Supply Chain - Project Planning & Surveying - Site & Ground Investigation

The Carmoney to Strabane Strategic Trunk Main represents the completion of nine years of planning and construction, backed by a £17 million investment from NI Water. This major infrastructure project delivers a new strategic water main connecting Carmoney Water Treatment Works (WTW) in Eglinton to Castletown Service Reservoir (SR) in the Strabane area. Identified as a priority in both NI Water’s 2012 Water Resource Plan (WRP) and the 2017 Water Resource & Strategic Resilience Plan (WR&SRP), the project enhances connectivity between the Northern and Western water resource zones. By establishing this vital link, the scheme addresses key infrastructure gaps, strengthens supply resilience, and supports the continued delivery of high-quality drinking water to the region. Project scope

To achieve the goal of enhanced interzonal connectivity and meet regulatory requirements, the Carmoney to Strabane Strategic Trunk Mains Project was divided into three distinct phases:

Phase 1: Completed in June 2024: This phase involved the construction of the new Avish Water Pumping Station at Carmoney WTW. The facility, with a capacity of 17 million litres per day (MLD), was designed to pump water to Corrody Service Reservoir (SR). Phase 1a: Finalised in April 2025: This phase comprised the installation of approximately 10 km of 500 mm diameter trunk main from Edenreagh Road junction to Corrody SR. A key feature of this phase was a 400m horizontal directional drill beneath the River Faughan; a watercourse of international significance due to its Atlantic salmon population and designation as a Special Area of Conservation (SAC). Phase 2: The final phase: Not yet commenced, but will involve the construction of a new water pumping station at Corrody SR and approximately 22km of trunk main extending to Castletown SR. This phase will traverse both private and public lands and include multiple trenchless crossings.

This paper focuses in detail on Phases 1 and 1a of the project.

[caption id="attachment_26644" align="alignnone" width="1200"] HPPE trunk main being strung out during installation - Courtesy of DAWSON-WAM & NI Water[/caption] Project aims & drivers

The primary objectives of the Carmoney to Strabane Strategic Trunk Main are to eliminate supply-demand balance deficit and to enhance resilience for 17ML/d within the Western Resource Zone in the event of incidents or outages at water treatment works.

Phase 1: This phase replaced the existing water pumping station (WPS), which is over 25 years old and equipped with MEICAT systems that have exceeded their operational life. The new infrastructure delivers increased operational robustness and improved security of supply within the Northern Resource Zone. Phase 1a: This phase reinforced the Caugh Hill–Corrody Trunk Main and supports the completed Northern Resilience Phase 3 project. It enables larger flow transfers to Corrody SR during outages at Carmoney WTW, without negatively impacting high-level customers in DMAs directly supplied from the trunk main. This enhancement further strengthens system resilience and security of supply in the Northern Resource Zone. Phase 2: This phase will enable bi-directional water transfer between the Northern and Western Resource Zones, up to 17 ML/d westwards and 8 ML/d northwards. Once complete, it will significantly increase operational flexibility and resilience across both zones. [caption id="attachment_26646" align="alignnone" width="1200"] Mains laying operations - Courtesy of DAWSON-WAM & NI Water[/caption] Carmoney to Strabane: Supply Chain - key participants Client: NI Water NEC project management: McAdam Principal contractor: Murphy/DAWSON-WAM JV Civils contractor: DAWSON-WAM Ltd MEICA contractor: Murphy Process Engineering Ltd Civil design: RPS Ireland Ltd MEICA sub-contractor: Pronto Automation Systems Ltd HDD contractor: Peter McCormack & Sons Ltd Archaeological services: Gahan & Long Ltd Pipe & fittings: APP Fusion Group Quarry products & reinstatement: P Woods & Son Ltd W & J Chambers Ltd Northstone NI Ltd Phase 1 - Avish Water Pumping Station

This phase involved the complete demolition of the existing facility and the construction of a new, purpose-built water pumping station (WPS) to supply both Avish Service Reservoirs (SRs), with onward pumping to Corrody SR via the Edenreagh Road infrastructure. The station operates using three pump sets (duty/assist/standby) and was prioritised as Phase 1 due to planning application and approval constraints. The works were successfully completed in June 2024.

[caption id="attachment_26643" align="alignnone" width="1200"] The new Avish Pumping Station - Courtesy of DAWSON-WAM & NI Water[/caption]

In addition to the three pump sets, the new installation includes a surge vessel, a new motor control centre (MCC), and associated pipework at both the water pumping station and Avish Service Reservoirs.

The upgraded WPS provides the NI Water Operations team with the ability to remotely manage and optimise system performance via telemetry, offering four distinct daily process control modes:

Mode 1 - Level control: Pump operation is based on reservoir level setpoints. Pumps start and stop according to low and high level thresholds, with flow rate automatically reduced as the reservoir approaches its maximum level. The assist pump is enabled or disabled based on flow demand. Mode 2 - Volume control: This mode delivers a specified volume of water either as a one-time operation or on a recurring schedule. Mode 3 - Flow control: In this mode, the system maintains a constant flow rate. The duty pump adjusts speed to meet a defined setpoint, with the assist pump activated if the flow target cannot be achieved by the duty pump alone. Mode 4 - Pressure control: Designed for use in abnormal operating conditions (e.g. bypassing a reservoir during maintenance or washing), this mode maintains a constant delivery pressure. The duty pump modulates speed to meet the pressure set point, and the assist pump engages as required.

To optimise operational expenditure (OPEX), the system also incorporates controls for managing high-tariff and pre-high-tariff top-ups, ensuring more efficient energy use during periods of peak demand.

[caption id="attachment_26645" align="alignnone" width="1200"] HDD drilling rig in operation - Courtesy of DAWSON-WAM & NI Water[/caption] Phase 1a: Edenreagh to Corrody Trunk Main

This phase involved the construction of 10 km of trunk main from the Edenreagh Road infrastructure to Corrody Service Reservoir (SR), consisting of approximately 9.6 km of 500 mm diameter ductile iron pipework and 0.4 km of 560 mm diameter high-performance polyethylene (HPPE) main installed via horizontal directional drilling beneath the River Faughan.

While the majority of the pipeline was laid through private agricultural land, the route also included several road crossings, most notably the A6; and a section along Trench Road within the public domain.

To support integration with the existing network, new flow meters, inlet control valves, scour and air valves, and cross-connections were installed, ensuring full inter-connectivity between the new and existing mains.

The entire works were delivered with no disruption to customers and successfully removed 17 District Metered Areas (DMAs) from the DG2 register. In addition to improving supply reliability, this phase significantly enhanced the resilience and security of supply within the Northern Resource Zone.

[caption id="attachment_26648" align="alignnone" width="1200"] Pipe bridge installation - Courtesy of DAWSON-WAM & NI Water[/caption] River crossings

The scheme included two significant watercourse crossings: the previously mentioned horizontal directional drill (HDD) beneath the River Faughan and the construction of a pipe bridge across the Burngibbagh River. For both crossings, maintaining ongoing communication with the Northern Ireland Environment Agency (NIEA) was essential. In line with NIEA requirements, sheet piles were installed at the drill entry and exit points to prevent any potential contamination of the River Faughan; recognised for its ecological importance as a designated watercourse.

