Details:

A restructuring of their farms, driven by a need to increase their irrigation capabilities required the client to instigate the Farm Irrigation Pump Stations project involving expanding an existing Irrigation pump station as well as building a new pump station.

SPL were contracted to provide a turn-key solution for the entire project involving:

• Civil Works - including Geotech Ground Testing, Earthworks, Piling, Silo Foundation Design & Build, Pump Station Foundation Design & Build and building the workshop, control room & MCC,
• Silo Supply & installation,
• Mechanical Design, Fabrication & Installation,
• Electrical Design & Installation,
• Automation,
• Commissioning.

During the procurement phase of the project SPL worked closely with the client to reuse their existing equipment wherever possible & to ensure the supply of site preferred equipment for all new supply items.

Located on a farm, away from site, the new pump station provided the perfect setting to be run as a ring fence project, with SPL in control of inductions, H&S, contractor management & Permit to Work system. Over 4000 hrs worked without any MTIs (Medical Treatment Injuries), LTIs (Lost Time Injuries) or Environmental incidents.

Details:

While renewing their environmental resource consent with the local authority, it came to light that our client’s stormwater system did not comply with the latest regulations. To comply, the system required multiple divert points, a storage pond, water quality sampling stations, a number of extra manholes & underground pipe. To rectify this situation the Stormwater Upgrade Project was undertaken, with SPL contracted to manage the mechanical, electrical & automation works. The scope of works included the design, procurement, fabrication & installation of the following, as well as commissioning the entire system:

• Continuous pH, Conductivity & Turbidity sampling of stormwater at multiple locations across site,
• A range of valves from ¾” Manual Ball Valves up to Ø900 mm Air Actuated Penstock Valves.
• A certified compressed air system – Suitably sized to drive the Penstocks closed within specified time limits,
• Baffles in the manholes – These needed to be removable without compromising on their sealing ability,
• Bespoke Pontoon to float pumps on the storage pond to circulate &/or pump out water from the pond,
• Submersible pumping,
• Automatic waste stream selection based on sampling results.

The system was inspected & approved by the local authority & has been working well since, preventing multiple unconsented environmental discharges.

Details:

Faced with an increasing demand for their Butter and an ageing plant unable to keep up with production due to bottlenecks at the Cream De-Odourising & Cream Crystallising stages, the client decided to undertake a major plant upgrade.

The upgrade was a turn-key project involving Process Engineering, Civil Engineering, Construction, Silo supply & installation, Mechanical design, fabrication & installation, Electrical Work, Automation & Commissioning. The project’s timeframe was tight; the old plant needed to be removed & the new plant installed & commissioned within the winter shut, which involved:

-         Repurposing an existing Silo to handle an extra 2 product streams,

-         Replacing existing flow plates with automated valve manifolds,

-         Constructing an engineered silo foundation,

-         Installing 2x new 150 m³ Silos,

-         Converting an existing hallway to Redline standards & adding a Silo Gallery.

-         Corresponding with a 3^rd Party Overseas Equipment Supplier to ensure the plant design met the new Cream De-Odouriser’s requirements.

-         Modifying the fat rework system to improve efficiency & cleanability.

As the head contractor SPL oversaw the project from initial design, to managing the sub-contractors inside the ring fence through to final commissioning. Completing the project safely & on time while minimizing impact on site required clear communication between SPL, Site Management, Site Operators & Sub-Contractors.

Details:

The client approached SPL with a request to assist with a boiler heat recovery system.

SPL offered a turnkey solution that integrated a heat exchanger into boiler stack along with a VSD driven Fan to maintain constant boiler backpressure.

The system has been integrated into the PLC control system and provides process status of the operating condition on the HMI screens throughout the site.

The system offers recovery of up to 20% of the boiler capacity.

The project was commissioned in a tight shut down window, requiring interfacing with other projects in the same area.

The project was completed with no near misses or MTIs in conjunction with the customer site inductions and permit to work systems.