Stopper Specialists support Ward & Burke with reliable pressure-testing equipment
Project Overview
The Sindlesham & Bearwood Water Booster Station (WBS) Phase 2 project formed part of a wider programme to increase water supply capacity and improve resilience across the Arborfield area.
Ward & Burke was responsible for delivering the works, which involved significant upgrades to the existing booster station, including new outlet pipework from the Bearwood Service Reservoir, a new discharge main and a new surge vessel arrangement.
The works had to be carefully coordinated around the existing operational network. Due to limitations on reservoir outages, the new outlet pipework had to be installed and commissioned in three separate stages. The new discharge main and surge vessel arrangements were also installed and commissioned in two stages.
This phased approach created a number of pressure-testing requirements, with equipment needed at different points throughout the installation and commissioning sequence.
Stopper Specialists supported Ward & Burke throughout the works by supplying pressure-testing equipment, test plates and test spades for the different stages of the project.
The Challenge
Working on an operational water network meant that new and partially commissioned pipework needed to be reliably isolated from live sections of the system.
The limited shutdown windows made the timing and availability of testing equipment particularly important. Equipment needed to be on site when required, correctly configured for the planned testing activity and in good working condition.
The project also involved a range of pipework sizes and testing requirements. This meant the testing arrangement needed to change as different sections of the works progressed.
The main priority was therefore to have the appropriate equipment available when required, without introducing delays into the planned commissioning sequence.
The Solution
Stopper Specialists supplied pressure-testing equipment, test flange and spades to support the project’s phased installation and commissioning sequence.
DN150 and DN250 test flanges were used across the new reservoir, surge vessel and outlet pipework for filling, venting, pressure testing, flushing and disinfection. DN250, DN350 and DN400 test spades were also procured and fitted during installation, providing isolation points for future testing as each section was commissioned.
Equipment was required for connections ranging from 150mm to 600mm, with testing pressures varying from approximately 1.5 to 8 bar depending on the application.
A key testing requirement involved a newly cast section of pipework through the reservoir wall. A DN600 test flange was used to hydrostatically test the section at 1.5 bar before the internal reservoir pipework progressed. Testing at this stage allowed the team to verify the connection before the reservoir cell was recommissioned, reducing the risk of further shutdowns or remedial works later in the programme.
With testing activities tied to tight shutdown windows, equipment availability and condition were critical. The client highlighted that the equipment arrived in good working order, with many of the DN150 test flange in as-new condition.
Rory Kelly, Project Manager, said
“Most of the flanges we got on hire, particularly the DN150 flanges, were in as-new condition with new valves and fittings, which definitely helped to ensure no leaks or issues when it came to testing.”
Stopper Specialists also provided a single supplier for the testing requirements, coordinating equipment deliveries and collections as the commissioning sequence progressed.
“Having one supplier provide the testing equipment, test flange and spades helped as it made the process of ensuring the correct equipment was ordered and delivered to site on time more efficient, in an already tight commissioning sequence.”
This combination of equipment flexibility and coordinated supply helped manage the changing testing requirements across each stage of the works.
Rory continued,
“The efficient and reliable service helped with the successful completion of the works, and we will be using Stopper Specialists for future projects.”
The Result
The Sindlesham & Bearwood WBS Phase 2 works were completed with the upgraded infrastructure brought into operation as planned.