Top System Integrators for Water & Wastewater Automation

Introduction

In the modern municipal water and wastewater landscape, the System Integrator (SI) occupies a critical role that transcends simple equipment supply. Unlike pump manufacturers or valve suppliers who provide discrete mechanical assets, the SI is responsible for the facility’s central nervous system—the Supervisory Control and Data Acquisition (SCADA) system, Programmable Logic Controllers (PLCs), Human Machine Interfaces (HMIs), and the telemetry networks that bind geographically dispersed assets together.

For consulting engineers, public works directors, and plant superintendents, the selection of a System Integrator is arguably one of the most consequential procurement decisions in the lifecycle of a utility. The automation system dictates the operational efficiency, regulatory compliance, data integrity, and cybersecurity posture of the entire treatment and distribution infrastructure. An effectively integrated system provides operators with real-time situational awareness, predictive maintenance capabilities, and automated responses to process variables. Conversely, a poorly executed integration project can lead to chronic alarm fatigue, proprietary vendor lock-in, unstable control loops, and vulnerabilities to cyber-physical attacks.

The scope of work for an SI in water and wastewater applications typically includes the design and fabrication of UL-listed control panels, the programming of PLC logic according to process control narratives, the configuration of SCADA software, and the commissioning of complex communication networks ranging from fiber optics to licensed radio frequencies. This equipment operates in harsh environments—often characterized by high humidity, corrosive gases (such as hydrogen sulfide), and varying temperatures—requiring robust industrial-grade hardware and impeccable fabrication standards.

Furthermore, the industry is currently undergoing a significant shift toward “Smart Water” technologies and the convergence of Operational Technology (OT) with Information Technology (IT). Integrators are no longer simply wiring relays; they are architecting secure Ethernet networks, implementing historical databases for regulatory reporting, and configuring remote access solutions that allow operators to monitor lift stations and booster pumps via mobile devices. This evolution places a premium on SIs that possess a dual competency in traditional electrical engineering and modern software development.

The decision-making process is further complicated by the tension between “open architecture” and “proprietary solutions.” Engineers must weigh the benefits of customized, single-source responsibility against the long-term flexibility and competitive bidding potential of non-proprietary hardware. This article provides a comprehensive technical analysis of the leading System Integrators serving the water and wastewater sector, evaluating their methodologies, technical capabilities, and suitability for various municipal applications.

How to Select a System Integrator

Selecting a System Integrator for water and wastewater projects requires a rigorous evaluation of technical competency, project management methodology, and long-term support capabilities. Unlike purchasing a piece of machinery where the specification is defined by physical performance curves, hiring an SI is akin to selecting a technology partner for the lifetime of the control system. The following criteria are essential for engineering specifications and utility decision-making.

1. Open vs. Proprietary Architecture Philosophy

The most fundamental strategic decision in selecting an SI is determining their approach to hardware and software openness.

• Open Architecture: SIs that specialize in open architecture utilize non-proprietary hardware (e.g., standard PLCs from major global manufacturers) and commercially available SCADA software. The programming code is typically owned by the utility upon project completion. The advantage is that the utility is not tied to the original SI for future modifications; any qualified integrator can service the system.
• Proprietary/Single-Source: Some SIs manufacturer their own Remote Telemetry Units (RTUs) and develop their own SCADA software. This “bundled” approach often offers seamless integration and simplified troubleshooting because one entity controls the entire stack. However, it creates a vendor-lock situation where the utility relies exclusively on that specific SI for parts, upgrades, and support.

Engineers must explicitly define the requirement for “non-proprietary hardware” in Division 25 or Division 40 specifications if vendor independence is a priority.

2. Telemetry and Network Engineering

Water and wastewater systems are inherently distributed. A central treatment plant must communicate with remote lift stations, water towers, and booster stations. The SI’s ability to design robust telemetry networks is paramount.

• Radio Telemetry: Requires expertise in propagation studies, path analysis, and FCC licensing. SIs must understand the nuances of licensed (UHF/VHF) vs. unlicensed (Spread Spectrum) radios.
• Cellular/VPN: As carriers phase out older networks (2G/3G), SIs must demonstrate competence in modern LTE/5G private APN configurations that secure utility data from the public internet.
• Fiber/Ethernet: For plant-wide networks, the SI must be proficient in designing redundant fiber rings (e.g., Device Level Ring or Rapid Spanning Tree Protocol) to ensure single points of failure do not sever communications.

