mwh innovation in action newsletter for severn trent water - june 2013

Innovation In Action June 2013 of 8

News brief -‐ Innovation In Action Positive engagement with customers is a key Severn Trent Water initiative, and a One Supply Chain (OSC) group has been set up to help deliver this strategic aim. MWH are key members of this group and recently met some of our customers at Draycote Water Visitor Centre near Rugby. Following refurbishment, this popular Severn Trent Water attraction officially re-‐opened on April 26th, followed by a Family Fun Day on the 27th. Despite torrential April showers and hailstorms, the Customer Engagement Group managed to have its display up-‐and-‐running for both the VIP day and the Open Day itself. With photos, leaflets, posters and project case studies, the OSC stand attracted a large amount of visitors. People were genuinely interested in what we are doing to improve the infrastructure and all feedback was extremely positive. The £4m Rugby Newbold project attracted a lot of local interest with aerial photographs showing the layout of the new equipment. The OSC display stand also featured examples of how we help various local groups with community-‐based projects. Our visitors were pleasantly surprised to hear about these activities, which allow us to leave a positive legacy in the areas where we work. We also explained about our involvement with the Considerate Constructors Scheme to improve the image of construction.

This was the first external event attended by the Customer Engagement Group and the response from the public was extremely promising. With colleagues from the Educational and External Communication teams, we were able to meet our customers in a relaxed and friendly atmosphere, whilst raising the profile of our activities.

MWH and NMC Nomenca both provided staff and resources to support the Open Day, which attracted over 1000 visitors. The events at Draycote Water were superbly organised by Leanne Town and Natasha Golding from Severn Trent Water. ‘On the day’, we met a wide range of people who were inquisitive, challenging and interested in what the OSC are doing. This response is extremely encouraging as we plan further customer engagement meetings.

Mike Daly from MWH (right) meeting one of the many families who attended the Open Day at Draycote Water Visitor Centre on April 27th

Showcasing the activities of the One Supply Chain -‐ Pete Howard (MWH)

Keeping everything sweet -‐ Annie Withnall (STW) with a rather delighted four-‐year old and Mum

Raising the profile of the One Supply Chain with our customers


News brief -‐ Innovation In Action

Communities of Practice (CoP) and the associated ‘Wise Rooms’ are business tools that actively promote collaborative working. The contribution that these forums make to business improvement has been recognized by establishing annual CoP Awards. These are in three categories:

• Connect -‐ spreading good practice and lessons learnt

• Re-‐use -‐ adopting previous examples of best practice and lessons learnt

• Experience -‐ proactive in sharing lessons learnt to prevent recurrence

The joint winner in the Experience category was MWH Process Engineer Paul Kellett, who works at our co-‐located offices in Derby. As facilitator of the Inlet Works CoP, Paul regularly contributes to this forum, helping teams reach optimum Inlet Works solutions. Working closely with CoP members, Paul promotes best practice relating to the design and installation of inlet works structures, primary/storm treatment and associated equipment. Through on-‐line discussions and peer group meetings, this CoP provides a valuable resource for collating Inlet Works’ information, best practice and lessons learnt. Paul’s pro-‐active involvement in the CoP is one of the ways that MWH continues to add value for Severn Trent Water. Some practical examples of Paul’s contribution to MWH schemes at Melbourne, Burton-‐on-‐the-‐Wolds and East Markham are shown on the column opposite.

Adding value at Melbourne Sewage Treatment Works The Inlet Works ‘design template’ asks for the drainage in the screenings handling area to be returned upstream of the screens. At Melbourne sewage works, the upstream drainage return couldn’t be achieved without installing a pump well. Paul was able to discuss this issue with his colleagues on the Inlet Works CoP. They agreed that in this instance the small area around the skip could drain by gravity into a chamber downstream of the inlet works. This saved the need for an additional pump and well with associated programme and cost savings. Agreement on this alternative proposal was readily agreed through the CoP, negating further delay.

