Originally awarded to Earth Tech in 2005, McKay’s involvement in the project began in 2009, delivering the electrical, control and instrumentation portion of the works for the main treatment plant and 13 associated sewerage pump stations. Over the course of the project, the principal contractor evolved through several organisations including WI Group, Pentair and Trility, with the plant now operating as part of Kaipara District Council’s three waters infrastructure under the management of Ventia.
McKay was involved from the early stages of the project, contributing to the electrical and control concept design, including development of the control philosophy and switchboard design. This was followed by detailed design, installation, testing and commissioning of the complete electrical, control and instrumentation systems. The scope incorporated the delivery of custom-designed switchboards, programmable logic controller (PLC) systems, SCADA and historian platforms, telemetry systems, instrumentation and motor control infrastructure.
The control system architecture was designed to maximise operational efficiency and reliability while reducing installation complexity. For the main treatment plant, McKay implemented a smart communication-based control structure that significantly reduced field wiring requirements. The pump station switchboards were specifically engineered for the project with a strong emphasis on durability, operational accessibility and ease of maintenance in all weather conditions.
The completed system incorporated Prisma and Cubic switchboards, Schneider Premium PLCs with Advantys I/O for the main plant, Kingfisher CP11 RTUs for outstations, Citect SCADA and Historian platforms, DNP3 telemetry communications, Schneider switchgear and speed drives, and Endress & Hauser instrumentation. The integration of these systems provided a robust and highly functional control environment capable of supporting the long-term operation of the wastewater treatment network.
Following completion, McKay continued its involvement with the facility as the maintenance contractor for the control systems, supporting ongoing optimisation, reliability and asset performance. This long-term relationship reflects McKay’s capability in delivering complex water and wastewater infrastructure projects and providing ongoing technical support for critical community assets.
Delivered on time and within budget, the Mangawhai Wastewater Treatment Plant project demonstrates McKay’s expertise in electrical engineering, industrial automation and infrastructure delivery, as well as its ability to work collaboratively across evolving project teams and operational stakeholders to achieve successful project outcomes.
