: Lintott Control Systems Ltd Mechanical installation: Alpha Plus Ltd Electrical installation: PLR Building Services Ltd Civil works: Indepth Civil Engineering Safety showers: Aqua Safety Showers International Ltd [caption id="attachment_14972" align="alignnone" width="1200"] Google Maps images of the sites: (top left) Thorne STW, (top right) Aldwarke STW, (bottom left) Lundwood STW, and (bottom right) Castleford STW[/caption] Design

In order to best meet the needs of the four sites, the design team needed to develop the most efficient and effective solutions for each individual site and application. A collaborative multidisciplinary approach was taken to produce each solution whilst looking for the efficiencies in the standard elements of the portfolio.

The team engaged with Yorkshire Water in weekly collaborative planning meetings to review design; technical challenges and construction programme together with reviewing project Risk & Value (R&V). By adopting this collaborative approach, we achieved design and delivery consistency while utilising standard solutions delivered by a design team comprising of civil, mechanical, electrical, and process engineers.

Construction progress

At the time of writing (July 2024) the projects are progressing well:

Thorne STW: As the first project in the portfolio and therefore the most advanced, Thorne STW has progressed through to commissioning and the Glanua Group team are preparing to bring the plant online.

Aldwarke STW: Significant progress has been made with the completion of the civil works and installation of the ferric dosing kiosk. The delivery team have now moved on to completing the mechanical and electrical installation. This has included the potable water connections, installation of the secondary dosing lines to kiosk dosing rigs. The team has also installed three VSDs to provide a more flexible control of the replaced ram pumps and the blowers have been installed to facilitate air mixing at the point of application.

[caption id="attachment_14971" align="alignnone" width="1200"] Aldwarke STW ferric sulphate dosing installation - Courtesy of Glanua Group[/caption]

Lundwood STW: The civil works are complete and kiosks have been installed on site. We we have also progressed with the mechanical and electrical installation works including the installation of the point of application units as well as air mixing pipework. The electrical installation has progressed and cables are being pulled to allow for the second phase of installation prior to commencement of commissioning.

Castleford STW: The civil works are progressing in line with the programme and this includes the demolition of the roadway prior to piling and kiosk base construction, as well as the integration of the drainage and commencement of roadway reinstatement to form the chemical delivery bunded area.

Digital delivery

The primary Common Data Environment (CDE) and information delivery platform used programme is Autodesk’s BIM360 software. Utilising this, Glanua Group has been able to control the flow and dispersal of information throughout the project and delivery teams, enabling the information management workflow process and review to align with the ISO 9001 Quality Management Process.

The information management platform allows us to control how and when the various projects teams see and receive information ensuring the right information is delivered in the most efficient and effective way. This collaborative approach has ensured the right information is received at the right time.

[caption id="attachment_14977" align="alignnone" width="1200"] 3D renders (left) of Aldwarke STW, (top right) Castleford STW and (botton right) Lundwood STW - Courtesy of Glanua Group[/caption]

Multiple digital tools were utilised to facilitate the safe design and construction process, this includes the Autodesk Revit suite for the civil structures and all mechanical and electrical equipment which was all modelled in 3D with subsequent sheets produced to facilitate a review and approval process as well as provide construction coordination, assessment, and as-built markups where required. Glanua Group utilised reality capture technology to establish baseline data and monitor progress against this.

Through the asset function of BIM360 Glanua Group has been able to replicate the client’s asset data requirements to collate data prior to submission on to their asset management database.

Within this function the procurement and construction/installation status could be tracked whilst assigning supplier and design information in preparation for the O&M and H&S file information.

Summary

Whilst significant progress has been made of all four projects, there is a number of key elements still need completing, a lot of work has been undertaken to help meet the project’s completion dates including completion of civil works, mechanical and electrical installation and wet and dry commissioning.