The project team also carefully considered the findings of the ecology survey and the Habitats Regulations Assessment to ensure full environmental compliance. Environmental challenges, including the presence of Japanese knotweed and active badger setts within the working area, were effectively managed and mitigated without impacting the programme.

Archaeological discoveries & historic preservation

Throughout the course of the project there were numerous archaeological and historical discoveries. Ancient structures and artifacts were discovered, with the team collaborating closely with archaeologists and HED to carefully document and preserve these findings, ensuring the site’s historical significance was respected throughout the construction process.

[caption id="attachment_26649" align="alignnone" width="1200"] Archaeological operations - Courtesy of DAWSON-WAM & NI Water[/caption] Environmental awareness

As the pressures of climate change and population growth in the North-East region increase, the Edenreagh Road to Corrody SR trunk main was constructed to ensure security of supply and cleaner water for the wider Northern Zone.

This 10km pipeline was constructed whilst adopting a number of cost saving and environmentally responsible methods, namely maximising the amount of reused excavated materials through a screening process. This minimised the amount of imported material and reduced the number of deliveries to site by a significant amount.

Additionally, where practicable, materials and aggregates were sourced from local suppliers near the site to reduce transportation distances and minimise the project’s carbon footprint.

Community & landowner engagement

It was recognised early in the Early Contractor Involvement (ECI) period that building strong relationships with landowners would be critical to the project’s success, with early engagement meetings held with the Ulster Farmer’s Union. As such, collaboration with local farmers and landowners remained a core focus throughout, ensuring minimal disruption to their land and promoting sustainable land use practices.

To support this approach, a dedicated Lands Liaison Officer was appointed for the duration of the works. Their role was to build and maintain strong relationships with landowners and to ensure transparent, ongoing communication with the local community—keeping all stakeholders informed and engaged throughout and contributing to the successful delivery of the project.

[caption id="attachment_26647" align="alignnone" width="1200"] Mains laying operations - Courtesy of DAWSON-WAM & NI Water[/caption] Health & Safety initiatives

The project was recognised by the Considerate Contractors Scheme for its health and safety initiatives, with the Contractor (Murphy DAWSON-WAM JV) receiving a Gold award for the project as a whole, but in particular for the installation of single use defibrillators within all excavators across the project.

The outcome

The Carmoney to Strabane Strategic Trunk Main is a great example of how the NI Water project team including consultants and contractors can successfully collaborate and engage with the local community to deliver a vitally important piece of infrastructure, whilst respecting the local environment.

Essex and Suffolk Water, part of Northumbrian Water Ltd, supplies drinking water to 794,000 properties. Maintaining a supply to those customers requires the distribution of up to 670 Ml/d of high-quality drinking water. In Essex, the two primary treatment works are Hanningfield WTW, a physio-chemical works near Chelmsford and Layer WTW, a biological works, near Colchester. These are supplied by raw water stored in two large reservoirs at Abberton and Hanningfield. In 2016, and more recently in 2022 low levels of rainfall and hot weather compromised the raw water quality in Abberton Reservoir which led to significant challenges to the biological process at Layer WTW. This meant unprecedented demand was placed upon the chemical works at Hanningfield WTW, which in turn drew down the water level in Hanningfield Reservoir to levels not seen since the summer of 1996. The challenge Whilst this low water level at Hanningfield Reservoir was observed, the level in Abberton was healthy due to the process constraints of the biological works at Layer. To mitigate the scenario of having two reservoirs, one relatively full, and another extremely low, occurring in the future, Northumbrian Water applied for enhancement funding in AMP7 to construct a 20km pipeline between Layer WTW and Langford WTW, also a physio-chemical works, where water from Abberton could be reliably treated. This in turn would allow water from the River Chelmer and River Blackwater that would normally be treated at Langford, to augment the water level in Hanningfield Reservoir by utilising existing transfer pumping facilities between Langford and Hanningfield Reservoir. Providing this connectivity, albeit by substitution, will allow Northumbrian Water to balance the water levels in both Abberton Reservoir and Hanningfield Reservoir, and mitigate a potential scenario where no water is available to supply Hanningfield WTW. The project In 2019 Essex & Suffolk Water teams began to plan a pipeline route between Layer WTW and Langford WTW for a pipe that could support flow rates up to 50 Ml/d. This figure was determined as the optimum flow rate to allow balancing of the reservoirs to take place and ensure security of supply when faced with long term drought conditions. The pipeline will take advantage of the capacity and capability of the existing pumping station at Abberton which can deliver up to 255 Ml/d to Layer WTW. The route would begin with a strategic connection into the existing raw water mains that deliver water from Abberton Reservoir into Layer WTW. From this point a route was sought that would allow water to run under gravity conditions to Langford WTW where it would be discharged into two existing bankside storage reservoirs each with a capacity of 35 Ml. The pipeline from Layer to Langford would operate as a gravity main, with the upstream head being set by the pressure in the rising main at the take-off point. With approximately 5 bar of available driving head, the flow out of the pipeline will be controlled by a downstream flow control valve. The pipe sizes have been selected to ensure a positive pressure is available throughout the pipeline and to provide sufficient differential pressure at the outlet at maximum flow. Hydraulic profile The hydraulic profile shown below (pipeline pressure is shown in red) extends from Abberton Pumping Station to the outlet at Langford WTW. Chainages are measured back from the Langford outlet (at chainage 0m) and the start of the new pipeline construction is at approximately chainage 20,000m. Note the falling available head due to friction losses along the pipeline and its change in gradient at approximately chainage 12,000m. This change in gradient is due to a change in pipe size which is the result of the pipeline optimisation. [caption id="" align="alignnone" width="1200"] Hydraulic profile - Courtesy of Stantec UK[/caption] The direct connection from the pumped rising main to Layer introduced a number of hydraulic complexities. A key issue was the control of transient pressures, particularly associated with a sudden loss of output at Abberton Pumping Station. Existing surge vessels provide robust surge control, however, the addition of the 20km extension to Langford would require careful consideration. The time to close the outlet valve at Langford, particularly following a sudden loss of pumping at Abberton, would need to be sufficiently long to avoid exacerbating transient pressures while a closing time too long would risk depressurising the pipeline and the risk of drawing air into the pipeline. The occurrence of transient air pockets at high points could create further transient pressures if encountered by the initial pressure waves. While these challenges could be largely avoided by separating both pipelines entirely with a break tank, the tank would need to be sufficiently large and elevated to provide the same driving head. The design team are, instead, progressing an optimised solution to avoid these additional capital works through thorough detailed understanding of the problem, careful selection of the control valves and the implementation of a control system that remains simple yet capable of maintaining pressures within acceptable limits. Ground investigations To support the design of the pipeline Essex & Suffolk Water has now completed ground investigation work along the route to determine ground and groundwater conditions and help inform excavated material management decisions. The ground investigation work comprised: 63 dynamic sampler boreholes up to 6m in depth. 11 cable percussion boreholes up to 10m in depth. 27 soil resistivity tests. Post-installation groundwater monitoring at approximately 12 locations. This work was completed by Essex & Suffolk Water’s framework partner Allied Exploration & Geotechnics (AEG) in October 2022 based on a specification written by Stantec UK. This ground investigation work will help Stantec to determine the appropriate pipeline material. [caption id="" align="alignnone" width="1200"] (left) Ground investigation work and (right) pipe installation - Courtesy of Essex & Suffolk Water[/caption] Pipe material selection The use of steel, ductile iron (DI) and polyethylene (PE) were all considered. Due to aggressive ground conditions, appropriate corrosion protection would be needed for ferrous materials. PE would remove the corrosion risk but the large diameters needed and the associated pipe thickness would require careful control of welding during construction. At the time of writing (June 2023), final selection is ongoing but, following initial assessment of cost, constructability and maintenance issues, either an all DI pipeline or a mix of DI and PE are considered most favourable. Project planning The project is currently moving through the detailed design phase and one activity that has been conducted concurrently is the liaison with the council districts that the pipeline crosses, both Colchester City Council and Maldon District Council. In the experience of Essex & Suffolk Water, large diameter cross country pipelines have typically required Environmental Impact Assessments to support the planning process. For this project, an alternative approach was taken where the team designed the pipeline and its construction methods, including associated compound areas, to have the least possible impact from a number of perspectives including ecology, visual impact and traffic and transport in advance of submitting our EIA Screening Request. This design, including examples of how measures were introduced to provide a less impactful route than one that may have been presented prior to completing these mitigations, helped support the EIA Screening request. In response to that request both Councils viewed the screening request favourably and allowed the team to complete the work using permitted development rights recognising the efforts of Essex & Suffolk Water to plan and design the least impactful route possible. Archaeology Essex & Suffolk Water now plans to complete the archaeological work associated with the project over the summer period of 2023. Throughout the early phase of the project Essex & Suffolk Water has worked closely with AECOM to complete a desk based assessment and then develop a Written Scheme of Inspection. This has now been approved by the council archaeologist and comprises 552 trenches measuring 2m x 30m across a 40m corridor along the 20km pipeline route. This work will be completed over a 16 week period, 8 weeks for the field work and a further 8 weeks for recording and report preparation. Due to the archaeological history in the area it is expected that some archaeological artefacts of interest will be uncovered. This may in turn necessitate further mitigation trenching along the route. Layer to Langford Pipeline - Supply chain (as of June 2023) Principal designer: Stantec UK Ground investigation: Igne Land owner engagement: Savills Technical input: Saint Gobain PAM UK Archaeology: AECOM Pipe installation: Northumbrian Water Pipe supplier: Electrosteel Castings (UK) Ltd Schedule The installation of the majority of the 20km pipeline will begin in February 2024 in order to complete the work in March 2025, allowing Essex & Suffolk Water’s in house team to complete the installation in one pipelaying season. Work has already commenced on a number of minor road crossings to coincide with the work of other developers in the area and minimise impact on our customers. Work is also scheduled to commence on the directional drill crossing that will be required beneath two main rivers as part of the project, the River Blackwater and the Langford Cut in September 2023.

