Post-Digester Refurbishment and Asset Renewal at a Major Pharmaceutical Manufacturing Site

As part of its long-term operation and maintenance contract at a major pharmaceutical manufacturing facility in Irvine, the site's post-digester tank and integrated gas storage system were identified for upgrade. The asset plays a critical role in the site's anaerobic digestion process, providing biogas storage and supporting the safe and efficient operation of the gas handling system, including the CHP engine and flare.

With key components approaching the end of their design life, Alpheus developed and delivered a comprehensive refurbishment programme designed to improve operational reliability, extend asset lifespan and enhance the resilience of the site's renewable energy infrastructure.

Project Scope

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The project aimed to strengthen the long-term resilience of a critical asset within the site's anaerobic digestion process, including:

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Temporary biogas storage installation and operational continuity planning.
A full clean and inspection of the post-digester tank to assess asset condition and support future maintenance planning.
Refurbishment of the integrated gas storage system and associated infrastructure.
Installation of new level monitoring technology.
Testing, commissioning and return to service of the refurbished asset.
Delivery of all works while maintaining uninterrupted wastewater treatment and energy recovery operations.

Design and Delivery Services Provided

Maintaining Continuous Operations

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One of the project's most significant challenges was completing major refurbishment works without disrupting site operations or biogas utilisation.

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To achieve this, Alpheus designed and implemented a temporary biogas storage solution, allowing the post-digester tank to be isolated safely while maintaining ongoing anaerobic digestion and CHP operations. Extensive management of change procedures, DSEAR assessments and temporary works planning were undertaken to ensure safe operation throughout the programme.

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Tank Isolation, Cleaning and Inspection

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Following isolation and nitrogen purging, the post-digester tank was drained, cleaned and prepared for entry. Working with specialist contractors, Alpheus managed a detailed cleaning and inspection programme, removing accumulated deposits and carrying out structural inspections in accordance with recognised industry standards.

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The works provided valuable insight into the condition of the asset and enabled future maintenance requirements to be assessed while supporting the site's wider asset management strategy.

Gas Storage System Refurbishment

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The existing inner and outer gas membranes were replaced with a new double-membrane gas storage system. Associated ductwork, fixings and ancillary components were renewed, while modifications were introduced to improve future maintenance access and asset management.

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The refurbishment restored the gas storage system to modern operational standards and provided a renewed design life for this critical infrastructure.

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Instrumentation Upgrade

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The project also replaced the existing rope-length level transmitter with two independent monitoring technologies.

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This new duty/standby arrangement eliminates a historic single point of failure and provides more accurate gas volume measurement, with reduced maintenance requirements. The upgraded system also enables future inspection and maintenance activities to be carried out without interrupting plant operation.

The Outcome‍

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The project was completed safely and without disruption to site operations, wastewater treatment or renewable energy generation.‍

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The refurbishment modernised critical gas storage and monitoring infrastructure, improving reliability, reducing maintenance requirements and extending asset life. The works also provided valuable asset condition data to support future investment and lifecycle planning.

Post-Digester Refurbishment and Asset Renewal at a Major Pharmaceutical Manufacturing Site

Project Scope

Design and Delivery Services Provided

Maintaining Continuous Operations

Tank Isolation, Cleaning and Inspection

Gas Storage System Refurbishment

Instrumentation Upgrade

The Outcome‍

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