The Phosphorus Removal Enhancement Programme (PREP) Batch is a group of projects within United Utilities. These projects provide improvements delivering the Environment Agency (EA) Water Industry National Environmental programme (WINEP) outputs for a future population growth based on a 2035 design horizon. With a focus on ensuring the lowest ‘whole life cost’ solution, the team recognized the opportunity to employ a phased approach along with repeatable template solutions. They have both developed solutions within the batch and drawn on solutions from the wider programme of work to meet the lowest whole life cost. Treatment works details The PREP Batch consists of improvement works to meet tightened final effluent total phosphorus permits at five existing wastewater treatment works (Bury, Worsley, Rochdale, Tyldesley and Chorley WwTWs) situated in the north Manchester area; with a joint population equivalent of 504,410. The £15m programme of work is being delivered by United Utilities’ Construction Delivery Partner (CDP) Framework Advance-plus, a joint venture between MWH Treatment, J Murphy & Sons and Stantec UK. The contract was awarded in January 2020 with construction commencing in January 2021. [caption id="" align="alignnone" width="1200"] Tyldesley WwTW ferric dosing unit installation - Courtesy of Advance-plus[/caption] Worsley WwTW: FtFT 12,010m3/d: Total P permit: 0.5 mg/l Treatment is via settlement and activated sludge process, after secondary settlement the treated wastewater is pumped to a BAFF plant and discharged to Astley Brook, which is a tributary of the River Glaze. The project scope includes new primary ferric dosing equipment, refurbishment/replacement of existing ferric dosing equipment for secondary dosing, additional sludge storage and mixing facilities, provision of caustic dosing for alkalinity correction, provision of on-site storm detention tank and associated pumping station and asset renewal of existing primary settlement tank de-sludge pumps. Anticipated completion is 1 March 2022. Bury WwTW: FtFT 203,904m3/d: Total P permit: 0.4 mg/l Treatment is via settlement and activated sludge process, after secondary settlement the treated wastewater is pumped to a BAFF and discharged to the River Irwell. The project scope is for the provision of new primary and secondary ferric dosing equipment, and replacement of existing rectangular primary tank scraper bridges and rail systems. Anticipated completion is 30 March 2022 for the chemical dosing plant, and 1 August 2022 for the replacement primary settlement tank bridges. Rochdale WwTW: FtFT 116,986m3/d: Total P permit: 0.4 mg/l The works is a large conventional activated sludge plant treating domestic and commercial flows. It includes storm overflow and settlement, screening and grit removal, primary settlement followed by ASP incorporating conventional final settlement tanks, there is no dedicated tertiary treatment. The project scope is for the provision of new primary and secondary ferric dosing equipment. Anticipated completion is 17 September 2021. [caption id="" align="alignnone" width="1200"] Tyldesley WwTW ferric dosing unit installation - Courtesy of Advance-plus[/caption] Tyldesley WwTW: FtFT 16,243m3/d: Total P permit: 0.8 mg/l Serving the metropolitan area of Wigan, treatment is via settlement and biological filters, after secondary settlement the treated wastewater is pumped to a NTF plant for ammonia removal, then to a COUF plant and discharged to the river. The scope of works is for new primary ferric dosing equipment, additional sludge storage and mixing facilities, provision of caustic dosing for alkalinity correction and new FtFT flow control. The anticipated completion date is 2 February 2022. Chorley WwTW: FtFT 80,006m3/d: Total P permit: 0.4 mg/l The works is a large conventional activated sludge plant treating domestic and commercial flows. The works includes storm overflow and settlement, screening and grit removal, primary settlement followed by ASP incorporating conventional final settlement tanks, tertiary solids removal is provided for the secondary settled effluent through a rapid gravity filter. The scope of works here is for the provision of new primary and secondary ferric dosing equipment, additional sludge storage and mixing facilities, odour control and provision of caustic dosing for alkalinity correction. Works should be completed by 30 March 2022. Phased delivery approach The notional solution for the five projects contained in the PREP Batch was chemical treatment of the effluent, and tertiary treatment to achieve the required phosphorus consent levels. Following a review of the existing treatment processes by United Utilities, a phased delivery approach was proposed as it became clear that upgrades to the existing chemical dosing systems allied with other plant improvements could meet the consent levels, negating the need for tertiary treatment. Therefore, a two phase approach has been adopted. The first phase of the works was programmed to provide new or upgrades to the existing chemical dosing systems on each site. If proven successful, the requirement for tertiary treatment will be removed from the final solution, which could provide a significant cost saving across the five projects (circa £1m per project). To support the plan, collaborative planning sessions were undertaken to create a programme that would allow the chemical treatment to be commissioned first and tested to ensure the consent was achieved, but allow time for the installation of tertiary treatment should there be any issues. [caption id="" align="alignnone" width="1200"] Bury WwTW PST MCC DfMA solution - Courtesy of Advance-plus[/caption] Phosphorus Removal Enhancement Programme: Supply chain - key participants Project delivery: Advance Plus MWH Treatment J Murphy & Sons Stantec UK Dosing equipment: Northern Pump Suppliers Ltd (NPS) Sludge storage tanks: Stortec Engineering Ltd Systems integrators: Tata Consultancy Services (TCS) Systems integrators: Cougar Automation Ltd MCCs: Lloyd Morris Electrical Ltd MCCs: BGEN PST bridges at Bury WwTW: JK Fabrications Ltd Design templating As the AMP7 delivery programme needed to move at pace, the decision was made to develop a template solution on early projects, known as donor projects and then utilise the template on the remaining recipient projects. The PREP Batch’s delivery schedule made it both a donor project for some assets and a recipient project for other assets. Chemical dosing equipment was a key focus for templating with other asset types of sludge storage, pumping stations, MCC kiosks, sampling systems and ICA equipment all areas for template development. A key principle of the templating effort was the need to ensure that once a template had been developed, it had client