Modernizing One of the Nation's Largest Closed-Loop Wastewater Systems
Rebuilding the controls behind one of the nation's largest closed-loop industrial wastewater treatment plants — modern alarms, multi-station visibility, and the ability to see a fault before it becomes a violation.
One of the nation's largest closed-loop industrial wastewater treatment plants was running on hardware that no longer had spare parts, alarms that no longer fired reliably, and code that didn't follow any modern standard. For a facility of this size, that's not a maintenance problem — it's a regulatory and operational risk.
The challenge
- Limited remote visibility into the status of dozens of motors, tanks, and valves.
- Equipment unreliability driving constant manual intervention.
- Alarms only visible from a single location — slow response when something went wrong.
What we did
- Engineered a control system that delivers critical alarms with detail — and routes them to operators wherever they are in the plant.
- Distributed monitoring and command across multiple workstations so the response window matches the size of the facility.
- Rebuilt the programming foundation with standards that support optimization, predictive maintenance, and graceful fault handling.
The outcome
- Faults arrive with descriptions that point to a fix, not a guess.
- Tank, motor, and valve status is monitored reliably and reported plant-wide.
- Operators across the facility see the same picture in real time.
Key Results
Multi-station
Operator Visibility
Faster
Emergency Response
Predictive
Maintenance Posture
Technology Stack
Let's build something
that actually works.
Whether you need to modernize legacy controls, build out data infrastructure, or deploy ML models on the factory floor — we're ready when you are.