3. Panel Design and Fabrication Standards

The physical quality of the control panel directly impacts reliability. SIs should operate UL 508A (or UL 698A for hazardous locations) certified panel shops.

• Thermal Management: Panels located outdoors in direct sunlight require active cooling or heat exchangers. The SI must perform heat load calculations to size these components correctly to prevent VFD and PLC failure.
• Corrosion Protection: In wastewater headworks or lift stations, H2S gas attacks copper circuitry. SIs should specify NEMA 4X (Stainless Steel or Fiberglass) enclosures and potentially conformal coating for electronic boards.
• Wire Management: High-quality SIs distinguish themselves through meticulous wire labeling, separation of high-voltage and low-voltage signal cables (to prevent noise interference), and the use of finger-safe components.

4. Software Development and Programming Standards

The “logic” of the plant resides in the PLC code. Poorly written code is a liability.

• Standardization: Does the SI use standard function blocks and Add-On Instructions (AOIs)? If the code is “spaghetti logic” (unstructured and messy), troubleshooting will be expensive and slow.
• Tag Naming Conventions: The SI should adhere to a consistent tagging standard (often defined by the utility or the consulting engineer) that makes it easy to identify variables across the PLC and SCADA.
• Documentation: The deliverable must include fully annotated PLC code and unlocked HMI applications. “Black box” programming, where the utility does not have administrative access to the code, should generally be avoided in municipal specifications.

5. Cybersecurity Competence

With the rise of ransomware attacks on municipal infrastructure, the SI is the first line of defense.

• Network Segmentation: Implementing DMZs (Demilitarized Zones) to separate the business network (Enterprise) from the control network (SCADA).
• Access Control: Configuring strong authentication, managing user privileges, and disabling unused physical ports on switches.
• Standards Compliance: Familiarity with ISA/IEC 62443 standards and AWIA (America’s Water Infrastructure Act) compliance requirements.

6. Project Management and Commissioning

The SI’s process for executing the project is as important as their technical skill.

• Submittals: Producing detailed wiring diagrams, loop drawings, and BOMs for engineer review before fabrication begins.
• Factory Acceptance Testing (FAT): Staging the entire system in the shop to simulate inputs/outputs and verify logic before shipping. This minimizes downtime during onsite startup.
• Site Acceptance Testing (SAT): The formal process of verifying the installed system against the Control Narrative in the field.
• Cutover Planning: A critical capability for retrofit projects. The SI must demonstrate a plan to migrate from the old system to the new system with minimal interruption to plant processes.

Comparison Table

The following table compares the top System Integrators based on their core operational models, typical application scales, and distinguishing characteristics. Engineers should interpret “Model” to understand whether the company primarily acts as a custom integrator of third-party hardware or a provider of proprietary/standardized solutions.

System Integrator	Core Role	Typical Applications	Strengths	Limitations	Best-Fit Scenarios	Lifecycle Considerations
Tesco Controls	Design-Build Systems Integrator & OEM	Large municipal plants, regional distribution, traffic/water convergence.	Large-scale capacity, combines power distribution (switchgear) with controls, extensive design-build experience.	May be over-qualified/expensive for very small, single-pump applications.	Major plant upgrades requiring both power and automation; Alternative Delivery projects.	Strong long-term support; focuses on major hardware platforms (Rockwell/Siemens/Schneider).
Data Flow Systems (DFS)	Proprietary OEM & Solution Provider	Remote telemetry, wide-area SCADA networks, lift station monitoring.	Single-source responsibility, proprietary “TAC II” robust telemetry, backward compatibility guarantee.	Proprietary hardware creates vendor dependency; harder to bid out maintenance to third parties.	Utilities seeking a “set it and forget it” telemetry network with unified hardware/software support.	Excellent “forever” support for their own products, but migration away requires full replacement.
Dorsett Technologies	SCADA System Integrator	Municipal water/wastewater, federal/military facilities, smart city integration.	Strong focus on InfoScan SCADA software, integrated building management & HVAC with water controls.	Geographic concentration in Southeast/East Coast; proprietary software elements.	Municipalities needing integrated SCADA for both water utilities and building facilities.	Service-oriented model with strong regional field support.
Advanced Integration & Controls	Custom Systems Integrator	Industrial wastewater, complex process control, municipal retrofits.	Deep technical expertise in logic conversion, legacy migration, and complex process loops.	Focus is purely integration; does not manufacture power equipment or proprietary telemetry hardware.	Complex retrofit projects requiring deep knowledge of legacy PLC platforms and custom coding.	Platform-agnostic support; typically delivers open code for easy future maintenance.
Primex Controls	Panel OEM & Cloud Integrator	Pump stations, lift stations, standardized water applications.	Cloud-based “icontrol” monitoring, standardized pump control panels, efficient fabrication.	More product-focused than custom plant engineering; less focus on massive plant DCS.	Distributed networks of lift stations; utilities wanting cloud-based remote monitoring without IT overhead.	Simplifies remote monitoring via subscription models; hardware is widely supportable.
Control Assemblies	Industrial Control Panel Manufacturer & SI	Process automation, material handling, water treatment.	High-volume UL panel fabrication, robust industrial design standards, diverse industry experience.	Roots in broader industrial automation, bringing factory-floor rigor to water applications.	Projects requiring high-quality custom panel fabrication and straightforward PLC integration.	Reliable fabrication quality reduces physical maintenance; standard components used.

