Supporting the resilience and reliability of the UK's critical water infrastructure requires modern, intelligent control systems capable of maintaining operations while enabling essential asset upgrades.
Mardy Borehole Pumping Station (BPS) forms part of Severn Trent's drinking water network and serves a vital role in maintaining water supply. As part of a Drinking Water Inspectorate (DWI) improvement scheme, MMB required a new construction reservoir to replace an abandoned asset while allowing the existing reservoir to remain operational until inspection and repair works could be completed.
The project presented a significant technical challenge. The site's ageing common control system relied on relay-based logic and needed to be integrated with a modern PLC-based control solution, all within a compressed programme and without disrupting operational water services. Delivering this upgrade safely and efficiently was critical to maintaining continuity of supply and supporting the long-term resilience of this key infrastructure asset.
Solution
A complete control and automation solution was developed and delivered, centred around the design, manufacture and installation of a new Local Control Panel (LCP) incorporating modern PLC technology.
The new control system was designed to provide intelligent management of:
- Reservoir levels and process control
- Site operating modes
- Integration between the existing MCC and new control functions
- Reliable telemetry and operational visibility
Drawing on specialist technical services capabilities, the project combined electrical engineering, control system design, software development, panel manufacture and commissioning expertise to create a seamless interface between legacy infrastructure and modern automation technologies.
Scope of Works
The delivery included:
- Intrusive site surveys to establish a complete understanding of the existing control systems
- Design, manufacture and supply of a new Local Control Panel (LCP)
- PLC and HMI software development
- Modification of the existing Motor Control Centre (MCC)
- Telemetry integration
- Site testing, commissioning and operational handover
- Development of updated electrical schematics reflecting both the legacy and new control systems
A key element of the project was understanding and documenting the interaction between the existing relay-based control architecture and the new PLC-controlled system. Detailed investigations, verification works and comparison against historical drawings enabled the creation of accurate as-built documentation, providing the client with improved asset knowledge and a platform for future upgrades.
Overcoming Technical Challenges
Delivering Within a Critical Programme
The requirement to inspect and repair the operational reservoir created a fixed delivery window. Close collaboration between project teams ensured design, manufacture, installation and commissioning activities were prioritised and executed within the required timeframe, enabling subsequent project phases to proceed without delay.
Managing Legacy Infrastructure
As is common across many critical infrastructure assets, existing documentation was outdated and did not fully reflect the installed systems. An intrusive survey was undertaken to verify wiring, control philosophy and equipment interfaces, allowing the new automation solution to be integrated with confidence.
Physical Site Constraints
Limited space within the existing installation required careful consideration during design. Bespoke panel arrangements, including 180-degree door hinges, were incorporated to maximise access for maintenance while complying with Severn Trent standards.
Operational Site Conditions
Works were undertaken while maintaining operational requirements and managing the challenges associated with periods of elevated temperatures. Flexible planning and close coordination ensured safe and efficient delivery throughout the project lifecycle.
Results
The project was successfully delivered within the required programme, enabling the new reservoir to be integrated into site operations while maintaining continuity of service.
The upgraded control system provides improved operational flexibility, enhanced reliability and a modern platform for future development. The client also benefited from updated asset documentation, improved telemetry capabilities and greater visibility of site operations.
Most importantly, the project supported the resilience of a critical water infrastructure asset, ensuring continued delivery of a reliable drinking water supply while facilitating essential inspection and repair works.
Technical Services Capability
This project demonstrates the ability to deliver complex control and automation solutions across critical infrastructure environments, combining multidisciplinary technical expertise with safe and reliable project execution.
Key capabilities demonstrated include:
- Control and automation engineering
- Electrical design and system integration
- PLC and HMI software development
- MCC modifications and upgrades
- Telemetry and remote monitoring solutions
- Panel design and manufacture
- Testing, commissioning and validation
- Asset verification and documentation
- Delivery within operational critical infrastructure environments
- Collaborative project execution under challenging programme constraints
By bringing together design, engineering, manufacturing, software development and commissioning expertise, a fully integrated technical services solution was delivered from concept through to operational handover.
