Top OEMs for Electrical Control Panels in Water & Wastewater

Introduction: The Neural Network of Water Infrastructure

In the modern landscape of municipal and industrial water and wastewater treatment, the electrical control panel serves as the central nervous system of the facility. While pumps move the fluid and valves direct the flow, it is the control panel—engineered and fabricated by specialized System Integrators (SIs)—that dictates the logic, ensures safety, and facilitates the interface between human operators and mechanical assets. For municipal consulting engineers, utility superintendents, and plant managers, the selection of a control panel manufacturer or system integrator is not merely a purchasing decision; it is a critical infrastructure choice that dictates the reliability, maintainability, and operational intelligence of a system for decades.

Electrical control panels in this sector operate in some of the most challenging environments imaginable. They are frequently located outdoors, exposed to extreme thermal cycling, direct solar loading, and precipitation. In wastewater applications, they are often subjected to corrosive atmospheres containing hydrogen sulfide (H2S), requiring specialized material selection and pressurization strategies. Furthermore, the regulatory context is stringent. Panels must not only comply with the National Electrical Code (NEC) but also adhere to specific safety standards such as UL 508A for industrial control panels and UL 698A for panels relating to hazardous (classified) locations. The convergence of power distribution, low-voltage control logic, and complex telemetry requires a level of engineering rigor that distinguishes professional system integrators from general panel shops.

The distinction between a generic electrical enclosure and a purpose-built water/wastewater control system lies in the integration of process knowledge. A panel designed for a lift station must account for ragging issues, pump alteration logic, and storm event management. A panel for a potable water booster station must prioritize pressure maintenance, water quality monitoring, and precise flow pacing. Consequently, the “OEM” in this context is often a specialized System Integrator who designs, builds, programs, and commissions the panel. These entities bridge the gap between hardware manufacturers (like PLC and VFD vendors) and the end-user’s operational requirements.

This article provides an in-depth, engineering-focused analysis of the leading System Integrators and OEMs specializing in electrical control panels for the water and wastewater sector. It avoids marketing rhetoric to focus on technical competencies, fabrication standards, and application suitability, ensuring that specifiers can make informed decisions based on lifecycle value and engineering merit.

How to Select Electrical Control Panels and System Integrators

Selecting the right partner for control panel fabrication and system integration is a multi-dimensional engineering challenge. It requires balancing immediate capital costs with long-term operational expenditures (OPEX), technical capability with local support availability, and standardization with customization. The following sections detail the critical technical criteria that engineers and owners must evaluate when specifying control systems.

1. Functional Role and Complexity

The first step in selection is defining the functional scope. Is the project a standalone duplex lift station, or is it a plant-wide SCADA upgrade involving multiple master PLCs and distributed I/O?
Standalone Control: For simple applications, such as small pump stations, the focus is on standardization and simplicity. The panel must provide reliable motor control (via starters or VFDs), basic alternation logic, and robust alarm notification. In these scenarios, SIs with “standard product” lines or configurable templates often offer the best value and lead times.
Complex Integration: For treatment plants or complex distribution networks, the panel is a custom-engineered solution. It must integrate disparate protocols (Modbus, EtherNet/IP, DNP3), manage complex PID loops (e.g., aeration control, chemical dosing), and provide sophisticated HMI visualization. Here, the selection criteria shift heavily toward the SI’s engineering depth, programming standards, and ability to document complex logic.

2. Operating Conditions and Environmental Hardening

Water and wastewater environments are notoriously hostile to electronics. The SI’s ability to design for these conditions is a primary differentiator.
Enclosure Ratings: NEMA 4X (typically 304 or 316 stainless steel) is the industry standard for corrosion resistance and washdown protection. However, in non-corrosive outdoor environments, NEMA 3R or NEMA 4 (painted steel) may suffice. For extreme corrosion (e.g., headworks buildings), fiberglass or polycarbonate enclosures may be specified, though they present challenges regarding heat dissipation and EMI shielding.
Thermal Management: Heat is the enemy of solid-state electronics (PLCs, VFDs, power supplies). SIs must perform detailed heat load calculations. Passive cooling (vents) is rarely sufficient for VFD panels. Active cooling solutions, such as filtered fans, heat exchangers, or air conditioning units, must be sized correctly. Crucially, in wastewater environments, introducing outside air via fans can introduce corrosive gases; therefore, closed-loop cooling systems are often preferred to maintain the NEMA rating and protect internal components.
Condensation Control: Temperature fluctuations cause condensation, which leads to board-level failure. Quality panels include thermostatically controlled anti-condensation heaters. The placement and sizing of these heaters are indicators of a thoughtful design.

