• Client:Thames Water PLC
• Type:

Project Overview

Following a comprehensive, plant-wide inspection of the GAC Plant, the existing cyclones were found to be significantly degraded due to long-term wear and tear. To ensure continued operational efficiency and compliance, a decision was made to fully replace the cyclones across three Thames Water sites as part of the wider GAC Plant refurbishment programme.

The Challenge

The cyclones play a critical role in separating sand and Granulated Activated Carbon (GAC), allowing the carbon to be recovered and reused within the freshwater filtration process. Their deteriorated condition posed a risk to both performance and reliability, requiring a coordinated replacement programme across live operational sites.

Our Solution

Each cyclone was individually surveyed to verify specifications and ensure the correct replacement units were sourced. In accordance with Thames Water site requirements, all necessary documentation and permits were prepared, submitted, and approved prior to the commencement of works.

Fully trained and certified personnel were assigned to the project, ensuring all activities were carried out to the highest technical and safety standards.

Project Delivery

Across the three sites, four cyclones per site were safely removed and replaced. Specialist lifting equipment was used to manage the removal and installation of the units, with all works conducted in a controlled environment to minimise disruption to ongoing operations.

Safety and Compliance

All works were delivered in full compliance with CDM Regulations. The project was executed with a strong focus on safety, planning, and coordination, ensuring a smooth and incident-free installation process at each location.

Outcome

The successful replacement of all cyclones restored the integrity of the separation process, enabling continued reuse of Granulated Activated Carbon and supporting the long-term performance of the GAC Plant across all three Thames Water sites.