BGEN Delivers Major Upgrade for Ayr Shore Road WwPS as Part of WGM-B JV

BGEN is delighted to share that as part of the WGM-B JV partnership another successful capital works project has been completed. At Ayr Shore Road WWPS, BGEN carried out an extensive overhaul of the site due to obsolescence site wide. From scope development through to commissioning and handover, BGEN under CDM were appointed as both the Principal Designer and Principal Contractor.

Project Overview

Effective wastewater management in South Ayr is critical to maintaining water quality and infrastructure resilience. BGEN has delivered a comprehensive upgrade which has been designed to modernise control systems, enhance operational reliability, and future-proof the site. Key elements of the upgrade include:

SCADA and Network Modernisation:

· Installed a new SCADA server panel and UPS to ensure system stability and power redundancy.

· Developed an updated SCADA and network Functional Design Specification (FDS) to align with current standards.

· Deployed a site-wide fibre network with a dedicated communications panel, significantly improving data throughput and system connectivity.

Advanced PLC and HMI Integration:

· Replaced legacy Allen-Bradley PLCs with modern units using conversion kits, reducing on-site installation time and minimising operational disruption.

· Integrated a ProSoft Ethernet/IP to Modbus Serial Gateway module to enable seamless protocol bridging.

· Installed new Rockwell HMIs to enhance operator interface, diagnostics, and control capabilities.

Telemetry and Sludge Grinder System Overhaul:

· Decommissioned obsolete telemetry PLCs and installed new Modbus-compatible modules for improved data acquisition.

· Upgraded sludge grinder control systems with new PLC assemblies and custom enclosures to boost reliability and maintainability.

Seamless Migration and Installation:

· Developed a detailed migration strategy based on thorough on-site verification.

· Removed outdated control panels and redundant cabling.

· Installed new containment and cabling infrastructure to support clean integration and facilitate future system expansion—with minimal disruption to ongoing operations.

Benefits and Expected Outcomes

The upgrade significantly modernised and improved the performance of the WWPS. Through strategic planning and BGEN’s technical expertise, the transition from outdated, non-compliant equipment to a modern, user-friendly asset was executed safely, smoothly, and successfully delivering long-term value for Scottish Water on the West Coast.

As illustrated in the diagrams above, BGEN conducted a thorough review and update of the ICA schematics during the PLC replacement. This ensured a clean, accurate set of drawings that will support future upgrades within the MCC.

Given the nature of the project—replacing obsolete equipment—BGEN also undertook comprehensive removal works, including the extraction of redundant cabling. New containment systems were installed to improve accessibility and streamline future maintenance. The before-and-after diagrams above clearly demonstrate the transformation achieved through these works.

Following a successful migration phase, Scottish Water and BGEN reviewed the existing process and produced several software enhancements that would bring elements of the software in line with the latest Scottish Water specification requirements. It was not only software BGEN were able to upgrade, although local LCPs were replaced with a like for like replacement, watchdogs and fail-safe logic was designed and delivered to allow effective monitoring of the plant.