3. Reliability, Redundancy, and Safety

Municipal systems are critical infrastructure; downtime can result in environmental violations or public health risks.
Power Reliability: The inclusion of Uninterruptible Power Supplies (UPS) is mandatory for the control circuit (PLC/telemetry). A high-quality SI will size the UPS to maintain monitoring and alarming capabilities for a defined period (e.g., 2–4 hours) during a power outage.
Backup Control: “Hardwired backup” is a philosophical and engineering decision. In the event of a PLC failure, can the station be operated? Quality designs typically include Hand-Off-Auto (HOA) switches and relay-based logic that allow for manual or float-based pump operation independent of the microprocessor. This “dead-front” architecture ensures basic service continuity during catastrophic controller failure.
UL Standards: Adherence to UL 508A is a baseline requirement. However, for wastewater lift stations where methane may be present, adherence to UL 698A (Industrial Control Panels Relating to Hazardous (Classified) Locations) is critical. This involves the correct application of intrinsically safe barriers to limit the energy delivered to sensors in the wet well, preventing ignition sources.

4. Materials, Construction, and Craftsmanship

The longevity of a control panel is directly tied to fabrication quality. This is where the difference between a “garage shop” and a professional SI becomes visible.
Wire Management: Look for ample wire ducting (Panduit) with 20-30% spare capacity. Wiring should be neatly routed, bundled, and secured.
Labeling and Identification: Every wire, terminal block, and component must be labeled with machine-printed tags that correspond exactly to the as-built schematics. Heat-shrink wire markers are superior to adhesive flags, which degrade over time.
Termination Quality: The use of ferrules on stranded wire terminations is a hallmark of quality. Ferrules prevent stray strands from causing short circuits and ensure a gas-tight connection at the terminal block.
Component Spacing: Manufacturers specify minimum clearance distances for heat dissipation and arc flash prevention. Professional SIs adhere strictly to these spacing requirements, even if it means moving to a larger enclosure.

5. Lifecycle Cost and Open Architecture

Engineers must guard against “vendor lock-in.” Proprietary controllers or “black box” code can hold a municipality hostage to a single vendor for maintenance and upgrades.
Open Architecture: The industry standard is to use non-proprietary hardware (e.g., Rockwell, Siemens, Schneider PLCs) and open communication protocols. The SI should provide unlocked source code upon project completion.
Documentation: The deliverable is not just the panel, but the documentation package. This includes full schematics, BOMs, network architecture diagrams, and O&M manuals. Without these, troubleshooting becomes an expensive guessing game.

Comparison Table: Leading System Integrators

The following table compares key Automation System Integrators based on their typical market focus, strengths in the municipal sector, and considerations for lifecycle support. Engineers should use this to align vendor capabilities with specific project profiles, distinguishing between those best suited for massive custom integration versus those optimized for standardized, replicable solutions.