Top System Integrators

Tesco Controls

Tesco Controls establishes itself as a heavyweight in the water and wastewater automation sector, particularly known for its “power and control” philosophy. Unlike many integrators that strictly focus on the low-voltage control side (24VDC to 120VAC), Tesco has significant capabilities in manufacturing and integrating power distribution equipment, including switchgear and motor control centers (MCCs). This capability allows them to provide a consolidated solution where the power distribution and the automation logic are engineered by a single entity, reducing the risk of interface conflicts between the electrical contractor and the systems integrator.

Technically, Tesco is largely platform-agnostic regarding PLCs, frequently deploying major platforms such as Rockwell Automation (Allen-Bradley), Siemens, and Schneider Electric (Modicon), depending on the client’s existing install base or engineering specification. Their approach to SCADA is similarly flexible, supporting Wonderware, Ignition, and FactoryTalk View.

Tesco is particularly adept at the “Design-Build” and “Construction Manager at Risk” (CMAR) delivery methods. In these scenarios, they collaborate early with the civil/mechanical contractors and the utility to design the system, rather than simply bidding on a finished design. This makes them a preferred partner for large-scale municipal plant expansions and greenfield water treatment facilities where coordination between power feeds, backup generation, and process control is critical. Their panels are built to strict UL standards, and they maintain a large field service fleet for startup and commissioning.

Data Flow Systems

Data Flow Systems (DFS) occupies a unique niche in the market by operating as a true OEM of telemetry hardware and software, rather than purely an integrator of third-party components. Based in Florida, DFS is best known for its TAC II telemetry system and the Hyper-TAC SCADA software. Their philosophy centers on the challenge of obsolescence. In the standard PLC world, manufacturers frequently phase out hardware series, forcing utilities into expensive upgrade cycles. DFS counters this by guaranteeing backward compatibility for their RTUs, often allowing 20-year-old modules to communicate on the same network as modern units.

The technical differentiator for DFS is their radio telemetry technology. They utilize a narrow-band, packet-switching protocol designed specifically for the low-bandwidth, high-reliability requirements of water/wastewater networks. This approach often yields superior communication stability in difficult terrain compared to generic Modbus-over-radio implementations.

However, engineers must recognize that specifying DFS often involves committing to a proprietary ecosystem. While the system is highly integrated and robust (single source for software, RTU, and radio), it does not offer the “open architecture” interchangeability of a standard Allen-Bradley or Siemens PLC. For utilities that value “one throat to choke” for support and long-term hardware stability over open competition for parts, DFS is a strong contender. Their “Symphony” product line attempts to bridge this gap by offering compatibility with open protocols while maintaining their core reliability features.

Dorsett Technologies

Dorsett Technologies is a prominent integrator with a strong footprint in the Southeastern United States, serving municipal, federal, and military clients. Their core strength lies in their holistic approach to “Smart City” integration. While they are deeply rooted in water and wastewater SCADA, they frequently bridge the gap into Building Management Systems (BMS) and HVAC controls, providing a unified view of municipal infrastructure that extends beyond just the treatment plant.

