Problems solved.

Customer Stories

Tulsar Canada works with clients from municipalities to major petrochemical companies to help solve their complex water control system challenges. Often when a company seeks out Tulsar Canada, it’s because there’s no off-the-shelf product which meets their needs, or the existing product on the market won’t work in the hazardous or hostile conditions present.

That’s where our expert team of engineers, technologists, and fabricators come in. We provide a comprehensive analysis, and design a tailored solution unique to each customer’s needs. Here are just a few cases where Tulsar Canada took on some of the most challenging design problems:


Protecting Clean Water for Communities

Tulsar Canada control panels help ensure Canadian communities have clean drinking water. A remote mining community in Nunavut draws all of its potable water from a nearby lake. The local water treatment plant ensures the water is safe for drinking, but if the operating system at that water plant were to fail, the health and safety of the entire community would be at risk. That’s exactly what happened. Tulsar was called in to restore operation and ensure the community had safe drinking water.

The computer operating system of the panel that controlled the valves and pumps drawing water in the treatment plant crashed. The original supplier was unable to address the problem, and Tulsar Canada was commissioned by the Territorial Government through one of Tulsar’s biggest customers, to find a solution. Tulsar was required to:

  • Arrive in Nunavut as soon as possible.
  • Identify whether the problem was a software or hardware issue.
  • Reboot and repair the system, and install protection against future crashes
Within 24 hours of the call, our engineers had gathered typical spare parts that could be required, identified solutions within the software to reboot the operating system of the control panel and were on site making the required repairs.

Faulty parts were replaced and the system was repaired and restarted. This work included a test to ensure the problem wouldn’t re-occur and an assessment of the entire system to identify future problems that may arise.

Tulsar Canada also installed a fix to the programming that will allow the system to self recover in the event of a future crash, with a specialized code to instruct the processor to restart itself should a similar fault occur, which should clear any bugs and allow the system to continue running safely and smoothly.

Besides ensuring community residents continue to have access to clean water, the solution implemented by Tulsar Canada is a protection against future failures. The effort also provided a list of future hardware and software upgrades that will further protect the integrity of the system.

Among the recommendations is the installation of a remote modem that will allow our engineers to address problems in the system — whether troubleshooting or fixing faults in the programming — remotely from anywhere there is an Internet connection.

Custom pump and water control solutions

Making Tough Problems Simple

Tulsar Canada worked with a customer who was sending divers with special equipment into a well to determine successful insertions and extractions. The well was both deep and wide, making it difficult to confirm correct engagements and disengagements. The well was also located in an area with explosion risk (Class 1 Hazardous Area) requiring significant precautions. Tulsar got the job done right.

The circumference of the well was significant, requiring a system that could reach out over the hole to place the assembly in the center of the bore. There was more:

  • The depth of the wet well was 100 feet (30 m) from the surface.
  • The area was classified as a Class 1 Division 1 (Constant Gas/Vapor Explosive Risk).
  • We needed to build a system with a low amp draw as it would be powered by a portable generator.
Given the size of the well, Tulsar fabricated a retractable boom that could easily get the control assembly to the center of the well. We also put the unit on wheels to make it easier to move around. In addition, we also:

  • Added intrinsically safe relays, allowing the safe operation of the equipment in an area with explosive vapor hazards (Class 1 Division 1).
  • Used special slip rings and limit switches for the low voltage application.
Our customer no longer requires the services of expensive divers with special equipment to go to the bottom of the well to confirm the engagement or disengagement of the assembly. The device we created provides instant confirmation of a successful insertion or extraction.
Water and Wastewater control solutions

Unique Solutions or Unique Needs

Tulsar specializes in custom designed control panels that solve unique problems. Tulsar recently worked with a municipality that experienced flood risks from a local canal. It was costly to hire staff to manually monitor the water level in the canal, and call in other staff on overtime in the event of a flood. The municipality called in Tulsar Canada to solve their problem. Our creative solution saved them tens of thousands of dollars.

