Issue 8
Winter 2012
Significantly reducing carbon impact This is How it’s Done Inside this issue...
RWM Conference
WaterAid
Sustainability
Howdon
Message from Bruno Speed
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elcome to our Autumn issue of ImtechFlow. Since the beginning of 2012 we have had an influx of new employees to Imtech Process. Around 200 permanent and temporary staff have joined the team since January, with new recruits appointed across the board in a variety of roles and across all of our regions countrywide. We have a firm commitment to recruit staff to bring their talents and experience to the business and to further develop individuals and teams to maximise their positive contribution to the projects and services we provide.
News in Brief New Company joins ITSL Capula is a specialist in advanced automation and real-time business intelligence, working in the nuclear, power generation, utilities, environmental, oil & gas and industrial markets. Its core offerings are in consultation, automation, IT and support. As an independent system integrator, it has solutions renowned for innovation, project delivery, quality and safety. The company demonstrates pragmatic engineering expertise in its delivery of solutions and services for Capital Programmes, Operational Performance and Compliance.
Client and Partner Reality Checks 2012 We are in the process of carrying out our client and partner reality checks for 2012. These are carried out by an external agency. Your feedback helps us find out the good and the bad, so if you are contacted for your views, please help us by responding openly and frankly to the questions.
As you know, we are an engineering and construction management contractor and part of Imtech Technical Services (ITSL), which is a subsidiary that is wholly-owed by Netherlands-based Imtech NV. We recognise that our people are our greatest asset and strength. The company boasts a strong leadership team and over 350 qualified, experienced designers, engineers, project managers and associated support teams. This has enabled us to establish and maintain a place as one of the UK’s leading engineering contactors, working within the water, wastewater, waste and energy sectors. By looking to the future – in terms of the industry’s technological developments and also the people who work for the company – we are aiming to strengthen our acumen and position. As a result, we will continue to recruit more staff at all levels to work for the company, in the UK and overseas. As Imtech continues to be awarded large-scale contracts it is imperative we have the best resources at our disposal. As far as we are concerned, it’s about recognising talent and recognising people who are a good fit for the company, who can contribute to our high standards and expertise, but also embody our values. This will ensure a sustainable future, for both company and industry.
Biosolids Conference ence Imtech will be presenting again at this year’s Biosolids Conference at the Royal Armouries in Leeds, 19 - 21 November. This year the papers will feature Cardiff and Afan AD with Dŵr Cymru Welsh Water and Howdon AD with Northumbrian Water.
Contact For further information on Imtech Process please contact
Kind regards Bruno
Duncan Wildgoose on 01543 496600 or by email - duncan.wildgoose@imtech.co.uk Imtech Process Ltd Imtech House, 5 Newlands Court, Attwood Road, Burntwood, Staffordshire WS7 3GF Tel 01543 496600
Bruno Speed Imtech Process Managing Director
...It works
For editorial enquiries, please contact Clara Hughes on 07702 736763 or by email - clara.hughes@zebra-comms.co.uk.
Awards update RoSPA Gold We are delighted to announce we were awarded RoSPA Gold again this year. This will be the fourth year we have achieved this recognition of occupational health and safety success. GTM was also awarded RoSPA Gold for its work on the Anglian Water framework.
Imtech offered visitors to its stand at ADBA and RWM the chance to become Carbon Neutral We exhibited at two of the key waste and energy shows this year. The Anaerobic Digestion and Biogas Association’s (ADBA) Conference and Exhibition in July and the Resource and Waste Management (RWM) exhibition in September, which is run in partnership with CIWM.
ADBA Award for Best AD Project of the Year We were also recognised in the inaugural ADBA Awards, for a submission relating to Cardiff AD. The Institute of Water Wales Innovation Awards Dinner takes place in November and we are waiting to find out how we have performed. We have also been shortlisted in the Construction Marketing Awards with a submission into the ‘Sustainability as a Marketing Strategy’ category. The winners of these awards will be announced in December.
To demonstrate our commitment to helping businesses become more sustainable, at both these shows we offered visitors to our stand the chance to win carbon credits, to off-set their carbon usage for a year. Both shows proved to be an excellent opportunity to showcase the business and we were able to present the winner of the carbon credits from ADBA with their certificate at RWM. Phill Allan from Welham Waste Recycling visited our stand at RWM to collect his certificate. Gavin Lawrenson, Imtech Business Development Manager – Waste and Energy commented: “The shows this year have been great for us. Not only were they well attended and well organised, but the visitors were exactly of the high calibre we were hoping to engage with. Our aim is to develop a high profile within the waste sector, and ADBA and RWM are both the right type of exhibitions to enable us to do this.”
