Corrosion-Resistant Pump Station Control for Coastal Water Infrastructure

Sector: Water & Wastewater
Application: Sewer and stormwater pump station controls
Location: Australian coastal city

Background
A municipal water authority needed to modernise pump station controls along a coastal corridor. Existing mild-steel enclosures had suffered from corrosion, internal condensation, and component failures due to salt-laden air and high humidity.

Challenges

  • Continuous exposure to salty coastal air and wind-driven rain required high-grade stainless steel and robust IP66 sealing.
  • Internal condensation at night and during winter led to recurrent failures of control relays and communication hardware.
  • Limited space at existing sites demanded compact footprints and flexible mounting arrangements.
  • The authority required full compliance with IEC/EN 62208, IEC/EN 61439 and IEC/EN/AS 60529 for low-voltage assemblies.

Solution

The design team selected IP Enclosures stainless steel enclosures in grade 316L with IP66 and IK10 ratings for all external pump station and telemetry panels.

Key design features included:

  • Single-door stainless steel cabinets sized to accommodate VFDs, PLCs, and telemetry while remaining serviceable inside small pump compounds.
  • Anti-condensation heaters and thermostatic control installed in all stations, maintaining internal temperatures above dew point and preventing moisture accumulation on electronics.
  • IP-rated cable glands, gland plates, and stainless mounting hardware to maintain system integrity.

Products Used

  • SS1 stainless steel electrical enclosures, IP66 IK10, grade 316L for wall-mounted single-door pump control panels.
  • Anti-condensation heaters and climate-control accessories integrated per IP Enclosures’ catalogue guidance.

Results

  • Elimination of condensation-related failures across upgraded stations, with dramatically fewer site callouts in winter months.
  • Significant increase in enclosure life, with stainless cabinets performing reliably in locations where painted mild-steel previously required frequent replacement.
  • Standardised enclosure layouts and accessories simplified asset documentation and streamlined new project roll-outs along the coastal corridor.