Guildford Borough Council (GBC) are progressing with the development of approximately 41 hectares of brownfield land located along the west bank of the River Wey as it runs through central Guildford and north through Slyfield Industrial Estate. Guildford Sewage Treatment Works (STW) lies within this land and requires relocation in order to enable the development to proceed. This relocation forms a critical part of the Slyfield Area Regeneration Project, and will allow the delivery of up to 1,550 new homes, partially on land occupied by the existing STW, to enable local housing needs to be met. The new sewage treatment works will be built to the north of Slyfield Industrial Estate on land that has been used for quarrying, and in turn used as a landfill site, and is currently largely unused. In addition to the construction of a new works, relocation of the works to this location will require the construction of a new transfer tunnel to divert existing incoming flows to the new site, and the construction of a new outfall to the River Wey. The existing STW must also be decommissioned to enable use by the Weyside Urban Village (WUV) Development. Design flows The new Guildford STW is designed for a population equivalent (PE) of 125,300, with room to expand the site in the future. Design criteria Flow rate Dry weather flow (DWF) 322 l/s Average flow 368 l/s Flow to full treatment (FtFT) 746 l/s IPS peak capacity 2,250 l/s Location of new works The site was formerly quarried for sand and gravel during the 1960s and 1970s, with the resultant voids filled with waste materials progressively moving from west to east (i.e., towards the River Wey), which continued until the late 1980s. There is no record relating to the exact nature of the fill materials. The site was understood to have taken household and commercial wastes, but not special or difficult wastes. Following this, the site has remained vacant and undeveloped. [caption id="" align="alignnone" width="1200"] (left) Location of new sewage treatment works and tunnel route and (right) Slyfield Regeneration Project area - Courtesy of Adams Hendry[/caption] Transfer tunnel The STW transfer tunnel will consist of a 1.4km long, 1500mm internal diameter, 1780mm outer diameter tunnel, made of precast concrete pipe, which will be installed by pipejacking (microtunnelling) method. Six shafts are required to facilitate its construction and will serve as temporary launch and reception shafts. Network modelling by Arcadis verified the designed flow velocities remain self-cleansing and provide for the flow rates required. A geotechnical interpretive report has been prepared in review of the ground conditions for the scheme as whole, and to ascertain suitability for shaft sinking and tunnelling. The principal geological stratification for the site consists of Made Ground overlain principally with River Terrace Deposits, with sections of overlapping Alluvium, overlaying the solid geology of firm to very stiff clay of the London Clay Formation (LCF). The selected method of microtunnelling was chosen as it allows long pipeline sections to built, and its suitability to the ground conditions within LCF at Guildford, while limiting the exposure to personnel to underground works, against traditional methods. The microtunnelling is operated from a central control cabin at ground level, and only limited personnel access into the tunnel is required to service the microtunnel boring machine during construction. A ground movement assessment has been prepared and modelled using XDisp software by Oasys. The analysis constitutive model is based on the O’Riley & New method. The method predicts ground movements resulting from ground loss which produces strain of the soil within the influence zone, and projects the settlement in a gaussian distribution curve. Ground improvement & remediation The project team has consolidated decades of site investigation data into a unified format and 3D model. The process involves first combining data within OpenGround software and applying scripted translation to a common description - for example having all London Clay called ‘London Clay’, rather than ‘LC’ or ‘Clay’. [caption id="" align="alignnone" width="1200"] RIC 1 and 2 pass areas - Courtesy of BAM Enpure Ltd JV[/caption] This combined dataset is then used in Leapfrog 3D geological modelling software, which applies intelligent interpolations, and highlights anomalies that can be quickly assessed and removed. The resultant 3D model has then been used to enhance communication in the engineering AutoDesk BIM 360 federated models, and in the proprietary Arcadis SmartAtlas GIS viewer. Rapid Impact Compaction (RIC) is a method of imparting energy to the ground using a repeated but relatively short drop-weight, where a base plate (or “puck”) is in constant contact with the ground. RIC is preferred over a larger drop-weight technique due to its more progressive and less disturbing impact on the ground it is being used on. The method is also faster and uses smaller scale setups. A challenge for the RIC method was whether the energy it imparts is sufficient to densify the ground, versus other higher energy drop-weight methods. A trial was deemed necessary to demonstrate the suitability of this method. RIC is proposed to be applied over the majority of the site with an expected densification of landfill down to approximately 4.5m. Areas where assets will not be supported on driven full depth piles will undertake a second pass of the RIC method, reducing the long-term settlement of the landfill material. The predicted reduced surface will be levelled as required by the infill of depressions with imported stone or other suitable material. Improvement of the existing ground by reinforcement through installation of Vertical Rigid Inclusions (VRI) method across the site. Supporting of level sensitive and heavier elements will be on precast driven piles founded below the landfill material. The combination of methods will be designed to achieve Thames Water’s settlement performance values over 40 years, and remain within the allowable values of 50mm and 100mm. This will reduce the need for full depth driven piling which would otherwise be required. Reduction of infiltration to the landfill materials by ensuring impermeable surfaces drain to the treatment works and are released at the outfall away from the site. Gas and leachate well monitoring is provided along the perimeter of the site to monitor any impact and provide leachate removal points if required. [caption id="" align="alignnone" width="1200"] (left) Rapid impact compaction rig and (right) pile under test - Courtesy of BAM Enpure Ltd JV[/caption] Guildford STW Relocation Project: Supply chain - key participants Client: Thames Water Principal contractor & designer: BAM Enpure Ltd JV Client designer: Jacobs Civil designer: Arcadis Planning consultant: Adams Hendry Consulting Ltd Process & M&E: Enpure Ltd CFD analysis: The Fluid Group Physical modelling: Hydrotec Consultants Ltd Tunnel design: Joseph Gallagher Ltd Temporary works/shoring: MGF Ltd Precast structures: A-Consult Ltd Precast structures: FLI Precast Solutions Rapid impact compaction: Cofra Ltd Piling: Aarsleff Ground Engineering Ltd XDisp software: Oasys Controlled modulus columns: Vibro Menard Ltd Inlet works and PST odour covers: Power Plastics Ltd Inlet pumps: Grundfos Imported sludge Strainpress: Huber Technology Escalator screens: Longwood Engineering Company Ltd Grit removal plant: Jacopa PST scrapers: Colloide Engineering FST scrapers: Purac AB Odour control plant: Odour Services International Ltd FBDA grids and blowers: Xylem Water Solutions Sludge thickening & dewatering: Kent Stainless Ltd Cake Silo: Saxlund International Cloth pile filters: Eliquo Hydrok Ltd Polymer batching & dosing: Richard Alan Engineering Ferric plant: Colloide Engineering Tank logging system (WASP): JR Pridham Services Ltd Glass lined steel tanks: Balmoral Tanks Ltd Sludge tank mixing: Landia UK Ltd Pumps, mixers & flocculators: NOV Welfare building: M-AR Limited Guildford STW - the new sewage treatment works Inlet pumping station The new STW is being designed to maintain inflow from the external catchment ranging from dry weather to 1 in 100-year storm (plus climate change allowance) with future-proofing