Water & Wastewater Projects

City Of Pflugerville

Pflugerville, TX

This project entails the replacement of outdated Unitronics and Allen-Bradley PLCs across multiple sites. Work includes the removal of existing RTUs, installation of new PLC hardware, terminal blocks, interposing relays, wire labels, and neatly organized wiring with tie wraps and wireway covers installed as needed. Enclosures are cleaned post-installation. Instrumentation for temperature regulation such as heaters and fans will be installed with control panels to maintain safe operating conditions.

Activities

  • Project Management
  • Engineering and Documentation
  • Equipment Procurement
  • Integration and Testing (FAT)
  • Equipment Shipping
  • Installation and Commissioning
  • Functionality validation and interconnection
  • Project Closure

Platforms

  • Allen Bradley CompactLogix

    City of Deer Park

    Deer Park, TX

    This project aims to enhance the SCADA system by implementing a wireless radio communication network and integrating critical monitoring functionalities. Key efforts will focus on designing user interfaces that display generator statuses, developing and approving lift station screens, and incorporating the Avon screen into the existing system. The ultimate objective is to ensure the VTSCADA system operates effectively for both water and wastewater systems.

     

    Activities

    • Project Management
    • PLC Programming
    • SCADA Programming
    • On site Commissioning
    • IP Address and Communication

    Platforms

    • PLC: SCADAPack 32, MicroLogix 1400
    • HMI/SCADA: VTScada

    City of Friendswood

    Friendswood, TX

    The project involved upgrading the City of Friendswood’s entire SCADA infrastructure, focusing on modernizing the VTScada platform and establishing secure, reliable connectivity across all facilities. SOAP Engineering migrated the existing VTScada Runtime system to the latest Development + Runtime version, upgraded software licenses, and deployed a secure VPN-based network to interconnect 42 sites including lift stations, surface water plants, and wells. The work encompassed configuration of thin clients for multi-user access, setup of automated alarm notifications via SMS and email, and complete verification of Modbus TCP/IP communications. The project also included Siemens PLC and HMI support, ensuring seamless data exchange and enhanced cybersecurity throughout the water and wastewater control network.

    Activities

    • SCADA Server Upgrade (VTScada Runtime → Development + Runtime)

    • VPN Setup & Port Forwarding (42 sites)

    • Thin Client Configuration & Testing

    • Alarm Notification Setup (SMS/email)

    • Siemens PLC/HMI Communication Support

    • FAT & SAT Testing

    • Documentation & Knowledge Transfer

    Platforms

    • PLC: Siemens PLCs

    • HMI/SCADA: VTScada (Development + Runtime)

    • Communications: VPN, Modbus TCP/IP

    • Other: Cellular modems, alarm notifications

      Texas Department of Criminal Justice

      Navasota, TX

      SOAP Engineering executed the design and implementation of a new SCADA system for the Navasota Water Wells serving the Texas Department of Criminal Justice. The project aimed to modernize monitoring and control functions while providing full remote access to field operations. The scope included engineering a new control architecture, producing a 100 % design package with drawings and I/O lists, and fabricating RTU panels built around SCADAPack 300E PLCs. InduSoft Web Studio SCADA software was deployed to handle approximately 150 tags, integrating real-time data from flow meters, transmitters, and sensors. The team installed Maple HMI terminals, configured Freewave radios and antenna systems, and performed field commissioning and validation. Operator training and delivery of as-built documentation completed a fully integrated turnkey SCADA solution providing improved reliability and visibility of the water wells.

      Activities

      • Control System Design (PFDs, P&IDs, I/O Lists)

      • PLC Programming & HMI Development

      • Panel Fabrication & Instrumentation Setup

      • Installation & Commissioning (RTUs, radios, sensors)

      • SCADA Integration & Testing (FAT/SAT)

      • Operator Training & Documentation Delivery

      Platforms

      • PLC: SCADAPack 300E

      • HMI: Maple Systems PC1212AP

      • SCADA: InduSoft Web Studio (150 tags)

      • Communications: Freewave Radios, Yagi/Omni Antennas

      National Park Service

      Grand Canyon, AZ

      This emergency maintenance project for the National Park Service covered the complete restoration of the Grand Canyon National Park’s water treatment SCADA system based on Allen-Bradley CompactLogix controllers and FactoryTalk View Site Edition HMI servers. SOAP Engineering carried out a comprehensive on-site investigation of PLCs, HMIs, and the communications network to identify hardware and software failures affecting plant automation. The scope included troubleshooting, repair or replacement of defective components, reconfiguration of PLC logic and HMI graphics, and validation of control sequences for intake pumps, chemical feed, and process systems. Functional testing, backup restoration, and detailed documentation ensured the system’s return to full operation, restoring dependable monitoring and control capability for the park’s critical water treatment infrastructure.