Dorsett utilizes their InfoScan SCADA software, a platform designed to be intuitive for operators while providing powerful historical data analysis tools. Their engineering teams are experienced in designing complex control loops for water treatment plants and wastewater reclamation facilities.

One of Dorsett’s key technical strengths is their “intelligent” RTU configurations, which distribute control logic to the edge. This ensures that remote sites (like lift stations or well houses) maintain autonomous operation even if communication with the central SCADA host is lost. They offer comprehensive lifecycle services, including panel fabrication, software configuration, electrical installation, and ongoing maintenance contracts. For municipalities looking for a partner that understands both the IT requirements of modern SCADA and the electromechanical realities of pumps and valves, Dorsett provides a balanced, service-heavy approach.

Advanced Integration & Controls

Advanced Integration & Controls (AIC) functions as a classic, high-competency systems integrator, focusing heavily on the customization and complex logic required for sophisticated treatment processes. Unlike OEMs that push a specific product line, AIC operates as a consulting-style integrator, tailoring the hardware and software selection strictly to the engineering requirements of the project.

AIC is frequently selected for challenging retrofit projects where legacy systems (such as old TI, Modicon 984, or PLC-5) need to be migrated to modern platforms like ControlLogix or S7-1500 without interrupting plant operations. This requires a deep understanding of legacy code structures and the ability to “reverse engineer” undocumented logic.

Their expertise extends to industrial pretreatment and complex biological nutrient removal (BNR) systems where the process control variables are non-linear and require PID loop tuning expertise. AIC is known for delivering “open” systems; they typically provide the client with fully annotated, unencrypted source code, empowering the utility to maintain ownership of their system. This transparency makes them a favorite among engineering consultants who prioritize specification compliance and long-term flexibility for their municipal clients.

Primex Controls

Primex Controls has carved out a significant market share by standardizing the control of water and wastewater assets, particularly for lift stations and distribution pumps. While they are fully capable of custom plant integration, they are widely recognized for their “icontrol” product family—a cloud-based SCADA solution that simplifies remote monitoring for small to medium-sized utilities.

The Primex value proposition often centers on reducing the IT burden for the utility. Traditional SCADA requires on-premise servers, static IP addresses, and complex firewall management. Primex’s cloud architecture allows operators to monitor levels, flows, and pump status via secure web portals and mobile apps without maintaining heavy on-site server infrastructure.

From a hardware perspective, Primex is a volume manufacturer of control panels. Their standardized designs for duplex and triplex pump stations allow for cost-effective, rapid deployment. They integrate VFDs and soft starters into NEMA-rated enclosures with consistent build quality. For utilities managing vast networks of distributed lift stations, Primex offers a scalable solution that standardizes the operator interface and hardware platform, simplifying spare parts inventory and training.

Control Assemblies

Control Assemblies brings a broad industrial pedigree to the water and wastewater market. With over 50 years of experience, their roots in diverse industrial automation (including food & beverage and material handling) translate into a rigorous approach to control panel fabrication and system architecture.

Their strength lies in their fabrication capabilities. Control Assemblies operates large-scale UL-certified panel shops that can handle high-volume production as well as massive, custom multi-bay enclosures. For water treatment plants, this ensures that the physical infrastructure of the control system—the wiring, thermal management, and layout—meets the highest industrial standards.

On the integration side, Control Assemblies is platform-neutral, with deep expertise in Rockwell Automation, Siemens, and other major PLCs. They are particularly effective in projects that require integration of disparate equipment packages. For example, a large wastewater plant might have a blower package, a centrifuge, and a UV system, all coming from different mechanical OEMs with different PLCs. Control Assemblies excels at acting as the master integrator, networking these “islands of automation” into a cohesive plant-wide SCADA system. Their focus is on reliability, code standardization, and providing robust documentation packages that facilitate easy maintenance.

Application Fit Guidance

Selecting the right integrator depends heavily on the specific nature of the application. The “best” integrator for a massive reclamation plant may not be the most cost-effective or agile choice for a rural water district with ten lift stations.

Municipal Treatment Plants (Water & Wastewater)

For central treatment plants, the complexity of the process requires an integrator with deep process knowledge and the ability to handle thousands of I/O points.

