SCADA & Communications Upgrade Phase III

Challenge

• Phase III was the first significant upgrade to any system in 10–15 years.

  • Emphasis on upgrading the legacy Autocon systems from the 1980s.

• SCADA communications were a collection of two dedicated bridged phone systems which had become obsolete.

  • One communicating to the 1980’s era Autocon facility controllers that made up 80% of the facilities.

  • The other connecting five obsolete Rockwell controllers.

• Two very different HMI systems (OnSpec and Wonderware) increased the complexity and learning curve for operators.

• COVID restrictions significantly reduced the availability of direct contact.

Solution

• Complete replacement of all the existing communications systems.

  • Transitioned to a government-level private cellular communications system.

  • Increased priority of the facilities and reduced the cost over the previous, obsolete system.

• New CompactLogix PLCs in all Phase III facilities to support a long lifespan.

• Upgraded SCADA system to Systems Platform 2017.

  • HMI development across all systems, SQL historian, and Win911 for alarming.

  • Backup hardware-based alarm notification system. 

Outcome

• Total upgrade of SCADA and HMI systems:

  • Including servers, OT networking, and cybersecurity-conscious solutions.

• Communications platform upgraded to current-generation technology with a higher priority level and reduced costs across facilities.

• The entire project was completed without any direct contact with District staff due to COVID restrictions.