Process Utilities

Process utilities (or process services) include:

Water treatment
- Potable water
- Cooling water
- Chilled water
- Hot water
Effluent treatment
Electricity
Steam
Compressed air
Refrigeration
Air conditioning and ventilation
Industrial gases (e.g. carbon dioxide, nitrogen)
Industrial chemicals (e.g. caustic soda, nitric acid)

Peter Walker Consultants has specific expertise in specialised water treatment systems, however as you will see below, we have vast experience across the board in providing process utilities.

We have seen others install 10 bar steam when 20 bar was required, hot water services that made so much noise they couldn't be used, cooling water that couldn't be made cold enough, and witnessed condensation (an ideal place for bugs to grow) form on pipes in what was supposed to be an hygienic plant. Would you like to avoid these and dozens of other costly mistakes? If so, we're here to help.

PWCL's project management ensures your utilities are correctly sized relative to the rest of your plant. We will specify the utilities, tender and recommend contractors, write the contracts and oversee the work. We will commission the services and ensure they ultimately provide what is required of them.

Previous Experience

The following is a list of our previous experience that is directly related to process utilities. All figures are in New Zealand dollars unless otherwise stated.

Unattended Boiler Operations, NZ ($1.0m)

Project Management and Technical Engineering advice to convert existing fully attended boilers to unattended status allowing 24 hrs per day, 7 days per week operation, without a boiler attendant. Boilers converted include gas fired units up to 15MW.
Spray Drier Air Heating System - Fonterra Dairies Ltd, NZ ($1.6m)

Turn-key rebuild of Hot Air System for No. 2 Spray Drier including new filters, supply fan, steam/air heater, ductwork, steam supply and control systems and plant automation.
Boiler Installation, Associated Steam Pipework and Waste Water System Modifications - Kiwi Dairies Ltd, NZ ($3.2m)

Engineering design and site supervision of the installation of a new 8MW boiler and associated piping. Site supervision of major modifications to the site waste water treatment system. Management of upgrades to the plant HVAC and sewerage systems.
Multi Dip Ice Cream Plant - Tip Top Ltd, NZ ($680,000)

Complete civil design and project management including all services reticulation for new multi-coated ice cream manufacture and packaging
Relocation of Cheese Packing Plant - Milk Products Holdings Pty Ltd, Melbourne, Australia ($A600,000)

Project Management and design work for the removal of five cheese packing lines and their installation and commissioning at a new site, including building alterations and the installation of services.
Pasteuriser Installation - Mainland Products Limited, NZ ($1.4m)

Project management contract for design, installation and commissioning of a 25m³/hr separator, homogeniser and pasteuriser (NZCP7 compliant) for town milk supply at Mainland Products Limited, Longburn. All accounting, purchasing etc internal to Peter Walker Consultants.
Note: PWCL has project managed some $500m of work on the Kiwi Dairies Ltd Whareroa site, taking its milk processing capacity from about 6 million litres per day to in excess of 12 million litres per day. It is one of the largest milk-processing sites in the world.
Cogeneration Plant - Kiwi/Todd Joint Venture, NZ ($70m)

Project management for the co-generation plant consisting of four gas turbines (10MW each), four supplementary fired waste heat recovery boilers with a total steam capacity of 180 tph, a 28 MW steam turbine, 11/110 kV transformers and switchyard and 110 kV export line for connection to the national grid.
The project also included associated buildings, cooling towers and water treatment plant, plus the necessary resource consents etc. Also responsible for designing the steam attemperation system for the supply of conditioned steam to the associated dairy factories, as well as all piping systems, plus managing construction and commissioning of all the plant.
The primary purpose of the Cogeneration plant is to provide steam and electricity to the dairy factories, with the secondary purpose being to export electricity. This leads to the need for some novel control algorithms to ensure continuous steam and electrical supply while optimising the power generated for export.
Powder 5 Plant - Kiwi Dairies, NZ ($110m)

Project management of milk treatment upgrade, evaporators and drier, powder transport and packing, services and utilities, effluent (including chemical recovery), civil design and construction of the 53m high concrete process building, labs, offices, and boot exchange areas.
At the time of completion Powder 5 was the largest milk powder plant (at 20 tonnes per hour) in the world. A significant aspect of the project was integrating the existing Powder 3 and Powder 4 operations with the new plant, particularly the control room, powder transport system and powder packing.
Pipe Bridge Project - Kiwi Dairies, NZ ($25m)

Design, consultation, engineering, procurement and construction management contract for the design and build of one services pipe bridge. The structure is 400 metres long, 14 metres high and is comprised of ten concrete support clusters constructed from 1700 m³ of concrete supporting 20 modules with a total steel weight of 400 tonne.
This pipe bridge carries six kilometres of various services including; pressure steam (6 barg - 400 & 600 dia, 40 barg - 250 & 300 dia), hot and cold water (up to 300 dia), cooling water (up to 500 dia), compressed air, ammonia, chemical lines and assorted product reticulation systems.
Research Facilities Upgrade - New Zealand Dairy Research Institute, NZ ($11m)

Project management of design and construction of new administration wing and the complete refurbishment of five multi-storey research laboratory wings.
Waste Water Disposal System - Kiwi Dairies, NZ ($2.5m)

Project management contract for design and construction including pumping station for the disposal to sea of 30 million litres of waste water per day. This line is 3 kilometres overland with an additional 1.8 kilometres of ocean outfall.
Site Services Upgrade - Kiwi Dairies, NZ ($30m)

Project management, design and site supervision of major revisions to the site Hot Water, Domestic Cold Water, Cooling Water, Chilled Water and Compressed Air systems including:
- 14MW of additional hot water heating
- 10ML/Day of additional treated domestic cold water plant
- 56MW of additional cooling water capacity
- 10MW of additional chilled water capacity
- 1200lpm of additional dried compressed air
- All major reticulation changes associated with these services.
Milk Evaporator Condensate Treatment Plant - Kiwi Dairies, NZ ($3m)

Project management, design and site supervision of the installation of a water treatment facility capable of handling up to 7Ml/day of evaporator condensate. Product water is sterile and has greatly reduced taste and greatly reduced smell compared with raw condensate. This allows the high quality water to be used for high grade product washing and dilution.
Powder 3 and 4 Plants - Kiwi Dairies, NZ ($55m and $80m resp.)

Project management of the design, construction and commissioning of P3 (6.25tph) and P4 (10tph). At the time of commissioning the P4 plant was the largest of its type in the world. These projects included the necessary milk treatment upgrade, evaporators and drier, powder transport and packing, services, utilities, effluent removal (including chemical recovery), and civil design and construction including labs, offices, and boot exchange areas.
WPC 80 Complete Plant - Kiwi Dairies, NZ ($80m)

Project management of the design, installation and commissioning of a complete WPC80 production plant for both sweet and lactic whey, from whey clarification to powder packing.
WPI and Alamin Complete Plants - Kiwi Dairies, NZ ($8m and $12m resp.)

Project management of the design and installation of the world's first commercial WPI and "Calcium Salts from Whey" plants.