Sanivar delivers precise solution for complex sludge pipeline refurbishment with SaniTube®

By Sanivar

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Overview

SaniTube® was selected for a challenging refurbishment of four sludge pipelines at Yorkshire Water’s Blackburn Meadows Treatment Works. The pipelines spanned above and below ground, with restricted access that required a bespoke liner solution. Success required early technical involvement, accurate planning and close coordination between every organisation involved.

Working alongside Peter Duffy Ltd and designer Eric Wright Ltd, Sanivar developed and supported the installation of four 200 mm SaniTube® liners, providing secondary containment for pipelines running across pipe bridges over the River Don.

The project covered three above-ground steel pipelines and one buried polyethylene pipeline, each approximately 80 metres long. In total, around 320 metres of bespoke liner was installed.

Challenges

The existing fire main ran adjacent to established trees and under a transformer room meaning that replacement or open excavation was not really an option both in terms of cost and environmental considerations.

By using SaniTube we were able to keep access to minimal civil footprints equating to 2msq at launch and reception pits, furthermore SaniTube provided an opportunity to define an exact length allowing for the connection to onward infrastructure including pressure valves.

A demanding installation environment

The pipelines carry sludge through an operational treatment works and across the River Don. Any lining solution had to provide reliable secondary containment while working within the physical and operational constraints of the site.

Each liner needed to be manufactured to an exact length between existing flanged access points. There was no room for error: inaccurate measurements could have affected both installation and reconnection of the pipelines.

Thermal movement presented another important consideration. The above-ground steel pipework expands and contracts as temperatures change, with expansion joints incorporated into the host pipelines to manage this movement. The lining system needed the flexibility to operate alongside this existing arrangement.

Access was also tightly controlled. For operational reasons, work could only take place during specific time slots across a four-week programme. Materials, operatives and technical support all had to be available at the right time.

Once installed, every liner would also need to withstand a 7.5-bar pressure test.

The Sanivar teams’ early planning made overcoming these constraints possible. The team worked to develop a solution that would succeed within a live treatment works where delays and last-minute changes could have affected the wider programme.

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Developing the right solution

Sanivar worked with Peter Duffy Ltd and the project design team for two years, supporting the development of the scheme from its early design stages.

After reviewing the pipeline configuration, operating conditions and installation restrictions, Sanivar proposed its SaniTube® pressure-lining technology.

The SaniTube® system offered the combination of pressure capability, flexibility and installation practicality required for the project. Its ability to accommodate longitudinal movement was particularly important for the above-ground pipelines, where temperature changes could cause the host pipework to expand and contract.

Sanivar remained closely involved as the draft and final designs evolved, providing technical guidance and helping the team resolve project-specific challenges before work began.

This early collaboration gave the project partners confidence that the proposed system could be installed safely, efficiently and within the available access windows.

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Turning the design into a workable installation plan

Following final design approval, Sanivar and Peter Duffy Ltd carried out a joint site visit to confirm the details of each installation.

The teams reviewed access arrangements, checked pipeline diameters and measured the exact distance between the flanged access points. They also agreed how the liners would be terminated and connected back into the existing pipework. Each liner was bespoke, so the information gathered on site directly informed its manufacture and the installation sequence.

Sanivar then provided off-site training for Peter Duffy Ltd’s installation team. This gave operatives the opportunity to understand the product, handling requirements and installation method before entering the live site environment.

A phased delivery plan was also developed around the four-week programme. Materials were supplied in line with the agreed sequence rather than delivered in a single consignment, helping to minimise congestion and ensure the correct components were ready for each access window.

By planning for all these details in advance, the team reduced risk on site and kept the installation programme moving.

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Installation and testing

Technical queries were addressed quickly, while the combination of accurate measurements, expert support and carefully timed deliveries allowed each installation to happen at the right time.

Once the liners had been installed and the pipeline connections completed, all four lines underwent the specified 7.5-bar pressure test, with every liner passing, and the project being completed on time.

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Installation and testing

The Blackburn Meadows project demonstrates the value of bringing specialist suppliers into complex infrastructure projects at an early stage.

Sanivar’s expert support supported Yorkshire Water beyond the supply and manufacture of liner. The team contributed to solution development, draft and final design, site measurement, installer training, logistics planning and delivery support.

This end-to-end approach allowed technical and operational risks to be identified early, rather than dealt with during installation.

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Ben McCluskey, Lining Project Manager at Peter Duffy Ltd, said:

“From the early design stage, the technical support and expertise provided by Tim and the wider Sanivar team helped us develop a practical and efficient solution for the installation of the four 200 mm liners. Their early involvement meant technical challenges were addressed quickly and gave us confidence in the final design.”

“The collaborative approach between Peter Duffy Ltd and Sanivar was a key factor in the successful delivery of the project. It has been a pleasure working together, and we look forward to continuing this strong partnership.”

Tim Farley of Sanivar added:

“This was a technically demanding project, and one we were delighted to support. By working closely with Peter Duffy Ltd and Eric Wright Ltd from the design stage onwards, we were able to develop a solution around our SaniTube® pressure liner that addressed the specific challenges of the site.”

“Close communication between every stakeholder was essential. The result reinforces the value of supporting a project from initial design and planning through to installation and final testing.”

The outcome

The project achieved:

• The refurbishment of four 200 mm sludge pipelines.
• Approximately 320 metres of bespoke SaniTube® lining.
• Secondary containment for pipelines crossing the River Don.
• A flexible solution suited to movement within the above-ground pipework.
• Installation within restricted operational access windows.
• Practical off-site training for the installation team.
• Phased material deliveries aligned to the site programme.
• Completion within the agreed schedule.
• Successful pressure testing of all four liners at 7.5 bar.