Challenge

The client’s steam generator relied on an outdated relay-based control system, resulting in limited process visibility and increased downtime risk. Manual intervention was frequently required, impacting operational stability.

Solution

NT Electrical delivered a comprehensive upgrade: replacing legacy controls with a fully automated architecture, installing IFM instrumentation via IO-Link, and integrating a field-mounted HMI with the site’s ControlLogix processor. This improved data visibility, process accuracy, and reliability.

Challenge

The Eves Valley treatment plant underwent major process upgrades requiring new instrumentation, field devices, and expanded automation capability. However, the existing control system had reached its limits — the PLC I/O was fully occupied, the backplane had no spare slots, and the original control panel was overcrowded from decades of modifications.
To support the new 5500L boron mix tank installation and additional process changes, a reliable and scalable electrical and instrumentation solution was needed. The system also had to integrate smoothly with Koppers Chemicals’ existing PLC and SCADA platform, requiring accurate instrument scaling and clearly defined control logic.

Solution

NT Electrical designed and delivered a complete E&I upgrade tailored to the plant’s new operational requirements. A new control panel was engineered and installed, featuring a 12-slot PLC backplane with remote communications, new digital I/O, and expanded analog capacity. This provided the necessary room for current upgrades while ensuring ample capacity for future expansion.
The boron mix tank was fitted with a Vega radar for continuous level monitoring and a Vega point switch for high-level shutdown protection. NT Electrical supplied all instrument scaling, configuration details, and operational requirements, enabling Koppers to implement accurate PLC logic and SCADA updates. The result was a modernised, scalable, and reliable control infrastructure fully aligned with the plant’s upgraded processes.

Challenge

In late 2023, the site experienced significant water loss from its portable water supply system, with tank levels dropping rapidly and no clear indication of the leak location. The existing control system lacked modern monitoring, communication, and diagnostic capability, making it difficult to track flow, detect faults, or remotely observe tank and pump performance. The system was aging, relied on outdated instrumentation, and did not provide reliable real-time data to operators via SCADA. This created operational risk, inefficiency, and prolonged troubleshooting during critical water loss events.

Solution

NT Electrical led a comprehensive investigation and upgrade project. The leak detection phase included excavation work with contractors, strategic use of a clamp-on flow meter to follow a 0.5 L/s reference flow downstream, and Ground Penetrating Radar support to safely locate the pipe. Once exposed, the leak was quickly identified at a reducing elbow and repaired the same day, immediately stabilising tank levels.

Recognising the wider system limitations, NT Electrical developed and delivered a full modernisation plan. The upgrade introduced a Banner wireless radio network using a DXM700 receiver and DX80DR field units for robust long-distance communication between the bore pump shed and the hilltop control panel.

A solar-powered control cabinet was designed using a 435W solar panel, Victron SmartSolar charge controller, and dual 12V battery bank to supply stable 24V control voltage for remote I/O. New instrumentation included three level radar transmitters, a Krohne Water Flux flow meter with 4–20mA and pulse output, a Vega radar for the buffer tank, and two line pressure transmitters on the bore and booster pump lines.

All sensor data is collected by the DXM700 and transmitted to an Allen-Bradley ControlLogix PLC. New PLC code was written to manage bore and booster pump operations, with integrated alarms and SCADA visibility for tank levels, pressures, pump status, and faults. The result is a fully modernised, reliable, and highly monitored water system where leaks and operational issues can be detected and resolved quickly.

Challenge

Downer required a complete upgrade of the control infrastructure at the Waimea Bores 10 & 11 site. The existing equipment was aging, lacked modern functionality, and offered limited reliability for ongoing operations. A new control panel, updated field connections, and improved instrumentation integration were needed to support future control logic and SCADA improvements. The project required a fully engineered solution — from scoping and design through to fabrication and commissioning — while ensuring seamless handover for Downer’s PLC and SCADA teams.

Solution

NT Electrical delivered a full design and build package for the control system upgrade. This included scoping the initial requirements, producing all electrical schematics, and engineering a new control panel tailored to the site’s operational needs. AML provided the switchboard shell. NT Electrical built the panel in-house, replaced both bore pump junction boxes, and connected all field instrumentation as part of the upgrade.

Downer handled PLC programming and SCADA configuration, with NT Electrical providing on-site commissioning support to ensure smooth integration and reliable operation of the entire system. The result was a modern, robust, and fully engineered control solution that enhanced the performance and maintainability of the Waimea bore sites.