Upgrading the operating system and automation applications of a wastewater treatment plant—a utility that your local constituents rely on—can seem like an overwhelming task. Concerns about system downtime, staying within budget, and potential disruptions often lead to delays in upgrading vital automation systems. However, the long-term benefits far outweigh the short-term challenges. At FrommConnect, we understand these concerns and specialize in ensuring a smooth transition to modern systems while minimizing operational interruptions.
Here’s how we helped one local government wastewater treatment plant successfully modernize their outdated systems, enhance operational efficiency, reduce downtime, and ultimately cut operating costs—all while improving service delivery for their community.
For years, the facility faced operational challenges caused by its reliance on legacy automation systems running on outdated Windows operating systems. Their legacy infrastructure, which was critical to the plant’s daily operations, required a substantial upgrade to maintain functionality, ensure regulatory compliance, and increase system reliability. The utility turned to FrommConnect to develop a solution that would address these issues without disrupting service.
Key Upgrades and Solutions Implemented
A significant challenge faced by the wastewater treatment center was their aging Supervisory Control and Data Acquisition (SCADA) system. This system was running legacy versions of essential software, including:
- Rockwell FactoryTalk View SE: A software platform used for monitoring and controlling applications from a single computer, allowing only one user at a time.
- XLReporter: A data reporting tool that, while functional, was unable to provide the depth of insights needed for informed decision-making.
- Microsoft Access Database: The facility’s data was stored on an outdated MySQL database, limiting its scalability and creating concerns over data integrity and accessibility.
FrommConnect designed a comprehensive upgrade plan, which included migrating all systems to a current Windows operating system and updating the relevant software. The new solution featured:
- SCADA System Upgrade: We updated the Rockwell FactoryTalk View SE software to a version that supports single-user access, improving overall system efficiency and allowing operators to monitor and control the facility’s processes more effectively.
- Enhanced Data Reporting: The XLReporter tool was upgraded to a more advanced version that provides richer, real-time data insights, enabling the utility to make more informed, data-driven decisions.
- Database Migration: We migrated 18 months of historical data from the outdated Microsoft Access database to a modern Microsoft SQL server system, ensuring the utility’s data was secure, scalable, and easily accessible. This also ensured compliance with Pennsylvania’s strict regulatory standards.
Seamless Transition and Minimal Disruption
A crucial element of this upgrade was maintaining the functionality of the existing system while transitioning to the new platform. FrommConnect implemented a strategy where the upgraded systems were launched concurrently with the old systems, ensuring no data or functionality was lost during the migration. This approach allowed the facility to continue operating without any interruptions to service.
Our carefully planned implementation and thorough testing procedures meant that the entire process was seamless, and the facility’s system is now fully operational with enhanced features that improve their day-to-day operations.
The Long-Term Benefits
The upgrade not only modernized the facility’s infrastructure but also provided a range of long-term benefits, including:
- Reduced Repair Downtime: With updated systems, the need for frequent repairs and workarounds was significantly minimized.
- Enhanced Data Collection and Reporting: The upgraded data collection and reporting tools allow for more accurate decision-making and greater operational insights.
- Lower Operating Costs: With better-performing systems and streamlined processes, the wastewater treatment facility has reduced its overall operating costs.
- Compliance Assurance: The new infrastructure ensures that the facility is in full compliance with regulatory requirements, preventing costly disruptions.
Future-Proof Your Utility’s Operations
If your utility is still running on legacy operating systems, outdated SCADA systems, or inefficient data collection tools, it’s crucial to start planning for a transition to modern solutions that are more secure, efficient, and scalable. FrommConnect is here to help you navigate this process with minimal disruption, ensuring your systems continue to meet the needs of your community while improving your bottom line.
We understand the unique challenges faced by local government utilities and are dedicated to helping you stay ahead of the curve with technology that enhances operational efficiency and sustainability. Let FrommConnect assist you in upgrading your infrastructure and systems, so your utility can continue providing exceptional service to your constituents for years to come.