Project Snapshot | Wastewater Treatment Solution Provider

Client: Wastewater treatment solution provider – Canada
Industry: Water treatment
Location: Vancouver, Canada
Services provided: Electrical control panel design, MCC and PLC panel engineering, instrumentation and I/O definition
Software used: AutoCAD Electrical 2022
Key result: Robust and maintainable control panel design supporting reliable plant operation, easier troubleshooting.
Duration: 6 months - from concept design to final approved drawings

Client & Project Background

The client develops and operates water treatment plants and needed a comprehensive control panel design for a new treatment facility handling multiple process stages. The objective was to design MCC and PLC panels that could reliably control pumps, valves, blowers, dosing systems, and field instruments, and integrate seamlessly with the plant’s SCADA system. APC Engineering Services was appointed to deliver the complete electrical control panel design and associated documentation as part of the plant’s overall automation package.

Challenge / Requirements

The plant process included several treatment stages (such as raw water intake, clarification, filtration, dosing, and storage), each with multiple motors, valves, and instruments to be controlled and monitored.
Control panels had to be designed considering environmental conditions typical of water treatment plants (humidity, dust, chemical exposure) and appropriate clearances and segregation for safety.
The client required clear separation of power and control sections in MCC and PLC panels, standardized panel layouts, and detailed documentation for future maintenance and upgrades.
Instrumentation and I/O mapping had to be carefully structured to support reliable PLC-SCADA communication and real-time monitoring of critical process parameters.

Solution (APC approach)

1. Design & Engineering

Studied process and P&ID documents to understand each treatment unit (pumps, clarifiers, filters, dosing skids) and derive a complete list of motors, valves, and instruments requiring control and monitoring.
Designed MCC and PLC panel schemes in the chosen CAD platform, including power distribution, motor starters, VFD feeders (where applicable), control wiring, and interlocks.
Applied relevant panel design practices for water treatment environments, including adequate IP ratings, spacing, ventilation, and provision for cable entries and maintenance access.

2. Instrumentation, I/O, and Communication

Defined detailed I/O lists for all process signals: level, flow, pressure, turbidity, pH, conductivity, pump and valve feedbacks, and alarms.
Structured PLC I/O cards and marshalling to group signals logically by process area (intake, treatment, clear water), simplifying field wiring and troubleshooting.
Prepared network and interface drawings to show PLC–SCADA communication, remote panels, and field junction boxes as required.

3. Documentation and Standards

Generated detailed schematic diagrams, terminal plans, panel GA/layout drawings, cable schedules, and BOMs for each control panel, following applicable standards and client specifications.
Included clear tagging and naming conventions across all drawings so maintenance teams and SCADA engineers can easily trace signals from field devices through panels to PLC and HMI.
Supported the client’s commissioning team with clarification of drawings and I/O checks to ensure smooth integration with PLC logic and SCADA screens.

Results & Benefits

Delivered a complete, standardized control panel design package that improved clarity for installers, commissioning engineers, and maintenance teams.
Enhanced plant reliability and operational efficiency by ensuring correct selection of components, clear segregation of power and control, and robust documentation of interlocks and protections.
Simplified PLC-SCADA integration and future upgrades through well-structured I/O lists, network diagrams, and signal tagging aligned with process areas and P&IDs.
Provided the client with a scalable control panel architecture that can be replicated or extended for additional water or wastewater treatment projects.

Tools & Technologies Used

Design: AutoCAD Electrical for schematics, panel layouts, terminal diagrams, and BOM generation.
Control & automation: PLC-based control and SCADA integration (architecture prepared to work with modern PLC-SCADA platforms, such as Siemens-based solutions using TIA Portal, as used in many water/wastewater projects).
Standards & practices: Panel layout, clearance, and environmental considerations aligned with water treatment plant guidelines and relevant electrical standards for control panels and MCC rooms.

“APC Engineering Services provided a complete and well-structured control panel design for our water treatment plant. Their documentation made installation and PLC-SCADA integration straightforward, and the final panel layouts are practical for daily operation and maintenance. The scalable design will help us standardize future plants on the same architecture.”

Case Study