consulting engineers

global engineering solutions

The Tidal Defence Barrier, Hull, North East England

Front cover | The Media City Swing Bridge, Greater Manchester, North West England Xayaburi HPP, Laos PDR Dalseong Weir, Nakdong, South Korea

KGAL offers a complete range of structural, mechanical, electricaland hydraulic engineering services in three core market areas:water control, hydropower and moving structures.

Each of our disciplines is championed by experts in their field. Their depth of knowledge and theexperienced teams they lead offers KGAL clients thereassurance needed to know that their objectives willbe met: safely, securely, on time and on budget.

Our engineers thrive on the creative challenges involvedin the design of commercially, socially and environmentallyresponsible solutions to complex problems. Commerciallyin that they are economic; socially in that they areefficient and environmentally in that they areuncompromising and sustainable.

We’re adept at developing teams dedicated to deliveringprojects in collaboration with others.

For over 25 years we’ve been working with utilitycompanies, government agencies and leading contractorsand consultants in providing the engineering expertiseto bring their own projects to fulfilment.

Whether you’re an owner, lender, contractor orconsultant - gathering advice, considering an appointmentor just looking for a second opinion - our collaborativeexperience means there’s less risk.

This brochure gives you a better understanding of ourcapabilities and some project examples from ourinternational portfolio of work. For more informationplease visit our website or get in touch. You’ll find ourweb address and contact information on the back page.

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The Kariba Dam, on the Zambezi River border between Zambia with Zimbabwe | KGAL scope included the design of the new hydro-mechanical works as part of the vast refurbishment project

From specific hydraulic steel structures to pumpingstations, from model testing to project management,from feasibility to complete installations: for flooddefence, river control, ports, harbours and marinas,hydropower, dams and reservoirs, irrigation anddrainage; KGAL has the range and depth of experienceto deliver engineering excellence to clients, consultantsand contractors.

Pumping stations and outfalls

Our market clients are predominantly in utilities or the public sector, for whom knowledgeable experienceof working with near-continuous processes is anessential prerequisite.

With our inter-disciplinary credentials in structural,mechanical, electrical and hydraulic engineering we canundertake everything from asset surveys to a fullrefurbishment irrespective of the application: flood defence,machine cooling, land drainage, marina level management,canal locks, water supply and pumped storage.

Barriers and barrages

Whether it’s for design, inspection, maintenance orrefurbishment, owners and operators of large, moving,sea-resistant surge barriers know that to maintain theirreliability KGAL is the UK consultancy with moreexperience than any other.

Unlike the barrier, barrages are often subject toconstant adjustments in response to ecologicalchanges; there’s rarely a lengthy safe ‘possessionperiod’ for maintenance or refurbishment. It’s asituation with which KGAL is familiar and we havedeveloped a responsive approach to help overcomesuch obstacles.

Hydraulic steel structures

As the next few pages show, for flood defence, rivercontrol, navigable waterways and hydropower, KGALhas more years of experience in water control gatesthan any other UK hydraulic steel structures engineer.

As the catastrophic events of flood and drought continue to show,controlling water will forever remain a challenge. But it’s a challengethat KGAL rises to every day.

Water control

Xyaburi HPP, Mekong River, Laos PDR

At any one time more of our engineers are working on hydraulicsteel structures than any other activity; it’s a specialist disciplinewhere KGAL is a UK market leader.

Flood defence

Engineering for flood defence is a core element ofKGAL’s work. And within that discipline, gate designtakes a dominant share. We’ve applied our expertise tomany locations in the UK, especially along the eastcoast where the combination of strong northerly windsand lower pressures from deep Atlantic depressionscan cause sea levels to rise (storm surge).

From skinplates to the structural framing (in wood ormetal), sills to lintels, anchorage assemblies tooperating mechanisms; KGAL’s engineers have thedesign capabilities and field experience to deliver theperfect solution: for refurbishment, rehabilitation,replacement or an entirely new installation.

And, although we’re recognised as gate leaders, we canalso demonstrate a track record in penstocks, valves,specialist hoisting equipment and reverse engineering.

Our additional services include:

• Feasibility studies• Technical due diligence• Techno-economic modelling• Probabilistic reliability assessment• Project management• Hydraulic modelling and simulation• Procurement and contractual advice• Asset inspection• Controls and instrumentation• Finite element analysis• Tender management• PUWER audits• Preliminary / conceptual design• Detailed design and engineering• Electrical safety and compliance

Floating sector gate, Yeonsang, South Korea (insert: gate hinge) Radial gate at Minworth, Birmingham, England

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Comprehensive expertise

With skills in scheme concept optimisation, hydroturbine selection, transient analysis, control systemdesign and project management, KGAL can provideanything from a pre-feasibility study for a green fieldsite to the finished power station.

For older plant, KGAL can run through the ‘what ifs’and define the best solution for your specific needs.We will assess the condition of existing equipment,analyse the potential remaining life and presentoptions for future use and upgrading.

This hydropower proficiency is complemented by ourexpertise with all the other engineering elements thatcombine to form the complete mechanical andelectrical package for a hydropower station: the watercontrol gates for spillways, draft tubes, intakes, lowlevel outlets and fish passes, the penstocks and all thenecessary controlling and operating equipment.

