Davyhulme project reaches another major milestone

  • Laing O’Rourke will now operate and test the Inlet Works and surplus activated sludge (SAS) plant before completion of the Process Establishment and Reliability Tests (PERT) over to United Utilities in September 2018
  • DfMA strategy has played a crucial role in the successful delivery of the construction phase
  • Innovative Digital Engineering software helps the project team, design partners and client configure their project with a greater degree of accuracy

The Davyhulme modernisation project has reached another major milestone, as the second phase ‘turn of flows’ has begun and the project has entered the final commissioning, testing and  processing stages, which will run until handover expected in March 2019.

The Davyhulme site is United Utilities largest works, serving over 1 million customers across Greater Manchester. The water treatment works has been operating since 1894 and the modernisation project is the latest in a long line of upgrades that have been carried out.

Laing O’Rourke has been on site since April 2015, delivering the £144m scheme which has included the design and installation of all the process, mechanical, electrical, software  and civils works on the project, including the construction and commissioning of:

  • MCERTS flow measurement
  • A new FTFT inlet works (coarse and fine screening)
  • Refurbished grit removal plant
  • FOG (fats oil grease) removal system
  • ASP3 pumping station
  • 6 (No.) 40m diameter primary settlement tanks
  • 10-lane activated sludge plant (ASP)
  • 10 (No.) 43m diameter final settlement tanks
  • New HV power supply
  • Motor Control Centres and LV install
  • Software and hardware

As well as the refurbishment of the existing:

  • Odour control plant
  • Inlet works (to become storm works)
  • Pumping stations

Digital Engineering and DfMA have been a critical component in the project’s success, according to David Marsh, project leader.

“I’ve no doubt that we could not have delivered this scheme in the time we have, without the use of Digital Engineering and DfMA.” explains David. “It really has been critical to the project’s success and the digital models will continue to be an invaluable resource as we go through the commissioning stages.

“We also have a client in United Utilities who are fully committed to the ongoing development of DfMA. They even have a DfMA project manager, employed to ensure contractors are exploiting the benefits of offsite construction.

“To see a client employ someone with ‘DfMA’ in their job title is a really significant development, as DfMA is obviously Laing O’Rourke terminology. To me, it’s further evidence that the industry, and in particular, clients are seeing the benefits DfMA brings, and that Laing O’Rourke strategic ambition to become the recognised leader for innovation and excellence is coming to fruition.”

Configure yourself

As part of the project, the digital engineering and design teams have worked with the client, Laing O’Rourke’s manufacturing businesses and our wider supply chain to develop a DfMA ‘configrator’. The software allows users to configure standardised components and includes a host of design data that allows the team to build and develop.

The team have piloted the software to help deliver the Motor Control Centre (MCC) units on the project; 14 kiosks that house mechanical and electrical equipment to control various areas of the water works. Using the software, the team was able to reduce the amount of physical connections that would need to be completed from the thousands, to just one connection, meaning each unit was ‘plug and play’ when it arrived on site.

Watch the case study video above to learn more about the configurator software.








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