Cardiff AD wins ADBA Award for ‘Best AD Project of the Year’
We also presented papers at both shows. Andrew Thompson, Imtech Technical Manager spoke at ADBA on ‘Anaerobic Digestion in the Water Industry - Current and future performance’ and David O’Malley, Imtech Technical Manager - Waste presented on ‘MYT, the new MBT’, about the new mechanical and biological treatment technology at RWM.
Schemes Update We are pleased to announce that we are in the final commissioning stages for two of the major schemes we have been working on. We have successfully completed Five Fords Sludge and Habitat scheme in North Wales for Dŵr Cymru Welsh Water and Howdon AD for Northumbrian Water.
The Howdon Project GTM, the joint venture between Galliford Try and Imtech, has successfully completed the key installation of its latest Advanced Digestion (AD) scheme in the North East of England for Northumbrian Water. The £34 million Howdon AD scheme forms an integral part of Northumbrian Water’s Sludge Strategy and marks an important shift towards energy self-sufficiency and sustainable wastewater treatment. Northumbrian Water’s Sludge Strategy aims to provide advanced anaerobic digestion plants at two main sludge centres in the North East of England. These sludge treatment centres have the capacity to treat up to 80,000tds/year of the total sludge production in Northumbrian Water’s area.
Sludge and Habitat scheme at Five Fords, the largest wastewater treatment works in North Wales Dŵr Cymru Welsh Water has invested £23 million at its Five Fords Wastewater Treatment Works (WwTW), near Wrexham, North Wales. The project includes improvements to wastewater treatment – as part of the Habitat quality improvement programme – and a new anaerobic digestion plant, which is part of the AMP 5 Sludge Strategy. Following outline design and agreement of target cost, work commenced in late 2010, and the project has been successfully delivered through partnership with Costain and Imtech. Construction was completed in March 2012 and the plant is now fully commissioned, generating renewable power and undergoing a period of extended performance testing before final handover.
Five Fords, the largest wastwater treament works in North Wales
£34 million Howdon AD scheme
Completed in September 2012, the Thermal Hydrolysis Advanced AD plant at Howdon STW treats an average of 32,000tds/year. It has the capacity to treat indigenous sludge from Howdon and sludges imported from other outlying sewage treatment works. This integrated project comprised of the design, construction, commissioning and optimisation of a complete, new advanced digestion plant, including a two-stream thermal hydrolysis plant.
We are busy throughout North and South Wales for Welsh Water, in South Wales, we are well underway with the construction phase of the Swansea WwTW MBBR Project. There are a number of major schemes still ongoing with Anglian Water, including Biosolids schemes at Basildon and Cliff Quay (Ipswich). There are two Regional Sludge Transfer Centres at Market Harborough and Thetford, which are nearly completed and two clean water schemes at Elsham and Lincoln. The technical article by Stewart Bell on pages six and seven looks at the Lincoln WTW scheme in more detail. At Thames Water, progress continues at Crossness and Beckton STWs and we are looking forward to be working on further projects with Thames Water as part of the Tamesis JV with Laing O’Rourke. Imtech is also the framework contractor for Affinity (Veolia) Water and schemes in delivery include a number of projects at Egham WTW and four UV schemes at Northmoor, Hare Street, Chartridge and Chesham.
Crossness
The team at Swansea Bay
We are pleased to be working with Bristol Water on two of its clean water schemes. These are Shipton Moyne WTW and Sherborne Springs WTW. At South Staffs Water we are working on a number of schemes including various new pumping stations. Commissioning work at Formby WwTW is progressing well for United Utilities and we are also working on a scheme at Runcorn WwTW. The Waste and Energy side of the business is developing well and we will hopefully have some exciting news on this in the next few months. We are also delighted to announce we have been awarded one of our first overseas contracts to develop the detailed design for TCO Kazakhstan.
Cliff Quay
Feature article Imtech Process delivers market leading drinking water solutions By Stewart Bell, Technical Manager, Imtech Process
Over the last two AMP delivery periods Imtech Process, along with Galliford Try, its civil construction partner, has established a growing reputation as one of the leading suppliers of drinking water treatment solutions. This began in 2007, when Anglian Water selected GTM (Galliford Try/Imtech JV) to design and construct the new 90 Ml/d Morcott WTW. This scheme was required to secure future supplies to the growing towns of Milton Keynes, Bedford, Northampton, Wellingborough, Kettering and Corby. The proposed works was built alongside the existing treatment works at Wing, extending the combined supply capacity from 270 to 360 Ml/d and was the largest water project in the country during AMP 4. Building on this success, GTM is now in the detailed design phase for two new AMP 5 schemes for Anglian Water. The first is a 15 Ml/d extension of the existing non-potable treatment capacity at Elsham WTW and the second is a new surface water treatment works on the banks of the River Trent to supply Lincoln. Outside of Anglian Water, Imtech has secured AMP 5 framework partnership agreements with both Affinity (Veolia) and Bristol Water and have a long-term framework with South Staffordshire Water to provide specialist water treatment design and construction services.