beyond the 2041 design horizon. [caption id="" align="alignnone" width="1200"] (left) inlet pumping station physical model and (right) inlet pump testing physical model - Courtesy of Hydrotec Consultants Ltd[/caption] The pump design has been developed to fulfil the project brief load requirements (future peak IPS capacity 2585l/s) and some flexibility either side of the requirements is available due to the standard capacity equipment design offered from the supply chain. The proposed arrangement now consists of a wet well 12.5m diameter, approximately 20m deep. A common inlet will be provided to dissipate any entrained air, and two selectable pumped sections with double isolation will be provided by wall mounted penstocks on full height walls. The pumping well will be constructed in two halves, hydraulically connected in normal operational mode however each half will be able to be isolated (using motorised penstocks) in accordance with specification requirements surrounding double isolation, to allow person entry into half of the wet well at a time. Each half of the wet well will have three pumps installed giving a capability to provide full flow to treatment from two pumps with a standby permanently installed. The pumping station was first modelled by computational fluid dynamics (CFD) to demonstrate the assumed flow patterns that will occur. The pumping station was then physically modelled to comply with the specification and process design requirements particularly with respect to distribution, mixing, settlement, turbulence, dispersion, and freeboard for the full range of flows that each structure is expected to receive. [caption id="" align="alignnone" width="1200"] Storm overflow physical models - Courtesy of Hydrotec Consultants Ltd[/caption] Inlet works The inlet works is being designed to receive all pumped flows from the inlet pumping station (including future peak IPS capacity 2585 l/s), inlet works drainage and screening liquor return flows. Flows will enter the inlet works and then separate across the four escalator screens inclined at an angle of 45°. Each screen will be provided with a local proprietary control panel. Each panel will incorporate a differential ultrasonic level control. An emergency bypass will be provided upstream of the screens to accommodate all four screens blinding at the same time. Three 1200mm wide duty screens will be required to screen flows from low flow up to 2585 l/s, screening 6mm in two directions. The inlet works and grit treatment plant will be covered with odour covers which will be connected to the inlet works and PST odour plant. The inlet works has been classified as a Zone 2 Area under the odour covers and all equipment beneath the odour covers will be ATEX rated. Storm tanks Storm flows from the inlet work storm separation chamber will flow into two storm tanks via a 1400mm above-ground pipe. Within the 1400mm pipe between the storm separation chamber and the storm tanks there will be a partial pipe MCERTs certified flow meter to measure the total flow into the storm tanks. During normal operation the blind tank will fill first, then the spill tank will fill. In the event that both tanks are full to capacity (and still in storm flows) the spill tank will overflow via a weir and the storm tank will discharge to river. [caption id="" align="alignnone" width="1200"] Elevated inlet works - Courtesy of BAM Enpure Ltd JV[/caption] The storm tanks contents will automatically return to the inlet pumping station via 700mm gravity pipe when the flow being pumped to the inlet works drops below a predetermined set point. The return flows will be controlled to approximately 0.5 DWF via an automated valve controlled by an electromagnetic flow meter located in the gravity main, returning to the common inlet well of the inlet pumping station. Storm tank cleaning will be a pumped system with the two pumps located external to the storm tanks. Storm tank cleaning will be initiated during the latter part of the storm tanks draining back to the inlet pumping station and will not operate when the tanks are filling. The pump discharge pipe work will include connections for flushing with washwater. Ferric storage & dosing Two 45m3 ferric storage tanks will be located in a concrete bund with the dosing skid packages and control system located within an adjacent kiosk. The bund will be capable of containing 110% of the one of the storage tanks plus 10% allowance for rainwater. A drive-in bunded area for chemical deliveries will be provided and an underground chemical interceptor will contain any local spillages, complete with a Castell interlocked 3-way valve to allow the bunded drainage area either to drain into the interceptor (during a chemical delivery) or to drain into the site drainage (normal operation). Chemical dosing points will be provided upstream of the PSTs, on the common outlet channel of the ASP, and upstream of the tertiary treatment plant. The dosing points will utilise sparge systems to ensure adequate distribution of chemicals into the channels. Odour control plant The odour plant is a 2-stage system. Stage 2 filters will discharge into an 18-metre-high odour stack. The plant has been designed to achieve a minimum removal efficiency of 98% of H2S and 99% removal of odour, based upon a total system duty of 8432 m3/hr (of which 4813 m3/hr is from the inlet works and 3619 m3/hr from the primary settlement tanks). Service water A potable water main supplies a service water break tank via a ballcock (float valve). The service water break tank has a working volume of approximately 30m3 which gives a nominal retention of approximately three hours at average throughput. Service water booster pumps draw water from the tank and transfer it to the service water main network where it feeds the polymer make-up system for all thickeners and dewatering belt presses. Primary settlement distribution chamber The distribution chamber has been CFD modelled to calculate the flow split to each downstream primary settlement tank from first principles, and assess whether the proposed design would deliver an equal flow split (+/-5%) for seven future flow scenarios. This required the inlet bellmouth to be turned down to improve flow splitting. [caption id="" align="alignnone" width="1200"] PST distribution chamber CFD models: (left) with four PSTs in service and (right) with six PSTs in service - Courtesy of The Fluid Group[/caption] Primary settlement Primary settlement consists of four 47.15m long by 10m wide tanks, with a depth ranging between 6.24m at the hopper end and 5.3m at the outlet length (equating to 1 in 50 floor slope). Each PST tank has three sludge hoppers at the inlet end. The outlet of the PST discharges into a common 1000mm wide outlet channel. From this outlet channel the 1000mm outlet pipe from the drop box combines with the 700mm RAS lines into an above-ground 1200mm pipe. Retractable odour covers will be provided across the PST tanks to allow for future inspection, cleaning and maintenance. The odour covers will be connected via ducting to the inlet works/primary settlement tank odour plant. All mechanical equipment installed below the covers will be constructed from 316 stainless steel or high performance plastics. The primary settlement tanks have been classified as a Zone 2 Area, and all electrical equipment beneath the odour covers will be ATEX rated. The design of the PST Tanks is based upon a maximum inflow of 3022m3/hr to all four in-service tanks, and a peak flow to each tank of 1007m3/hr with one PST out of service. In normal operation all four PST tanks will be in service. Within each PST tank a chain and flight scraper system will be provided which will utilise high-tech non-metallic materials as the main materials of construction. Scum from the primary tanks will gravitate via a rotating surface skimmer pipe to the above-ground primary settlement scum tank. The primary scum return pumps are progressive cavity pumps, operating in a duty standby configuration. The pumps are fixed speed pumps operating between a high and low level in the scum tank. The PST sludge hoppers will desludge based upon a SCADA-adjustable interval and duration. The primary desludge pumps are progressive cavity pumps, operating in a duty/standby configuration. The