Supply Chain - Project Planning & Surveying - Ultrasonic Surveys

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.

St Augustines Road is a busy thoroughfare in Chesterfield linking the town to Matlock and the south-eastern edge of the Peak District. Lying within the Yorkshire Water (YW) waste catchment area, the road is steep in its nature with gradients often exceeding 7%. Due to the local hydraulic catchment and topography, during heavy rainfall events flooding occurred at the road’s intersection with Derby Road (A6). The flooding lifted manhole covers from their frames which caused significant damage to the highway. It also caused internal and external damage to the surrounding properties. To combat this, mitigation was carried out by Yorkshire Water and Chesterfield Borough Council (CBC), including the implementation of mitigation measures such as non-return air bricks and flood gates, however, this had limited success. CBC also commissioned the construction of a detention basin to the rear of the flooding properties; but again with limited success. Hydraulic study As a result of the mitigation’s limited success, a hydraulic study was commissioned by Yorkshire Water. This confirmed the root cause of the flooding was hydraulic overloading of both the foul and surface water sewers. A notional solution was developed by Yorkshire Water which included the upsizing of these sewers, with some form of temporary storage for the foul system to retain flows in a rainfall event. Later iterations of the hydraulic model revealed that improvements to the surface water network would in fact also reduce the frequency of flooding on the foul water network due to interactions between the two systems during storm conditions. In light of this information, in May 2021 Yorkshire Water secured funding to implement a series of significant improvements on St Augustines Road. Preferred solution The preferred solution included the construction of a new outfall into the River Rother and the transfer of all flows from the surface water sewer in Derby Road. This would provide a much greater flooding resilience in the existing system. The existing 225mm surface water sewer was to be upsized to Ø750mm along its 320m length. It would then be diverted via a tunnel underneath Derby Road into the wetland area immediately adjacent into the River Rother. Here, a new outfall would be constructed to discharge the surface water sewer into the river network. [caption id="" align="alignnone" width="1200"] (left) The preferred option and (right) flooding on St Augustines Road - Courtesy of Galliford Try[/caption] Constraints and engineering challenges The preferred solution progressed to detailed design with several technical challenges to be overcome. Several of these challenges were exacerbated by the need to construct the outfall into the River Rother outside of the salmonoid spawning season. An Environment Agency (EA) bespoke Flood Risk Assessment Permit, (FRAP) was required to construct the outfall and all in-channel activities were required to be undertaken before 1 October 2021 in order to mitigate the impact on any spawning salmon. A significant flow rate of up to 0.89m3/s would be discharged into the river during storm events and river scour was a concern. In order to combat the scour on the riverbed and riverbanks, there was a requirement to reduce the velocity of the flow before it interacted with the River Rother, causing excessive turbulence. To achieve this, box culverts were selected due their unique cross section and significant channel width. This slowed velocities down to near 1m/s, which is widely regarded to have negligible effects on turbulence and thus reducing scour. The headwall was also designed to allow flows to enter the River Rother at a 45° angle, as per EA Standard Rules SR2015 guidelines, further reducing the risk of scour on the opposite riverbank and riverbed. Outfall design This design however did not come without complications, such as the need to carry out the structural design, build and installation of a bespoke outfall within a few months. BSP Consulting was commissioned to carry out the structural design of the outfall which was to be precast, reducing the need for in situ concrete handling adjacent to the sensitive receptor. Off-site build (OSB) also reduced the construction programme and allowed the headwall to be manufactured concurrently within the determination period of the FRAP. [caption id="" align="alignnone" width="1200"] Outfall under construction - Courtesy of Galliford Try[/caption] Poor ground and underfoot conditions adjacent to the River Rother proved too risky and problematic for traditional mobile crane lifts, so all lifts of the precast sections were to be undertaken with a tracked excavator. This further constrained the design and restricted the maximum mass of each section to 13 tonnes. Consequently, in its final iteration the precast headwall was designed