5 MLD automated ETP with PLC-controlled dosing, aeration and multi-stage filtration — delivering real-time SCADA monitoring and automated compliance reporting.
The client operates a large-scale industrial facility generating high-strength effluent from chemical and dye manufacturing processes. The existing manual treatment process was non-compliant with Gujarat Pollution Control Board (GPCB) discharge norms and relied on operator judgement for dosing decisions — resulting in inconsistent treatment quality and failed compliance checks.
Stellar Systems was engaged to design, supply and commission a fully automated PLC-SCADA solution covering every stage of the 5 MLD ETP — from primary collection and chemical dosing through biological treatment, clarification, filtration and treated water discharge.
The control architecture uses a single Siemens S7-1500 CPU with distributed I/O via PROFINET — keeping field wiring short while maintaining a single point of configuration. All dosing pump speed references are calculated in the PLC from inline pH and flow measurements, eliminating manual set-point guessing. The biological stage blowers are driven by Siemens G120 VFDs modulated against DO transmitter feedback to maintain the 2.0 mg/L set-point regardless of inlet load variations.
The WinCC SCADA provides a full process mimic at the operator workstation plus a secure remote client on a 4G router, allowing plant management to monitor effluent quality, chemical inventory and blower run-hours from anywhere. The compliance module automatically packages the CPCB-specified 15-minute average data into the required XML format for direct upload to the GPCB OCEMS portal.