System Integrator	Core Role	Typical Applications	Strengths	Limitations / Considerations	Best-Fit Scenarios
Tesco Controls	Custom System Integrator / OEM	Large-scale water/wastewater plants, regional SCADA, complex lift stations.	Massive manufacturing capacity; comprehensive engineering support; deep expertise in complex PLC/SCADA integration; significant Western US presence.	High demand can affect lead times for smaller projects; premium positioning may impact cost for simple applications.	Major treatment plant upgrades, region-wide SCADA implementation, complex custom logic projects.
Data Flow Systems	Telemetry OEM / Integrator	Remote monitoring, distributed lift stations, rural water districts.	Specializes in telemetry and radio communications; offers “utility-friendly” durable hardware; strong backward compatibility focus.	Often utilizes proprietary hardware/software ecosystems which may limit open-architecture flexibility compared to pure PLC integrators.	Utilities seeking a single-source responsibility for telemetry and SCADA with long-term legacy support.
Dorsett Technologies	SCADA & Controls Integrator	Municipal water distribution, wastewater collection, smart utility management.	Turnkey approach covering hardware, software, and installation; strong focus on intelligent SCADA interfaces and enterprise integration.	Geographic focus tends to be stronger in specific regions; proprietary elements in some turnkey solutions require evaluation.	Municipalities needing a holistic “glass-to-field” solution for distributed assets.
Advanced Integration & Controls (AIC)	Custom Systems Integrator	Industrial wastewater, specialized municipal process control, hazardous locations.	High technical competency in complex logic and process optimization; strong industrial crossover expertise; flexible platform agnosticism.	Smaller scale compared to massive national OEMs, which may limit capacity for concurrent mega-projects.	Projects requiring highly specific, non-standard control logic or challenging industrial process integration.
Primex Controls	Pump Station Control OEM	Lift stations, booster stations, stormwater monitoring.	“Arc Armor” safety features; cloud-based monitoring solutions (Prime Web); highly standardized and configurable panel designs.	Standardized product lines may be less flexible for extremely idiosyncratic legacy plant retrofits.	Municipalities looking to standardize lift station fleets with reliable, repeatable, and safe control panels.
Control Assemblies	Industrial Control Panel Builder	Large-scale process automation, material handling, water treatment.	Exceptional fabrication quality and volume capacity; strong electrical engineering background; strictly agnostic regarding PLC platforms.	Roots in broader industrial automation mean specific municipal civil engineering nuances must be clearly specified.	Large, spec-driven infrastructure projects where high-volume, high-quality panel fabrication is the priority.

Top OEMs / System Integrators: Deep Dive

The following analysis provides a detailed breakdown of the selected System Integrators. This section explores their technical philosophy, manufacturing capabilities, and specific value propositions for the water and wastewater market.

Tesco Controls

Overview: Tesco Controls has established itself as a heavyweight in the water and wastewater automation sector, particularly dominant in the Western United States. They function as both a custom manufacturer and a full-service system integrator, bridging the gap between hardware assembly and high-level software engineering.

Technical Capabilities: Tesco is renowned for its vertical integration. They design and manufacture their own enclosures for specific applications while also serving as a premier integrator for major PLC platforms like Rockwell Automation and Siemens. Their engineering staff typically includes disciplines ranging from electrical power distribution to software architecture.

Application Focus: Tesco excels in projects requiring “total system responsibility.” This includes main plant control panels, power distribution centers, and complex telemetry networks. Their ability to fabricate large walk-in enclosures and integrate Motor Control Centers (MCCs) with PLC sections makes them a preferred choice for large treatment plants.

Engineer’s Perspective: Specifying Tesco often reduces integration risk. Because they handle the panel build, the programming, and the commissioning, the “finger-pointing” that often occurs between panel shops and programmers is eliminated. Their documentation standards are generally high, adhering to rigorous municipal specifications.

Data Flow Systems

Overview: Data Flow Systems (DFS) occupies a unique niche by focusing heavily on the telemetry and remote monitoring aspect of the water industry. Based in the Southeast, they have cultivated a reputation for durability and backward compatibility, addressing the specific pain points of rural and suburban water utilities.

Technical Capabilities: Unlike integrators that strictly use off-the-shelf PLCs, DFS manufactures its own RTUs (Remote Telemetry Units) and SCADA software (HT3), although they also integrate standard platforms. Their “TCU” (Telemetry Control Unit) architecture is designed specifically for the low-bandwidth, high-reliability requirements of water towers and lift stations. They utilize a modular approach that simplifies field maintenance for operators.

Application Focus: DFS is a strong fit for distributed collection and distribution systems where radio communication is the primary link. Their systems are optimized for data integrity over challenging terrain. They offer a “guaranteed” radio path analysis, which removes a significant risk variable for consultants designing remote sites.

Engineer’s Perspective: The decision to use DFS often hinges on the philosophy of open vs. single-source architecture. While their proprietary solutions offer seamless integration and rock-solid reliability, engineers must weigh this against the desire for generic, non-proprietary hardware. DFS mitigates this by ensuring long-term support for legacy products, avoiding the “planned obsolescence” common in the broader tech industry.