pumps are variable speed pumps operating to maintain a SCADA-adjustable flow set point. Once the effluent has flowed through each PST it will enter into a common 1000mm wide outlet channel. From this outlet channel flows transfer to the ASP distribution chamber via a drop box and 1000mm above-ground pipe. [caption id="" align="alignnone" width="1200"] ASP overview - Courtesy of BAM Enpure Ltd JV[/caption] Activated sludge plant The ASP plant will have a distribution chamber using the same general arrangement as the primary settlement distribution chamber. The activated sludge treatment tank consists of four ASP lanes. Each ASP lane has a selector tank followed by an anoxic zone and then the three aerobic zones. The main aeration lane will be fitted with aeration pipework and fine bubble diffusers. The aeration vessel is 80m long and 6.1m wide with a water depth of 7.05m. The total instantaneous maximum air demand of the ASP is 10,438 m3/h. The first third of the aerated fraction of each lane will contain 50% of the aeration capacity, the middle third 30%, and the final third 20%. Each aeration lane will have three passes, arranged as channels of 6.15m width. The air for the diffuser grids will be supplied from three ASP air blowers operating on a duty/assist/standby basis. The aeration system will be controlled by an ammonia based real time control (RTC) system utilising a feed forward ammonia load input and a feedback ammonia concentration. Once the effluent has flowed through each ASP lane it enters into a common 1000mm wide outlet channel. From this outlet channel flows transfer to the FST distribution chamber via a drop box and 1200mm above-ground pipe. [caption id="" align="alignnone" width="1200"] Anoxic and aeration zones flows - Courtesy of BAM Enpure Ltd JV[/caption] Final settlement tanks The FST plant will have a distribution chamber using the same general arrangement as the primary settlement distribution chamber. The four FSTs will consist of 32m diameter flat bottomed circular tanks with a side wall depth of 6.15m. The FST will separate solids from the flow via settlement, producing a clarified effluent which overflows a peripheral weir into a launder channel, before gravitating to the tertiary treatment distribution chamber via a 1000mm below-ground pipe. The combined clarified outlet flow from the four tanks will be monitored by a common flow meter, as well as suspended solids and phosphorus monitoring instrumentation, all provided on the common line to tertiary treatment. The design of the FSTs is based upon a maximum inflow to each tank of 1741m3/hr with one FST tank out of service. In normal operation all four FST tanks will be in service. Each tank will have a 700mm inlet pipe, which will flow into a central diffuser drum before entering the FST tank. Each tank features a 600mm outlet pipe fed via a peripheral launder channel, as well as a 400mm RAS gravity outlet pipe. Each of the four tanks features a full bridge rotating scraper system which will run continuously in normal operation. [caption id="" align="alignnone" width="1200"] 32m final settlement tanks & sludge return (RAS pumping station) - Courtesy of BAM Enpure Ltd JV[/caption] Sludge return (RAS/SAS pumping station) Sludge from each pair of FSTs will enter one of two RAS/SAS desludge chambers. The two chambers will be located side by side and will share a set of three duty/duty/standby RAS transfer pumps, which will recycle the settled sludge from both RAS/SAS desludge chambers to the activated sludge plant distribution chamber feed line. The variable speed centrifugal RAS transfer pumps will be capable of pumping 2200m3/hr at a maximum head of 8.9mhd. The pumps will operate between high and low level in the duty RAS/SAS desludging chamber, with both chambers provisioned. A pair of duty/standby SAS pumps is provided, which will facilitate wastage of surplus sludge, with each pump drawing from a single RAS/SAS desludge chamber. The fixed speed centrifugal pumps will transfer sludge to the SAS buffer tank. Control of the SAS pumps will be carried out either on a timer or based on the level in the SAS buffer tank, with the common discharge line featuring flow monitoring. Tertiary treatment Clarified effluent flow from the FSTs will pass to the tertiary ferric mixing and flocculation (post-precipitation) stage, where the option will exist to dose ferric sulphate solution into the flow in order to encourage flocculation of remaining solids. This stage will be split into two parallel streams, with flow from the FSTs initially entering via a single bellmouth inlet into a common inlet channel, before passing via twin overflow weirs into two rapid mix chambers, and subsequently overflowing into two flocculation chambers. The design of the rapid mixer chambers will ensure complete mixing (>95% CoV) of chemical in less than 4 seconds. Flow from the flocculation chambers will weir into a common outlet channel leading to a flow distribution chamber feeding the tertiary treatment stage. The distribution chamber has been CFD modelled to calculate the flow split to each downstream cloth pile filter from first principles, and assess whether the proposed design would deliver an equal flow split (+/-5%) for seven future flow scenarios. The tertiary treatment stage will comprise six cloth pile filters, which will operate with all filters in service - however the peak flow will be able to be treated with only five filters in service. The filters will be sized to accommodate a peak flow of 840 l/s, producing a final effluent of 20 mg/l TSS (95%ile) and 0.2mg/l TP (average). Bypass pipework is to be provided adjacent to the cloth pile filter structure, by which clarified effluent from the FSTs may bypass the tertiary ferric dosing/flocculation and cloth pile filter stage. Each of the six cloth pile filters will feature a central rotor drum onto which filter discs are attached. The rotor and discs will be fully submerged within the tank, with the discs supporting the physical cloth filter media. Flow entering the filters will flow from outside the discs through the cloth into the discs’ interior, with solids collecting on the external surface of the cloth pile, creating a headloss. As this headloss increases, the water level in the tank will rise and at a pre-set water level (as detected by an ultrasonic level sensor) a cleaning cycle will be initiated. [caption id="" align="alignnone" width="1200"] Tertiary treatment flocculation chambers: Eliquo Hydrok Mecana cloth pile filters - Courtesy of BAM Enpure Ltd JV[/caption] Filtered final effluent (FFE) from the inside of the filter disc and rotor drum assembly will pass forward through the unit via a low-level aperture to an outlet chamber, from which flow will weir into the common final effluent outfall chamber. An emergency overflow weir is to be provided, allowing unfiltered effluent from the filter tank (external to the discs) to weir over into the outlet chamber. Backwash liquors from the backwash pumps will exit the filters via a common manifold, draining by gravity to the grit plant liquor PS. Eight backwash pumps will be provided per machine, giving a total of 48 pumps across all six machines. The pumps will be submersible units placed within the tank, with each pump being dedicated to three filter discs. The backwash flow rate is rated for 10 l/s (subject to the installed pipework design/headloss). Each of the six filter tanks will see some solids settlement occurring (and potential accumulation of other debris), which will create a build-up of sludge in the bottom of the tank. This sludge will be periodically removed by a set of two duty/standby sludge pumps per machine (i.e. 12 sludge pumps installed in total). The discharge from each sludge pump will be connected to the common backwash manifold, leading to the grit plant liquor pumping station. Final effluent discharge Flows leaving the cloth pile filters will pass out from the main filter chamber via a low level aperture into a small outlet chamber, from which flows will weir over into the common outfall channel. The final effluent (FE) will flow under gravity through an FE flow measurement flume, with an ultrasonic instrument for measurement of final effluent flows discharged to outfall. The FE outfall channel will