At Processplus, we pride ourselves on delivering intelligent engineering solutions that not only meet current operational needs but also pave the way for future site expansion. Our recent project at a client’s Wastewater Treatment Works (WWTW) is a prime example of this forward-thinking approach.

The Challenge

The client required the replacement of two aged and unreliable inlet flowmeters, as well as two storm open channel flowmeters, to ensure accurate and consistent measurement. In addition, the client sought to upgrade the site infrastructure to allow for seamless expansion in the future. This included automating new Rotork inlet valves using 4-20mA control signals from the flowmeters and installing new field services. Complete with marshalling panels and spare capacity, wired back to the MCC.

Our Solution

Processplus provided a detailed, all-encompassing quotation to deliver every aspect of the client's brief:

• Inlet Flowmeters: We proposed and installed Nivus POA insertion flowmeters with hydrostatic pressure devices in two partially filled pipes. These units accurately measure both water velocity and level to derive volume flow. Thanks to the hot tap installation method, we were able to carry out the work without needing to isolate the pipeline.

• Storm Channel Flowmeters: Siemens LT500s with XRS-5 sensors were selected as like-for-like replacements, offering a reliable and accurate measurement solution.

• Electrical & Field Expansion Works: To support future expansion, we designed and delivered a robust electrical solution, including the off-site manufacture of instrument panels, power/signal enclosures mounted on Unistrut frames, and large multicore signal cables. Comprehensive power calculations ensured correct cable sizing, while the containment systems were designed for expansion.

• Safe Access: We partnered with People Safety Ltd to supply bespoke scaffolding, ensuring safe and compliant cable installation access routes. The cable pulls and containment routes were thoroughly assessed and surveyed in advance.

Execution

Following our meticulous planning, we carried out all preparatory works at our dedicated workshop. Panels and enclosures were pre-built, labelled, and tested before being transported to site. Over a four-week period, our experienced team completed the on-site electrical installation. Including cable pulls, glanding, terminating, labelling, and ferruling to the highest standard.

As Siemens solution partners, our team expertly commissioned the open channel instruments, while hot tapping of the pipelines was conducted by SWAN Pipelines. Nivus engineers then completed the commissioning of the inlet flowmeters, ensuring a fully integrated and functional system.

The Result

The project was delivered safely, efficiently, and without incident. A testament to the strong collaboration between the client, subcontractors, and our team. The upgraded instrumentation is now ready for integration into the MCC, allowing for enhanced control and future system growth.

This project highlights Processplus’s capability not just to meet the brief, but to think ahead. We were proud to be involved in this modernisation project that equips the site with robust, scalable infrastructure ready for tomorrow’s needs.

If you have instruments on site that require an upgrade, or even the site itself, get in contact with a member of our team.