Effluent Reuse Scheme (ERS) – pump station automation upgrades

Overview

Karratha Electrical Group (KEG) delivered a comprehensive program of electrical infrastructure and automation upgrades across the City of Karratha’s Effluent Reuse Scheme (ERS), which distributes treated wastewater for irrigation of sporting facilities, parks and public open spaces throughout Karratha.

The project involved modernising ageing pump station infrastructure, replacing legacy SCADA and programmable logic controllers (PLCs) with a new Tridium Niagara automation platform, and upgrading associated electrical distribution, motor control and instrumentation systems.

KEG managed the electrical design, equipment procurement, specialist controls engineering coordination, installation and commissioning across multiple operational pump stations, with works carefully staged to minimise interruptions to essential irrigation services.

Scope of works

  • Complete project management, electrical design coordination, equipment procurement, installation and commissioning.
  • Removal of obsolete PLCs, legacy SCADA telemetry equipment, redundant control panels and associated wiring.
  • Migration of existing pump station automation systems to the Tridium Niagara platform, incorporating JACE controllers and distributed I/O modules.
  • Design, supply and installation of new main switchboards, motor control centres, distribution boards and control enclosures.
  • Upgrades to existing electrical distribution infrastructure, including circuit protection, earthing and control systems.
  • Supply and installation of variable speed drives (VSDs) and soft starters for pump motor control, replacing fixed-speed operation where applicable.
  • Integration of automatic pressure regulation, pump sequencing, tank filling, motor protection and manual override functions.
  • Supply, installation and integration of electromagnetic flow meters, pressure transducers and VEGA ultrasonic tank-level instrumentation.
  • Installation of 4G communications equipment, routers, network switches and remote telemetry interfaces.
  • Installation of uninterruptible power supplies (UPS), battery backup systems and associated monitoring equipment.
  • Integration of existing irrigation controllers, storage tank monitoring, recycled water valves, alarms and field instrumentation.
  • Installation of underground conduits, power and control cabling, cable ladder and associated electrical infrastructure.
  • Design and installation of temporary pump control systems to maintain irrigation services during equipment replacement and system changeovers.
  • Point-to-point testing, control system integration, staged commissioning, operational verification and final handover.

Outcomes

The upgrades modernised the City of Karratha’s Effluent Reuse Scheme pumping infrastructure, replacing ageing legacy SCADA and PLC systems with a modern Tridium Niagara automation platform, reducing reliance on outdated control equipment and improving long-term system supportability.

The transition from fixed-speed pump operation to variable speed drives (VSDs) enables improved energy efficiency by matching pump output to actual irrigation demand, reducing unnecessary power consumption and providing more precise pressure regulation.

The upgraded systems provide enhanced operational reliability, centralised monitoring, improved fault diagnostics and greater flexibility in managing pumping operations across the City’s recycled water network.

The program demonstrates KEG’s capability to deliver complex, multi-site electrical and automation upgrades, integrating power distribution, motor control, instrumentation and modern automation technology while maintaining essential operational services.

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