Custom SCADA and control system design for optimised operation, monitoring, and regulatory compliance.
modernise water treatment plant controls with PLC upgrades, SCADA integration, online Analysers, and remote monitoring systems.
Pulp and paper wastewater treatment for scada architecture for critical applications.
Containerised SCADA: Tier 1 Basic to Tier 4 Enterprise DCS. Siemens, Allen-Bradley, cloud analytics, digital twin.
SCADA and control system integration for critical water treatment processes plants.
Intelligent automation transforms operational efficiency, reliability, and compliance.
Automated sequences handle start-up, shutdown, chemical dosing, and sludge withdrawal with minimal operator intervention. Staff focus on oversight rather than manual adjustments.
Closed-loop control maintains process parameters within tight bands regardless of influent variability. Eliminates human error and ensures 24/7 compliance with discharge limits.
Continuous logging of flow, pH, COD, TSS, and other key parameters provides trend analysis and early warning of process upsets before they impact effluent quality.
Optimal chemical dosing based on actual demand rather than fixed rates reduces reagent consumption by 15-30%. Energy optimisation cuts power bills during off-peak periods.
Prioritised alarms with SMS and email notification direct operators to critical issues first. Alarm flooding is eliminated through smart suppression and grouping logic.
Automated interlocks and emergency sequences protect equipment from damage during power failures, pump faults, or high-level events. Safe states are always maintained.
Tailored control architecture from sensor selection to HMI configuration.
We specify Siemens S7, Allen-Bradley, or Schneider PLCs based on your site standards, spare parts policy, and integration requirements. Redundant CPU options for critical processes.
pH, ORP, dissolved oxygen, turbidity, flow, level, and pressure sensors are selected for accuracy, reliability, and compatibility with your process conditions and maintenance capabilities.
PID, cascade, feed-forward, and model-predictive control strategies are tuned for your specific process dynamics. Adaptive algorithms handle diurnal and seasonal load variations.
Intuitive operator screens with process mimic diagrams, trend displays, and alarm summaries. Colour-coded status indicators and one-click report generation reduce training requirements.
Industrial Ethernet, Profibus, or Modbus networks connect field devices to the control room. Segregated networks ensure cybersecurity while maintaining data availability.
OPC-UA, Modbus TCP, and proprietary protocol gateways bridge your new treatment system with existing SCADA, DCS, and building management systems seamlessly.
24/7 visibility into your treatment plant from any device, anywhere.
Responsive web dashboard accessible from phones, tablets, and desktops. View real-time process values, historical trends, and alarm status without installing software.
Escalating alarm notifications via SMS, email, and push notifications. Acknowledge and annotate alarms remotely. Maintenance reminders prevent unexpected failures.
Years of process data stored securely in the cloud. Export to Excel or CSV for regulatory reporting. API access connects to your ERP and environmental management systems.
Our engineers log in securely to diagnose issues, adjust setpoints, and update control logic without travelling to site. Reduced mean-time-to-repair and lower support costs.
Daily, weekly, and monthly performance reports generated automatically and emailed to stakeholders. Includes effluent quality summaries, chemical consumption, and compliance status.
VPN-encrypted connections, role-based access control, and audit trails protect your operational data. Compliant with IEC 62443 industrial cybersecurity standards.
