Suprafilt – Wanlip: Air Main Support Structure FEA Verification
Barair Systems Limited supported a wastewater-sector project at Wanlip with mechanical engineering verification and design support to de-risk delivery and ensure the equipment and supporting structures were suitable for the intended duty. Water and wastewater applications typically combine continuous duty, wet/corrosive environments, and maintenance constraints; meaning the design must be robust, buildable, and supported by evidence that can be used for sign-off.
The objective of this work was to provide a clear engineering position on the design and supporting structure, identify any vulnerabilities, and recommend practical actions to improve reliability and maintainability before installation or modification work proceeded.
The challenge
Projects in operational wastewater environments commonly face a combination of:
restricted access and limited shutdown windows
corrosion and contamination driving wear and degradation
interfaces to existing plant where legacy drawings may be incomplete
the need for clear documentation to support internal/client approval
For Wanlip, the priority was to ensure that the mechanical design basis was sound and that any structural and interface risks were identified early, before they could become operational issues or cause installation delay.
Engineering scope
Barair’s scope typically includes the elements below (applied as relevant to the specific equipment/system):
Review of the mechanical arrangement, interfaces, and load paths
Verification checks for strength, stiffness and deflection where appropriate
Review of connections and joints (bolted interfaces, welded features)
Identification of corrosion-prone details and maintainability risks
Recommendations for practical improvements and risk reduction
Clear “decision-grade” documentation to support sign-off
Where geometry and load paths justified it, finite element analysis (FEA) was used to support local stress/deflection assessment; otherwise, targeted hand checks were used to confirm the design basis efficiently.
Method (how we approached the work)
Inputs review
Drawings, available dimensional data, photos/site context and operating duty were reviewed to define assumptions and credible load cases.Design basis and boundary conditions
Support conditions and interfaces were defined so that verification work reflected real installation conditions rather than idealised constraints.Verification checks
Critical members and interfaces were assessed for utilisation, deflection and stability risks. Where needed, checks were supported with FEA to validate local effects.Risk identification
Practical vulnerabilities were captured to avoid later issues: access for maintenance, alignment strategy, wear points, corrosion traps, and interface tolerances.Actions and close-out
Findings were translated into a clear action list to support safe implementation and improve long-term reliability.
Deliverables
Engineering review summary with scope, assumptions and conclusions
Verification checks (strength/stiffness/deflection/stability as applicable)
Risk-based action list (critical / major / minor)
Marked-up notes on interfaces, access, and maintainability improvements
Optional FEA verification summary (where applied)
Evidence pack structure suitable for project approval and handover
Outcome
The output of this work was a clear, practical engineering position that supported project decision-making and reduced delivery risk. By identifying mechanical and interface vulnerabilities early, and by providing verification evidence in a usable format, the project team could proceed with greater confidence that the installation/modification would be robust in service.
Adrian Lowes BEng(hons) CEng MIMechE ASME
Adrian Lowes is a Chartered Mechanical Engineer and the founder of Barair Systems Limited, with over two decades of experience delivering innovative engineering solutions.
A graduate of the University of Bradford, he has worked on projects from automated vision systems for the automotive industry to oil and gas research with Cranfield University. He has developed products for brands including Microsoft, ICI, Toyota, and Florette. His expertise spans machinery design, finite element analysis, CE marking, and industrial accident investigation.
A lifelong musician, Adrian has directed Skipton Brass and Brass Ten, and served on the Alumni Committee of the National Youth Brass Band of Great Britain. Based in West Yorkshire, he combines technical precision with creative problem-solving in every project.
Key deliverables
Engineering review summary with clear assumptions and conclusions
Verification checks (strength/stiffness/deflection/stability as applicable)
Risk-based action list (critical / major / minor)
Interface and maintainability notes to reduce implementation risk
Optional FEA verification summary (where applied)
Evidence pack suitable for client/internal sign-off
Call to action
If you have a wastewater asset that needs mechanical verification, retrofit design, or reliability-focused improvement with evidence suitable for sign-off, request a design review. We’ll define the constraints and deliver buildable outputs with the right level of verification.