Water & Utilities · 🇪🇬 Egypt · 2024
PLC migration for a 200,000 m³/day water treatment plant — Egypt
Legacy-to-current PLC migration and SCADA modernisation for a 200,000 m³/day municipal water treatment plant in the Nile Delta.
Our role
Migration engineering and equipment supply — controller upgrade, network re-architecture, SCADA redeploy.
The challenge
What we walked into.
Original control system commissioned in 2007 with controller modules end-of-support. Daily forced manual interventions due to spurious trips. Plant could not be taken fully offline.
Approach
How we delivered.
- 01Engineered a phased migration plan across 7 process areas, each cut over during low-demand windows.
- 02Supplied current-generation PLCs, I/O, network switches and HMIs.
- 03Re-architected the controls network from a flat topology to redundant ring with managed switches.
- 04Performed factory acceptance testing in our Nanjing lab before shipment.
Outcome
What changed.
Plant kept operational throughout the 9-month migration.
Spurious trip rate reduced from 2.4/week to <1/quarter.
Maintenance team trained on new platform across two on-site sessions.
Technologies & equipment
Current-generation PLC controllers and I/O modules
Industrial managed switches and ring topology
HMI panels and SCADA workstations
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