Dorsett Technologies

Overview: Dorsett Technologies provides comprehensive SCADA and control solutions with a strong emphasis on intelligent enterprise integration. They focus on turning raw data into actionable intelligence for municipal managers.

Technical Capabilities: Dorsett combines robust panel fabrication with advanced software capabilities. Their InfoScan SCADA software is a hallmark of their offering, designed to be intuitive for water operators. They provide end-to-end solutions, from the sensor in the wet well to the dashboard on the utility director’s tablet. Their panels often feature intelligent controllers that can operate autonomously in the event of communication loss, ensuring process continuity.

Application Focus: They are particularly strong in municipal water/wastewater utility management where “Smart City” concepts are being adopted. Their systems often integrate security, energy management, and process control into a single unified interface.

Engineer’s Perspective: Dorsett is often selected for design-build projects or upgrades where the utility wants a turnkey transformation of their control infrastructure. Their strength lies in simplifying the complexity of modern SCADA for the end user, though specifiers should ensure the underlying hardware meets the project’s long-term non-proprietary goals if that is a constraint.

Advanced Integration & Controls (AIC)

Overview: AIC is a versatile system integrator that brings a rigorous engineering approach to control panel design. While they serve various industries, their application of industrial best practices to water and wastewater projects results in highly robust systems.

Technical Capabilities: AIC is platform-agnostic, with deep expertise in Rockwell, Siemens, and other major automation platforms. Their strength lies in custom logic development for complex biological or chemical processes. They are adept at handling complex PID loops, cascade control, and integrating intelligent instrumentation via fieldbus protocols (EtherNet/IP, Profibus).

Application Focus: AIC is an excellent fit for industrial wastewater treatment plants (pre-treatment) and municipal plants with specialized process technologies (e.g., MBR, RO, Ozone). They thrive in environments where standard “pump up/pump down” logic is insufficient.

Engineer’s Perspective: When specifying a unique process or a retrofit with significant constraints, AIC’s flexibility is valuable. They are known for collaborative engineering, working closely with the process mechanical engineer to ensure the control logic perfectly matches the hydraulic reality.

Primex Controls

Overview: Primex Controls is a dominant force in the standardized pump station control market. They have successfully productized the control panel, offering a balance of customization and standardized reliability that appeals to many municipalities.

Technical Capabilities: One of Primex’s key differentiators is their focus on safety, specifically their “Arc Armor” enclosure system which isolates the low-voltage control compartment from the high-voltage power compartment, reducing arc flash risk for operators. They also offer the Prime Web cloud-based monitoring solution, which provides SCADA-like visibility without the heavy IT infrastructure investment.

Application Focus: Primex is the go-to for lift station standardization programs. Utilities looking to replace aging controls across 50+ lift stations often turn to Primex for a repeatable, high-quality solution that maintenance staff can easily learn and service.

Engineer’s Perspective: Primex panels are specification-friendly due to their widespread acceptance and UL certifications. The Arc Armor feature is a significant selling point for safety-conscious utilities. While they can do custom work, their sweet spot is in their configurable standard product lines.

Control Assemblies

Overview: Control Assemblies brings decades of industrial automation experience to the table. They are a high-volume, high-quality panel builder capable of handling large infrastructure projects with demanding specifications.

Technical Capabilities: As a CSIA (Control System Integrators Association) certified member, Control Assemblies adheres to the highest industry standards for fabrication and business practices. They excel in electrical engineering, offering UL 508A and UL 698A certified panels. Their capacity allows them to handle large batch orders of panels with consistent quality control.

Application Focus: They are well-suited for large-scale municipal expansion projects where multiple diverse panels are required (e.g., blower panels, filter consoles, chemical feed panels). Their background in broader industrial sectors means they bring a high level of rigor to wire management, thermal design, and electrical protection.

Engineer’s Perspective: Control Assemblies is a “builder’s builder.” If the consulting engineer provides a solid design, Control Assemblies will execute it with precision. They are less about proprietary software and more about execution excellence in hardware fabrication and standard PLC programming.

