Overview

A municipal water authority constructed a new surface water treatment plant and required comprehensive electrical distribution and instrumentation to ensure safe and efficient operation. The facility needed switchgear, variable frequency drives (VFDs), motor control centers (MCCs), lighting distribution panels and transformers, along with a wide array of process instruments. A controls integrator was selected to supply this equipment, manage electrical studies and provide commissioning support.

Challenge

• Supply and integrate all major electrical distribution equipment for a new treatment facility
• Coordinate short‑circuit, protective device coordination and arc‑flash studies
• Design and build multiple local control panels for process areas
• Provide a diverse set of flow, pressure, level, temperature and analytical instruments
• Conduct extensive testing, configuration and training while meeting tight construction schedules

Solution

The integrator furnished switchboards, VFDs, MCCs, lighting panels and transformers through a rigorous submittal process. They managed a subcontractor to perform short‑circuit analysis, protective device coordination, arc‑flash studies and electrical equipment acceptance testing. Seven local control panels were designed and built to support process area control, and numerous instruments were supplied and configured, including magnetic and variable area flow meters, thermal flow switches, pressure transmitters and switches, ultrasonic and vibronic level devices, temperature transmitters and analytical instruments for pH, oxidation‑reduction potential, free chlorine and turbidity. The team also provided a clamp‑on ultrasonic flow meter and a bubbler level monitoring system. Extensive on‑site and off‑site testing, VFD manufacturer start‑up services, functional testing, operation and maintenance manuals and operator training were all delivered as part of the project.

Technical Scope

• Electrical distribution equipment: switchboards, MCCs, VFDs, lighting panels and transformers
• Short‑circuit, protective device coordination, arc‑flash and acceptance studies
• Design and fabrication of seven local control panels
• Instrumentation: magnetic flow meters, thermal flow switches, variable area flow meters, pressure transmitters and switches, float tilt switches, ultrasonic and vibronic level transmitters, temperature transmitters, analytical probes (pH, ORP, free chlorine, turbidity), clamp‑on ultrasonic flow meter, bubbler level monitoring
• Warning indicators, intrusion monitoring and network hardware
• Instrument configuration, functional testing, O&M documentation and operator training

Results

The comprehensive electrical and instrumentation package enabled the surface water treatment plant to operate safely and reliably from day one. Proper protective device coordination and arc‑flash analysis enhanced personnel safety and equipment protection. The diverse instrumentation suite provided accurate measurement of critical process variables, improving control and water quality. Custom local control panels simplified operator interaction with various process areas, and thorough testing and training ensured the plant staff were prepared to operate and maintain the new systems.

Key Advantages Delivered

• Turnkey electrical distribution and instrumentation package
• Enhanced safety through thorough electrical studies and coordination
• Accurate process measurement across flow, pressure, level, temperature and chemistry
• Custom control panels tailored to process areas
• Comprehensive testing, documentation and training for smooth handover

Closing Summary

By supplying and integrating all major electrical distribution equipment, control panels and instrumentation, the integrator enabled a new surface water treatment plant to come online reliably and safely. The project delivered a cohesive solution that supports ongoing water quality and operational excellence.

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