Industrial

Sewerage Pumping Station, Pressure Main and Receiving Gravity Sewer

03/02/2020 By EpesEditor

Sewerage Pumping Station SP1197, Pressure Main and Receiving Gravity Sewer Slide 1

Sewerage Pumping Station SP1197, Pressure Main and Receiving Gravity Sewer

Mechanical, Civil and Structural Detailed Design

EPES were engaged by Zinfra as Sydney Waters D&C contractor for the design and construction of SP1197 sewerage pumping station, pressure main and receiving gravity sewer at Emerald Hills in the South West Growth Centre, Leppington NSW.

Design package included:

1. 71L/s Sewage pumping station consisting of two sets of submersible pumps, precast wet well, valve chamber, inlet maintenance hole, outdoor electrical kiosk, bypass pumping arrangement, emergency storage tank, chemical dosing unit and associated works

2. Pressure main consisting of 1,130m of DN315 HDPE pipe including scours, jetting points and associated works

Project Information

Location: South West Growth Centre, Leppington, New South Wales, Australia
Client: Zinfra c/o Sydney Water
Engagement: Detailed Design Consultant
Sectors: Industrial, Water and Waste Water
Services: Construction and Design Consulting, Digital Engineering, Infrastructure Engineering, Piping Engineering, Water and Waste Water
Year: 2015-2017

3. Receiving gravity sewer consisting of 1,770m of DN355 HDPE pipe draining to the receiving maintenance hole

The scope of the works included all mechanical, civil and structural design elements including development of various approval documentation including Design Management Plans, Safety in Design, CHAIR, FMECA and various design reviews with Sydney Water management and operations teams.

Design deliverables were prepared following tendered Concept Design through 30% and 80% Detailed Design, Workshop Coordination and Works-as-Constructed (as Approved by Sydney Water). Site inspections during construction.

The Problem

Several challenges were identified during the design delivery effort, such as:

We were also tasked with ensuring that the information we produced was coherent, organised and in a suitable format to be integrated into AFMOnline.

Analysis and Implementation

Ongoing and regular communication with stakeholders enabled issues to be raised as early as possible, with an agreed path to resolution. Identifying key concerns and risks in the design enabled the design to take a pragmatic approach with buy-in.

Outcome

The project has been operational since 2017 with no technical issues identified.

Using experienced technical staff and ensuring that communication channels are always open presents an opportunity to deliver a challenging project with final acceptance. Long term reliable operation follows diligent design.

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Kenya Water Treatment Plant – Brine Discharge Pipeline

03/02/2020 By EpesEditor

Kenya Water Treatment Plant – Brine Discharge Pipeline Slide 1

Kenya Water Treatment Plant – Brine Discharge Pipeline

Engineering Design

The Kenya Water Treatment Plant is located outside of Chinchilla in Queensland and treats by-product water from coal seam gas operations. Following the reverse osmosis (RO) process, reject is further concentrated in brine concentrators.

High temperature brine is discharged from the brine concentrators and is transferred via a pipeline to a storage pond. Various performance issues were related to the original design due to the elevated temperatures and corrosivity of the fluid.

EPES were engaged to design a replacement brine discharge pipeline to address the performance issues being experienced with the line. The objective of the design process was to ensure performance of the pipeline during discharge of elevated temperature brine discharge to the storage pond without impacting operation of the water treatment plant. Our scope included:

Project Information

Location: 35km from Chinchilla, Queensland, Australia
Client: Laing O’Rourke
Engagement: Design Consultant
Sectors: Industrial, Oil and Gas, Water and Waste Water
Services: Construction and Design Consulting, Digital Engineering, Independent Reviews and Audits, Piping Engineering, Specialist Analysis, Water and Waste Water
Year: 2016

The Problem

Several technical challenges exist with high temperature fluids in pipelines, particularly fluids with high chloride concentrations such as brine discharge. Non-metallic materials are typically unsuitable and metallic materials need to be carefully considered with respect to corrosion and durability of materials.

Pipeline leakage or rupture is not acceptable recognising the environmental risks.

Analysis and Implementation

Pipelines subject to elevated temperatures are designed in accordance with pressure piping standards to account for thermal expansion (temperature difference between non-operating and operating cases) as well as other static and dynamic load cases.

Once design loads cases are defined, the pipeline is subject to pipe stress analysis to ascertain both compliance of the pipeline allowable stresses, and primary support loadings to be used in the structural design of the secondary support system.

Typical design considerations including liaison with stakeholders, safety in design, risk assessment and constructability reviews were incorporated into the design process.

