At ELECTROSERV Engineering, our mission is to maximize the performance and lifespan of industrial electrical systems through strategic preventive maintenance. This case study highlights our real-world engagement at the Suri Water Treatment Plant, under the Public Health Engineering Directorate, Government of West Bengal.
With frequent panel tripping, operational downtime, and safety issues plaguing the plant, we were brought in by Oriental Engineering Co., the site contractor, to diagnose the problem and implement a lasting solution. Our approach didn’t just fix faults, it cut panel downtime by 90%, improved energy efficiency by 12%, and extended equipment lifespan by 3 years.
The Facility & Challenge
The Suri Water Treatment Plant is a vital public infrastructure unit, managing both Raw Water and Clear Water treatment operations. The systems relied heavily on motorised valve actuators and pumps, but inconsistent control, equipment tripping, and lack of preventive care had created a chain of issues:
- Frequent panel failures and tripping disrupted water flow schedules.
- Manual valve operation introduced inefficiencies and potential for human error.
- There was no centralised control or monitoring system, making issue detection slow and reactive.
- The facility had no formal preventive maintenance history, increasing operational risk.
These issues not only threatened day-to-day operations but also compliance with government energy and safety standards.
Our Preventive Maintenance & Automation Solution
We implemented a multi-phase strategy designed to restore reliability, enhance control, and ensure long-term sustainability. Our scope included:
1. Comprehensive Electrical Preventive Maintenance
- Thermal Imaging & Visual Inspections: We scanned all HT and LT panels to detect hotspots, loose terminals, and aging components.
- Electrical Testing: IR (Insulation Resistance) testing and Earth Resistance checks were conducted using calibrated 5kV Meggers.
- Load Profile Analysis: Voltage profiles, load balancing, and power factor correction opportunities were documented.
2. SCADA System Development & Installation
- We developed a custom SCADA (Supervisory Control and Data Acquisition) system tailored to the operational logic of the plant.
- The system enabled automated control and real-time monitoring of valves and pumps for both Raw and Clear Water treatment facilities.
- Data was visualised across three monitors installed in the centralised control room near the Raw Water Pump House.
3. PLC Ladder Logic Programming
- We programmed control sequences for motorised valve actuators and pumps, ensuring smooth coordination between water intake, treatment, and dispatch.
- Built-in fault alerts and emergency shutdown protocols were configured for maximum reliability.
Technical Highlights
- IR Testing: Improved insulation values from a risky 30 MΩ baseline to 200+ MΩ across all HT panels.
- Thermography: Detected and rectified 7 overheating terminals, one of which reached 82°C under load.
- Power Factor Correction: Identified underperforming capacitors; post-correction, system power factor improved from 0.91 to 0.98.
- Panel Cleaning & Component Replacement: All relays, contactors, and terminal lugs were cleaned, tightened, or replaced where necessary.
Results Delivered
The transformation was measurable, and the benefits tangible:
- ✅ Reduced panel downtime by 90%
- ✅ Extended equipment lifespan by 3+ years
- ✅ Improved operational control with SCADA-based automation
- ✅ Increased energy efficiency by 12%, reducing operating costs
- ✅ Achieved full compliance with P.H.E. standards during inspection
These changes empowered the facility to operate more consistently, with fewer interruptions and a significant reduction in maintenance emergencies.
Client Testimonial
“Thanks to ELECTROSERV Engineering’s thorough preventive maintenance, our facility no longer faces unplanned operation of Pumps & Valve Actuators. Their team was professional, prompt, and knowledgeable.”
— Project Manager, Suri Water Treatment Plant
Why This Case Matters for Industrial Facilities
This project at Suri Water Plant underscores a fundamental truth: preventive maintenance is more cost-effective than reactive repairs. By proactively addressing electrical and automation challenges:
- We safeguarded a public utility that thousands depend on daily.
- Enabled seamless coordination between systems that were previously isolated and prone to error.
- Reduced long-term costs while enhancing technical control.
Whether you’re running a water treatment facility, industrial manufacturing plant, or logistics center, regular preventive maintenance and smart automation can be game-changers.
Is Your Water Treatment Plant Due for a Preventive Check?
If your facility is facing tripping, poor load distribution, outdated manual operations, or simply hasn’t had a preventive audit in the last 6 months, it’s time.
ELECTROSERV Engineering specializes in custom preventive maintenance, SCADA development, thermal diagnostics, and industrial automation for mission-critical facilities.
Book a Free On-Site Audit Today
Conclusion
This case study from Suri Water Treatment Plant is more than a success story, it’s a blueprint. With the right expertise and strategy, it’s possible to drastically cut downtime, reduce costs, and meet compliance without disrupting operations.
If you’re a facility operator in Eastern India looking to future-proof your plant, we’re ready to help.
Talk to an ELECTROSERV Engineering Preventive Maintenance Expert Today.