Hazardous Area Chemical: Stormwater Upgrade
A full control system modernisation for a stormwater containment gate at an Australian chemical manufacturing site, replacing a 1990s legacy system without touching the existing pneumatic hardware.
Industry
Chemical Polymers
Duration
3.5 Weeks
Project Value
$100,000
Services
Control System Modernisation, Panel Build, Remote Monitoring
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Download this case study as a PDF to keep or share.A 1990s system that could no longer be trusted
Our client, a major Australian chemical manufacturer, relies on stormwater containment gates to prevent spills from leaving the site and entering the environment. The existing control system, originally installed in the 1990s, had reached end-of-life and was no longer reliable, compliant, or capable of providing the monitoring required under modern environmental and WHS expectations. The pneumatic gate hardware needed to remain in place, meaning a full control system modernisation was required without replacing the physical gate mechanisms.
A modern control system, built around legacy hardware
Reverse-engineered the legacy control logic and operational sequences
Designed a fully modernised control architecture and documentation package
Built two new control panels with RF communication between remote locations
Integrated 300Ah battery backup for full operation during mains failure
Added SMS alerting for alarms, gate position, and spill-response visibility
Provided commissioning, testing, verification and EPA approval support
EPA-approved, and built to stay online
Our client now operates a fully modernised, reliable and EPA-approved stormwater protection system that integrates seamlessly with the existing pneumatic hardware. The new solution provides real-time status visibility, uninterrupted operation during power outages, and significantly improved compliance, safety and operational confidence, without civil works, cabling runs or major infrastructure replacement.
Project Facts
Full Case Study
Get the complete write-up, including project scope and outcomes, as a one-page PDF.
Download PDFA stormwater system built to stay compliant
Delivered in 3.5 weeks without replacing the existing pneumatic gate hardware.
Modernisation supporting full environmental compliance
Uninterrupted operation during power outages
Visibility and SMS alerting for spill-response events
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