• Best Fit: Tesco Controls, Control Assemblies, Advanced Integration & Controls.
• Why: These companies have the engineering depth to manage complex P&IDs, implement redundancy (hot-standby PLCs), and coordinate with multiple mechanical vendors. Tesco is particularly strong if the project involves significant electrical switchgear work alongside controls.

Remote Telemetry and Lift Station Networks

For networks consisting of geographically dispersed assets (lift stations, wells, elevated tanks) where communication reliability is the primary challenge.

• Best Fit: Data Flow Systems, Primex Controls, Dorsett Technologies.
• Why: DFS excels here due to their robust radio telemetry capabilities. Primex is ideal for utilities wanting a cloud-based, low-IT-overhead solution. Dorsett provides a strong integrated SCADA solution for regional monitoring.

Retrofits and Legacy Migrations

For projects involving the replacement of obsolete controls in an active plant where downtime must be measured in minutes, not days.

• Best Fit: Advanced Integration & Controls, Tesco Controls.
• Why: These scenarios require custom engineering and “hot cutover” planning. The integrator must be able to write code that mimics the old system’s behavior while introducing modern features, requiring deep software expertise.

Small to Medium Municipalities

For towns and districts with limited engineering staff that need a reliable, turn-key partner to manage everything from the panel to the screen.

• Best Fit: Dorsett Technologies, Primex Controls.
• Why: These companies often offer a service-heavy model that relieves the municipality of complex system administration duties.

Engineer & Operator Considerations

Regardless of the System Integrator selected, engineers and operators must prioritize specific elements during the project lifecycle to ensure long-term success.

Installation and Commissioning

The most common point of failure in automation projects is the interface between the field wiring and the control panel. Engineers should specify that the System Integrator must perform “Loop Checks” (verifying the signal from the field instrument to the SCADA screen) for 100% of the I/O points. Sampling is not acceptable. Furthermore, the SI should be contractually obligated to be on-site during the “7-Day Performance Test” to immediately address code bugs or tuning issues.

Maintenance Access and Documentation

Operators must insist on a “System Administration Manual” distinct from the O&M manual. This document should detail IP addresses, usernames/passwords (including default manufacturer passwords which must be changed), software license keys, and backup procedures.

Spare Parts Strategy: The specification should require the SI to provide a list of critical spares (PLC processor, power supply, communication cards, I/O modules). For proprietary systems (like DFS), the utility must budget for sole-source procurement. For open systems (like Control Assemblies or Tesco typically install), parts can be sourced from local electrical distributors.

Long-Term Support and Training

Training should be bifurcated: “Operator Training” focused on navigation, setpoints, and alarms, and “Maintenance Training” focused on hardware troubleshooting, module replacement, and software backups. It is highly recommended to include a block of “Post-Commissioning Support Hours” (e.g., 40 to 80 hours) in the contract. This allows the utility to call the SI back 3-6 months after startup to make minor logic adjustments or graphic changes once the operators have settled into the new system.

The “Black Box” Risk

A critical consideration for engineers is ensuring the utility owns the application source code. The contract must explicitly state that all PLC programs, HMI applications, and configuration files are “Works Made for Hire” and are the property of the utility. The SI should deliver these files on digital media at project closeout. This prevents the utility from being held hostage by an integrator who refuses to release the passwords or source code required for another vendor to service the system.

Conclusion

The selection of a System Integrator for water and wastewater automation is a strategic partnership that defines the operational capability of the utility for decades. There is no single “best” integrator; the right choice depends on the specific balance between custom engineering vs. standardized products, and open architecture vs. proprietary reliability.

Firms like Tesco Controls and Control Assemblies offer robust, open-architecture solutions ideal for complex, heavy-civil infrastructure. Data Flow Systems provides a distinct, highly reliable proprietary alternative for telemetry-heavy networks where communication stability is paramount. Dorsett Technologies and Primex Controls offer specialized strengths in regional SCADA and cloud-based monitoring, respectively, while Advanced Integration & Controls excels in the intricate details of process logic and legacy migration.

Engineers must craft specifications that clearly define the required architecture, testing protocols, and documentation standards. By doing so, they ensure that the selected SI delivers not just a control panel, but a resilient, secure, and operator-friendly system that safeguards public health and the environment.

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