feature a pipe leading to the FE washwater system, with a further line branching off this pipe servings as the suction line for FE Meteorburst Analyser. On exiting the FE outfall channel, flows will enter a dedicated FE outfall main, which will drain by gravity, discharging to the river north of the STW site. [caption id="" align="alignnone" width="1200"] New Guildford STW: 3D model night-time overview - Courtesy of BAM Enpure Ltd JV[/caption] Guildford STW - Sludge Treatment Plant Sludge thickening equipment Primary sludge from the PSTs will be pumped via the primary sludge pumps to the primary sludge buffer tank, which will have a volume of 120m3 and will be sized to provide 4-hours of intermediate storage prior to thickening. A set of two duty/standby primary sludge thickener feed pumps will be provided to transfer sludge (at up to 7.0%DS) from the primary sludge buffer tank to the primary sludge gravity belt thickeners. Two primary sludge gravity belt thickeners (GBTs) will operate in a duty/standby configuration in normal operation, although the streams will be able to run as duty/assist if required. Each machine will be able to handle up to 51m3/h (771 kgDS/h) of primary sludge, at up to 7%DS achieving a solids capture rate of 95%. Surplus activated sludge (SAS) from the FSTs will be pumped via the SAS pumps to the surplus activated sludge (SAS) buffer tank, which will have a volume of 67m3 and has been sized to provide 4-hours of intermediate storage prior to thickening. A set of two duty/standby SAS thickener feed pumps will be provided, which will transfer sludge (at up to 2.0% DS) from the SAS buffer tank to the SAS gravity belt thickeners. Two SAS gravity belt thickeners (GBTs) will operate in a duty/standby configuration in normal operation but will be able to run as duty/assist if required. Each machine is sized to handle up to 55m3/h (332kgDS/h) of SAS, at up to 2%DS, achieving a solids capture rate of 95%. Sludge balancing/blending tanks Thickened primary sludge, surplus activated sludge, and screened sludge imports will be pumped to two thickened sludge blending tanks. The tanks will have a combined volume of 2150m3 (1075m3 each), and will be sized to provide a combined total of 4-days retention time prior to dewatering of the blended sludge. The tanks will operate in a duty/standby configuration, with either tank being available for selection as the duty unit for either filling or emptying. [caption id="" align="alignnone" width="1200"] Thickened sludge blending tanks - Courtesy of BAM Enpure Ltd JV[/caption] Each tank will feature separate inlet connections for the three types of sludge being received, with actuated valves and crossover lines allowing all sludges to be directed to either of the two tanks. The tanks will also feature outlet actuated valves, which will allow either tank to be isolated from the sludge belt press feed pumps downstream, thereby ensuring the pumps only draw from a single tank at any given time. A set of three duty/duty/standby sludge belt press feed pumps will be provided, which will transfer blended thickened and imported sludge from the thickened sludge blending tanks to the sludge belt presses. The pumps will be variable speed progressive cavity units, with a peak capacity of 30m3/h (i.e. 15m3/h per pump) at a maximum head of 48.5m, based on sludge of up to 7.0%DS. Dewatered cake leaving each belt press will enter a discharge cake hopper leading to the suction end of a sludge cake pump. Three pumps will be provided, with a single pump dedicated to a single machine; each pump will operate in conjunction with the associated belt press upstream. The pumps will be variable speed progressive cavity units, with a peak capacity of 7.4m3/h of sludge (up to 30%DS). The pumps will transfer the cake via individual discharge lines to the sludge cake silos, with manual discharge crossover facilities allowing sludge from the pumps to be directed to either of the two silos as required. Cake silo storage & discharge Dewatered sludge cake will be pumped to two truck-loading cake silos, with a combined storage capacity of 600m3, sized to provide 7-days of storage at average cake production. Each silo will feature a discharge screw conveyor (with a sliding frame ‘anti-bridging’ device) which will discharge the cake through a hydraulically operated slide gate valve. Odour control plant The odour plant will be a 2-stage system. Stage 2 filters will discharge into an 18-metre-high odour stack. The plant has been designed to achieve a minimum removal efficiency of 98% of H2S and 99% removal of odour, based upon a total system duty of 6629m3/hr, extracted from the various tanks and thickening/dewatering machines in the sludge plant area. New STW outfall Outfall route The outfall route from the new works site location was assessed thoroughly in the ITN 2 stage of the project’s life and from exiting towards the middle of the works site, proceeds north towards the River Wey. The route deviates initially to minimise any impact on significant trees that exist within the floodplain, and any impact on the band of vegetation around the perimeter of the site. Final effluent & stormwater pipeline The final effluent pipeline will be a 750mm diameter pipe. This will be situated above ground from the final effluent channel to the edge of the site, and will be supported by piles when within the treatment works site. The pipeline then proceeds below ground through the embankment (to be reinstated using clay stanks) and under the adjacent ditch via an inverted siphon arrangement. A jetting/access point will be provided just before the pipeline dives below ground, giving the facility to clean this arrangement and flush from a more direct point than the pipes exit from the final effluent channel. Air relief may also be provided at this point, subject to detailed design. The storm overflow pipeline will be a 1050mm diameter pipe. This will be situated below ground from the storm tanks to a sampling manhole at the edge of the site; supported by piles when within the treatment works site. The pipeline will then proceed from the manhole through the embankment (to be reinstated using clay stanks) and under the adjacent ditch via an inverted siphon arrangement. The sampling manhole will provide an ability to clean this arrangement. [caption id="" align="alignnone" width="1200"] (left) Outfall route plan - Courtesy of Bam Enpure Ltd JV, and (right) outfall low flow scenario CFD model - Courtesy of Arcadis[/caption] Outfall structure The outfall structure will consist of a reinforced concrete headwall, set back from the river channel, to be founded in the river terrace deposits and flared to direct flows downstream and minimise the impact of upstream debris from collecting. The headwall will have duckbill valves on the discharging pipes, and erosion control products utilised in the surrounding area to tie the headwall into the natural riverbank and bed. The erosion mattress employed following the headwall structure will provide a secondary point at which turbulent flows can dissipate energy without eroding the natural bed of the river. Where the headwall ties into the natural riverbank, the hard/soft interaction between headwall and natural soil will be reduced by the installation of Rock Rolls erosion control and willow stakes at the base, and the installation of a natural hydro-seeded CocoBN blanket or equivalent (to be seeded with local seed varieties) which will retain the slope shape until vegetation establishes and provides an effective natural erosion control. This will also provide a gradual slope to access down to the river. Programme The project obtained planning permission in October 2022, with construction works starting on site in July 2023. Detailed design of the civil, mechanical and electrical works are due for completion by December 2023. Construction of the works will be complete by August 2025, with commissioning due to commence in from April 2025 through to December 2025. Flows from the existing works will be diverted to the new works from December 2025 (10% flow) in a 7-stage commissioning process with 100% flows diverted to the new STW by March 2026. Following 100% flow diversion the existing STW will be de-commissioned ready for handover to Guildford Borough Council.