Outcome

The outcome for the project was a pipeline suitable for the intended duty offering users a robust and reliable transfer pipeline for delivery of concentrated brine to the storage pond. With careful consideration of the design requirements, durability issues, performance requirements and constructability, the pipeline offered a low impact construction with a superior outcome for the project.

Taking the time to properly understand the technical and construction constraints ensures that the project can be delivered within the stakeholder expectations in a reliable, practical and robust way.

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Aimeliik Cargoline Replacement Project

03/02/2020 By EpesEditor

Aimeliik Cargoline Replacement Project Slide 1

Aimeliik Cargoline Replacement Project

Engineering Design

EPES in partnership with Endeavour Inspection Services (based in Guam), undertook the detailed survey and engineering design for replacement of the replacement of the existing 12” cargo pipeline enabling diesel fuel transfer from the jetty to the Power Plant tank farm in Aimeliik, Republic of Palau. The existing pipeline was showing signs of excessive corrosion and undermining of supports.

Scope of the technical services included:

Civil and structural design works for new sea retaining wall and pipeline supports
Detailed engineering design to ASME piping codes for the replacement of the existing transfer pipeline and waste oil pipeline
Detailed survey of the existing transfer pipeline between the Jetty and the storage tank nozzles within the Tank Farm
Replacement of spill booms, hose reels and interfaced valving arrangements

Project Information

Location: Aimeliik, Republic of Palau
Client: Palau Public Utilities Corporation
Engagement: Detailed Design Consultant
Sectors: Industrial, Oil and Gas
Services: Commissioning Assistance, Construction and Design Consulting, Digital Engineering, Petroleum Engineering, Piping Engineering, Specialist Analysis
Year: 2017

The Problem

The existing pipeline was commissioned in 1983 from bare carbon steel piping and was showing extensive evidence of severe corrosion from exposure to seawater both internally and externally. Due to its exposed coastal location, significant undermining of supports from wave action was also evident.

Given the age and location of the existing facility, very little documentation was available to understand the design of the existing pipeline. Quality control of procurement and construction works is also a challenge in this region.

Analysis and Implementation

EPES with EIS undertook significant surveying works of the existing pipeline, geotechnical conditions and ground levels along the pipeline alignment. This was necessary due to the absence of original design documentation.

We then undertook detailed engineering design with a key focus on simplifying the construction process and addressing further risk of corrosion by specifying coating technologies suitable for the exposed environment.

Design documentation including 3D model, plan drawings and Technical Specifications were prepared in combined SI/Imperial units to aid in communication with local Contractors and Clients. EPES also offered technical advice in maintaining quality control and supervision of the procurement and construction works.

Outcome

EPES were able to deliver a high quality and detailed set of design deliverables that assisted the Client in tendering and controlling the Procurement and Construction works. The Client can rely on high quality documentation with an emphasis on ensuring that construction works is completed with a high degree of commercial control.

Good quality documentation and diligent preparation of design in brownfield environments offers a high level of commercial control (i.e. de-risking).

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Dyno 3 Mechanical Ventilation

03/02/2020 By EpesEditor

Dyno 3 Mechanical Ventilation Slide 1

Dyno 3 Mechanical Ventilation

Mechanical Engineering

EPES were engaged to undertake engineering design for the design of a ventilation system for a new exhaust hood in Dyno 3, which includes:

1. New custom design retracting hood configuration designed especially for the side loading engine dynamometer

2. Required to remove high volumes of fumes and heat during testing

The Problem

The engines tested in Dyno 3 produce extremely high volumes of heat and fumes during dynamometer testing in the facility. The current arrangement in use at the facility is not effective and inefficient.

Project Information

Location: Rockhampton, Queensland, Australia
Client: Hastings Deering Rockhampton
Engagement: Engineering Consultant
Sectors: Buildings, Industrial
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Digital Engineering, Specialist Analysis
Year: 2017-2019

Analysis and Implementation

EPES analysed that a retractable hood arrangement was the preferred solution to enable the engine under test to install and removed easily, making the changeover process more efficient.

The ventilation system consisted of Two (2) exhaust fans at 35,000L/s each, and one (1) supply air fan at 30,000L/s as well as natural ventilation openings for removal of heat and exhaust fumes during testing. Large exhaust duct was reticulated within the constraints of the adjacent building structures.

Outcome

The resulting design was a robust ventilation system design that offered flexibility or engine change overs and included bypass air to overcome high temperature issues with mechanical equipment. Recognising the operational challenges was crucial to the success of this design, our engineers have previous experience working with dyno test facilities and were able to prepare a practical and functional design solution for a unique problem.

