Case Study: Full Water Treatment Plant Automation Achieves 24/7 Unmanned Operation

This case study demonstrates how a fully integrated automation and SCADA system enabled a Water Treatment Plant (WTP) to operate 24/7 without on-site operators, delivering higher reliability, faster response, and significantly improved cost efficiency—while maintaining stable and compliant water quality.

Inefficiencies in Manual Operations

Before modernization, the WTP relied heavily on operators to manually manage:

• Pump operations
• Chemical dosing
• Filter backwash sequences
• Water level control
• Flow balancing
• Daily manual reporting

This led to several operational challenges:

Problems Before Automation

• Inconsistent operation across shifts
• High labor cost due to 24/7 staffing
• Slow issue detection and delayed response
• Incomplete or inaccurate manual logs
• Fluctuating water quality

A full automation upgrade was required to ensure stable and efficient operations.

Solution: Integrated Automation, SCADA, and Smart Instrumentation

WSI designed and deployed a complete automation architecture enabling full unmanned operation around the clock.

Smart Instrumentation Upgrade

Critical online analyzers and sensors installed across all process stages:

• Turbidity sensors
• pH and ORP analyzers
• Flowmeters
• Level transmitters
• Pressure transmitters
• Residual chlorine analyzers

Providing continuous, real-time data for automated decision-making.

PLC-Based Process Automation

Comprehensive automation logic implemented for:

• Pump sequencing & protection
• Feedback-based chemical dosing
• Automatic filter backwash (DP or timer)
• Water level control & flow balancing
• Safety interlocks to ensure fail-safe operation

Centralized SCADA System

The SCADA platform provides:

• Full mimic diagrams of all processes
• Historical trends
• Prioritized alarm management
• Auto-generated daily reports
• Remote access via web & mobile

Supervisors no longer need to be onsite.

24/7 Unmanned Operation Mode

After full integration:

• No on-site operator required
• Remote alarms sent directly to supervisors
• Automatic chemical dosing and backwash
• Pump operation based on demand and water levels
• Automated energy optimization scheduling

Operators only visit the site for periodic inspections or emergencies.

Results: A Fully Autonomous and Stable WTP Operation

Performance Indicator | Before Automation | After Automation

Operator Requirement | Onsite 24/7 | Unmanned (remote supervision only)
Issue Response Time | > 30 minutes | < 2 minutes (SCADA alerts)
Water Quality Stability | Fluctuating | Consistent & compliant
Operational Cost | High | Reduced by 42%
Filter Backwash | Manual | Automatic
Chemical Usage | Inefficient | 18% optimized
Reporting | Manual | Fully digital

Advanced Analytics for Higher Efficiency

WSI also implemented optional analytics modules for:

• Turbidity prediction
• Chemical dosing optimization
• Pump efficiency assessment
• Predictive maintenance
• Weather-to-raw-water quality correlation

Transforming the facility into a smart water treatment plant.

WSI Project Experience in Full WTP Automation

WSI has extensive experience delivering full Water Treatment Plant process automation across multiple locations in Indonesia.

🏛️ SCADA Kalidendeng

• Full process WTP automation, from intake to clear water
• Automatic pumping, dosing, backwashing, and balancing

🏛️ SCADA Kedung Putri

• Complete WTP automation with integrated instrumentation
• SCADA monitoring for process quality and operations

🏛️ PAM Jaya

• Full WTP and distribution automation
• Integrated water quality sensors and pressure zone optimization

🏭 WTJJ (WIKA TIRTA JAYA JATI LUHUR)

• Fully automated WTP operations
• Complete instrumentation for chemical and filtration processes

✈️ I Gusti Ngurah Rai International Airport

• Automated clean water system for airport utilities
• SCADA monitoring 24/7 integrated with the Building Management System (BMS)

🏭 Adaro

• Water supply and raw water intake automation in mining operations
• SCADA remote monitoring for remote, difficult-access sites

A Modern Blueprint for Water Treatment Automation

Full automation provides:

• Higher operational reliability
• Stable and consistent water quality
• Reduced labor cost
• No on-site operator required
• Data-driven decision-making
• Extended asset lifetime

This model is now a modern standard for water treatment infrastructure.

💡 Ready to Automate Your Water Treatment Facility?

WSI offers:

• WTP & WWTP automation
• SCADA & IoT remote monitoring
• Smart instrumentation
• Chemical dosing optimization
• Predictive process analytics

Visit wsi.co.id for consultation and a free feasibility study.