The WA Cooke Group – Turn-Key Effluent Treatment Plant
Group Supply:
Watermark Projects division – Design & Commissioning
Engineers division– Fabrication
Site Services division – Mechanical & Electrical Installation
Description of Works:
The WA Cooke Group was contracted by a major UK dairy to design, fabricate, install & commission a new wastewater treatment plant for their dairy processing & bottling facility.
Following our initial due diligence and treatability trials with the client, it was determined that a DAF (Dissolved Air Flotation) system would be suitable for primary treatment due to the effective Fat, Oil & Grease removal capability.
Manufactured at our Manchester fabrication facility, the DAF system was designed to handle flow rates of up to 40,000 litres per hour with additional balancing included to handle high peaks due to the client production process. The complete DAF system, as well as all fittings and interconnecting pipework, was manufactured in T304 Stainless Steel.
Due to the nature of the effluent it was also deemed necessary to include the following equipment to ensure treatment optimisation and system automation:
Balancing – 30,000 litre Effluent Balance Tank complete with mechanical agitation and radar level sensor with relay to provide automated feed into the treatment system
Material:- MDPE with T304 Stainless Steel Fittings
Self-Cleaning Rotary Drum Screen – Gross solids removal prior to treatment. To reduce wearable parts the screen was installed at height (on a galvanised steel platform), providing gravity discharge.
Material:- T304 Stainless Steel with Galvanised Mild Steel Platform
Chemical Storage & Dosing – 3off 30,000 litre bunded Chemical Storage Tanks were fitted with suitable chemical dosing pumps connected to relay within the DAF control panel to provide automatic chemical dosing. Radar Level Sensors were also fitted to provide accurate level measurement.
Material:- MDPE with T304 Stainless Steel Fittings
Upon completion of fabrication, the W.A Cooke & Sons site services division were responsible for the complete M&E installation, as well as all steel platform assembly & erection, of the primary treatment plant as well as all ancillary equipment.
Mechanical Installation Works:
Interconnecting pipework complete with both manual and automatic valve connections, between all equipment.
Electrical Installation Works:
Our electrical engineers fitted varying instrumentation to the equipment including –
- pH Electrodes (DAF mixing Tank & Effluent Balance Tank)
- Radar Level Sensors (DAF Sludge Holding Tank, Effluent Balance Tank, 3off Chemical Storage Tanks)
- Chemical Dosing Pumps (3off Chemical Storage Tanks, DAF Polymer Make-Up System)
- MAG Flow Meter (DAF Inlet)
- Transfer Pumps (Inverter Driven Feed, Sludge Transfer, Balance to Rotary Screen)
- Audible & Visual alarms for fault & level sensor (chemical storage levels) notification
With the scale & footprint of the plant including ancillary equipment, the system was designed to utilise one central Control Panel housed within a GRP enclosure. All instrumentation installed was connected to this Control Panel providing complete automation and ease of use for the client.
Now up and running the plant is operating at an average flow rate of 34,000 litres per hour, 24 hours a day and provides improved effluent quality for both local discharge consent & reduced environmental impact.
