From wastewater characterisation to manufacturing documentation. Process design, 3D CAD modelling, CFD validation, structural & thermal analysis, and complete fabrication packages backed by ASME, PED, and ATEX compliance.
One team carries a wastewater challenge from characterisation to a fabrication-ready, commissioned plant — process, mechanical, hydraulic, structural, controls and build under one roof.
Wastewater characterisation, treatability testing and mass & energy balances that set the design basis.
ExplorePipe sizing, pump duty, NPSH and pressure-drop calculations across the treatment train.
Explore3D modelling, clash detection, BIM integration and full plant layout drawings.
ExploreContact-zone, mixing and thermal CFD to optimise performance before any steel is cut.
ExploreMaterial selection and corrosion engineering matched to your chemistry and duty.
ExploreComplete, automated chemical dosing systems and skids — designed and built, not bought in.
ExploreASME/PED-compliant fabrication and custom builds to fabrication-ready documentation.
ExploreGated design process with review milestones at 30%, 60%, 90%, and IFC issue
Every bespoke design begins with a rigorous process engineering foundation. We characterise your wastewater, establish design bases, and develop heat and material balances that govern all downstream engineering decisions.
Flow profiling, composite sampling, COD/BOD/TSS/FOG analysis, heavy metals screening, and treatability testing.
Mass flow rates, component balances, energy requirements, and hydraulic profiles across the full Treatment Process.
Pipe sizing (Darcy-Weisbach), pump selection (NPSH, curves), valve specification, and pressure drop calculations.
Duty/standby configurations, redundancy requirements, turndown ratios, and control philosophy development.
SolidWorks-based 3D modelling with full clash detection, BOM generation, and LOD 400 fabrication detail. BIM-compatible exports available for integration with existing plant models and structural frameworks.
Part modelling, assembly design, weldment structures, and sheet metal development for all pressure-bearing and structural components.
Automated interference checking between equipment, piping, electrical trays, and structural steel before fabrication.
IFC exports compatible with Autodesk Revit, Bentley OpenPlant, and Intergraph Smart 3D for brownfield integration.
General arrangement (GA), fabrication isometrics, detail drawings, and exploded assembly views for site installation.
Computational fluid dynamics validates contact zone hydrodynamics, white water distribution, sludge removal efficiency, and thermal profiles before any steel is cut. Our brewery CFD case study demonstrated a 16% improvement in TSS removal.
Bubble-floc contact efficiency, white water distribution uniformity, and short-circuiting analysis.
Rapid mix G-value validation, flocculation tank residence time distribution, and velocity gradient profiles.
Lamella plate flow distribution, sludge hopper collection efficiency, and density current prediction.
Heat exchanger performance, insulation requirements, freeze protection, and temperature stratification.
Pressure vessel design to ASME VIII Division 1 and PED 2014/68/EU, structural steel to Eurocode 3, seismic loading per IBC/UBC, and thermal insulation specification for energy conservation and personnel protection.
ASME VIII Div.1, PED Category III/IV, EN 13445, design pressure/temperature, corrosion allowance, and MAWP calculations.
Eurocode 3 (EN 1993) beam/column design, platform and walkway loading, lifting lug verification, and seismic bracing.
Heat loss calculations, insulation thickness optimisation, steam tracing specification, and freeze protection.
Stress concentration analysis, fatigue life prediction, and deformation verification for non-standard geometries.
Material selection is dictated by wastewater chemistry, temperature, abrasiveness, and regulatory requirements. Every material certificate is traceable to mill test reports.
| Application | Recommended Material | Standard / Grade | When to Specify |
|---|---|---|---|
| General wastewater | SS304 / SS316 | EN 1.4301 / 1.4401 | pH 6ā9, chloride <200 mg/L |
| Chloride-rich / seawater | SS316L / Duplex 2205 | EN 1.4404 / 1.4462 | Chloride >200 mg/L or marine |
| Acidic effluent | SS316L + Halar coating | PTFE / ECTFE lining | pH <4 or aggressive chemicals |
| Abrasive slurry | Hardox / rubber-lined | HB 400ā500 / NR rubber | Sand, grit, mining tailings |
| High temperature | SS316L / 904L | EN 1.4404 / 1.4539 | >60°C process temperature |
| Hazardous areas | SS316L + ATEX | IECEx / ATEX II 2G | Zone 1/2 gas, Zone 21/22 dust |
Formal design review gates ensure client alignment, regulatory compliance, and manufacturability before advancing to the next phase. Change management is controlled through revision-controlled document sets.