in two sections and was combined with an in situ toe and infill slab/wall which completed the structural design. Design During the design stages, extensive ground investigation was carried out. This identified water bearing sand and gravel strata adjacent to the river which transitioned to mudstones and clays towards St Augustines Road. It was this change in strata which posed a significant challenge for the no-dig section of the work beneath Derby Road. This section of work was critical as it linked the outfall to the upsizing work on St Augustines Road. Discussions were held with Active Tunnelling Ltd who proposed the use of the guided auger bore technique to install the sewer in this transitional strata. Although initially designed as a 750mm diameter sewer, this was reduced to 600mm which was the maximum diameter which could be accommodated by the tunnelling contractors. Hydraulic modelling was undertaken by RES Environmental to confirm the viability of this proposal and in order to compensate for this localised throttling, the pipeline had to be upsized locally to 900mm immediately upstream of the tunnel. The alignment of the tunnel was severely limited due to proximity of existing buildings on Derby Road. BSP Consulting was again called into action as pre-condition surveys and settlement calculations were commissioned in order to understand the impact of the tunnelling works on these at-risk properties. [caption id="" align="alignnone" width="1200"] (left) Installation of drive pit on St Augustines Road, (middle) guided auger bore rig, and (right) the transition between 600mm and culverts - Courtesy of Galliford Try[/caption] Settlement calculations were undertaken using the “Guide to best practice for the installation of pipe jacks and microtunnels technique” and a predicted settlement of <3mm was deemed to be acceptable. The pre-condition surveys highlighted only minor cosmetic issues and were used as reference to the state of repair of the properties prior to construction work commencing. The majority of the civil design was undertaken in house. This element included a design coordination role combining and processing the information received from the consultants and stakeholders. An example of the numerous stakeholders which were consulted is that of the Coal Authority. Initial searches indicated the presence of historical coal workings. More detail was sought and records indicated the presence of an adit within 20m of the proposed pipeline. A coal permit was sought from the Coal Authority and the design progressed whilst this was processed. St Augustines Road (Chesterfield) Flood Alleviation: Supply chain: key participants Principal contractor & civils design: Galliford Try Temporary works & headwall design: BSP Consulting Hydraulic modelling: RES Environmental Ltd Ecological consultants: Middlemarch Environmental Traffic management: Amberon Traffic Management GRP & utility mapping: Cloud Conversion Ground investigation: Grange Geo Consulting Ltd Pipelaying & outfall construction: Arthur Civil Engineering Trenchless installation: Active Tunnelling Ltd Cofferdam design & supply: National Trench Safety UK ‘EndSafe’ safety barrier: Groundforce Shorco Cofferdam installation: Ivor King The Piling People Dewatering: Alba De-Watering Services Ltd Precast concrete: Bonna Sabla CCTV, CIPP & cleansing: CPS Drainage Solutions Handrailing & grille design: Galliford Try (Fabrications) Silt curtain: Murlac Land and Marine Environmental Solutions Pumping: Selwood Ltd Ridgistorm pipes: Polypipe Civils Pipe & flap valve supplier: Keyline Civils Specialists Landscaping & site clearance: Landscape Maintenance Services Ltd Reinstatement of traffic signals & street furniture: Swarco Aggregates & muck away: JC Balls & Sons Brickwork: Derwent Joinery & Construction Gates & fencing: SFC (Midlands) Limited Surfacing: BDS (Yorkshire) Ltd [caption id="" align="alignnone" width="1200"] Service detection - Courtesy of Galliford Try[/caption] Installation The Environment Agency granted the FRAP on 13 August 2021, and the detailed design was finalised and submitted to Yorkshire Water’s technical approval committee on 16 August 2021. Work began on site a few days later, leaving just six weeks to construct the headwall and cease all in-channel activities as per the conditions of the FRAP. Work commenced immediately on the enabling works, with particular attention paid to the temporary works. Haul road To provide drainage to the waterlogged land adjacent to the River Rother, a land drainage scheme was commissioned, designed and installed by Lincolnshire Drainage. This provided a more suitable foundation on which to install the haul road and working laydown areas. The haul road was designed by BSP Consulting and was of substantial construction given the underlying strata, at 700mm thickness with geotextile layers to improve longevity. Ground dewatering After the installation of the haul road, wellpoint