The municipality was located on an island, and a local canal in the area was at flood risk. We needed to:

  • Minimize the need for staff monitoring, and to call out staff on overtime during flooding events.
  • Optimize the recording of operating data (levels, cycles, run times, faults, etc.).
  • Operate year round, including during cold winter months when temperatures drop significantly below zero.
In an effort to reduce staffing costs without endangering public safety, we created an automated system to regulate the water level in the canal and around the island.

  • The operating interface shows current trending data.
  • A bubbler system protects the stiller tube from freezing
  • Autodiallers were installed as a backup if personnel are required to be called out for a major event.
The custom-designed solution met all of the client’s needs. With its internal and mechanized system of checks and balances, the control panel significantly reduced the number of staff called out – and the overtime being paid – during flood events by the municipality.

Modern Solutions to Age-Old Problems

Tulsar Canada specializes in tailoring unique solutions to unique problems experienced by our clients. Many municipalities in Canada have aging infrastructure, and quite common in these cities and towns are underground pipes that carry both rainwater and sewage to a treatment plant. Known as combined sewers, they start to show their age when new development and growth in older urban areas exceeds their capacity, raising the risk of flooding and backups. An Ontario municipality faced such a situation when a new provincial government building tapped into a combined sewer line that was close to capacity.

The threat of raw sewage spilling in the neighbourhood was real. The stop-gap measure was to bus staff off site when they had to use the washroom. Tulsar was asked to:

  • Conceive a solution that would allow wastewater from the building to safely flow into the municipal combined sewer pipes.
  • Ensure staff in the building could use the washrooms in the building.
  • Protect against the risk of future sewage spills.
We designed a control panel to divert sewage from the building into a holding tank, where it is stored until there is capacity in the city’s forcemain combined sewer line.

When the wastewater level in the forcemain drops to a safe and acceptable level, the control panel diverts material from the holding tank into the sewer line. The panel also monitors the level in the holding tank, and not only pumps it out when safe, it also flushes and cleans the tank to ensure optimum operation.

Provincial staff working in the building are now able to use the washrooms in their facility without having to go offsite, and the municipality is comforted knowing that wastewater from the building is being safely managed with minimal risk of flooding.
In the event of a Century Storm coinciding with the building’s holding tank being full, the panel will shut down the system and alert security to shut down the washrooms. This would be a rare occurrence, but is built into the logic of the panel as a protection.
Heavy Industrial Pumping

Driving Industrial Solutions

Tulsar Canada control panels are helping hundreds of industrial and manufacturing companies around the world better manage their operations.  One of our manufacturing clients creates complex industrial systems for the fabrication of various products, including rotoform pastillation, a system using a heated drum and conveyor belt to make things like pet food pellets, plastics, dryer pellets, make up, soap — even flash freezing shrimp at a cannery.

The key to the Rotoform Pastillation System is timing and temperature. If it runs too hot, the product will be slurry. Too cold and the system will jam. If the heated drum and conveyor belt are not in perfect synchronization, the process will fail. Working with the client, Tulsar Canada was asked to:

  • Perform a safety audit to assess hazards in the existing system.
  • Design a solution to address shortcomings identified in the audit.
  • Build and implement a control panel that accurately manages the precise timing and temperature of the Rotoformer to ensure its safe and efficient operation.
After assessing the system, we designed a Category 3 panel that went an extra step with safety, engaging limit and safety guard switches to ensure the safe operation of the Rotoformer, with two contacts per device that will alert nearby staff if the device has failed.  But the panel also controls the operation of the Rotoformer to protect against failure. It maintains the temperature of the system to within half a degree, and ensures the speed of the belt perfectly matches the speed of the drum.
With a Tulsar Canada control panel, the client’s complex Rotoform Pastillation System is able to run smoothly, efficiently and safely with continual monitoring for possible failures in its operation.