Penstock Replacement – Ensuring Environmental Compliance

A major UK Water Company faced a critical issue when a process critical penstock failed, allowing untreated wastewater to bypass the treatment process. This immediately presented a significant risk of environmental pollution and site non-compliance. The urgent need was to deploy effective prevention controls to mitigate the immediate pollution risk, followed by a rapid, permanent repair or replacement of the failed asset. Access to the penstock was severely restricted, requiring specialist methods to avoid costly site shutdowns and extensive scaffolding. The project was further complicated by challenges with water intrusion into the work area and the rapid drying of specialist mortar due to hot weather, demanding swift and precise execution.

Upon immediate instruction from the client, TEXO Utilities rapidly deployed prevention controls to eliminate any immediate pollution risk. Our specialist IRATA Rope Access mechanical engineering inspection team conducted a thorough asset condition assessment, quickly determining the penstock was beyond repair due to age and harsh environmental wear.

Leveraging their expertise and the unique capabilities of our team, we swiftly identified suitable replacement units from Ham Baker Engineering. Our IRATA Rope Access team then developed a precise and safe methodology for installation. This approach, utilising IRATA Rope Access and Rescue Equipment, negated the need for costly site shutdowns and extensive scaffolding, providing efficient access to the confined and restricted work area. Despite significant challenges with water intrusion into the work area and the rapid setting of the specialised mortar in hot conditions, the TEXO Utilities team worked with exceptional speed and precision.

The TEXO Utilities team successfully completed the installation of both penstocks within an impressive two-day timeframe. This rapid action immediately restored critical control over the effluent, effectively eliminating the risk of accidental pollution and bringing the site back into environmental compliance.

Our client was highly satisfied, stating: “With the major works being undertaken at this site taking place, TEXO were a pivotal point in progressing these works. Without TEXO completing this step of work onsite, the plant’s operations and large overhaul of assets could not take place, we are very happy with the results that TEXO accomplished and the timescale they achieved it in.”

TEXO’s success in this project was attributed to the diverse capabilities of our Specialist Access Engineering Team, our ability to minimise impact on operational functionality, and our swift response in sourcing specialist parts and executing the scope. This project highlights TEXO Utilities’ unique capacity to undertake very complex and time-sensitive work in challenging environments where other companies cannot, ultimately enabling our framework partner to progress critical plant overhauls.