Automating Century-Old Infrastructure: A Case Study in Modernising 100-Year-Old Penstocks

Score partnered with a contractor to automate the penstocks

Ian Elliott manages electric actuation projects and services for Score

As water regulator Ofwat has cleared the way for an £88 billion investment during AMP8, including a targeted 44% reduction in storm overflow spills, the evolution of industrial infrastructure necessitates replacing or proactively upgrading legacy systems to meet current standards.

This article delves into a case study involving the automation of century-old flow control penstocks at a UK reservoir, highlighting critical industry issues such as asset obsolescence, manual handling challenges, and the pursuit of enhanced plant reliability and availability.

Industry Issues: Navigating Asset Obsolescence

Asset obsolescence and ageing infrastructure present substantial challenges for industries reliant on legacy systems. Ensuring plant reliability and availability is paramount, and downtime can have far-reaching consequences for production and environmental compliance. Modernising assets involves carefully considering whether to repair or replace them, balancing cost implications, production impact, and environmental footprint.

Leveraging Advanced Actuation Technology

Score, the world’s future-focused provider of advanced engineering services, has supported the UK water industry for over 40 years with its $200m+ global inventory and expertise in valves and actuation solutions. Ian Elliott, who manages electric actuation projects and services for the company, stresses the importance of a holistic approach when selecting the best product or service for each specification.

Case Study: Automating 100-Year-Old Penstocks

During one project, Score partnered with a contractor to automate 100-year-old manually operated storm overflow penstocks at a UK reservoir. The extensive upgrade programme involved designing, engineering, and installing new automation solutions, including actuators and gearboxes.

The Solution

Score engineers designed and calculated operational requirements and power consumption needed to ensure reliable 24/7 operation. Actuators were mounted to bevel gearboxes and equipped with vandal-proof covers. Additionally, the project required the design and installation of power supplies and extensive on-site machining to modify the manual penstocks for automation. 

Benefits Realised: Enhanced Reliability

Automation of the penstocks delivered significant benefits, including reliable flood control and efficient water flow management. The risk of injury associated with manual control has been minimised. These improvements are vital for maintaining operational stability and meeting environmental legislation.

Conclusion: Embracing Change for Success

The modernisation of 100-year-old penstocks underlines the importance of embracing change and leveraging advanced technologies to address industry challenges. When replacement is not the best option, industries can transform legacy systems into efficient, reliable, and future-ready assets, ensuring success and paving the way for a more resilient and sustainable industrial landscape.

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