Alameda County Water District implemented a modern, scalable SCADA system that allowed for better visibility, reporting and control.
The District's ONSPEC SCADA system and old PLC hardware had been operating for over 21 years. Their system was running fine, but they knew it was time to upgrade because integrating ONSPEC with new hardware and finding development support was difficult. They also wanted mobile access, which wasn’t supported by the current technology. The District's leadership knew they needed a modern and secure system that would run smoothly for the next 20-30 years. The proposed solution was to use Ignition for leapfrogging into the future, Perspective for building High Performance graphics that can be opened in any screen, Canary as a powerful historian which will give them valuable insights, and Kepware as an intermediary until the PLC system is upgraded.
The District first ran a feasibility study and then hired Vertech to implement a pilot project. The development team was presented with over a dozen rigorous requirements, including the need to maintain 100% uptime and reporting during the development, testing, and implementation.
We chose to upgrade the SCADA first, so the existing PLCs would need to work with both the old SCADA and the new until they could upgrade the PLC hardware. Their operators were also used to working in very specific ways. Finally, they were also updating their network at the same time, requiring collaboration with their other technology teams.
Through workshops with the operators, we found ways to incorporate new, modern SCADA screens into their current ways of working while enhancing their existing processes. New tag and graphics templates were developed which were compatible with both the old and new systems. We processed over 2 billion rows of data to bring their 21 years of historical reporting into the new, modular enterprise system. Finally, we provided multiple training sessions tailored to different departments along with robust user and development documentation so that every operator felt comfortable with the new screens.
Now with Ignition, The District has a modern solution built on scalable technology that can be rolled out to all of their sites and supports future PLC upgrades.
The new SCADA system will give better context to the operators. They can see the system in its present state but also in relation to the high/low limits and if the values are headed in the right direction or not.
This screen efficiently displays useful and readable information for the entire facility and showcases how leveraging popups and templates makes it easy to allow for control of devices no matter how the operator is viewing their process. Sparkline components provide a glanceable historical view into important chemical readouts and tank levels, while dynamic alarm graphics allow operators to quickly identify problems. Additionally, template popups launched from any of the device indicator graphics allow for access to controls from any status screen.
Templatized popups with easy access to device controls help operators manually actuate equipment from any screen while keeping primary displays clean and easy to read. Popups also provide quick trends for operators to quickly view history on a tab without launching a full Axiom trending session.
Tracking operations were very important to the customer. Most of their process is executed by operators directly controlling devices from the SCADA, so they needed a way to keep track of who changed what and how it correlated with their residuals data and alarms. We created custom tools to track their tag events and provided a database display allowing the customer to search and sort operations events for reporting and process tracking.
This primary chemical screen provides a view of one part of the blending process. The traditional PID layout gives a view of the equipment connections in the field, while modern SCADA display components allow for glanceable device statuses and sparkline tag history displays. The screen is kept clean and is clearly laid out so that operators know exactly where to look for their information, and any abnormal process readouts quickly stand out.
The high-performance HMI graphics make information more readable, especially the sparkline displays, which allow for important process variables to be shown at a glance. These space-efficient displays give the operators easy access to key information
Accessibility has improved because they can now access the screens from a web browser from any location and any device in their network. Because of how the system is designed, future development can easily incorporate more calculations, graphs and other data visualization.
Operators now have access to data without causing damage intentionally or unintentionally to the broader system.
The new SCADA system gives the operators better context. The sparklinks show trending data for the last 15 minutes… especially directionally. So, for example, they can tell not just that “the tank level is 10” but whether it is filling up or emptying.
The screens are less cluttered and operators can get anywhere in two clicks; the third click is the action they would take.
Before, they had a “flooding of alarms.” This meant that any major problem meant operators had to scroll through screens to determine which alarm was the root cause and which was a symptom of the problem. Now, alarms can be quickly interpreted and acted upon.
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