dewatering was installed around the outfall area and along the proposed culvert alignment. The dewatering was installed by Alba De-Watering Services Ltd at 1.5m centres. However, due to the underlying mudstone, each well had to be pre-augered and was then installed using the more traditional spout method to ensure that a reasonable well depth was achieved to adequately dewater the working area. A silt curtain was supplied and installed by Murlac Land and Marine Environmental Solutions prior to the channel works to minimise silt and sediment damage downstream from the works. It proved to be very effective during the cofferdam installation. [caption id="" align="alignnone" width="1200"] Cofferdam and silt curtain - Courtesy of Galliford Try[/caption] Cofferdam A cofferdam was required to retain the River Rother and this was designed and supplied by National Trench Safety UK and installed by the primary subcontractor Arthur Civil Engineering. The cofferdam was unique in design in that it utilised Larsson piles in a trapezium shape (plan) to minimise over-dig yet still accommodate the headwall and first culvert. The cofferdam was installed by Ivor King The Piling People using a 35t excavator with a Movax side grip pile driver attachment. The cofferdam was effective but 4” end suction pumps supplied by Selwood Ltd were still required to maintain the cofferdam and keep water levels low. Headwall installation Once the cofferdam was watertight, the headwall toe was cast in situ, after which the precast headwall arrived in two sections as planned. It was lifted into position by Arthur Civil Engineering using a 50t tracked excavator. An administrative issue led to the need to negotiate a 2-week FRAP extension with the EA and the headwall was completed and the cofferdam removed by 14 October in accordance with the conditions of the revised FRAP. Pipeline works Construction works on the remainder of the project continued in March 2022. A temporary one-way system was implemented to provide a safe working area to install the remainder of the pipeline with open cut works commencing on 14 March. The open cut works progressed steadily with over 100 services safely crossed. The later spring and summer months provided excellent conditions for online sewer relay with drought-like conditions, culminating in hosepipe bans for the majority of the UK. [caption id="" align="alignnone" width="1200"] Open cut pipelaying - Courtesy of Galliford Try[/caption] Prior to the tunnelling works commencing, concern was raised over the proximity of the tunnel as it crossed under a 225mm foul water sewer in Derby Road. With a clearance of just 300mm, the existing foul sewer was inspected by CPS Drainage Solutions using CCTV and a precautionary 5m cured-in-place patch liner was installed to strengthen the sewer prior to the guided auger bore operation. No-dig works commenced in early June and progressed well without incident and were completed towards the end of the summer. No settlement was detected during the installation and no visual deformations were reported from the nearby structures. Open cut works continued late into the summer with flooding benefits delivered by 5 October. Significant rainfall events have since occurred and the feedback from residents previously affected by the flooding has been positive. Off-site build Off-site build was utilised heavily without which it would not have possible to abide by the conditions set in the FRAP and achieve the tight programme when constructing the outfall into the River Rother. The headwall and culvert manhole cover slabs were precast by Galliford Try off site and the hand railing and grille were fabricated by Galliford Try (Fabrications). The flap-valve was fabricated off-site by Keyline Civils Specialists. [caption id="" align="alignnone" width="1200"] 900mm Ridgistorm pipe from Polypipe Civils ready for installation - Courtesy of Galliford Try[/caption] Public engagement & community impact Throughout the project customer engagement was a priority for Galliford Try and Yorkshire Water. Although COVID-19 curtailed some of the engagement meetings which were planned at the start of the project, regular communication with residents of St Augustines Road and surrounding area took place. A significant quantity of the communication was made to the local residents Facebook group, which provided timely and accurate updates on progress. Traditional letters were also posted as back up and for those who didn’t have access to Yorkshire Water’s online updates. Towards the end of the project volunteers from Galliford Try and Yorkshire Water spent a day helping out at the local food bank on St Augustines Road and made a donation of £500 to assist with their ongoing charitable cause. Project success The project is considered huge a success for Galliford Try and is the largest single project completed on the Infrastructure Framework for Yorkshire Water within the AMP7 period.

