Digital Engineering

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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Inverell Hospital – Redevelopment Stage 1B

31/01/2020 By EpesEditor

Inverell Hospital – Redevelopment Stage 1B Slide 1

Inverell Hospital Redevelopment Stage 1B

Parts 1 – 9 Concept Design, Design Development, Contract Documents and Construction Services

This project involved the major refurbishment of the original hospital building which was built in the 1930’s served by a wide variety of air conditioning and heating systems or varying age and condition.

The refurbished facility will include Oral Health, Ambulatory Care, Women’s & Children and Office areas or Education and Telehealth.

Our role in this project is to develop a practical and robust solution to the ongoing provision of heating, cooling and ventilation for the changed building usage and maintain consistency with Stage 1A design.

Project Information

Location: Inverell, New South Wales, Australia
Client: Health Infrastructure
Engagement: Mechanical Services and Medical Gases
Sectors: Buildings, Hospitals & Healthcare
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Digital Engineering
Year: 2019

Additionally, we were engaged as the Watching Brief consultant for Stage 1A ($30m budget) which includes a new Clinical Services Building with Emergency Department, Paediatric and Maternity Facilities, Palliative Care, medical Imaging, Operating Theatres, Day Surgery and new main entry.

The Problem

The existing building has various systems installed throughout the life of the hospital for heating, cooling and ventilation with poor levels of compliance with current standards and guidelines.

Several challenges were identified:

1. Complex building geometry and constraints

2. Gaps between current day standards and what was existing

3. No documentation for existing systems

4. Significant redundant equipment left in place

5. Very little consistency of types of systems

Analysis and Implementation

With a brownfield site such as this, there is very little choice other than detailed survey works to properly understand what systems and equipment are in place, what is redundant, what is working and its condition, maintenance history and compliance.

We commenced our work with extensive surveys of existing equipment, recording existing systems and the areas they served. Additionally, we discussed the performance of existing systems with staff and maintenance personnel to get a picture of how the existing systems were performing.

Through our engagement on Stage 1A, we were also able to align our design decisions with the technology and approach used in the new building further simplifying the maintenance tasks for local staff. This approach offers many benefits to the LHD by enabling consistent maintenance contracts across both stages of the project.

We opted to introduce a chilled water plant, consistent in technology and controls to that of Stage 1A and to interconnect with existing hot water boilers exploiting a surplus in heating capacity. Existing medical gas recirculation were able to be repurposed for the new usage.

Outcome

Simple design solution tailored to the long-term use of the building:

Better temperature control and heating performance in cold winter conditions
Capitalise on surplus existing heating capacity reducing new equipment
Consistent equipment and controls across the site, reduced maintenance costs
Ease of maintenance
Long term solution, 25 years to major upgrade/replacement

Take the time to study existing systems and understand the constraints of users in rural or remote areas. Consistency and simplicity is key to successful outcomes.

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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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Port Macquarie Base Hospital – Mental Health Expansion

29/08/2019 By EpesEditor

Port Macquarie Base Hospital

Port Macquarie Base Hospital – Mental Health Expansion

Parts 4–9 Design Development and Construction Services

Health Infrastructure delivered a new 24 bed acute mental health inpatient unit and refurbishment of existing unit at Port Macquarie Base Hospital within the Mid North Coast Local Health District. This stage was handed over in February 2019.

Design requirements required to Building Code of Australia, Australian Health Facility Guidelines and NSW Health Engineering Services Guidelines.

EPES were engaged by Health Infrastructure to deliver the Mechanical Services and Medical Gases design and were involved in the Construction and Commissioning of the works.

Project Information

Location: Port Macquarie, New South Wales, Australia
Client: Health Infrastructure
Engagement: Mechanical Services Consultant
Sectors: Buildings, Hospitals and Healthcare
Services: Building Services, Commissioning Assistance, Construction and Design Consulting, Digital Engineering
Year: 2017

The Problem

There are several key design challenges with mechanical services within an acute mental health unit requiring careful and pragmatic considerations:

1. Safety precautions and special anti-ligature requirements

2. Restricted access into inpatient areas and ceiling voids

3. Potential high levels of disruption with maintenance access in the unit

4. Safety risks for staff accessing the space to perform maintenance

5. Sustainable focus on reducing energy use

6. Maximising value for tax payers

7. Minimising additional maintenance costs for the Local Health District

Analysis and Implementation

We considered several different options for delivering heating, cooling and ventilation to the facility, with careful review of how the site currently operated:

How is existing maintenance performed?
Can we design out maintenance access inside the unit?
What maintenance contracts are in place and with who?
How do maintenance staff think these problems should be overcome?
Is there opportunity to utilise existing systems to avoid introducing new plant?

The design solution dramatically reduced the need for maintenance personnel to enter the unit with all air conditioning and ventilation plant located within the building under croft accessible without having to enter the unit.

Interconnected new unit with high efficiency water cooled chillers already in operation with high levels of surplus capacity
Relocated all air handling plant and ventilation fans into the under-croft plant area so maintenance access into the unit was less than once a year and system issues could be resolved from outside the unit at any time of the day
Positioned the majority of fire and smoke dampers within the under croft for ease of access for inspections utilising fire rated boots below floor slab and minimising ductwork crossing of fire/smoke compartments.

Outcome

Benefits for the client and end users include:

Utilising existing chillers and boilers negated the need for any additional maintenance contracts or extension of existing agreements
Utilising existing BMCS provider
Engagement with maintenance staff and delivering a maintenance friendly solution will greatly improve reliability with lower costs
Energy savings will be significant as existing chillers offer much higher efficiencies than dedicated air-cooled options.

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Digital Engineering

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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Inverell Hospital Redevelopment Stage 1B

Parts 1 – 9 Concept Design, Design Development, Contract Documents and Construction Services

The Problem

Analysis and Implementation

Outcome

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

Mechanical Structural Analysis

The Problem

Analysis and Implementation

Outcome

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Port Macquarie Base Hospital – Mental Health Expansion

Parts 4–9 Design Development and Construction Services

The Problem

Analysis and Implementation

Outcome

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