Elevating best practice At Burton-‐on-‐the-‐Wolds and East Markham inlet works, initial proposals were for Huber combined screens. Through the Inlet Works CoP, Paul advised the project team about some new Longwood Elevator Screens. These screens have a superior capture rate to comparative Huber products and are a similar cost. Through the CoP we suggested that the Longwood screens could potentially be used at Burton-‐on-‐the-‐Wolds and East Markham, subject to successful trials. These proved successful and Paul has since been involved with developing the solution for incorporating the new screens. As a key member of the CoP, Paul received lots of information from the trial, which improved the design solution for the new screens, especially around the maintenance access areas.

Sharing knowledge across the One Supply Chain to develop solutions and improve project delivery

Paul Kellett (right) from MWH receiving his award for leadership in the Inlet Works Community of Practice



As part of our strategy to introduce innovation, MWH recently hosted a British Water sponsored innovation-‐exchange forum. We invited over 40 of our key suppliers to the event, each of whom gave a brief presentation about their innovative products and services. Although focussing on current AMP5 projects, round-‐ table discussions also looked at market changes and the innovation potential for AMP6. The supplier presentations were grouped into themed workshops that included:

• Innovation from other industries • TOTEX (term used when calculating the

total expenditure of projects or programmes of work)

• Modular design and repeatable solutions • Off-‐site fabrication and assembly

Each workshop was hosted by senior MWH staff who ensured that all ideas from the day were fully captured. All presentations were time-‐limited to ensure they remained engaging, passionate and lively, with excellent audience interaction. There were 120 attendees from across our supply chain and clients, including Southern Water, Wessex Water and United Utilities. There were many presentations on innovative topics such as:

• Real time control-‐ Hach Lange Ltd • Smart run pumping stations – Xylem Inc. • High efficiency motors – Corgin Ltd • 3D modelling -‐ Saviour Engineering

Services Ltd • Odour control technology – Odour

Services International Ltd (OSIL) • Roller compacted concrete – CEMEX UK • Weholite (pipes made from high density

polyethylene)-‐ Asset International Ltd

The supplier presentations covered a wide spectrum of innovative ideas and products, many of which were technology-‐led. As the day progressed, some key themes began to emerge. These included off-‐site construction, energy reduction, packaging of plants, data capture, precast products and process efficiency. Following the event, all presentations were reviewed by MWH to establish those that could add maximum value to our clients. We are now looking to implement these ideas in a phased programme driven by our Procurement team. The innovation forum demonstrates our commitment to business improvement by harnessing the knowledge within our supply chain. Innovation Exchange is a British Water initiative that MWH is proud to support. And the feedback that we have received endorses this strategy! “The ability to mix and match presentations from the various suppliers and specialists was a unique opportunity. A very successful day with many examples of excellence and innovation within the industry.” John Barrow, Head of Supply Chain, Central Services, Wessex Water “Excellent day, well spent in the company of people with genuine passion and commitment to deliver cost-‐effective results.” Graham Raggett, Odour Services International Ltd “Enlightening conference with great insight into the expectations of the utility companies for AMP6”. Suri Nathwani, KEE Process Ltd

MWH supply chain in full attendance at British Water Innovation Exchange forum

“MWH was delighted to host this unique event. It continues our evolution in how we work with our clients and supply chain to share innovation for mutual business benefit.” John Abraham (pictured below), Managing Director of MWH Treatment

Supply chain members from across the UK water industry discuss technology-‐led innovation



The HAVi monitor is a technology-‐led solution for managing exposure to Hand Arm Vibration. Used throughout MWH, the HAVi monitor is fixed to the hand tool using a fabric tie as pictured. The operator then inputs the vibration magnitude of the equipment being used, and the monitor is ready. As time elapses, the HAVi monitor displays the accurate ‘trigger time’ and converts this into the HSE’s HAV points. As per HSE guidelines, if an operator exceeds 100 HAV points (Exposure Action Value) in a day, the HAVi triggers an amber warning light. This means the operator must stop and take a break. If the HAVi triggers a red warning light, the operator must immediately stop work. This means they have reached 400 HAV points (Exposure Limit Value) which is the maximum daily HAV exposure limit as stipulated in HSE guidelines. When the operator finishes, they unstrap the monitor and simply make a note of the HAV points and trigger time in a log-‐book. The monitor can then be transferred to another device allowing HAV exposure to be monitored again.