Unique and complex problems are best resolved by engineers with experience.

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Smithfield – Precision Oxy Cut

31/01/2020 By EpesEditor

Smithfield – Precision Oxy Cut Slide 1

Smithfield Precision Oxy Cut

Mechanical Ventilation Design

EPES were engaged by Sell and Parker to prepare a compliant ventilation solution to address poor internal air quality due to plasma and oxy cutting processes.

Our scope for this project included:

1. Assessment of ventilation issues within the Plasma and Oxy Cutting Areas

2. Identification of constraints for installation of ventilation plant and equipment

3. Prepare contract design drawings and technical specifications for the recommended solution

Project Information

Location: Sydney, New South Wales, Australia
Client: Sell and Parker
Engagement: Design Consultant
Sectors: Buildings, Industrial
Services: Building Services, Construction and Design Consulting, Independent Reviews and Audits, Specialist Analysis
Year: 2014-2019

4. Ventilation calculations, equipment selections and controls

Sell and Parker required better ventilation for occupants of the space.

The Problem

The source of contaminants (smoke) was associated with plasma and oxy cutting, and existing ventilation provisions were inadequate. Significantly greater air quantities were required to maintain acceptable internal air quality. Generally, the ventilation system was subject to the requirements of Australian Standards.

Analysis and Implementation

Ventilation air quantity calculations were performed based on a required air change rate for the space volume and process. Ventilation equipment and ductwork was designed to maximise pick up and minimise additional noise whilst moving the additional quantity of ventilation air. Intake air was positioned to ensure clean air was drawn into the building.

Outcome

Compliant ventilation system custom designed for the space and the cutting processes being used, whilst minimising impact to current operations.

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WestConnex – M4-M5 Link

10/10/2019 By EpesEditor

WestConnex – M4-M5 Link Slide 1

WestConnex - M4-M5 Link

Pressurised Services and Dewatering Concept Strategy

The M4-M5 link is part of the WestConnex project in Sydney and involves the construction of twin 7.5km tunnels to link the new M4 at Haberfield and the new M5 at St Peters. EPES were engaged by LSBJV to perform conceptual design methodology for installation of pressurised temporary services for use during construction.

1. Dewatering systems

2. Compressed air

3. Industrial water

The works include the determination of installation, testing, inspection and maintenance requirements for the pressurised services systems, as well as nominating pumps, piping and valving requirements.

Project Information

Location: Sydney, New South Wales, Australia
Client: Lend Lease, Samsung, Bouygues Joint Venture (LSBJV)
Engagement: Temporary Works Design Engineer
Sectors: Industrial, Road Infrastructure (Tunnels)
Services: Construction and Design Consulting, Independent Reviews and Audits, Infrastructure Engineering, Piping Engineering, Specialist Analysis, Water and Waste Water
Year: 2019

The Problem

Pressurised services are complex on large construction projects and can be high risk in the event of a failure. They can also be highly problematic for construction works if they do not perform as required by the demands of the construction process.

Recognising the size and complexity of this project, as well as a need to ensure consistency across the various construction fronts, the objective of this design was to collate and coordinate all of the variable pieces of information and perspectives and achieve a common approach to pressurised services installation.

Analysis and Implementation

Several meetings with stakeholders in design, project management, construction and procurement were undertaken to collate the different ideas and information associated with the works. Design documents were developed, along with robust and practical engineering design to ensure consistency, standardisation and a clear path toward compliance with standards.

Outcome

Through this process significant commercial advantages were achieved through standardisation and sharing of plant and equipment, enabling early ordering of piping and valves and exploiting the opportunities of economies of scale.

Undertaking early planning and design concept development, as well as opening communication with various stakeholders early in the project life cycle there are significant commercial benefits as well as reduced level of risk.

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Melbourne Metro – Tunnel

03/09/2019 By EpesEditor

Melbourne Metro – Tunnel Slide 1

Melbourne Metro Tunnel

Temporary Works Engineering Packages

EPES were engaged by CYP to undertake various design packages related to temporary works during construction, including:

1. Concept design and planning assistance for pressurised services (dewatering, compressed air, recycled water and potable water) used in excavation works at the CBD North and South zones (covering 8 shafts and interconnecting tunnels)

2. Engineering design for adit and cavern hooks, cross over supports and shaft brackets, and verification of shaft service ladders and top shaft brackets

Generally, design packages incorporated engineering analysis, reviews for constructability, safety in design and coordination with construction teams to ensure that design was in alignment with site expectations.