The water network in the western end of the Thames Valley Supply Area is dominated by local borehole water sources. Over time, population growth coupled with general environmental drivers to reduce reliance on groundwater sources in sensitive chalk stream areas, Thames Water has sought to improve supply resilience and deployable output by linking local sources via trunk mains. This allows movement of water from one area to another as well as to reliably supply the intermediary supply zones. Typically, water from Oxford that is produced at Farmoor Water Treatment Works is transferred via a series of trunk mains to maintain resilient customer supplies to approximately 90,000 people in Swindon and the surrounding supply areas. Background The existing Faringdon Water Booster Station (WBS) to Blunsdon Reservoir transmission system comprises a 700mm diameter asbestos cement pipe and a 900mm diameter glass reinforced plastic (GRP) pipe built in 1987 and 2001 respectively. This transmission system is approximately 15.8km long and has various interconnections between the pipes to provide resilience in service. The Faringdon WBS to Blunsdon Reservoir 900mm GRP main represents one leg of this network. Due to the high frequency of failures, which had a significant impact on Thames Water’s ability to transfer treated water into the Swindon area, work began in AMP6 to replace the highest risk section in the Highworth area and 2.8km was completed, including a crossing of the River Cole. Following the successful replacement in AMP6, and an increased deterioration of the existing 900mm GRP main, the remaining balance of scope (13.7km) was approved for delivery in AMP7. To mitigate the frequency of bursts and the impact of the deteriorating asset on customer supplies, temporary emergency abstraction licences at Baunton WTW and Latton WTW were secured with the Environment Agency to allow the existing GRP main to be operated at a lower duty. Project summary The principal drivers for the project are: To reduce the supply interruption risk to customers in Swindon and the Cotswold area. In a reasonable worst-case scenario, without the current mitigations it could equate to over 14 million minutes. To minimise the risk of customer complaints associated with low pressure and/or no supply. In a reasonable worst-case scenario, without the current mitigations this could equate to over 90,000 properties. To eliminate reliance on groundwater sources under emergency licences to cover the loss of flow during a burst. To reduce reliance on groundwater sources that draw from chalk streams and the River Kennet during high demand and drought conditions. To increase trunk main capacity and transfer rates to accommodate increasing flows for future population growth (principally in the immediate Swindon area). To eliminate the frequent and expensive repair costs of the existing GRP main sections. To restore Thames Water’s trunk main network resilience and bulk transfer capability in this area, which is fundamentally impaired when the Faringdon to Blunsdon main is operating at a reduced duty rating. [caption id="" align="alignnone" width="1200"] Google Maps image showing pipeline route[/caption] Planning and design Pipeline route: Initial design work was completed during AMP6 by Stantec UK as part of the Phase 1 delivery. The proposed route closely follows the existing 700mm asbestos cement and 900mm GRP mains, and there are several advantages to following this existing route: This represents the most direct route between Faringdon WBS and Blunsdon Reservoir thus minimising the overall length of pipework required. It is mainly through farmland and minimises the need to work in residential areas. It minimises impact on landowners. Ease of access for Thames Water through use of existing way leaves Existing information from previous investigations can be utilised. The AMP7 project was awarded to Kier Infrastructure and Overseas Ltd when detailed design of the pipeline route was reviewed and refined, taking account of ecological constraints, requirements from landowners and planned developments along the route. Archaeological mitigation: A programme of archaeological mitigation was undertaken by Wessex Archaeology following consultation with the relevant county archaeological advisors. A mitigation strategy comprised excavation, recording and the strip, map, and sampling. The archaeological excavations formed part of a staged approach consisting of an archaeological desk-based assessment, geophysical surveys, and archaeological evaluations. Through collaboration with the approving authorities, Thames Water adopted targeted route changes to avoid known areas of high archaeological interest. Generally, a small number of finds were found with possibly the most significant being a crouched burial in the Blunsdon section of the pipeline. [caption id="" align="alignnone" width="1200"] Archaeological investigations and (right) crouched burial - Courtesy of Kier Infrastructure and Overseas Ltd[/caption] Pipe material: As part of the design deliverables a technical note was prepared comparing ductile iron, carbon steel and HDPE as the three commercially feasible materials for this diameter range. The recommendation was to adopt HDPE PE100 as the preferred pipe material, using 1200mm OD SDR17 from Aliaxis UK. Pipework used in cross connections, existing utility crossovers, shafts and other special cases was designed using ductile iron supplied by Saint Gobain PAM UK, with mechanically restrained VE joints as required. Furthermore, for the tunnel sections, steel pipework with the E-Joint system was utilised supplied by Noksel España. To ensure asset design life, steel pipework was maximised for the critical tunnel sections with pipe wall thickness specified at 10mm, which was greater than Thames Water’s asset standard of 6mm. Based on the pH levels of the water the pipe would be conveying, a far superior asset design life of 100+ years could be theoretically achieved. Environmental impact assessment (EIA): During the initial stages of the project, several desktop and detailed environment, archaeological and third-party assessments and reports were compiled. This highlighted areas where further surveys and investigations were later completed ahead of an Environmental Impact Assessment Screening Opinion being submitted to the relevant councils for review. A full EIA was requested but this was, however, successfully challenged with the Secretary of State who did not consider the environmental impact would be of a magnitude necessary to suggest a scheme of this scale would result in significant environmental effects, which would exceptionally necessitate an environmental statement. This successful challenge still obligated Thames Water to work closely with the local approving