Thinking aloud Changing personal attitudes to Health and Safety is one of the key aims of the MWH Behavioural Safety course. Led by H&S Manager Mike Kilbride, this initiative has recently been running at our Clay Mills site. Including both staff and sub-‐contractors, the course looks at the definition of safe and unsafe behaviours. It also looks to improve safety performance through observation, feedback and reinforcement of good behaviours. The training is delivered in an engaging format, using humour and real-‐life examples that everyone can relate to. Course feedback is excellent and behavioural safety training is shaping the right attitudes as we continually develop our H&S culture.

As part of our drive to continually improve, MWH held a Dragons’ Den day where staff were encouraged to ‘pitch’ their H&S ideas. One concept that has been successfully implemented is emergency ID stickers for safety helmets. Fitted to the outside of the helmet, the ID sticker contains an inner card that shows worker ID and vital medical information. In emergency situations, the card is easily removed from the outer part of the sticker using the red PULL TAG (circled below in red). This allows medical staff to quickly and safely identify an individual and become aware of any vital medical information. The system is unique as it allows access to crucial information without moving the patient or removing their helmet. Non-‐removal of the helmet is an important feature of the product and is crucial in reducing neck and spinal trauma.

Best practice tagged on site To improve safety across our sites, plastic tags are now being used to record information about excavations. Similar to ‘scafftags’, these durable labels are attached to excavation supports to show safety information relating to the dig. Excavation tags help us comply with legislative requirements and H&S best practice for inspecting and maintaining excavations. Suitable for use in most construction environments, the tags give vital safety messages about the excavation such as:

• Fit To Use • Do Not Enter • Inspection and

Maintenance dates

Safety related innovation and best practice driving improvements in performance

Reducing the risk of Hand Arm Vibration injury

Contains information such as emergency contact details and allergic conditions

Highly reflective, easily fitted and weatherproof



Happy landings for Melbourne project team Melbourne Water Treatment Works is located close to East Midlands Airport (EMA) and beneath one of the airport’s main flight paths. The MWH scheme at Melbourne WTW included fitting new covers to the existing DAF (Dissolved Air Flotation) Plant. This involved the extensive use of mobile cranes and temporary lighting. From ‘day one’, the site team recognised that our cranes and lighting could pose a hazard to aircraft using the airport. Working proactively, the MWH team contacted the safety department at EMA for guidance. Sub-‐agent Ed Tonks liaised closely with EMA Safety Officer Will Fuller to ensure we fully understood the relevant safety issues. Through detailed email correspondence and personal contact, the site team developed a broad understanding of the risks to aviation safety. This allowed us to introduce control measures to manage these risks without compromising the construction programme. These control measures included:

• Lighting towers installed in a South Westerly direction, angled downwards and only used at agreed times

• All crane movements notified in advance to EMA who would then relay information to Air Traffic Control

• Warning beacons fitted to all cranes in accordance with aviation safety procedure CAP 168.

Off-‐site construction and modular manufacturing were key themes in a recent Daily Telegraph ‘Careers in Engineering’ supplement. These initiatives have been widely adopted by MWH and Carlow Precast on the flagship Clay Mills project, as highlighted in the article… “Constructing Final Settlement Tanks for Severn Trent Water’s Clay Mills site from precast concrete was a major step forward for the UK water industry. It saved £90,000 through reduced use of aggregates and associated transport, and there were no temporary works and associated costs. It also significantly decreased working at height, reduced the total programme length by six to eight weeks and mitigated weather-‐related risks.”

Going underground to get people out of a jam The MWH Direct team pictured below have all completed the “Emergency Rescue and Recovery of Casualties from a Confined Space” course. Run by the experts at Mines Rescue Service Ltd, the MWH team have been trained to:

• Work as part of a team to help rescue staff during an emergency in confined spaces

• Prepare to work safely in confined spaces under emergency conditions

• Enter and exit confined spaces safely • Prepare and use Breathing Apparatus in

accordance with manufacturers’ specifications

This specialist training increases the level of safety for MWH staff and co-‐workers in confined spaces. It also allows us to improve the range of services that we can offer to the One Supply Chain.