support from an engineering, operations and maintenance perspective. [caption id="" align="alignnone" width="1200"] Tyldesley WwTW caustic dosing unit - Courtesy of Advance-plus[/caption] The approach taken was to take early designs outside the project environment and review them in a joint forum made up of the clients’ design leads, contractor’s designers and supply chain representatives. The designs were then reviewed by representatives for the Operations and Maintenance community and any comments incorporated. These designs were then locked down for reuse. Using this approach had several benefits: Working with the client’s design leads, Advance-plus were able to discuss and challenge asset standards which led to a number of agreed deviations making significant savings against the budget. These discussions were underpinned by a joint desire to ensure the designed assets were operable and maintainable with a common sense approach. Advance-plus, working collaboratively with C2V+ (United Utilities other construction delivery partner) brought shared ideas, shared effort and ensured that the template outputs would be delivered across the whole AMP7 programme. This would ultimately benefit United Utilities with common assets across their region. Supply chain input also ensured that the designs being developed were deliverable, with the supply chain giving excellent advice on the most effective way to deliver an idea. Operations and Maintenance team input ensured Advance-plus were able to fine tune the details of operability and maintainability and gave the final agreement to the templates. The templates could then be reused in the knowledge that they had everyone’s support. Once a template was agreed, multiple units would be delivered which meant Advance-plus were able to give the supply chain workload visibility and the ability to forward plan manufacturing. [caption id="" align="alignnone" width="1200"] Bury WwTW - (left) template POA arrangement and (right) valve chamber and spill tank - Courtesy of Advance-plus[/caption] The PREP Batch benefited from the work provided by other donor projects for chemical dosing, with the whole dosing area being developed including, storage, dosing equipment, tanker area, blind tank, showers, hose reels etc. The donor project developed the total design solution from P&ID’s, layouts through to ICA requirements. The solution for large external tank ferric and caustic dosing (smaller size dosing rigs are delivered within a kiosk solution) were reviewed by the joint team, with a significant focus on the layout of the storage area. Northern Pump Suppliers (NPS), one of United Utilities framework suppliers for chemical dosing equipment, supported the design development of the template bringing a wealth of experience to the discussions. Also, by having the United Utilities’ design leads involved, clarity on specification requirements could quickly be discussed and approach agreed, with NPS able to confirm how the solution would be delivered. The PREP Batch was therefore able to take all this design effort and implement it across the projects within the batch. This significantly reduced the timescales and effort needed to develop this batch of work. Furthermore, the supply chain for the majority of the equipment needed was already in place with purchase agreements. This again improved the ability to deliver this element of work reducing the time taken. [caption id="" align="alignnone" width="1200"] Rochdale secondary dosing - Courtesy of Advance-plus[/caption] Areas of development that the PREP Batch provided as a donor project Two key areas of development that the PREP Batch provided as a donor project were sludge storage and MCC kiosks. Sludge storage Through collaborative meetings, a number of solutions were put forward by both construction delivery partners. The need for access to the top of sludge storage tanks became a key area of focus. The discussions centered on the reason for access stairs to the top of the tank. It transpired that this access was required solely to maintain the ultrasonic level instrumentation at the top of the tank, so the team got to work to establish if something different could be done. The electrical engineers liaised with the supply chain and established that a radar or vibronic instrument would fulfil the same duty and more importantly the instruments do not need direct access for maintenance and can be tested and calibrated remotely. This allowed the staircase to be removed, which brought about significant savings to the delivery of this asset type. This solution is now being utilised on other projects across the programme. [caption id="" align="alignnone" width="1200"] (left) Worsley WwTW caustic dosing and (right) sludge storage tank from Stortec Engineering Ltd at Worsley - Courtesy of Advance-plus[/caption] MCC kiosks The PREP Batch supported the development of a modularised MCC kiosk solution. Early in the programme of work it was recognised that the majority of the MCCs would be a similar layout. Advance-plus engaged MCC framework suppliers Lloyd Morris Electrical Ltd, to establish a principle for a range of standard layout and sizing of MCCs and kiosks. Furthermore, Advance-plus required off site manufacturing to be undertaken wherever possible, and wanted the MCC delivered in its kiosk fully tested. Using the PREP Batch as the donor, Lloyd Morris Electrical Ltd developed a range of sizes for small, medium and large kiosk requirements. As the MCC and kiosk are built on a transportable base, and to minimise on site works, the MCCs have been raised off the ground therefore negating the need for full concrete bases with cable trenches. Overall, the templating approach is bringing benefits to the PREP Batch and across the programme. United Utilities has a consistent asset across the region making operator and maintenance familiarity better. Significant efficiency advantages are being seen in this approach which is supporting United Utilities’ aspirations to deliver the best whole life cost solutions. [caption id="" align="alignnone" width="1200"] Worsley WwTW sludge MCC DfMA assembly - Courtesy of Advance-plus[/caption] Progress update At the time of writing (September 2021), the design has been completed for all five sites, and each are now at various stages of construction, commissioning and optimisation. At Bury and Rochdale WwTWs, the ferric dosing systems have been installed and commissioned and both are in the optimisation period. Both Worsley and Tyldesley WwTWs are in the construction phase, with civils construction complete and M&E installations are underway. Demolition work has commenced at Chorley WwTW. All projects are tracking to programme with the ability to establish if the phased delivery approach is working on programme.