TEG Projects was engaged to assist Fonterra’s Project Manager throughout the life cycle of the project.
First the brownfield site required preparation for the new filtration system. This was an under-utilised processing hall, containing a redundant nano filtration plant. It was necessary that the disused equipment was removed, including all pipework, processing equipment, and pumps, as well as the electrical and software elements. Then the hall needed reflooring and painting.
To achieve AsureQuality and National Drinking Water standards, increase output of clean water and storage capacity the existing treatment plant needed to be fully replaced.
As well as upgrading automation for water management and distribution to the site, the sand filtration system needed to be removed and a new membrane based filtration system installed.
The membrane chosen was a Memcor membrane, which works by forcing dirty water through a fine filter at high pressure, clean water comes out the other side. The system provides improved performance, and superior filtration at a lower ongoing cost.
As part of the process, a flushing system was also installed to keep the filtration membrane clean, functional and efficient.
After the new filtration system was installed, the old sand filters needed to be demolished. This was a complicated undertaking as two 300mm steam and condensate pipes which supplied another part of the site, were supported by the structure of the redundant sand filters. As this steam supply couldn’t be interrupted by the demolition, new supports first had to be constructed in the narrow space between the sand filter building and an existing workshop. This required a complex engineering solution overseen by TEG Projects engineers.
After commissioning, TEG Projects continued to work closely with Fonterra throughout the handover stage. This part of the process formed a significant component as the upgrade considerably modernized operations and required a relearning of systems and processes, and a redevelopment of work streams for the plant and its operators.