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.

Potters Way, located in the Fengate area of Peterborough, is a recent housing development next to the A1139. The development was built on the grounds of the former Fengate Water Recycling Centre (WRC) which closed in 1988 following the construction of the Flag Fen WRC. In early December 2018, Anglian Water became aware of the collapse of a section of 1500mm diameter concrete sewer pipe in Potters Way when a small hole was found after a customer used a ride-on lawn mower over the area. Temporary repair works were undertaken by the Integrated Operational Solutions (IOS) Alliance - a partnership between Anglian Water, Kier, Barhale and Morrison Utility Services - while a permanent fix could be designed and implemented. Background By the end of December, the IOS Alliance had installed a temporary repair using a vacuum excavator to safely clear the collapsed pipe before using half-pipe and canvas to seal the collapse. The area was also fenced off to prevent pedestrian access and ensure site safety. During this period, Anglian Water received several complaints from customers over the odour created by the collapse. Following meetings with the residents, Anglian Water’s Water Recycling Networks (WRN) team further sealed the excavation and installed carbon filters to the air valves. At the same time, the team repaired holes found in the rising main pipework at the nearby tower. The site was then handed over to the Anglian Water @one Alliance to implement their repair solution with @one partner company Barhale engaged as principal contractor. [caption id="" align="alignnone" width="1200"] Installation of the overhead diversion - Courtesy of @one Alliance[/caption] Finding a solution One of the challenges presented in finding a solution for this project was the high flow rate of the pipework, with modelling of Potters Way showing flow rates of 3,700 litres per second in the event of a 1 in 30-year storm. Downstream of Potters Way, this rises to 4,000 litres per second. To make the matter even more complicated, the pipe featured several significant bends along the affected route that increased the difficulty of finding an adequate solution. An extensive survey of 2.8km of sewer identified 1.79km of concrete sewer pipework ranging in diameter from 1050mm to 1950mm had a condition grade of either 4 or 5. All these pipes were identified as having been subjected to a hydrogen sulphide (H2S) attack which had caused the significant deterioration. The @one Alliance set out to repair an area of the network by covering a key 500m of pipework which serves the majority of Peterborough. Potters Way Sewer Rehabilitation: Supply chain Project delivery: Anglian Water @one Alliance Temporary repairs: Integrated Operational Solutions (IOS) Alliance Principal contractor: Barhale Over pumping: Vanderkamp UK GRP pipe lining: Amiblu Norway AS Lining & manhole repair: OnSite Central Ltd Specialist CCTV Survey: Bright Innovations Group Foam concrete: GS Foam Concrete Diamond cutting: SCS Ltd Cover slabs: FP McCann Ltd Temporary works/shoring: Groundforce Pipe rehabilitation The @one Alliance solutions team opted for a multi-stage solution due to the complex nature of the pipework and the compact area the teams would be working in. In order to repair the sewer, it was decided that a mix of CIPP (cured in place pipe) and GRP (glass reinforced plastic) lining would be used. The majority of the rehabilitation was completed using CIPP lining which allows the lining to be inserted into the shell of the existing, damaged pipework where it is then pressurised and cured in place with ultraviolet (UV) lights. The CIPP relining was split into eight sections covering approximately 360m of the repaired pipeline. At 1375mm in diameter, this installation was the largest diameter CIPP liner that the @one Alliance had ever installed. Six of the eight lengths of CIPP were installed under the A1139. Over pumping In order to fit the CIPP liners, the team utilised an over pumping set up capable of 250 litres per second (l/s). By using bungs at split manholes on the nearby Bourges Boulevard, the team could redirect the flow and use the pumping set up to divert the rest of the flow. The over pumping solution was provided by Vanderkamp UK who had remote monitoring capabilities from the Netherlands and provided the site teams with a mobile app allowing them to see real time data giving them advanced warning of increased flows which would require the removal of the bungs. Without this passive flow management, the over pumping setup would have needed to be able to cope with an excess of 2,000 l/s. The set up was made up of two pipe bridges 350mm in diameter and 5.5m high to allow clearance for high-sided vehicles. GRP lining Alongside the CIPP lining, the team also used GRP lining on a 48m section of 1500mm diameter sewer executing the rehabilitation in live flow conditions of approximately 850 litres per second; the first time the @one Alliance had installed GRP lining in live flow conditions. [caption id="" align="alignnone" width="1200"] (left) Live flow conditions and (right) inserting a new section of Amiblu Norway AS GRP pipe - Courtesy of @one Alliance[/caption] Operating in live flow removed the necessity to install an additional over pumping solution that would have dealt with 95% of Peterborough’s sewage as it combined into one flow towards Flag Fen WRC. In order to commence the GRP lining, the crown of the pipe was removed on a bend and concrete platforms were constructed on either side ensuring a safe working area. A pipe pusher attachment was then used to insert segments upstream and downstream from the bend location. Finally, a prefabricated GRP bend section was installed and connected to straight sections. To safely cut the existing mains the team needed to excavate an area of 6m x 4.5m with a depth of 3.5m. While having to excavate in an urban area is an option the team would have liked to have avoided, the next best solution to the live flow repair would have included installing a temporary pumping station that would have taken up all of Potters Way’s parking and grass area requiring 10 pumps and a 10m x 7m x 7m temporary wet well to complete the required repair. This would have been a major inconvenience for residents and would have seen an increase in the overall cost of the project of 200%.

Amiblu relining pipes to protect sewer networks from H2S attacks - Courtesy of Amiblu Norway AS

