Construction and delivery of Killkenny Cheese Plant Effluent Line
Uisce Éireann
Design, Build and Operate
Co. Waterford, ROI
A new cheese production plant was planned at Kilkenny, close to the Waterford City Wastewater Treatment Plant.
To support its development a 600 metre 350DN pipeline was required to connect the cheese plant’s effluent line with the outfall chamber of the Waterford City WWTP.
Project Highlights
Goals
To enable the new cheese production plant to appropriately discharge treated wastewater, a pipeline was required to allow the safe discharge of treated effluent to the river via the Waterford City WWTP final effluent chamber.
The project involved careful planning and implementation to ensure existing treatment processes continued safely and compliantly.
Project Scope
CAW was responsible for constructing, commissioning and testing the new treated effluent pipeline, including upgrades to the existing outfall chamber infrastructure to increase capacity and ensure effective sampling and management to maintain compliance.
CAW continue to operate and maintain the pipeline following the successful completion of the project on behalf of the client.
Project delivery
CAW managed and implemented all temporary and permanent works to facilitate the successful delivery of the new treated effluent pipeline. These included:
- Construction of the treated effluent pipeline connecting the treated effluent outlet from the Kilkenny CPP, near the boundary of the existing Waterford City WWTP to its Final Effluent Chamber;
- Construction of Chamber MH1 and Installation of isolation valve on the new pipeline;
- Construction of Flow Measurement Chamber and installation of Flow Measurement Flume and associated instrumentation on the new pipeline;
- Construction of the Manhole Chambers on the new pipeline as specified in the Detail Design Report;
- Excavation and reinstating of road crossing within the WWTP site as required;
- Identification of and working around existing stormwater pipelines and surface water drainage pipelines on the Waterford City WWTP;
- Construction of a Scour Pipeline Valve Chamber with associated pipework and valves on the new treated effluent interconnecting pipeline;
- Supply and installation auto-samplers for:
- The secondary effluent pipeline from the Waterford City WWTP to the Final Effluent Chamber
- The Flow Measurement Chamber on the new treated effluent interconnecting pipeline.
- Specifically sampling the mixed secondary effluent and the treated effluent from the Kilkenny CPP at the Final Effluent Chamber;
- Relocation of the sampling point on the secondary effluent pipeline from the Waterford City WWTP connecting to new auto-sampler A-2703;
- Supply and installation of a perimeter wall extension frame, access stairs; handrailing and grating support structure at the Final Effluent Chamber;
- Routing of power supply and signal cabling/ducting from existing Belview Pump station to the proposed Flow Measurement Chamber.
- Modifications to the Control System and Telemetry and SCADA for Operations;
- Re-surfacing of Site Roadways and installation of protection and bollards to facilitate safe access to the proposed Scour Chamber for routine maintenance;
- Supply and installation of Task lighting;
- Revisions and updates to the Safety file and the existing Control and Operation philosophy.
Outcome
The eight-month project was completed in July 2023 on time and within budget, while maintaining service to Waterford City and industrial users within the network catchment with 100% compliance during construction.
To enable modifications to be made whilst the Waterford City WWTP remained fully operational and compliant, a hot tap system was used to allow for the connection. Hot tapping is a precise and controlled process that uses valves and fittings to facilitate the integration without affecting existing flow and processes.
Close coordination between the project team and operations team allowed the use of tanks elsewhere on-site throughout the construction phase, during the upgrade of the effluent chamber and platform and for the removal of redundant pipework and platform.
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