Selection of appropriate materials for aggressive chemistries, high temperatures, and abrasive conditions.
Custom automation and SCADA integration for critical water treatment processes plants.
Seamlessly integrate new water treatment equipment with your existing infrastructure.
Complete turnkey water treatment plants from initial concept through commissioning.
Comprehensive support packages including preventive maintenance, remote diagnostics, operator training and genuine spare parts.
Engineering-grade material selection based on your specific wastewater chemistry and duty conditions.
Comprehensive water chemistry analysis identifies chlorides, sulphides, pH extremes, and oxidising agents that drive corrosion. Material selection is based on data, not guesswork.
We apply ISO 9223 and ASTM G102 corrosion rate models to predict service life for each candidate material under your specific operating temperature and chemistry conditions.
Material selection balances initial cost against replacement frequency and downtime. Duplex or super duplex may cost more upfront but deliver 3x the service life in aggressive waters.
Food-grade applications require FDA-compliant materials. Pharmaceutical systems need ASME BPE certification. We specify materials that meet your sector requirements from day one.
For mild-to-moderate corrosivity, protective coatings and rubber linings on carbon steel offer efficient alternatives to solid alloy construction with proven field performance.
All materials supplied with EN 10204 3.1 mill certificates verifying chemical composition, mechanical properties, and heat treatment. Full traceability from melt to finished equipment.
From standard stainless to exotic alloys for the most aggressive industrial wastewaters.
Economical austenitic stainless for mild municipal and food applications where chloride levels are below 200 mg/L and pH is neutral.
Standard industrial grade with 2-3% molybdenum for improved pitting resistance. Suitable for most industrial effluents with moderate chloride content.
50/50 ferrite-austenitic structure delivers superior chloride stress corrosion cracking resistance. Ideal for marine, coastal, and high-salinity applications.
PREN > 40 for extreme chloride environments, sour gas, and high-temperature process waters. Service life exceeds 25 years in aggressive duty.
Nickel-molybdenum alloy for highly oxidising chemistries, strong acids, and halide environments where stainless steels fail rapidly.
Exceptional corrosion resistance in chloride, hypochlorite, and seawater. Used for high-purity pharmaceutical and offshore applications.
PREN is the primary screening tool for pitting and crevice corrosion resistance in chloride environments. We calculate PREN using the ASTM-standard formula:
PREN = %Cr + 3.3×(%Mo + 0.5×%W) + 16×%N
For conservative design, we require PREN ≥ 0.6 × chloride concentration (mg/L) for temperatures >30 °C. For seawater (~19,000 mg/L Cl⁻) at ambient temperature, minimum PREN 35 is recommended.
| Alloy | PREN | Max Cl⁻ (mg/L) at 40 °C | Relative Cost Index |
|---|---|---|---|
| SS304 (1.4301) | 18–20 | 50–100 | 1.0 |
| SS316L (1.4404) | 23–26 | 200–500 | 1.3 |
| Duplex 2205 (1.4462) | 34–36 | 3,000–5,000 | 1.8 |
| Super Duplex 2507 (1.4410) | 42–45 | 10,000–15,000 | 2.6 |
| SS254SMO (1.4547) | 43–46 | 10,000–20,000 | 3.0 |
| Titanium Gr.2 | Immune* | Unlimited | 4.5 |
*Titanium is immune to pitting in natural waters; susceptibility to hydriding limits temperature to <80 °C in alkaline conditions.
When solid alloy construction is uneconomical, protective coatings on carbon steel offer a efficient alternative:
| System | Thickness | Temp. Limit | Best For |
|---|---|---|---|
| Epoxy phenolic (2-coat) | 250–400 μm | 80 °C | Mild acids, potable water |
| Glass flake vinyl ester | 1,000–1,500 μm | 90 °C | Strong acids, chlorinated water |
| PTFE / ECTFE (Halar) lining | 2–3 mm | 120 °C | Aggressive chemicals, high purity |
| Natural rubber (NR) lining | 3–5 mm | 70 °C | Abrasive slurry, mild acids |
| Chlorobutyl rubber (CBR) | 3–5 mm | 85 °C | Hypochlorite, oxidising media |
| Thermal spray aluminium (TSA) | 200–300 μm | 500 °C | Atmospheric corrosion, splash zone |
Coating selection follows ISO 12944 for corrosivity categories (C1–C5-I/M). Surface preparation to Sa 2½ (ISO 8501-1) with a profile of 50–75 μm is mandatory for high-performance coatings. Holiday detection (spark test at 5 kV/mm) is performed on every lined vessel.
The design corrosion allowance is calculated from predicted corrosion rate and design life: CA = CR × tdesign + CAmargin, where CR is corrosion rate (mm/year) from ISO 9223 or ASTM G31 immersion testing, tdesign is the required service life (typically 20–25 years for water treatment infrastructure), and CAmargin is a 1–2 mm contingency for unexpected upset conditions. Remnant life during in-service inspection is estimated by: trem = (tmeasured – tmin) / CR, where tmeasured is the minimum remaining wall thickness from ultrasonic testing and tmin is the code-minimum wall (e.g., MAWP calculation per ASME VIII UG-27). Inspection intervals are set to ensure trem > 2× the inspection period at each survey.
Rigorous inspection and verification at every stage from raw material to finished equipment.
All raw materials are inspected on arrival for dimensional accuracy, surface finish, and certificate compliance. Spectrometric analysis confirms alloy composition matches specification.
WPS and PQR documentation for every weld procedure. Welder qualifications to EN ISO 9606. In-process visual inspection and dye penetrant testing on critical joints.
Solution annealing and passivation restore corrosion resistance after welding. Furnace charts and temperature records are included in the quality dossier.
Hydrostatic pressure testing to 1.5x design pressure verifies weld integrity and mechanical strength. Test certificates are provided for every pressure vessel.
CMM and laser measurement confirm fabrication tolerances. Critical dimensions for nozzle locations, flange bolt patterns, and interface points are verified against GA drawings.
Complete quality dossier including material certificates, weld maps, NDT reports, pressure test records, and surface finish measurements. Available in hard copy and PDF.
Custom automation and SCADA integration for critical water treatment processes plants.
View PageOur custom engineering team is involved in designing water treatment equipment to your exact specifications.
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.