Manhole rehabilitation As part of the pre-work checks, it was identified that eleven manholes along the section of pipework required rehabilitation of various levels with the most severely affected requiring structural repair as a result of H2S attacks. Core samples were taken from one manhole which identified that in some places, more than 150mm of concrete had been lost to H2S attacks with no rebar remaining in any of the samples. To repair the manhole, the team used a concrete spray to bring the walls back to their original 250mm thickness, once this had cured a primary and finishing layer were added to ensure full protection against H2S attacks in the future. A new cover slab was also installed after the original was removed to provide access to the manhole, made of precast concrete the slab was also treated for H2S protection. [caption id="" align="alignnone" width="1200"] (left) H2S attack on a manhole and (right) inside a relined section of pipe - Courtesy of @one Alliance[/caption] Challenges Weather provided a significant challenge for the implementation of the solution as the site experienced an unusually heavy rainfall. Flow rate analysis for Flag Fen WRC shows that in the previous five years the average rainfall for the area fell between 35mm and 60mm. August 2020 saw average rainfall of 137mm. Because of the heavy rainfall several weather warnings were issued placing all CIPP lining activities on hold. The impact of the weather was so severe the flow of water increased from its usual 850l/s to 4,000 l/s in just 10 minutes. In order to reduce the risk of flooding outside the Magistrates Court the bungs were deflated, and the flow reverted. Due to the innovative combination of flow diversion and overpumping used in the CIPP lining the impact of the delay was significantly reduced compared to if the team had used the temporary pumping station solution. Rising mains issues During the repair of the sewer the @one Alliance became aware of complaints from the residents regarding the twin rising mains on Potters Way which used to feed into the old Peterborough STW and was diverted into the new gravity sewer discharging into Flag Fen WRC. The primary complaint from customers was the odour produced by the rising mains. The old Peterborough STW was sold for development and the rising mains tower was marked for removal. In early 2022 the @one Alliance returned to Potters Way removing the rising mains and installing a pumping station kiosk removing the odour and significantly reducing the visible profile in the area. Result Anglian Water invested £2.8m into the Potters Way project which will now allow customers across Peterborough to continue to use their taps and flush their toilets without second thought. The relining of the sewer network has ensured the network in the Potters Way area is now protected from H2S attacks for the next 50 years. Colin Handley, Construction Manager said:

“There was fantastic team collaboration between our Tier 2 Supply Chain Partners, the Principal Contractor (Barhale) and the @one Alliance, making it one team delivering the programme. The teams worked tirelessly to monitor the smells and reduce odours, whilst working in open excavations. They purchased additional fans and diverted rising mains to lower H2S and to allow the teams to work safely.”

As assets age, they start to work less efficiently than they did at their installation. Anglian Water proactively CCTV surveyed the sewers and found evidence of hydrogen sulphide attack, which corrodes concrete sewers resulting in weakening of the pipework and eventual collapse. In September 2023, the @one Alliance Sewer Rehabilitation Team completed a project in Grays, Essex, off the A1012 Treacle Mind Roundabout near the A13, where they rehabilitated over 840 meters of 900mm concrete sewer pipe along Lodge Lane - a crucial lifeline for a highly populated residential area. Planning

From the outset, it was clear that this undertaking would require an innovative approach beyond conventional sewer lining and over pumping techniques. Two main challenges were faced by the project team.

The first challenge was to determine how to rehabilitate a 324m manhole-to-manhole stretch at this massive diameter at such a busy location and under tight highways restrictions. The team realised that they needed to trace the line and identify an optimal location for a new access point - a crucial step to break down the sewer into more manageable sections. Considering that the sewer crosses Lodge Lane halfway through, added with the need to avoid existing services and our bypass pipework, it became apparent that this was not a viable option.

[caption id="attachment_13360" align="alignnone" width="1200"] Overpumping pipework - Courtesy of @one Alliance[/caption]

The second challenge the team faced was the need for the sewer to be empty while the rehabilitation works took place. The team decided that in order to resolve this challenge, they needed to install a temporary above-ground pipe to divert the sewage flows.

This job was a significant undertaking, and one that required close collaboration with Vanderkamp UK. Working together, the @one Alliance/Vanderkamp UK team considered sustainable solutions to mitigate flows and ensure the continued integrity of Anglian Water’s infrastructure.

To manage flows and ensure uninterrupted service to customers, temporary connections were established on the existing 600mm and 375mm dia. rising mains within the Treacle Mine Roundabout. These mains, originating from the Stifford Corran Way and Stifford Clays Pumping Stations, require pumping of up to 350 l/s.

The aim was to maintain seamless flow and mitigate any potential flood risks, so the bypass was routed through in-line duty/standby booster pumps strategically positioned within the roundabout. This innovative approach eliminated the need for suction pits or wet wells. Through extensive modelling, the team identified the need to incorporate booster pumps, as the existing pumping stations could not pump the additional 1km of 500mm bypass pipework, which included 16 pipe bridges and hoppers.

Vanderkamp UK undertook continuous and meticulous remote monitoring which ensured the successful execution of this complex and critical project.

