Obsolete PLC Module Replacement for UK Water Utility

Challenge

A regional UK water treatment facility relied on a Siemens S5 PLC rack out of production for over 15 years, and when a critical CPU module failed, they faced regulatory non‑compliance unless restored within 14 days.

Solution

Our sourcing team scoured surplus networks across Germany, Austria, and the Netherlands to locate the exact CPU and I/O cards, then bench‑tested each in our London lab to simulate the plant’s control logic. After consolidating the modules with spare kits, we exported them from the Netherlands and arranged next‑day air delivery to Manchester, where our PLC expert guided local engineers via secure VPN through rack replacement and system validation.

Result

The system was restored on Day 12, maintaining continuous water treatment, and the customer saved 40% compared to an OEM upgrade, as well as an estimated £30,000 in downtime penalties.

Facing a similar equipment challenge?

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