DPS PACKAGE VALUE
£ 0 M
Modular Pumping Stations
- Municipal
DPS successfully delivered two large scale off-site constructed mobile clean water pumping stations to NI Water’s Northern Resilience Scheme.
DPS and RPS were appointed by BSG Civil Engineering, a Tier one partner to NI Water, to develop designs for mobile/modular water pumping stations and associated site locations and layouts.
An extensive review was undertaken as to how these designs could be integrated into the existing NI Water network and provide supply across the region, should issues arise with the Carmoney, Ballinrees or Caugh Hill Water Treatment Works.
Project Scope
DPS were appointed as the MEICA designer and RPS as specialist civil designers on the scheme by BSG Civil Engineering. The main ECI design works began, along with McAdam Design and EPS to evaluate the current network design and high level project requirements. It was clear from the offset that this scheme would require a number of complex design stages to ensure all aspects of the client’s operational modes could be delivered.
The main project drivers were as follows:
- To improve network flexibility
- Need for greater supply resilience
- Design a product that could be relocated
- Reduce project risk
- Reduce project programme
The outline solution consisted of:
- New pumping station located in Ballinrees WTP
- New surge system & LV feeder in Ballinrees WTP
- New break pressure tank on the Windyhill Road
- New pipework dwelling
- New pumping station located in Moys Service Reservoir
- New surge system & LV feeder located in Moys Service Reservoir
- Various automated valves & valve modifications
- Chemical dosing
- TDN links and SCADA system for safe operation
Project Background
The project was conducted under the ECI scheme to firstly review and investigate the client requirements, develop a scope and then fully design & develop the complex scheme in association with all stakeholders involved.
The off-site construction process was chosen as the best route forward for the scheme and began in early 2021 in parallel with the on-site civil engineering works, leading to a reduced project programme and delivery to site in Aug 2021.
We are delighted to announce this major investment in water resilience for the North West, which will greatly improve the robustness and resilience of the water supply infrastructure. This will be particularly important during the winter months and other unplanned events, to ensure maximum security of supply for our customers in the local area.
Solving the Problem
The solution was to develop two fully offline sites.
These would need to be constructed in Ballinrees WTW and Moys Service Reservoir and be able to deliver all specified modes of operation with regards to the varied flows and pressure from 24MLD at 16.6Bar to 4MLD for freshing modes. These sites also needed to have the ability to work independently and as part of a larger system. DPS developed two Versatile Modular Pumping Stations (MPS) units in association with our parent company EPS and our long standing partner for pumping solutions, KSB, which would be able to perform across a number of flows and pressures to meet the client’s mission brief as well as being designed to allow for relocation quickly in future phases. These demanding design drivers tested the team on a number of levels in relation to the structural designs and thrust forces within the buildings. The designs developed are outlined below.
These would need to be constructed in Ballinrees WTW and Moys Service Reservoir and be able to deliver all specified modes of operation with regards to the varied flows and pressure from 24MLD at 16.6Bar to 4MLD for freshing modes. These sites also needed to have the ability to work independently and as part of a larger system. DPS developed two Versatile Modular Pumping Stations (MPS) units in association with our parent company EPS and our long standing partner for pumping solutions, KSB, which would be able to perform across a number of flows and pressures to meet the client’s mission brief as well as being designed to allow for relocation quickly in future phases. These demanding design drivers tested the team on a number of levels in relation to the structural designs and thrust forces within the buildings. The designs developed are outlined below.
Ballinrees
4 No. 250kW Booster Station
Moys
4 No. 110kW Booster Station
Building Dimensions:
Length = 15m
Width = 4.2m
Height = 4.2m
Weight = 40 Tonnes
Width = 4.2m
Height = 4.2m
Weight = 40 Tonnes
24 MLD @ 16.6 Bar
4 No. 250kW 4 Pole Pumps
SR2 Building Security Rating
Integrated MCC room c/w all bespoke designed building services
12m3 surge system in separate kiosks
8-month programme
3-week site install
Building Dimensions:
Length = 13m
Width = 4.2m
Height = 4.2m
Weight = 30 Tonnes
18.5 MLD @ W13.8 Bar
4 No. 110kW 4 Pole Pumps
SR2 Building Security Rating
Integrated MCC room c/w all bespoke designed building services
12m3 & 4m3 surge system in separate kiosk
8-month programme
3-week site install
Digital Collaborative Planning
As this project was a first of its kind for NI Water, it was important that they partnered with a team who had significant off site and modular design experience. Through their capital framework BSG, RPS and DPS were selected for the contractor’s calibration group.
This was further extended to EPS and McAdam Design to support delivery of this critical project for NI Water from both water resilience and a modular demonstrator scheme.
The DPS/EPS team used digital engineering and our capabilities and experience in the successful delivery of projects using digital and DfMA principles.
This information as it developed was easily fed back into the civil design team in RPS to ensure all on-site integration points were within specified tolerances.
The project’s digital delivery platform brought a different way of thinking, by creating open dialogue between all the parties and a joined-up approach to getting the best out of construction activities.
Some of the digital tools used to enhance project outcomes included:
- Solidworks and Revit
3D design platforms were deployed to create the detailed 3D models to allow all engineering activities to be conducted. - Visual Project Initiation
This was deployed in two sessions along with a VR walk through with the design team to allow final comments prior to constructionT - BIM 360 Glue
A cloud-based tool to share 3D models, allowing effective interface with the federated 3D model for all stakeholders. It was also used for visualisation demonstrations with stakeholders.
DfMA Delivering Optimised Outcomes
By designing, manufacturing and testing the two Modular Pumping Stations in our DfMA Centre for Design and Manufacturing Excellence (CfDME), DPS were able to de-risk and significantly accelerate the on-site installation works on the project. DfMA principles were applied to over 90% of the overall MEICA scope of the project, with the exception of the surge systems which were constructed on site.
The two completed Modular Pump Systems produced and tested in the CfDME were transported to the sites in Northern Ireland via a two day convoy managed by Cooper Heavy Haulage and installed directly into their final positions on arrival using a 220ton crane from local company Quigley’s Crane Hire.
By eliminating on-site fabrication, hot work and the majority of working at height, DPS were able to significantly reduce safety, quality and weather-related risks, and ensure that the delivery of the project remained on-track.
How I consider the manufacturer got this design right is when I’m stood inside the facility at the full FAT test & I don’t realise it’s a mobile modular pumping station - it all feels very normal.