[caption id="attachment_13366" align="alignnone" width="1200"] Vanderkamp UK’s temporary overpuming pipework while OnSite Cental undertake the CIPP lining works - Courtesy of @one Alliance[/caption] Grays Sewer Rehabilitation: Supply chain - key participants Client: Anglian Water Project delivery: @one Alliance Bypass pipework (1km of 500mm pipe): Vanderkamp UK Cured in place relining: OnSite Central Ltd CIPP liner supply: IMPREG GmBH Traffic management: TBF Traffic The 324m manhole to manhole stretch

Addressing the first challenge of rehabilitating the large manhole to manhole stretch, the team collaborated closely with Tier 2 Supply Chain partner OnSite Central Ltd, to prove a cured in place pipe (CIPP) relining solution. The @one Alliance challenged OnSite to develop a game-changing method that would enable a one-shot installation of the 324m length.

After exploring various options, including a single-cure installation that posed complications due to power cables, a 50/50 cure approach was selected, partially curing the liner in both directions.

To ensure the liner’s integrity throughout this process, OnSite Central Ltd ingeniously employed special sluice bags to keep the liner inflated while moving the light train to the other manhole; effectively preventing any shear damage to the liner during the transition between cured and uncured sections.

[caption id="attachment_13362" align="alignnone" width="1200"] OnSite Central’s CIPP lining operation - Courtesy of @one Alliance[/caption]

The deployment of specialised equipment, including a large 20-ton winch, a larger roller bed, crane pads, and sluice bags, incurred additional costs, however, savings totalling approximately £35k included avoiding the need for an additional liner installation, a week of over-pumping, and substantial running costs. Additional significant savings were gained by removing the requirement for a new 6m deep access point and extended road closures.

In terms of sheer length, this installation now holds the record as the longest the Anglian Water @one Alliance Sewer Rehabilitation Team has ever undertaken. OnSite also suspect that it might even be a record-breaker for UV installations in the UK, if not globally! Typically, cable length restrictions cap such installations at around 300 meters, making this 324m achievement truly exceptional!

Challenges

As with any project, challenges arise. Added to the previous challenges mentioned, the team had plenty more to overcome.

Ensuring resources: Learning from concurrent @one Alliance projects, from the outset, the team knew that they needed to ensure resources were available for the project to commence, therefore early resourcing was required to overcome issues on programme later down the line.

Avoiding planning issues: Once the project started, the tight highways restrictions throughout and multiple live permits in the area could have caused planning issues if the team had not realised these early and planned for them at the start of the project, so they worked with Highways early to identify a suitable working window.

[caption id="attachment_13363" align="alignnone" width="1200"] Traffic management during the works - Courtesy of @one Alliance[/caption]

Emergency road closure: Another issue was having to emergency-close Lodge Lane due to two leaks across the pipe bridges. The team identified these by using treated final effluent to ensure no pollution events would occur. To resolve this issue, an emergency road closure was put in place on Lodge Lane for 2 hours from 8-10 PM in order to safely access the pipework at the leaks and tighten the bolts. After collaborations with Highways the closure in place safely put in place.

Additional cleaning: Once flows had been diverted and a detailed CCTV survey was undertaken, it was apparent that more cleaning of the sewer pipe was required, taking longer than was originally anticipated. In order to claw this time back and ensure the project completed on time, the team installed two liners in a week. To do so, the final liner installation needed to be extended into the weekend. This required an adjustment to the road closures on Windsor Avenue which was agreed with Highways and communicated to the local residents.

Avoiding potential issues: Challenges do not only affect the project team; they also affect customers. The team was made aware of visibility issues due to the temporary pipework obstructing the view from a junction, creating a potential blind spot. Responding promptly to feedback from the public, the team worked with the Highways Inspector to install temporary mirrors and mitigate the issue.

Customer engagement

The @one Alliance has a clear purpose to bring environmental and social prosperity to the Anglian Water region, and this is dones by ‘Making Today Great – every day, in every interaction’.

[caption id="attachment_13365" align="alignnone" width="1200"] Customer information boards - Courtesy of @one Alliance[/caption]

The @one Alliance was aware that the work at Grays would impact customers throughout the project lifecycle, so processes were put in place to effectively communicate with customers across the area in a variety of ways.

Open day: On April 26th, 2023 an open day was hosted at Stifford Parish Hall to give the community the opportunity to meet the team and ask any questions or share any insights before the project began to ensure they had a clear idea of the plan for the project. Communications: Customers were notified about the works via letters, emails, SMS campaigns and a dedicated scheme board. In total, over 1,444 letters and 970 emails were sent to residents on top of 13 SMS campaigns which resulted in 2,755 customers receiving text messages to let them know of specific road closures and project updates. Social media: Projects updates were regularly updated on Anglian Water’s “In Your Area” website for customers to view and on its Facebook page. The Facebook page reached 63,387 customers in total throughout the project. CSAT score: A record number of 9+ scores were received for a scheme with a resulting in a 9.18 CSAT score.