| Protocol | Data Rate | Typical Use | Cable / Medium |
|---|---|---|---|
| Profinet RT | 100 Mbps | PLC-to-I/O, motion | Cat 5e, industrial Ethernet |
| EtherNet/IP | 100 Mbps | Allen-Bradley ecosystems | Cat 5e, industrial Ethernet |
| Modbus TCP | 100 Mbps | Third-party integration | Cat 5e, Wi-Fi, cellular |
| Profibus DP | 12 Mbps | Legacy fieldbus I/O | RS-485 twisted pair |
| Modbus RTU | 115 kbps | Analysers, VFDs, legacy | RS-485 twisted pair |
| HART | 1.2 kbps | 4–20 mA smart instruments | Over 4–20 mA loop |
| OPC-UA | Broker-dependent | SCADA-to-ERP, MES | Ethernet, TLS-encrypted |
| I/O Type | Quantity (Medium WWTP) | Notes |
|---|---|---|
| AI (4–20 mA) | 32–64 | pH, DO, turbidity, flow, level, pressure |
| AO (4–20 mA) | 16–32 | VFD speed, control valve position |
| DI (24 VDC) | 64–128 | Pump run, high level, fault status |
| DO (24 VDC) | 48–96 | Pump start, valve open, solenoid |
| RTD / TC | 8–16 | Process temperature, motor bearing |
| Counter / encoder | 4–8 | Flow totalisers, belt speed |
Typical tuning constants for common water treatment control loops: pH neutralisation: Kc = 0.5–2.0, Ti = 30–120 s, Td = 0–5 s (highly non-linear; consider gain scheduling or split-range control for acid/caustic). Dissolved oxygen (aeration): Kc = 1.0–5.0, Ti = 60–300 s, Td = 5–20 s. Flow control: Kc = 0.5–1.5, Ti = 1–5 s, Td = 0 s (fast loop, PI only). Level control: Kc = 2.0–10.0, Ti = 60–300 s, Td = 0 s (P-only acceptable for surge tanks). These are starting points; final tuning uses Ziegler-Nichols open-loop or lambda methods with site-specific deadtime and process gain.
We implement defence-in-depth per IEC 62443-3-3: network segmentation ( Purdue Level 2.5 demilitarised zone), role-based access control with Active Directory integration, encrypted VPN tunnels for remote access, and audit logging of all setpoint changes. Security patches are tested in our lab before deployment to live plant.
Critical control loops execute on a 50–100 ms task cycle; sequencing logic on 250–500 ms; data logging and HMI updates on 1,000 ms. For high-availability applications we specify Siemens S7-400H or Allen-Bradley ControlLogix redundancy with bumpless switchover <50 ms. Mean time between failures (MTBF) targets >50,000 hours for the control system.
Online analysers (pH, COD, NHâ‚„-N, POâ‚„-P, TSS) are integrated with automatic cleaning cycles and calibration reminders. Calibration drift >2% triggers a maintenance alarm. We specify analysers with MCERTS or equivalent certification for regulatory reporting. Sample conditioning systems include filtration, cooling, and pressure reduction as required.
PLC code is written in structured text (IEC 61131-3) with modular function blocks, comprehensive commenting, and version control via Git. Every sequence includes pre-start permissives, run monitors, and post-stop confirmations. Software Factory Acceptance Testing (FAT) includes forced-fault simulation to verify interlock logic under all failure scenarios.
Our custom engineering team is involved in designing water treatment equipment to your exact specifications.
View PageAdvanced material selection and protective coatings for aggressive wastewater environments.
View PageWe design bespoke water treatment systems with guaranteed performance targets.
View PageSeamlessly integrate new water treatment equipment with your existing infrastructure.
View PageCompact and containerised water treatment plants for space-limited sites.
View PageEvery water treatment challenge is unique. Our bespoke engineering team designs, fabricates, and commissions custom equipment and systems that standard products cannot address. From exotic material selection to extreme duty specifications, space-constrained layouts, and integration with legacy control systems, we deliver solutions that work in your specific operational context.
3D CAD modelling and CFD simulation validate performance before fabrication commences.
SS304, SS316L, duplex, and exotic alloy welding and machining in our European workshops.
Control systems communicate with your existing SCADA, DCS, and PLC infrastructure.
Complete design dossier, HAZOP, FAT/SAT protocols, and O&M manuals provided.
Site survey, water analysis, and process requirement definition with your engineers.
Process flow diagram, P&ID, and 3D layout with performance guarantees and budget estimate.
Mechanical, electrical, and control design with material specifications and vendor selection.
Workshop construction with QA/QC inspection, weld records, and pressure testing.
Logistics, cranage, mechanical installation, and pipework connection by our teams.
FAT, SAT, performance trials, operator training, and handover documentation.
Standard corrosion-resistant stainless for municipal, food, and general industrial applications.
Superior chloride resistance for marine, offshore, and high-salinity process waters.
Maximum corrosion resistance for extreme chloride, sour gas, and high-temperature duties.
Hastelloy, Inconel, and titanium for aggressive chemistries and ultra-high purity requirements.
Our experts can design a system tailored to your specific requirements.
Our expertise spans multiple industries with sector-specific water treatment solutions.