Seamless integration of water treatment systems with your existing plant infrastructure, utilities, and control systems. Our engineering team ensures your new treatment equipment works harmoniously with current operations, minimising disruption and maximising efficiency from day one.
Custom automation and SCADA integration for critical water treatment processes plants.
Complete turnkey water treatment plants from initial concept through commissioning.
Comprehensive support packages including preventive maintenance, remote diagnostics, operator training and genuine spare parts.
Extend the life and capacity of your existing water treatment plant.
Installing new treatment systems in existing facilities presents unique challenges. Poor integration can cause operational disruptions, safety hazards, compliance issues, and reduced system performance. Our process integration expertise ensures seamless connections to your existing infrastructure.
Integration with existing electrical, water, steam, and compressed air systems. We ensure proper sizing, pressure ratings, and capacity for reliable operation.
Connection to existing process piping, wastewater collection systems, and discharge points. Minimises modifications to existing infrastructure.
Coordination with existing foundations, structures, and building services. Our compact designs minimise civil works requirements.
Integration with existing safety systems, emergency shutdowns, and environmental monitoring. Ensures regulatory compliance.
Our systematic integration process begins with a thorough review of your existing systems, identification of all interface requirements, and detailed engineering of seamless connections. We work closely with your operations, maintenance, and engineering teams throughout the project.
Comprehensive review of existing infrastructure, utilities, and operational requirements. We document all interface points and constraints.
Detailed engineering of all connection points including piping, electrical, controls, and civil works. Full P&ID development.
Phased installation approach to minimise production disruption. Coordination with your maintenance schedules and shutdown windows.
Systematic startup, testing, and optimisation. Training for your operators on the integrated system.
Our treatment systems integrate seamlessly with your existing SCADA, DCS, or PLC control systems. This unified approach provides operators with complete visibility and control from a single interface, minimising training requirements and operational complexity.
Full integration with existing SCADA platforms including Wonderware, WinCC, Ignition, and custom systems. Unified operator interface.
View SCADA SolutionsSupport for Modbus, Profibus, Profinet, Ethernet/IP, OPC-UA, and other industrial protocols. Seamless data exchange with existing systems.
Real-time data sharing between treatment systems and plant historians. Enables comprehensive reporting and trend analysis.
Cloud-based dashboards and mobile access for remote monitoring and alerts. Stay informed wherever you are.
Treatment equipment engineered for seamless plant integration
Equalization and buffer tanks that integrate with existing collection systems. Custom inlet/outlet configurations to match your piping.
View Storage TanksMixing tanks, reaction vessels, and contact tanks designed to integrate with your chemical dosing and process control systems.
View Process TanksPre-engineered systems in ISO containers for rapid deployment with minimal site preparation and civil works.
View ContainerisedCompact flotation and sedimentation systems engineered for tight spaces and easy connection to existing infrastructure.
View TreatmentMBBR, SBR, and MBR reactors with flexible configurations for integration into existing treatment processes.
View BiologicalDewatering equipment that integrates with your existing sludge collection and disposal systems.
View DewateringTailored equipment design to meet specific process requirements and performance targets.
Explore Custom EngineeringCompact and vertical designs for facilities with limited footprint or height restrictions.
Space-Constrained SolutionsComplete design, build, install, and commission services for hassle-free deployment.
Turnkey Delivery SolutionsProfessional piping and instrumentation diagram development for your integrated system.
View P&ID Design ServicesValidate process integration with on-site pilot units before full-scale implementation.
Learn About Pilot TestingComputational fluid dynamics modelling to optimise system integration and performance.
Explore CFD SimulationCustom 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 PageAdvanced material selection and protective coatings for aggressive wastewater environments.
View PageWe design bespoke water treatment systems with guaranteed performance targets.
View PageCompact and containerised water treatment solutions for sites with limited footprint.