authorities to deliver a comprehensive programme of environment and archaeological mitigation works for the route. [caption id="" align="alignnone" width="1200"] Pipes laid along route - Courtesy of Kier Infrastructure and Overseas Ltd[/caption] Faringdon to Blunsdon Trunk Main Phase 2: Supply chain - key participants Project delivery: Kier Infrastructure and Overseas Ltd Designers & specialist consultants: WSP Sahara survey: Water Research Centre Ltd Archaeological investigations: Wessex Archaeology Civil Engineering Contractor: CPC Civils Civil Engineering Contractor: OCC Services Ltd Trenchless crossings: HB Tunnelling Limited Shoring/temporary works: GroundShore Ltd Tunnel boring machine: Herrenknecht Precast jacking pipes: FP McCann HDPE PE100 pipe: Aliaxis UK Ductile iron pipes: Saint Gobain PAM UK Steel pipework: Noksel España Tunnel roller spacers: FT Pipeline Systems Pipe fittings, bends, tees & collars: George Green (Keighley) Ltd Pipe fittings: Wolseley Pipe fittings: Electrosteel Castings (UK) Ltd Pipe fittings: PTS (SA) Limited Valves: AVK UK Ltd Welding: Fabricon Ltd Welding: PTS Group Butt fusion welding machine: McElroy Manufacturing Independent weld inspector: Technical Innovation Servis Ltd Temporary fencing & gates: RF Gardiners Ltd Construction The project was classified as a ‘high consequence project’ requiring an enhanced level of quality assurance. To achieve this, several measures were implemented. As part of this strategy, the delivery contractor Kier Infrastructure and Overseas Ltd was briefed to deliver the project in phases to tactically reduce Thames Water’s operational risk until the project was fully commissioned. The project brief also included decommissioning of the existing fragile 900mm GRP which will be safely decommissioned following commissioning of the new DN1200 pipeline. The contractor will make allowances to ensure that the existing 900mm GRP main can be slip-lined in the future for additional resilience. [caption id="" align="alignnone" width="1200"] (left) Drive shaft, (middle) tunnel pipe insertion and (right) the completed tunnel - Courtesy of Kier Infrastructure and Overseas Ltd[/caption] Tunnelling: Open cut techniques were the predominant pipe installation methodologies and were undertaken by CPC Civils and OCC Services Ltd. However, several trenchless crossings were required for the major roads and rivers crossed by the pipeline route. The relatively straight forward digger shield tunnel boring machine was the predominant method used for trenchless crossings, including Bydemill Brook and the A361. The crossing of the B4019 proved more challenging however, when hard rock was discovered. This was because of a last-minute change in the location of the micro-tunnel shaft to avoid a new attenuation pond being built by a developer in the immediate area. Following a review of the new geotechnical investigation completed, it was agreed that the previous digger shield tunnel boring machine was not suitable to overcome the hard rock. Instead, the more robust variable density tunnel boring machine was employed with a specialist drill head brought in from Herrenknecht in Germany to cope with the density of the rock. Although the deployment of this complex machine took four weeks to set-up, the 180m long, 1.5m diameter tunnel was constructed in no time at all and was successfully completed in just over eight weeks. The trenchless crossings were undertaken by HB Tunnelling Limited. Pipe welding: An automatic butt fusion welding machine was utilised on the project to enable the joints to be made in what was an industry first. The machine from McElroy Manufacturing was shipped from the United States for the project, and enabled butt fusion joints to made up to 1200mm in diameter; a first of its kind in Europe. The automatic nature of the machine enabled far higher quality welds to be made and on a consistent basis as the human element of checking temperatures, raising of the welding plates etc. was eliminated. [caption id="" align="alignnone" width="1200"] Pipe welding operation and (inset) McElroy Manufacturing welding machine - Courtesy of Kier Infrastructure and Overseas Ltd[/caption] Welding work was undertaken by Fabricon Ltd and PTS Group with Technical Innovation Servis Ltd employed as an independent weld inspector to provide an additional level of assurance on the quality of the butt fusion joints made on the 1200mm OD PE100 SDR17 pipework. Commissioning Due to the large volume of water involved in commissioning each section of the new pipeline and significant flow rates required to achieve water quality standards, flushing lagoons were constructed to allow the safe and controlled disposal of the flushing water. Working in the community/customer communications Following disruption to landowners over many years due to frequent bursts on the existing GRP pipe, all contractors have been fully focused on maintaining and improving relationships with all landowners. At the time of writing (May 2023), Kier Infrastructure and Overseas Ltd and CPC Civils have worked very successfully with all landowners along the new pipeline route developing great working relationships. This has been demonstrated on a few occasions particular during the funeral of one landowner who CPC Civils had developed a great relationship with, when works were stopped so all workers could pay their respects. [caption id="" align="alignnone" width="1200"] (left) Funeral cortege - Courtesy of CPC Civils, and (right) Salvation Army Christmas present appeal 2022 - Courtesy of Kier Infrastructure and Overseas Ltd[/caption] Kier have also worked well with local councils donating materials for community initiatives, with CPC Civils also donating two portable defibrillators to support local campaigns, as well as supporting a Salvation Army present appeal on the run into Christmas 2022 to support families who would otherwise be unable to afford gifts for their children. The project has also given the opportunity to work with the royal agricultural university and bring students to site to understand the ecological and environmental impact and considerations on a project of this scale, as well as visiting their workshops to build owl boxes to be installed along the route of the pipeline. Summary Design of the £45m Faringdon to Blunsdon Pipeline Project commenced in November 2020 followed by a construction start in May 2021. [caption id="" align="alignnone" width="1200"] Flushing lagoons - Courtesy of Kier Infrastructure and Overseas Ltd[/caption] Commissioning and beneficial use of the pipeline is expected in November 2023 with all site works being completed by August 2024. This will complete replacement of the 15.8km transmission system providing resilience to supplies to help meet future supply and demand requirements.