Water Treatment Plant Monitoring

The problem

Treatment stages were automated at different times by different contractors, so filters, dosing and clear-water tanks sit on separate PLCs and SCADA screens.

Solution overview

MILESGO gateways collect data from PLCs, water quality analysers (pH, turbidity, chlorine, DO), dosing pumps, flow meters, level sensors, valve actuators over S7 / Modbus TCP / Modbus RTU / EtherNet/IP, and deliver it to SCADA, a historian / database (MySQL, SQL Server, InfluxDB), SMS, email and messaging alarms as OPC UA / MQTT. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

PLCs
water quality analysers (pH, turbidity, chlorine, DO)
dosing pumps
flow meters
level sensors
valve actuators

Protocol path

S7 / Modbus TCP / Modbus RTU / EtherNet/IP → OPC UA / MQTT

Implementation checklist for the project manager

Do not modify validated PLC programs; read existing data areas or add gateway-side mapping instead.
Commission in read-only mode first; enable write / control points only after the client approves each one.
Confirm the authority’s reporting requirements and data formats at the start of the project.
Keep OT networks segregated and use VPN for remote access instead of opening ports to the internet.
Configure NTP so trends, alarms and meter readings carry consistent timestamps.
Agree data retention and the report format needed for audits with the quality team at the start.

Project deliverables

Signed point table and protocol mapping
Gateway configuration files and backups
IP address plan and network drawing
FAT and SAT test records
As-built documentation and operator training

System architecture

Field layer: PLCs, water quality analysers (pH, turbidity, chlorine, DO), dosing pumps, flow meters, level sensors, valve actuators, connected over S7 / Modbus TCP / Modbus RTU / EtherNet/IP. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: SCADA, a historian / database (MySQL, SQL Server, InfluxDB), SMS, email and messaging alarms, which receives the data as OPC UA / MQTT. Remote access for maintenance runs over VPN rather than open internet ports.

System composition

Field devices: PLCs, water quality analysers (pH, turbidity, chlorine, DO), dosing pumps, flow meters, level sensors, valve actuators
Edge / integration: MILESGO protocol gateways and edge controllers
Upper systems: SCADA, a historian / database (MySQL, SQL Server, InfluxDB), SMS, email and messaging alarms (OPC UA / MQTT)
Tools and commissioning: Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Software and AI capabilities

Configuration screens generated from a natural-language description (SCADA gateway AI assistant)Pilot
Anomaly detection on trend dataRoadmap

Delivery steps

1
Site survey and point list
Inventory devices, protocols, register maps, panel space, power and network paths.
2
Design and point table sign-off
Map every point to the target protocol and system; agree it with the client and the upper-system contractor.
3
Configuration and FAT
Build the gateway configuration off site, simulate it and test against the signed point table.
4
Installation and wiring
Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.
5
SAT and alarm tests
Verify values against local readings, test every alarm and command end to end.
6
Handover and support
Hand over configuration backups, point table and as-built documents; train operators.

Customer value

One view of all subsystems instead of separate vendor consoles
Monitoring added without changing existing control programs
Timestamped records for compliance and reporting
Reliable trend data for optimisation and fault diagnosis

Tell us about your project

Send the protocols, point count and target system. A sales and engineering pair reviews every submission.

Discuss Your Project