Mentioned in dispatches – Clay Mills’ innovative construction methods

Improving H&S delivery by introducing best practice from the mining industry



Integrating assets through forward planning The MWH project at Melbourne sewage treatment works near Derby included a new inlet works and associated controls. The original plan was to house Control and Instrumentation equipment in a new kiosk adjacent to the inlet works. However, on-‐site investigations revealed that an existing MCC (Motor Control Centre) panel could be extended to accommodate the inlet works controls. The practicalities of this were discussed with CEMA Ltd, who supplied the original MCC. They confirmed that the modifications were both feasible and cost-‐effective. Working with supply chain partners CEMA and Lloyd Morris Electrical, the inlet works C&I panels were successfully added to the existing MCC. All work, including modifications to the existing controls, were completed with minimal disruption to normal operations at Melbourne sewage works. This efficient use of existing assets has:

• Reduced project capital costs and minimised the number of assets requiring future operation and maintenance

• Reduced on-‐site construction and lowered associated H&S risks

• Integrated existing controls to give operators a ‘full picture’ of the inlet works

Media correction brings benefits for Clipstone Adopting industry best practice is helping MWH achieve timely compliance with regulatory consent dates. Commissioning of the GAC (Granular Activated Carbon) vessels at Clipstone WTW was enhanced by using pH corrected carbon. Untreated new carbon gives a high pH into the incoming water for a relatively long time, delaying the ‘conditioning’ process. To counteract this, the carbon media used by the Clipstone team was (to a degree) pH corrected. This significantly reduced the volume of water and time needed to achieve correct pH, with each vessel taking approximately four days to ‘condition’. Careful planning ensured that our commissioning programme didn’t cause any unplanned plant shutdowns and there were no breaches of Prescribed Concentration Values (PCV). We also liaised regularly with nearby Edwinstowe sewage treatment works to ensure that our pumped flows of rinse water did not create any issues for them. Water quality was sampled daily, with all results discussed and agreed with Severn Trent Water.

MWH success on leakage framework MWH Treatment has recently been awarded a nine-‐year leakage detection framework with Severn Trent Water. With 130 Engineers and Technicians now mobilized, this programme allows MWH to become an integral part of Severn Trent Water’s distribution team. Following a competitive tender, MWH were selected with PN Daly to deliver leakage detection services. Morrison Utility Services were also chosen to provide repair and maintenance. The framework partners will work collaboratively, using an integrated management system. MWH are also providing staff for several operational and management roles to help deliver the framework’s strategic goals.

Bright idea maximises space and reduces costs

Successfully commissioned ahead of DWI dates

Innovative use of existing assets reduces the number of operator interventions



Site teams bring ‘buildability’ knowledge into design Led by Craig Thompson, MWH site staff are working with our Solutions’ teams to ensure project designs benefit from ‘site-‐input’. Buildability -‐ the ease and efficiency of which a structure can be built -‐ is a key aim of these joint sessions. An example of this is a spreadsheet developed by Craig’s team. This shows the cost-‐benefit analysis between traditional construction methods and caisson type structures for a range of site-‐based applications. The spreadsheet clarifies the decision-‐making process and reduces the times for making construction-‐related calculations. During Stages 2 and 3 of the current scheme at Rugelely sewage treatment works, Craig worked closely with the solutions’ team at Raynesway. In particular, they looked at the location and design of the new Interceptor and Rapid Mixer chambers, and the practicalities of combining the two structures. This option was discounted, as the risks from working around buried services in a congested construction footprint outweighed the benefits. Through discussion, an alternative ‘buildable solution’ was reached. This included re-‐designing the system by relocating the Rapid Mixer Chamber and reducing the size of the Interceptor Chamber. Craig also involved FRC sub-‐contractor STAM Construction Ltd during outline design of the Rugeley scheme. They were able to give practical advice about concreting, formwork and rebar details of the new Deep Bed Sand Filter unit

