Increasing Capacity via Intelligent Flow Transfer and Digital Engineering - Aqua-Tech | Water Sector Technical & Recruitment Solutions

Case Study

Increasing Treatment Capacity Through Intelligent Flow Transfer & Digital Engineering

Aqua-Tech were challenged with a wastewater treatment facility that required additional capacity to handle peak storm flows, but where expansion within the existing footprint just wasn’t possible.

Rather than forcing additional infrastructure into a constrained site, a more considered engineering solution was required. One that made better use of existing treatment capacity elsewhere, while integrating modern automation and digital survey techniques.

Objectives

Increase effective treatment capacity without expanding the existing site footprint
Enable controlled transfer of flows to a neighbouring works with available capacity
Deliver robust M&E design, installation and commissioning for new assets
Integrate automated control systems to protect downstream processes
Provide high-quality digital survey data to support design, delivery and future asset management

Challenge

The primary challenge was capacity. Not in treatment capability overall, but in how that capacity was distributed across sites. The existing facility could not be expanded easily due to physical and logistical constraints. Building additional treatment infrastructure would have introduced significant cost, complexity and disruption.

Instead, the solution we devised would require:

Transferring flows between two operational sites
Safely managing variable storm flows
Preventing overload at the receiving works
Integrating new assets into existing control systems
Coordinating multiple disciplines across civil, mechanical, electrical and ICA scopes

Solution Implemented

Aqua‑Tech delivered the full M&E design, control philosophy and installation for a new transfer pumping station and detention tank system, enabling dynamic flow management between the two sites.

Key elements of the solution included:

Design and installation of duty/standby pump control systems
Development of MCCs, control panels and LV power distribution
Installation of all cabling infrastructure and fibre communications
Implementation of a secure communications link between sites
Integration of an automated control philosophy that: a) Transfers flow during high demand periods, & b) Automatically inhibits pumps when the downstream detention tank approaches capacity

This solution ensured that available treatment headroom is fully utilised, while protecting the receiving works from overload.

In addition to the transfer system, the wider scheme included mechanical installation (by others) of: Chemical dosing systems, Booster washwater equipment and Safety shower infrastructure.

Aqua‑Tech supported these elements through:

Electrical infrastructure
Power distribution and cabling
Control integration into the wider system

Digital Survey & Engineering Capability

Alongside the M&E delivery, Aqua‑Tech deployed its in-house survey and digital capture capability throughout the project lifecycle.

This included:

Terrestrial laser scanning using a professional FARO scanner, which provided:

Millimetre-accurate point clouds
Data tied into known survey control points

Drone-based photogrammetry using a DJI Matrice 4E RTK platform, to give:

Orthomosaics and 3D mesh models
Dense point clouds and digital terrain models

These datasets were combined into a single, coordinated digital representation of the site.

The outputs from such digital services, help us and our clients support:

Design coordination and clash avoidance
Construction verification
As-built documentation
Long-term asset management and future modifications

Interactive LiDAR scans and video content further demonstrate both the installed solution and the underpinning digital engineering capability.

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Outcome

Increased effective treatment capacity without expanding the original site
Reliable, automated flow transfer between two operational facilities
Protection of downstream assets through intelligent control logic
Fully integrated electrical, control and communications infrastructure
High-quality digital survey data delivered for ongoing client use
A scalable solution that maximises existing treatment assets

Summary

This project demonstrates a more intelligent approach to capacity challenges in the wastewater sector — using automation, system integration and existing infrastructure rather than defaulting to expansion.
It also highlights the breadth of Aqua‑Tech’s offering across:

M&E design and installation
Control and automation
Commissioning support
Advanced digital survey and modelling

From initial concept through to a fully operational system, the project brought together multidisciplinary engineering teams to deliver a practical, efficient and future-ready solution.

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“Aqua-Tech has seamlessly fit into our project team, quickly becoming an indispensable part of the process. They’ve taken a lot of our headaches away by managing the technical complexities and ensuring everything aligns with our client’s expectations.”