PROVEN PERFORMANCE
With over dozen of successful municipal deployments, HL Controls delivers precision-engineered automation solutions that redefine operational reliability. Our track record spans complex water distribution systems, industrial manufacturing hubs, and large-scale utility networks where downtime is not an option.
Project Gallery
Custody Transfer SCADA Project
SCADA implementation project using VTScada to give Company operators monitoring/control of brand new asset. Scope includes a Functional Technical Specification (network architecture, redundancy, firewall security, alarms/trends/reporting), full SCADA build (screens, control strategies, alarms with email routing, trends, user security, commissioning), a structured FEED process (IO list/P&ID/network diagram collection, point normalization, object/template assignment, client review of alarm/historian definitions), communications design and field device testing, system testing (navigation/screens), factory acceptance testing, and onsite deployment.
PLC Programming and Integration
PLC modernization project for a wastewater treatment plant (WWTP), involving reprogramming of existing PLCs to upgrade control logic and improve process automation. Scope included designing and building new SCADA screens to reflect the modernized control strategies, integrating power monitoring for electrical assets, and enhancing alarm management with structured alarm definitions and notification routing to operations staff. The project focused on modernizing plant automation while minimizing disruption to ongoing WWTP operations, improving operator visibility, and strengthening alarm response through better-organized event handling and notifications.
High-Speed Batch PLC Logic
Control system modernization project replacing an obsolete Allen-Bradley SLC 503 PLC with a new Allen-Bradley CompactLogix platform, including full reprogramming of control logic. The key challenge was executing the upgrade while keeping the plant operational, requiring careful pre-planning of wiring and new transmitters, along with scheduling multiple operators to run the plant manually during the cutover window. This minimized downtime and process disruption while transitioning to a modern, supportable control platform with improved reliability and maintainability over the legacy system.
CASE STUDY
Municipal Water SCADA Modernization
- Challenge: Obsolete legacy hardware causing frequent system downtime and inconsistent data reporting for a regional water utility.Solution: Implemented a high-performance Ignitition SCADA platform with redundant PLC logic and advanced alarm rationalization.Outcome: 35% reduction in unplanned maintenance costs and real-time visibility for remote operators.
Industrial Impact
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HL Controls transformed our aging water treatment SCADA system. Their senior expertise ensured a zero-downtime cutover, and the new high-performance HMI has significantly reduced operator response times during critical alarms.
Director of Operations, Metropolitan Water District
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The technical precision HL Controls brought to our PLC migration project was refreshing. They didn’t just replace hardware; they optimized the entire process logic, resulting in a 15% increase in throughput for our main assembly line.
Senior Engineering Manager, Precision Manufacturing Corp
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