Project Information

Location: Melbourne, Victoria, Australia
Client: Cross Yarra Partnership (CYP)
Engagement: Engineering Consultant
Sectors: Industrial, Rail Infrastructure (Tunnels)
Services: Construction and Design Consulting, Independent Reviews and Audits, Infrastructure Engineering, Piping Engineering, Specialist Analysis, Water and Waste Water
Year: 2019

The Problem

Pressurised services are complex on large construction projects and can be high risk in the event of a failure. Identifying the correct design loadings, as well as risks associated with operation in a live construction environment were considered in the engineering analysis. Relative conservatism is this type of design package is pragmatic, whilst understanding the temporary nature of the works.

Analysis and Implementation

EPES performed analysis is accordance with the mandated standards and codes such as AS1170 for loading, AS4041 for pressure piping and AS4100 for steel structures. Close consultation with site construction enabled coordination with actual installation constraints as well as a means of clarifying design cases, limitations and risks.

Outcome

The outcome was a comprehensive design package with appropriate levels of buy in from temporary works managers, site teams and procurement. Design documents were prepared well ahead of the being required for site works which enabled proper planning to be undertaken and communication to respective site personnel.

Well organised and planned design work dramatically reduces both technical, safety and commercial risks for all stakeholders on a project.

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8LWR Seismic Analysis, Water Treatment Facility, New Zealand

03/09/2019 By EpesEditor

8LWR Seismic Analysis, Water Treatment Facility, Waikari, New Zealand Slide 1

8LWR Seismic Analysis, Water Treatment Facility, Waikari, New Zealand

Mechanical Structural Analysis

EPES were engaged by Pall Australia to perform an earthquake loading analysis of the 8LWR structure designed by Pall for support of water treatment equipment in the Waikari region of New Zealand.

Analysis was performed in accordance with NZS 1170.5 Earthquake Actions New Zealand and AS/NZS 4100 Steel Structures. The water treatment facility is required to remain operational following an earthquake with a design life of 80 years.

EPES were to determine of the structure would satisfy the standards requirements for seismic loading in this region.

Project Information

Location: Waikari, New Zealand
Client: Pall Australia
Engagement: Specialist Finite Element Analysis
Sectors: Industrial, Water and Waste Water
Services: Construction and Design Consulting, Digital Engineering, Infrastructure Engineering, Piping Engineering, Specialist Analysis, Water and Waste Water
Year: 2019

The Problem

The region has high seismic activity and high design loadings were calculated due to the stringent requirements of NZS 1170.5 and the requirement for the water treatment facility to remain in operation shortly after a design seismic event.

Analysis and Implementation

EPES utilised AS/NZS 1170.0 and AS1170.1 to determine design loadings for the proposed VR structure and MF module rack assembly. Design analysis was undertaken following NZS 1170.5 and application of Finite Element Analysis (FEA) using SolidWorks.

Analysis determined that for the MF Rack Assembly, higher than acceptable deflections were evident in the analysis and that in order to satisfy the design criteria, additional bracing was recommended. The VR frame was within acceptable limits.

Outcome

We identified deficiencies in the designed structure and methods required to rectify in order to achieve compliance with the local New Zealand earthquake design requirements. This was validated using Finite Element Analysis (FEA).

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Industrial

Sewerage Pumping Station SP1197, Pressure Main and Receiving Gravity Sewer

Mechanical, Civil and Structural Detailed Design

The Problem

Analysis and Implementation

Outcome

Find Projects

Kenya Water Treatment Plant – Brine Discharge Pipeline

Engineering Design

The Problem

Analysis and Implementation

Outcome

Find Projects

Aimeliik Cargoline Replacement Project

Engineering Design

The Problem

Analysis and Implementation

Outcome

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Dyno 3 Mechanical Ventilation

Mechanical Engineering

The Problem

Analysis and Implementation

Outcome

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Smithfield Precision Oxy Cut

Mechanical Ventilation Design

The Problem

Analysis and Implementation

Outcome

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WestConnex - M4-M5 Link

Pressurised Services and Dewatering Concept Strategy

The Problem

Analysis and Implementation

Outcome

Find Projects

Melbourne Metro Tunnel

Temporary Works Engineering Packages

The Problem

Analysis and Implementation

Outcome

Find Projects

8LWR Seismic Analysis, Water Treatment Facility, Waikari, New Zealand

Mechanical Structural Analysis

The Problem

Analysis and Implementation

Outcome

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