Morcott WTW The Morcott treatment works was designed to provide a resilient treatment process, which would operate in parallel with the existing works at Wing. The works is fed by a new pumping station, via an 8 km raw water main from Rutland Water.
Apart from challenging capital expenditure targets, the design team was also tasked with providing a treatment solution, which minimised operational costs whilst ensuring the process was robust. The selected process route was:
• • • • • • • • •
Mussel traps to collect zebra mussels displaced from the raw water mains Pre-oxidation with ozone generated from liquid oxygen Coagulation and flocculation with ferric hydroxide Dissolved air flotation using high-efficiency aeration nozzles Dual media filtration Main oxidation with ozone generated from liquid oxygen Granular activated carbon adsorption Superchlorination and dechlorination Ammonium sulphate and phosphoric acid dosing
This process flowsheet is well suited to treating the often algal laden raw water and has the ability to accept rapid flow changes. This flexibility was important to Anglian Water, as was the significant reduction in unit cost to produce water (in comparison to Wing WTW). Some examples of how lower operational cost has been achieved include careful selection and design of high-efficiency pumping plant, re-design of the hydraulics, to omit interstage pumping and selection of high efficiency gas dispersion systems, for ozonation and air nozzles for the DAF process. The project was successfully delivered on time and under budget in 2010.
Lincoln WTW Following on from the success of Morcott, the Imtech Process water team has been busy developing the outline design for a new 20 Ml/d WTW. This is to be located near Newton-on-Trent and will treat water abstracted from the river, to maintain the supply-demand balance in the Lincoln region.
Together with the difficulties presented by the challenging raw water quality, the design team has been working closely with Anglian Water to provide industry-leading affordability and carbon reduction targets for all AMP 5 schemes. The scheme is due to be commissioned and handed over to Anglian Water by the end of 2014.
This stretch of the River Trent has not been used to supply drinking water previously and the variable raw water quality has presented significant treatment challenges. The project team has developed an innovative and robust treatment process comprising the following:
• • • • • •
Raw water abstraction pumping to a 10-day raw water storage reservoir Granular Activated Carbon roughing filters to remove soluble metals and colour Submerged Ultra-Filtration membranes to remove suspended solids Ultra-violet irradiation and Hydrogen Peroxide dosing to oxidise pesticides and any remaining dissolved metals GAC polishing filters to remove the oxidised pesticides and metals Ultra-violet irradiation for final water disinfection.
The innovative treatment solution has minimised the use of chemical additives. This has allowed agreement with the EA to return the majority of the process wastewater back to the River Trent, with only minimal treatment. Consequently, enabling the selection of settlement lagoons, with resulting lower operating costs when compared to the sludge treatment processes used elsewhere, such as Wing WTW. The site at Lincoln WTW
KS4 Sustainable Water: We’ve delivered more flexible, efficient and resilient water treatment at Morcott. Now we’re taking a big step to chemical free water treatment with significantly reduced carbon impact.
People News Thousands raised for charity at Imtech The team at Imtech has been doing its bit for charity too. Over the last few months, the team has raised thousands of pounds. Nearly £2000 was raised for WaterAid at this year’s Imtech Summer Ball, which took place on Saturday 23 June, at the beautiful Forest of Arden Hotel and was a resounding success with over 200 attendees. The South Staffs WaterAid Flyfishing Challenge, which took place back in May at Abbots Bromley raised around another £9000, and a team took part in a 100 mile walk visiting Olympic venues and finishing in Windsor Great Park. There have also been Sailing Days and various walking challenges, which have tested the participants’ endurance levels, as well as more light-hearted fundraising in the offices, to mark many of the national fundraising days.
The ‘Mighty Imtech’ Team The ‘Mighty Imtech’ team raised over £700 for WaterAid. Congratulations to the Imtech team who took part in Dŵr Cymru Welsh Water’s Elan Valley Staff Challenge, which consisted of a number of activities including a 10-mile mountain hike. The team came in seventh place overall, but won the trophy for the ‘Top Fundraiser’ having raised £735.
DIARY DATES 19-21 November Biosolids Conference 2012, Leeds Royal Armouries
22 November IW Innovation Awards Dinner, Cardiff
6 December CMA Awards Dinner, London
12 December The team included Daniel Fowler, Matt Foley, Stephen Banfield, Andrew Thompson, David Nicholas, Chris Worts and Lucy Barber
www.imtech.co.uk
ADBA National Conference, London