New and existing hydro

With hydropower providing 71% of renewable energyfrom over 1.2 TW of capacity, and with an economicallyviable potential to double the installed capacity, newhydro has a vibrant future.

Much of the current base was installed in the 1900s.And even though hydropower is the longest lasting ofany generating plant, many installations are beginningto show their age. KGAL can offer all the services neededfor rehabilitation; from remaining life assessmentsthrough to the delivery of refurbished equipment or the complete replanting of a hydropower station.

Transient analysis

KGAL offers a complete service for hydro planttransient analysis. Based on the industry standard ofSIMSEN, KGAL has the experience and data base toanswer your needs on new and existing hydro plant.

KGAL’s hydro engineers have more years of international M&Eexperience than any other UK hydro consultant. It’s what givesKGAL the skill and scale to deliver outstanding solutions.

Hydropower

Scottish power station projects (clockwise from top left): Foyers; Glendoe; Storr Loch

Building a winning project - KGAL has the experience in Project Management

As well as having the technical skills to develop, designand specify your project, KGAL has the experience tomanage the delivery of your project through all stagesin its life-cycle.

Our project managers are uniquely skilled to tackle allaspects; the procurement, logistics, quality control,installation and commissioning – constantly dealingwith the wide variation in project scale across ourareas of engineering expertise.

We are skilled in contract management; we will adviseon the best commercial structures and procurementstrategies. We will take the role of Principal Designer,Principal Contractor or Designer as the requirementsof the project dictate. We will manage your supplychain (performing inspections, expediting delivery andmanage and attend factory site testing) and ensure youhave the O&M information when and how you need it.

In the UK, the NEC is a favoured suite of contracts and KGAL project managers are trained in itsimplementation and experienced in its application.Overseas, the FIDIC suite of contracts is oftenpreferred and KGAL has the experience with this andthe various contract forms used internationally.

Procurement

KGAL’s in-depth knowledge of the equipment marketenables us to give advice on potential suppliers and thecontract structures. We can prepare pre-qualificationand enquiry documents, tender schedules, tenderassessment and advise on contract awards.

Site installation and commissioning

Installation and construction of hydro schemes can bechallenging but very rewarding. KGAL’s engineers havebeen resident on construction sites in Africa, India,South East Asia as well as our home market in the UK.KGAL has managed the installation directly as thecontractor and as the client’s engineer.

Staying with you

Commissioning doesn’t mark the end of a project; itmarks the point where the asset starts to realise income.Protecting that income - key to its long-term profitability -requires maintenance management, planning, periodicinspections, operation and maintenance audits andcontinuous condition monitoring.

KGAL’s services have a beginning when you first start to think about the broad possibilities for yourproject, they do not really have an end - KGAL is yourlong-term partner.

Turbines: Fasnakyle Turbines: Dolgarrog

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Most structures are designed to stand still; thecorresponding consulting engineers use their skill andexpertise to ensure there is no movement, sagging,deflection or excessive vibration.

The engineering skills required for structures which arespecifically designed to move calls for an entirelydifferent approach; to withstand the pressures andstresses of everyday use whilst efficiently performingtheir function to rotate, or lift, or swing.

KGAL’s experts, many with strong contractor orconstruction backgrounds, specialise in all aspects ofengineering for ‘big things that move’: structural,mechanical, electrical and hydraulic. Their approach todesign is nurtured by a knowledge base developed fromexperience which is then applied - safely andconscientiously - within the over-arching projectparameters: objectives, function, location and budget.

Hydraulic design and engineering

Our hydraulic engineering experience has been earnedthrough a proactive engagement in all project stages;from the initial design, specification, and procurementthrough to final site acceptance testing and eventualproject hand-over and completion.

Mechanical design and engineering

Our engineers exercise a collaborative approach toprojects and problem solving to achieve the bestpossible solution for our clients’ requirements andchallenges. We strive for the right combination ofquality, economy, innovation and efficiency.

Electrical design and engineering

For power and control systems, remote links and CCTV,we’re able to deliver safe, robust and cost-effectivesolutions where risk control is part of the design criteria.

For moving bridges, passenger access bridges, shiplifts, linkspans,dockside equipment and unique structures: if it’s big, and itmoves, KGAL has the experience to deliver.

Moving structures

The Sean O’Casey pedestrian swing bridge, Dublin, Ireland

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From initial concept to site acceptance testing, KGAL’s expertscan undertake all stages of a moving structure project: design,specify, simulate, test, install, supervise and commission.

KGAL staff have an abundance of engineeringpractice providing an unrivalled depth of knowledgein understanding the challenges associated withheavy moving structures.

Our power systems modelling quickly determinesenergy needs to calculate through-life energy costsand ways to recover energy, whilst our hydraulicsimulation software enables us to accurately verifydesigns and minimise risk.

Throughout the process we maintain a continuousengagement with the client and stakeholders througha design development log (DDL) which records,informs and allows constant scrutiny of progress frominception to final commissioning.

