Sheeplands Water Treatment Works

Project Overview

In 2019, Thames Water appointed Satec Service Ltd to inspect and refurbish the nitrate removal vessels at Sheeplands Water Treatment Works, following over 14 years of continuous operation. The plant treats an average of 7.5 MLD of borehole water containing nitrate concentrations of up to 154 mg/l, reducing nitrate levels to 25 mg/l or below using four ion exchange filters containing Purolite A-200E resin.

Following the discovery of a corrosion defect on one vessel, Satec was commissioned to carry out a full condition survey, non-destructive testing (NDT), and refurbishment of all four nitrate filters.

Scope of Works

Our engineers inspected each pressure vessel and identified components requiring replacement, including gaskets, pumps, strainers, and automatic and manual valves. Following refurbishment, the system was recommissioned by balancing flow rates, verifying regeneration sequences alongside the client’s PLC engineer, and testing the condition of the ion exchange resin. The existing resin was found to be in excellent condition and was topped up before the vessel was returned to service.

Health & Safety

The project involved complex confined space working, working at height, and manual handling operations. Satec implemented a comprehensive safety plan that included:

• Temporary access platforms with handrails and toe boards
• Harness systems and emergency rescue procedures
• Continuous gas monitoring within the vessels
• High-level lifting equipment to safely transport resin to the access platform, eliminating manual handling risks

Project Outcomes

The refurbishment successfully extended the operational life of the nitrate removal vessels, improved system reliability, and safeguarded the site’s water supply while delivering significant cost savings compared with full vessel replacement.

Following the successful completion of the project, Thames Water awarded Satec additional refurbishment works at Sheeplands and Ufton Nervet Water Treatment Works.

Client Testimonial

“The knowledge and expertise offered by the team was outstanding, resulting in a practical and cost-effective solution. They identified additional defects during the refurbishment and resolved them efficiently. We were extremely pleased with the outcome and have since awarded Satec further work on this and another site. I would highly recommend their services.”

Andrew Grant, Technical Manager, Thames Water

Project Highlights

• Inspection and NDT of four nitrate removal vessels
• Pressure vessel refurbishment and repair
• Replacement of pumps, valves, strainers, and gaskets
• Ion exchange resin testing and reinstatement
• Flow balancing and PLC-assisted recommissioning
• Confined space and working at height specialist delivery
• Extended asset life and reduced capital expenditure
• Ongoing refurbishment contracts awarded following project success

Satec Service Ltd specialises in the refurbishment, repair, and life extension of pressure vessels, ion exchange plants, filtration systems, and water treatment assets, helping utility and industrial clients maximise equipment performance while reducing whole-life costs.