Meticulous planning ensured customers were aware, questions were answered, and feedback was received. Overall, customers have praised the work that has been undertaken; emphasising the minimal disruptions and their appreciation for the use of temporary traffic lights.

Outcome

The works started in June 2023 and completed in September 2023 with the removal of the temporary pipe bridges and traffic lights. Over 840 meters of 900mm sewer pipe have been successfully rehabilitated along Lodge Lane. The project was delivered on time, and gained positive customer feedback, positive relationships with the local council and Highways authorities and a great working relationships with our Tier 2 suppliers Vanderkamp UK and Onsite.

The River Lyd Pumping Station is consented to abstract up to 40 Mld from its intake source at Lifton, Devon during November through to March, pumping raw water approximately 7km to Roadford Reservoir. The pumping station was last used on a full operational basis during the mid-1990s and the original equipment had remained in a shutdown and non-operational state up until the point of the upgrade works. The existing electrical switchgear was deemed to be life-expired and beyond the state of any possible refurbishment. The primary driver for the scheme and the scope of works was to upgrade and re-commission the pumping station for operational use at full output design capacity. During the course of the capital works project, a temporary works scheme was implemented in order to maximise operational use of the available pump sets while the capital build was in progress. Background The pumping station is configured with six Pleuger-type QN borehole pumpsets supplied by Flowserve Ltd and which had been previously refurbished by the manufacturer in the intervening period, and the pumps were maintained in storage at Roadford Reservoir. Four pumps are sized at 5 Mld and two at 10 Mld, providing for a combination of flows up to 40 Mld. The discharge from the common pump manifold is to the 900mm diameter rising main to Roadford Reservoir operating with a system pressure at 11 bar. At the works, two surge anticipation valves protect the pipeline in the event of failures and resulting critical surge conditions. Downstream of the common pump discharge manifold, and within the section of pipework that forms the washout connection at the river headwall, are two pressure transducers which have been installed to provide high pressure alarms and initiate pump stop in the event of an adverse operating condition and to afford protection to both pumps and also the rising main. From the common discharge, manifold flows leave the site through the existing 900mm rising main and are measured by a new Siemens electromagnetic flow meter installed as part of the refurbishment works. Eel screens Prior to the upgrade and re-commissioning works of the pumping station, a separate contract was undertaken by Galliford Try in 2021 to replace the river eel screens. The scope of works in this respect was to make the connections between each of the eel screens designed and manufactured by Andritz Ltd and a new air-burst cleaning system. The air-burst compressed air system is a self contained package plant designed and built by Quantum Engineering Developments Ltd with its own local control panel and PLC which control the cyclical cleaning of each of the eel screens. Local alarms are initiated at the LCP and key alarms are relayed back to the main plant MCC as required. Duty/standby screw type air compressors are installed, supplying a single air receiver with operating pressure at 9 bar. There are six air lines that connect with its respective screen and the control of air is via electro-pneumatically operated valves installed at the air compressor skid. Flexible 50Nb air hoses are installed in ducts and connect each piped outlet with a connection to the eel screen. Within the pump chamber a piped manifold of manual isolating valves and air hoses has been installed to provide for the connection to each eel screen. [caption id="" align="alignnone" width="1200"] Airburst package plant - Courtesy of Galliford Try[/caption] HV & LV electrical works The scope of HV electrical works required the re-establishment of the HV supply to the site and these works have been undertaken by National Grid to provide a new 1250 kVA supply to their existing substation on the site and inclusive of new interconnecting HV cabling from their primary substation. A new transformer of required capacity has been designed and manufactured by Wilson Power Solutions Ltd under supply to Enerveo who have completed the site HV installation. The LV side of the transformer is connected to a new form 4A Type 3 MCC which has been designed and manufactured by Galliford Try. The build incorporates the six soft starts for each of the existing 190kW and 110kW pumpsets. The incomer is rated at 2000A and busbar 2500A. Phase failure, surge protection, and transformer protection are incorporated within the build. There are common controls section, distribution board feeders, 110V and 24V supplies. Plant control and surveillance is managed by a Schneider Electric PLC and HMI which are built within the C&I section. Water quality monitoring A containerised suite of raw water quality instruments has been installed in accordance with the requirements set out in South West Water’s Technical Standard for Intake Protection & Raw Water Monitoring. The respective quality parameters measured are colour, turbidity, ph/temperature, dissolved oxygen, and ammonia. The sample is drawn from the River Lyd by a pair of duty/standby Grundfos JP sample pumps and which are