Fast-‐tracked success at Swithland Pumping Station A new pressure vessel has been successfully installed at Swithland Pumping Station (PS) in ‘record time’ by MWH. Swithland PS is one of Severn Trent Water’s most strategically important assets and is also a Listed Building! Following failure of the old pressure vessel at Swithland, it was decided to fast-‐track vessel replacement. This would minimise the possibility of disruption to the supply network. A Gate 1 business-‐case was produced by Water Production in October 2012 and Service Delivery was approved in the same month. The paper was presented to the Programme Board in November 2012, and taken straight to Gate 3 as an emergency project. Working closely with Quantum Engineering, a new stainless steel pressure vessel was procured and manufactured soon after. After successfully completing off-‐site inspection and tests, the new vessel was delivered to Swithland in January 2013. Working to an agreed lifting plan, the new vessel was safely off-‐loaded, while the redundant vessel was removed. The new vessel was then lifted into position at the front of the building in a two-‐crane lift. Using load skates, the vessel was safely manoeuvred into the building, before being lifted into position by the overhead crane. Excellent collaboration between Asset Creation, MWH and Service Delivery ensured that the vessel was safely installed to extremely challenging timescales. This was all achieved without damaging a historically important building!

Leaving a positive legacy During MWH Direct work at Barton-‐Under-‐Needwood WwTW, the site team took a really proactive approach to H&S. They decided to sponsor the completion of ‘Improve It’ cards by donating a cash amount for each one raised. This went into a fund that eventually reached £100, which was subsequently donated to Thomas Russell Infants School.

Using the expertise in our Supply Chain – Rugeley Site Engineer Matt Norton with STAM supervisor

Ensuring site teams positively influence design solutions through ‘buildability’ reviews. Craig Thompson, MWH

‘Building a better world’



Graveyard shift cleans up at Longnor A team of volunteers from across the One Supply Chain has successfully cleared the churchyard of St Bartholomew’s church in Longnor. Over the years, the churchyard had become overgrown with brambles, trees and tangled undergrowth. This made it difficult for people who wanted to visit the churchyard. Responding to a request for help from the local Parish Council, volunteers from MWH, Severn Trent Water and CT Construction agreed to lend a helping hand.

The quiet of the Derbyshire countryside was broken by the sound of power tools spluttering into life as the teams made headway into the undergrowth. With only minimal stops for coffee and biscuits (one to be precise), the areas were painstakingly cleared after years of neglect. There was definitely a camaraderie buzz to the day, as everyone worked tirelessly and with great humour. An al-‐fresco lunch of fish and chips provided the necessary fuel for the afternoon’s ‘final push’ to complete the works. The day finished about 3.00pm and the final result was astonishing. A neglected and dangerous area had been transformed into a visually appealing open-‐space. In fact, the local Parish Council are so delighted with the final result that they have written to us saying, “Just being able to walk up

and down the graveyard unimpeded is a minor miracle”. To know that we have made such a difference to a local community should be a source of great pride for all of us.

Getting to know our neighbours at Overseal STW Continuing on the theme of positive customer engagement, the project team at Overseal STW recently hosted a public visit. This was a unique opportunity for over 30 of the local residents to see at first-‐hand the refurbished sewage treatment works. The reaction from the residents of Overseal was very encouraging and everyone was complimentary about the new equipment. We also met a local resident who works for the EA who was suitably impressed by the plant, and the quality of the final effluent! To round-‐off the evening, we presented a cheque for £500 to a local football team on behalf of MWH and Hollywood Plant Services.

Major awards success for Clay Mills and Waterhouses MWH and Severn Trent Water enjoyed a memorable and winning evening at a recent ICE (Institution of Civil Engineering) awards ceremony. The annual East Midlands Merit Awards showcase the very best in excellence from the region’s many construction projects. The Clay Mills e5 project scooped two of the five awards on offer, whilst our project at Waterhouses was highly commended in another. Commenting on their web-‐site, the ICE says ”The Merit Award winner of both the Medium and the Small Project categories was Clay Mills WwTW… submitted by MWH for its precast final settlement tanks and soil stabilization projects”. The ICE also said “Significant project cost and time savings have created an aesthetic solution of precast concrete and a UK first that impressed the judges. Their soil stabilisation project involved the introduction of a new product to the UK; innovative and courageous thinking by those involved marked them out as winners!”

Contributions welcome For more information on the stories in this Newsletter, or if you have any ideas for future editions, please contact [email protected]

One team -‐ one goal -‐ One Supply Chain

MWH Business Manager Aidan Spillane accepts the ICE awards

Shauna’s new broom, sweeping clean at Longnor

mwh innovation in action newsletter for severn trent water - june 2013

Documents

open day

customers innovation

action positive engagement

customer engagement

supply chain osc group

vip day

draycote water visitor

osc display