| Gate | Deliverables | Review Focus | Typical Duration |
|---|---|---|---|
| 30% Conceptual | Process PFD, mass balance, preliminary GA, budget estimate | Process feasibility, technology selection, space plan | Week 2ā3 |
| 60% Preliminary | P&IDs, equipment datasheets, 3D model, Capital expenditure confirmation | Hydraulics, materials, instrumentation, electrical loads | Week 5ā7 |
| 90% Detailed | Fabrication drawings, BOM, control philosophy, specifications | Manufacturability, service access, safety, codes | Week 10ā12 |
| IFC Issue | Stamped drawings, ITP, quality plan, O&M manual draft | Final client approval, third-party inspector release | Week 13ā14 |
All CFD simulations follow a formal mesh independence protocol. We construct three mesh densities (coarse, medium, fine) and compare key output variables (pressure drop, velocity at monitoring points, separation efficiency). Mesh refinement stops when the relative change in the target variable is <2% between medium and fine meshes. For RANS turbulence models, wall-adjacent cell height is set to achieve y+ ā 1 (viscous sublayer resolved) or 30ā300 (wall function) depending on the turbulence closure. Typical mesh counts range from 2ā10 million cells for vessel-scale simulations.
Convergence criteria:
Structural finite element analysis uses linear elastic material models with mesh convergence verified against analytical solutions for standard geometries. For pressure vessels, stress linearisation is performed along paths through high-stress regions per ASME VIII Division 2, Part 5. Allowable stress limits:
The required insulation thickness is determined from the steady-state heat transfer equation: Q = 2ĻkL(Ti ā Ta) / ln(ro/ri) for cylindrical vessels, where k is thermal conductivity of insulation (typically 0.035ā0.045 W/mĀ·K for mineral wool or PIR foam), L is length, Ti is internal temperature, Ta is ambient, and ro/ri are outer/inner radii. We design for a maximum heat loss of 50 W/mĀ² for process energy conservation or a surface temperature <50 Ā°C for personnel protection per EN ISO 13732-1. Condensation risk on cold surfaces is checked by verifying that the insulation outer surface temperature remains above the dew point for the design relative humidity (typically 80% RH).
Design pressure = maximum allowable working pressure (MAWP) Ć 1.1 safety factor. Design temperature = maximum operating temperature + 20 Ā°C margin. Corrosion allowance = predicted corrosion rate (mm/year) Ć design life (years) + 1 mm contingency. For vessels under PED, we determine the conformity assessment module (H/H1, B+D, B+F) based on fluid group and pressure-volume product.
Dimensional tolerances follow EN 1090-2 Execution Class 2 (standard) or Class 3 (precision). Critical nozzle locations are held to Ā±2 mm. Vessel shell out-of-roundness is limited to 1% of nominal diameter. Plate edge preparation for welding conforms to ISO 9692-1. Weld distortion is controlled by sequencing, tack-welding fixtures, and post-weld stress relief where section thickness >25 mm or material yield strength >355 MPa.
ASME VIII Div.1 (U-stamp), PED 2014/68/EU (CE marking), EN 13445, AD 2000 Merkblatt
Eurocode 3 (EN 1993), AISC 360, BS 5950, EN 1090 (steel fabrication), ISO 3834 (welding quality)
ATEX 2014/34/EU, IECEx 02, EN IEC 60079 series, Zone 1/2 gas and Zone 21/22 dust certification
ISO 9001:2015, weld procedure specifications (WPS/PQR), NDT (RT/UT/PT/MT), hydrostatic testing, material certificates EN 10204 3.1/3.2
A core bespoke deliverable — complete chemical dosing systems and skids, fully automated, engineered to the same gated process above.
Chemical dosing is one of our most common bespoke builds. We engineer the whole system — storage, dosing pumps, injection, mixing, control panel and containment — to your duty and chemistry, then build and factory wet-test it as a skid-mounted or containerised plant. We design and build dosing systems; we don’t sell pumps off a shelf.
Skid-mounted, pre-piped, pre-wired and factory-tested, with an integrated, fully automated control panel.
The end-to-end service — scope, engineer, build and commission a complete dosing system.
Instrumentation, PLC control loops, control panel and SCADA integration designed in.
Pump capacity and turndown, tank volume and material selection from flow, dose and chemistry.
Coordinated, automated multi-point dosing of several reagents from one control panel.
Tanks, bunding, material compatibility and COSHH/DSEAR safety as part of the design.
Underpinned by the full chemical dosing engineering reference — equations, stoichiometry, process design and control strategy.
Our engineering team can take your wastewater challenge from initial concept through to fabrication-ready documentation. Contact us for a feasibility assessment and design proposal.
Our expertise spans multiple industries with sector-specific water treatment solutions.