connected to the river headwall by means of dedicated ducted 25Nb flexible sample pipes. Actuated GF ball valves within the piped discharge local to the pumps allow for the sequencing of the duty/standby changeover, air scour sequence and back wash of the sample lines during the changeover cycle. Flow monitoring to the instruments is by means of inductive type flow meters. The control, monitoring, alarm initiation and operator interface is via a local control panel complete with HMI and PLC. River Lyd Pumping Station: Supply chain: key participants Principal contractor & designer: Galliford Try Pumpsets: Flowserve Ltd Flow meters: Siemens PLCs & HMIs &amp; switchgear: Schneider Electric Eel screens: Andritz Ltd Air-burst compressed air system: Quantum Engineering Developments Ltd Generators: Aggreko UK HV transformer: Wilson Power Solutions Ltd HV installation: Enerveo JP sample pumps: Grundfos Software development & automation: Galliford Try Rising main: Kier Group Instrumentation: IFM Electronic Instrumentation: Partech Instruments Capital works delivery Before any works could be undertaken, significant tree and overgrown vegetation clearance had to be carried out at the entrance to the pumping station and along the lengths of the access paths and tracks that connect with the top of the site and the existing HV substation. GPR, topographical and ecological surveys were undertaken to establish conditions. There then followed a programme of dismantling works to remove the original GRP kiosk housing the 1990s MCC and transformer. The programme of civil works provided for the construction of reinforced concrete bases for the new 1250kVA transformer and air-burst package plant respectively. Installed on these bases are new GRP enclosures that provide the necessary protection for this equipment. A third GRP kiosk has been installed as the enclosure for the new MCC which utilised the original constructed base slab and trench albeit extended for the larger switchgear build. Elevated concrete piers have been constructed for the container housing the raw water quality instruments and with due consideration to the known risk of flooding at the site. The new enclosures required the submission and approval of a planning application. New ducts and drawpits have been installed to provide for the routing of pipework, HV and LV cables. The scope of mechanical installation works principally involved the re-installation of the refurbished Pleuger pumpsets and the associated pipework connections to the existing delivery manifold and rising main; the installation of the new airburst eel screening compressor skid and its hook up requiring a new air distribution system within the pumping chamber to supply each of the individual eel screens. The scope of the electrical installation works has been principally the uprating of the original 1000kVA supply to 1250kVA. This has required two new HV supply cables to be installed from the primary substation to the River Lyd site. A new HV transformer from Wilson Power Solutions Ltd and switchgear from Schneider  Electric has been installed to make the HV connection. The new Form 4 MCC has been designed and built as the replacement switchgear incorporating the most up to date electronic components and compliance with SWW Technical Standards. The software development and automation works has been carried out by Galliford Try. [caption id="" align="alignnone" width="1200"] (left) River water sampling container on flood prevention supports, (middle) Aggreko UK duty, primary assist and secondary assist generators, and (right) Generator flood prevention as design by the design team - Courtesy of Galliford Try[/caption] Temporary works During the period of the capital works build, and with continued falling level in Roadford Reservoir, Galliford Try was asked to put in place a temporary system of operation for the six installed pump sets using standby generators and temporary switchgear. Working with Kier Group, Galliford Try took charge of the works at the pumping station and Kier Group the rising main to Roadford Reservoir, responsible for checking, filling, flushing and pressure testing the pipeline; mindful that the system was last used in 1996. The original remit was to have the temporary plant installed and connected to allow the existing six pumps to operate by the 1 November 2022. All parties achieved their objectives, however South West Water was unable to obtain approval from the Environment Agency (abstraction permit) in the same timescale. This did however provide more time to allow Galliford Try’s capital works team to incorporate process elements of their capital build into the temporary works (flow meter replacement, air-burst compressed air system, telemetry and online operational water quality instruments). This has provided South West Water and the Environment Agency with a more robust pumping arrangement and water quality monitoring regime. Although the pumps and temporary works operation is scheduled to the end of March 2023, there is the possibility of an extension until the end of May 2023 which is being discussed between South West Water and the Environment Agency. Completion At the time of writing (April 2023) the capital works completion has been achieved insofar as it can be until such time as the temporary works operation has finished and the equipment removed off site. Following on from this, final landscaping will be completed along with those works required to complete all permanent connections to enable the pumping station to come back into operation from the beginning of November 2023.

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.