      Activities

      • On-Site Investigation & Troubleshooting

      • Repair & Replacement of Components

      • PLC Logic & HMI Reconfiguration

      • Functional Testing (FAT/SAT)

      • Documentation & Training

      Platforms

      • PLC: Allen-Bradley CompactLogix

      • HMI/SCADA: FactoryTalk View SE (redundant)

      • Hardware: Dell PCs, RIO-200 HMI

      • Systems Controlled: Pumps, chemical feed, chlorine machine

      Town of Andrews

      Grand Canyon, AZ

      The project consisted of upgrading the Town of Andrews’ control and monitoring infrastructure for three elevated tanks and three water wells. SOAP Engineering provided design, fabrication, installation, and commissioning services for new RTU panels equipped with IDEC SmartAXIS PLCs and integrated Rosemount transmitters and magnetic flow meters. Work included decommissioning obsolete equipment, installing stainless-steel electrical racks and enclosures, performing civil works for concrete foundations, and establishing a new cellular-based communications network using Teltonika routers. The team handled full SCADA integration with the town’s server, configured backup systems and surge protection, and executed testing and verification through FAT, IFAT, and SAT procedures. Operator and maintenance training finalized a robust and cost-efficient SCADA system owned and hosted by the municipality without subscription costs.

      Activities

      • System Design & Documentation

      • PLC Programming & SCADA Integration

      • Panel Fabrication & Field Installation

      • Instrumentation Installation (flow meters, transmitters)

      • Networking & Testing (FAT/IFAT/SAT)

      • Operator Training & Close-ou

      Platforms

      • PLC: IDEC SmartAXIS

      • SCADA: Town of Andrews server

      • Communications: Teltonika Cellular Routers

      • Field Instruments: Rosemount Transmitters, Magnetic Flow Meter

      Department of the Air Force (Shaw AFB)

      Sumter, SC

      The project encompassed modernization and automation of two production wells at Shaw Air Force Base, integrating new control hardware, process instrumentation, and SCADA functionality. SOAP Engineering developed and submitted all design phases (35 %, 65 %, 95 %, 100 %), procured process and electrical components, and performed installation of analyzers, sensors, and chemical feed equipment. The automation system was based on Allen-Bradley CompactLogix and Micrologix PLCs communicating with FactoryTalk View SCADA software and WIN-911 alarm notification systems through Cisco-managed routers and switches. Activities included programming, panel integration, field commissioning, operator training, and delivery of detailed as-built documentation. The resulting system provided reliable remote control and monitoring of wells, ensuring compliance with AWWA, NEC, ANSI, and Air Force technical standards.

      Activities

      • Design Engineering & Procurement

      • PLC/DCS/HMI/SCADA Programming

      • Networking (Cisco routers/switches)

      • Installation of VFDs, Sensors, Analyzers

      • FAT/SAT, Commissioning, Training, Documentation

      Platforms

      • PLC: Allen-Bradley CompactLogix / Micrologix

      • HMI/SCADA: FactoryTalk View, WIN-911

      • Software: Studio5000

      • Networking: Cisco Managed Devices

      City of Mason

      Mason, TX

      This project involved a complete modernization of the City of Mason’s Water Treatment Plant and associated remote wells and towers through upgrades to both PLC and SCADA systems. SOAP Engineering replaced legacy ControlWave controllers with new Allen-Bradley CompactLogix, MicroLogix, and Flex5000 series PLCs, re-engineered control panels, and implemented a redundant VTScada 10K-tag high-performance platform integrated with the existing wastewater treatment SCADA network. The scope included installation of cellular communication hardware and firewalls, configuration of HMI graphics, alarms, and data trends, and development of PLC logic within Studio5000. Comprehensive FAT/SAT testing, operator training, and documentation ensured full functionality and improved reliability of the city’s water treatment process, providing enhanced redundancy, alarm management, and operational efficiency across all facilities.

      Activities

      • PLC Programming & HMI Development

      • SCADA Configuration & Integration

      • Panel Fabrication & Installation

      • Cellular Equipment Setup

      • FAT/SAT, Commissioning, Training, Documentation

      Platforms

      • PLC: Allen-Bradley CompactLogix / MicroLogix / Flex5000

      • HMI/SCADA: VTScada 10K Tag Redundant System

      • Software: Studio5000

      • Other: Cellular modems, UPS, sensors, network switches