Wastewater Treatment Plant PLC/DCS Modernization Project

Hong Kong Saul Electric Co., Ltd.

Wastewater Treatment Plant PLC/DCS Modernization Project

Hong Kong Saul Electric Co., Ltd.

Project Background

The client, BlueRiver Environmental Solutions Ltd., operates a large-scale municipal wastewater treatment facility in Chengdu, China. Their plant was running on legacy PLC and DCS systems, which led to frequent process interruptions, limited automation, and high energy consumption. The client sought a comprehensive upgrade to improve operational efficiency, regulatory compliance, and environmental performance.

Challenges

Outdated PLC/DCS hardware with limited vendor support
Manual data collection and lack of centralized monitoring
Need to maintain continuous wastewater treatment during migration
Integration with a wide variety of field instruments and sensors
Stringent environmental and discharge regulations

Our Solution

Hong Kong Saul Electric Co., Ltd. provided a full-scope modernization solution:

Replaced legacy PLCs with Allen-Bradley ControlLogix controllers and upgraded DCS for plant-wide automation
Deployed a modern Wonderware SCADA system for real-time process visualization, alarms, and reporting
Implemented phased migration to ensure uninterrupted wastewater treatment
Developed custom interfaces for seamless integration with existing field devices
Provided comprehensive training and documentation for plant staff

Results & Benefits

Increased operational efficiency by 22%
Reduced unplanned downtime by 70%
Improved compliance with environmental discharge standards
Enabled predictive maintenance and faster troubleshooting
Enhanced data transparency and remote access for management

Contact Us

For more information about our wastewater treatment plant automation and modernization solutions:
Email: zoe0159@163.com
Phone: +86 18030274856

Outcome

The $4 million project was successfully completed in two separate phases with both phases coming in on schedule and the overall costs coming in under budget. Emergency repairs to the facility were completed on December 11th, 2014 which allowed for the facility to operate through the critical winter months. Permanent electrical repairs along with less critical site deficiencies were completed in April and May of 2016 when a longer facility shut-down could be tolerated.

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Wastewater Treatment Plant PLC/DCS Modernization Project

Wastewater Treatment Plant PLC/DCS Modernization Project