View PagePipe, Electrical & Structural Connection Points
Successful integration demands precise definition of every physical interface. Our interface datasheets eliminate ambiguity and ensure your M&E contractors receive unambiguous specifications.
| Utility | Typical Requirement | Connection Standard | Notes |
|---|---|---|---|
| Process Water | 2 โ 10 mยณ/hr @ 3 bar | BS EN 1092-1 flange | Potable or softened |
| Drain | Gravity or pumped | DN100 PN10 flange | Neutralisation if required |
| Vent | DN50 โ DN200 | BS EN 1092-1 flange | Odour control connection ready |
| Power | 15 โ 250 kW total installed | BS 7671 / IEC 60364 | Isolator within 2 m of panel |
| Controls | Hardwired + network | Cat 6A / fibre OM3 | Redundant paths for DCS |
Seamless Data Exchange with Existing Plant Systems
| Protocol | Physical Layer | Data Rate | Use Case | Our Support |
|---|---|---|---|---|
| Modbus RTU | RS-485 | 9600 โ 115200 bps | Legacy PLCs, simple I/O | Native |
| Modbus TCP | Ethernet | 100 Mbps | Standard PLC integration | Native |
| PROFINET | Ethernet | 100 Mbps โ 1 Gbps | Siemens ecosystems | Native |
| EtherNet/IP | Ethernet | 100 Mbps โ 1 Gbps | Allen-Bradley / Rockwell | Native |
| OPC-UA | Ethernet | 100 Mbps โ 1 Gbps | SCADA / MES / Cloud | Gateway |
| MQTT | Ethernet / 4G | Variable | IIoT cloud dashboards | Gateway |
| Profibus DP | RS-485 | 9.6 kbps โ 12 Mbps | Legacy fieldbus networks | Gateway + repeater |
| 4โ20 mA / HART | Twisted pair | Analog + digital | Instruments, actuators | Native |
Bi-directional data push to OSIsoft PI, Canary Labs, or Wonderware Historian. Timestamped process values, alarm journals, and operator actions exported via OPC-UA or SQL bridge. No proprietary lock-in.
ISA-18.2 compliant alarm rationalisation. Critical alarms (high-high level, pump failure) escalate via SMS and email. Nuisance alarm filtering reduces operator fatigue by 60% compared to legacy systems.
Proactive Engineering for Trouble-Free Start-Up
Risk: New pump installation creates water hammer or back-siphoning into existing tanks. Mitigation: Surge analysis using Bentley HAMMER or equivalent. Soft-start or VFD on all pumps > 5.5 kW. Non-return valves on discharge lines. Pressure transducers for real-time monitoring.
Risk: Additional VFDs introduce harmonic distortion exceeding G5/4 limits. Mitigation: Harmonic survey at design stage. Active or passive filters specified when THD(i) > 5%. Separate earth bus for instrument and power earths to prevent ground loops.
Risk: New coagulant reacts with existing effluent chemistry, causing precipitation in pipework. Mitigation: Jar testing and pilot trials before final chemical selection. Static mixer sizing based on velocity gradient (G-value 300โ1000 sโปยน). Compatibility check against existing polymers.
Risk: Tie-in works exceed available shutdown duration. Mitigation: Pre-fabricated spool pieces and Victaulic couplings for rapid pipe connections. Hot-tapping where permitted. 48-hour tie-in guarantee for DAF skids with pre-mounted inlet/outlet manifolds.
Risk: New ESD logic conflicts with existing safety PLC. Mitigation: SIL assessment to IEC 61511. Hardwired safety interlocks kept independent of process PLC. Cause-and-effect matrix reviewed with your HSE team before energisation.
Risk: New blowers or dryers overload HVAC. Mitigation: Heat-load calculation including motor dissipation and dryer exhaust. Ventilation rates to HSE HSG258 or ATEX requirements. Acoustic enclosures where noise > 85 dB(A) at 1 m.
Documented Stage-Gate Handover
Conducted at our works. Includes dry-run mechanical rotation checks, pump performance curves to ISO 9906 Grade 2B, PLC I/O forcing, HMI screen navigation, and hydrostatic test to 1.5ร design pressure. Client witness invited. FAT protocol signed before dispatch.
Alignment checks, torque verification on fasteners, pipe support inspection, and cable continuity tests. Instrument loop checks (4โ20 mA loop calibration to < 0.25% span error). Earthing resistance < 1 ฮฉ verified.
Clean-water run for 24 hours to verify hydraulics and control logic. Introduction of process effluent under supervised conditions. Chemical dosing tuned via jar-test correlation. Sludge scraper timing and DAF bubble-size optimisation.
72-hour performance trial against agreed inlet envelope. Daily sampling for BOD, COD, TSS, FOG, and pH. O&M manuals, as-built P&IDs, certified drawings, and spare-parts lists delivered. Operator training: 2 days classroom + 2 days shadowing.
Our experts can design a system tailored to your specific requirements.
Our expertise spans multiple industries with sector-specific water treatment solutions.