The DDL also records interaction with third parties(e.g. for approvals or consents) and, in this way,ensures that KGAL remains responsible and accountablethrough each stage of the project development.

Associated services

• Strand jacking and deck launching: KGAL hasexperience of managing hydraulic systems forincremental heavy lifting and slide erection in bridge construction.

• Site supervision: we can manage the project site,sub-contractors, deliveries and all compliance issues(including health and safety) to help ensure theproject is delivered on time and in accordance withapplicable codes and expectations.

• Asset inspections: from condition assessment and / orCE compliance authentication, either of the wholestructure or its component parts.

• Project management: we can manage all aspects ofa project from defining the initial design requirements,through the preparation of specifications and vendorassessments, to all facets of managing the designand build stages.

Ro-Ro linkspan, Dover Port Berth 6, England The Falkirk Wheel boatlift, Scotland Pont Y Werin bascule bridge, Wales

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Design services

For structural, electrical, mechanical and hydraulicsystems KGAL can provide a complete design service.Whilst cognisant of prevailing country-specificstandards, codes and laws, our designs are exclusivelyfocussed on client needs. We look at the whole lifefunctionality and create designs which optimise assetperformance in terms of risk, reliability and cost.

Structural and mechanical: our accredited engineersunderstand the mechanics of structures. Manually, and through finite element analysis, they undertakemathematical modelling and simulation to verifydesigns and push tolerances to future-proof projectproposals and, thereby, their economic viability. Wealso offer materials selection and production advice.

Electrical: we make risk control part of the designcriteria: systems which are, within the boundaries oftheir application, simple and safe to operate – systemswhich meet user expectations as opposed to asking theusers to adapt their behaviour to fit the technology.

Hydraulic: our experience has been earned through a ‘hands on’ engagement in all project stages:conceptualisation, preliminary engineering and planning,detailed design, execution, testing and completion.

System: in many cases work processes operate througha linear chain of dependencies; they are often complexwith multiple events triggering subsequent activity. AtKGAL we have considerable experience of optimisingsystems through intelligent design ensuring that aprocess operates seamlessly as a whole.

Project management services

If you are looking for a team to take you through the fullproject cycle we have the skills, processes and experienceto manage your project from the pre-contract phaseright through to commissioning and hand-over.

Asset inspections: from a routine visual inspection to a more thorough investigation we able to undertake afull review, in conjunction with risk and performanceassessments, to help ensure the efficient managementof assets.

KGAL exists to provide outstanding engineering solutions forclients in worldwide markets associated with moving structures,water control and hydropower.

Design, project management and specialist services

Flap gate replacement, St Katharine Dock, London Swing bridge and flood gates at Junction Lock, Bristol, England

CDM Principal Designer: the scope of the PD role iswide: everything from security to workers’ welfare. Ourcontractor background and technical knowledge ofconstruction adds value to this key function in coveringrisks and keeping clients ahead of their legal obligationsto stakeholders, supply chain employees and thegeneral public.

Site supervision: with systems in place for regular clientreporting, and working to a doctrine of ‘no surprises’,we ensure clients are kept fully informed of potentialproblems, current progress and latest forecasts. KGALcan also provide quality assurance and expediting services.

Procurement and contractual advice: we can advise onthe best forms of contract for a project and help negotiatethe best terms. We can manage the pre-qualificationprocess, the selection of potential bidders, review oftenders and the establishment of contracts withsuppliers and end-users.

Evaluation and adjudication: we ensure our finalevaluation and our subsequent recommendation isunique to the specific procurement, entirely defendableand delivered without favour or discrimination. Weapply transparency and fairness to our responsibility;we know it’s the stage in the procurement process mostfrequently challenged.

Health & Safety and risk assessment working as the soleconsultant, or as (or with) your CDM Principal Designer,we can undertake a range of assessments where ourspecialist knowledge goes beyond the legal requirementto provide the best advice for the safest workingenvironment even if, as is often the case in our markets,the nature of the work being undertaken changesthrough the course of the project.

Specialist consulting services

KGAL offers several specialist services, mostly related toour core markets, although many are of equal value to clientsin other areas where out-sourcing is the only option.Our unique combination of practical experience and nichebut diverse skills mean we’re well placed to help clientswith their own niche but diverse problems. Solving them,either through traditional routes or with a new and ingeniousapproach, is what our technical specialists do best.

This brochure doesn’t detail everything we do; after all,the list is constantly evolving as projects develop, newengineers join and our skills and knowledge base expands.

But, for clients considering an engineering service andwould like to know how the specialist consultingservices of our independent practice can help, thechances are we’ve done it before, or that the challengeis well within our capability.

Lock gates control room, Portishead marina, England

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email@KGALglobal.com KGALglobal.com

UK officesPoole +44 (0) 1202 786430Wakefield +44 (0) 1924 249825Gloucester +44 (0) 1452 741931

Representative officesKuala Lumpur, Malaysia +603 5161 6613Manilla, Philippines +632 889 6235Vientiane, Lao PDR +856 21 315 881consulting engineers

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KGAL Consulting EngineersWater Control Hydropower Moving Structures

350.07.17