Application Fit Guidance

Selecting the right SI involves matching the vendor’s strengths to the specific project profile. A mismatch here can lead to cost overruns or functional limitations.

Municipal Water Distribution

For water distribution (wells, boosters, tanks), the primary challenge is telemetry—moving data over long distances.
Recommendation: Data Flow Systems and Dorsett Technologies are strong contenders here due to their native focus on telemetry and wide-area SCADA. Tesco is also excellent for larger, complex distribution networks requiring high-end integration.

Municipal Wastewater Collection (Lift Stations)

This application demands corrosion resistance, safety, and reliability in harsh environments.
Recommendation: Primex Controls is a top choice for standardizing fleets of lift stations due to their Arc Armor safety features and specialized pump controllers. Tesco and Data Flow Systems also offer robust solutions for critical lift stations requiring complex bypass pumping logic or specific telemetry integration.

Complex Treatment Plants (Water & Wastewater)

Inside the fence line of a treatment plant, the complexity skyrockets. You need sophisticated logic, integration of MCCs, and high-density I/O.
Recommendation: Tesco Controls and Control Assemblies have the manufacturing capacity and engineering depth to handle large lineups and main plant control centers. AIC is highly effective for specific process areas requiring intricate custom logic.

Industrial Wastewater

Industrial clients (food and beverage, chemical, pharma) often have different standards than municipalities, prioritizing uptime, rapid deployment, and integration with existing plant-wide DCS/PLC systems.
Recommendation: AIC and Control Assemblies are often better suited here due to their cross-industry experience and ability to adapt to non-municipal specifications (e.g., specific brands of components, specialized voltage requirements).

Engineer & Operator Considerations

Even with a top-tier SI, the success of a control panel project relies on proper specification, installation, and lifecycle planning. The following considerations are critical for engineers and operators.

Installation Best Practices

• Conduit Entry: Never allow top-entry conduit for outdoor panels. It is the number one cause of water ingress and component failure. All conduits should enter from the bottom.
• Sun Shields: For outdoor panels, a sun shield (or shade structure) is not a luxury; it is an engineering necessity. Direct solar loading can raise internal temperatures by 20°F–30°F above ambient, causing nuisance tripping of VFDs and shortening PLC life.
• Sealing: Expanding foam or duct seal must be used inside conduits entering the panel to prevent corrosive gases (from wet wells) and moisture from migrating into the enclosure.

Integration and Commissioning

• FAT (Factory Acceptance Test): Engineers should mandate a witnessed FAT. This is not just a visual check. It should involve powering up the panel, simulating inputs (4-20mA signals), forcing outputs, and verifying the logic sequence before the panel leaves the shop.
• Loop Checks: During commissioning, every single I/O point must be “loop checked” from the field device to the SCADA screen. Documenting this process is essential for liability and baseline performance.

Maintenance and Spare Parts

• Standardization: Operators should push for standardization of components (relays, power supplies, PLCs) across the facility. This reduces the spare parts inventory value.
• Accessibility: Designs should ensure that fuses and breakers are accessible without reaching over exposed live busbars. Finger-safe terminals (IP20) should be mandatory.
• Documentation Pockets: A durable, high-impact plastic print pocket should be welded or adhered to the door, containing laminated copies of the schematic and the bill of materials.

Conclusion

The electrical control panel is the interface where engineering design meets operational reality. It is the component that operators touch and interact with daily. Consequently, the selection of a System Integrator is a decision that reverberates through the lifecycle of the facility.

Top-tier OEMs like Tesco Controls, Data Flow Systems, Dorsett Technologies, AIC, Primex, and Control Assemblies each offer distinct value propositions. For the consulting engineer, the task is to write specifications that enforce quality (UL standards, NEMA ratings, component grades) while selecting a partner whose core competencies align with the project’s complexity. For the owner and operator, the focus must remain on maintainability, safety, and open architecture.

By prioritizing engineering rigor over the lowest initial bid, utilities ensure that their control systems remain robust, safe, and supportable, safeguarding public health and the environment for years to come.

source https://www.waterandwastewater.com/top-oems-for-electrical-control-panels-in-water-wastewater/