Enhancing Water Management Efficiency at Craig-Yr-Hesg Quarry

Pump Supplies partnered closely with Hanson to design and install an advanced pumped water management system at Craig-Yr-Hesg Quarry in Wales. The objective was clear: improve discharge efficiency while significantly enhancing the clarity and quality of water leaving the site, ensuring full compliance with Natural Resources Wales regulations.

 

The existing drainage system relied on six settlement lagoons operating via a gravity weir. Pump Supplies re-engineered this approach, introducing a more effective system incorporating eight lagoons and controlled pumped discharge to optimise both settlement and flow management.

 

A Smarter, Controlled Approach to Water Treatment

The upgraded system manages water through a structured process of collection, settlement and controlled discharge. Water is pumped from two attenuation lagoons into six settlement lagoons, where suspended solids are treated using a polymer flocculant before being discharged into the River Taff at Pontypridd.

 

To ensure consistent performance and environmental compliance, the system continuously monitors:

• Lagoon water levels
• Pump flow rates
• Discharge turbidity levels

 

Operators can run the system in either a fully automated variable mode or a fixed-rate manual setting, offering complete flexibility depending on site conditions.

 

Engineered for Performance and Maintainability

At the core of the system are two Flygt 13.5kW 5100 hard iron submersible pumps, selected for their durability and performance in demanding environments. These were installed using rotating winch davits, allowing for safe and efficient removal during maintenance and routine silt clearance—both critical for long-term operational efficiency.

 

The pumps are connected to a fusion-welded pipework system, incorporating flocculant injection points. This setup feeds into outfall baffle boxes via a network of sluice gates and valves, giving operators precise control over water discharge.

 

Advanced Control, Monitoring & Automation

To house the system’s controls, Pump Supplies converted a standard shipping container into a fully equipped control room. This bespoke unit includes:

• Twin pump control panels
• Monitoring and analysis equipment
• Data logging systems
• Flocculant storage and dosing rigs
• Heating and lighting for a safe working environment

 

A backup 65kVA silent generator with an AMF panel ensures uninterrupted operation during power outages.

 

The system operates using a Pulsar ultrasonic level controller, which communicates with ABB 550 variable frequency drives via a PLC. This enables intelligent automation, including:

• Automatic pump start/stop based on lagoon levels
• Variable pump speeds for optimal efficiency
• Flocculant dosing adjusted in real time based on turbidity levels

 

This dynamic control ensures increased polymer contact time during high turbidity events, improving water quality before discharge.

 

Responsive Operation in All Conditions

Under normal conditions, a single pump operates on an alternating duty cycle to maintain efficiency and reduce wear. During periods of heavy rainfall or high inflow, the system automatically activates both pumps to manage increased demand.

 

Operators also have access to a manual override function, allowing full control over pump speeds and dosing rates when required.

 

Real-Time Visibility with Remote Monitoring

A web-based telemetry system provides 24/7 access to real-time operational data, including:

• Lagoon levels
• Pump performance
• Flow rates
• Turbidity readings

 

Automated alerts via SMS and email notify key personnel of any issues, such as power failure, pump faults, high water levels or elevated turbidity—ensuring rapid response at all times.

 

Ongoing Support and Long-Term Performance

Following installation, Pump Supplies implemented a structured maintenance programme to ensure continued reliability and peak system performance. The team continues to work closely with Hanson, providing ongoing support and optimisation to adapt to changing site conditions.

 

Delivering Smarter, More Efficient Pumping Solutions

This project highlights Pump Supplies’ ability to deliver intelligent, fully integrated pumping systems that improve efficiency, enhance environmental compliance and provide complete operational control.

 

By combining engineering expertise with advanced monitoring technology, Pump Supplies continues to support clients in achieving reliable, high-performance water management solutions across complex industrial environments.